51796-Case 410 420

410/420 SKID STEER
Service Manual
Bur 6-78950
Table of Contents
Publication
Description Section Number
Form Number
General Tab 1
Section Index - General 6-79040
Fluids and Lubricants 1001 6-79030
Standard Torque Specifications 1002 7-52931
Metric Conversion Chart 1003 7-52950
Engines Tab 2
Section Index - Engines 6-79050
Engine and Radiator Removal and Installation 2000 6-79130
For Engine Repair - See Engine Service Manual 6-79550
Fuel Systems Tab 3

Section Index - Fuel Systems 6-79060
For Fuel System Repair - See the Engine Service Manual 6-79550
Electrical Tab 4
Section Index - Electrical 6-79070
Electrical Specifications and Troubleshooting and Schematics 4001 6-79540
Battery 4005 7-51310
Starter and Starter Solenoid 4006 7-53091
Power Train Tab 6

Section Index - Power Train 6-79080
Hydrostatic System Troubleshooting 6001 6-79330
Removal and Installation of Hydrostatic Components 6002 6-79530
Drive Coupling 6003 6-79120
Piston Pump 6004 6-49580
Drive Motors (Eaton) 6005 6-79020
Single Speed Drive Motors 6005 6-79000
Sprocket, Chains, and Axle Assemblies 6007 6-79300
Wheels and Tires 6011 6-79310
Copyright © 2005 CNH America LLC.

CNH AMERICA LLC. All rights reserved.
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-78990 Issued February, 2005
410/420 SKID STEER
Service Manual
Bur 6-78950
Table of Contents (Continued)
Publication
Description Section Number
Form Number
Brakes Tab 7
Section Index - Brakes 6-79090
Removal and Installation of Park Brake Components 7002 6-79570
410 Brakes - Spring Applied - Hydraulic Release
(Refer to Section 6005 - Single Speed Drive Motor)
420 Brakes - Spring Applied - Hydraulic Release 7004 6-79580
Hydraulics Tab 8
Section Index - Hydraulics 6-79100
Hydraulic System Troubleshooting and Schematics 8001 6-79510
Cleaning the Hydraulic System and Hydrostatic System 8002 6-45290
Removal and Installation of Hydraulic Components 8003 6-79520
Gear Pump (Equipment and High Flow) 8004 6-79350
Cylinders 8006 6-79360
Flat Faced Couplers 8007 7-54740
Accumulator for Ride Control 8013 6-45550
Mounted Equipment Tab 9

Section Index - Mounted Equipment 6-79110
Pedals and Levers 9001 6-79500
Loader 9002 6-79390
Attachment Coupler 9003 6-79400
ROPS Canopy, Seat, Seat Belts, and Operators Compartment 9004 6-79410
Heater 9006 6-79450
Schematic Set
Hydraulic and Electrical Schematic Foldout In Rear Pocket 6-78970
Bur 6-78990 Issued 2-05 Printed in U.S.A.

SECTION INDEX
GENERAL
Section Title Section Number

Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003
Copyright © 2005 CNH America LLC

All rights reserved.
CNH AMERICA LLC
1001
Section
1001
FLUIDS AND LUBRICANTS
CNH AMERICA LLC Copyright © 2005 CNH America LLC

Racine, WI 53404 U.S.A. Bur 6-79030 February, 2005
1001-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Oil Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Viscosity/Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1001-3
CAPACITIES AND LUBRICANTS

FUEL TANK
Capacity .................................................................................................................... 83.3 litres (22 U.S. gallons)
Specifications .......................................................................................... See diesel fuel specifications on page 5
COOLING SYSTEM
Capacity ................................................................................................................................17 litres (17.9 quarts)
Recovery bottle capacity .......................................................................................................... 2 litres (2.1 quarts)
Specifications ................................................................................................ 50% water and 50% ethylene glycol
HYDRAULIC SYSTEM
Capacity - Total System .................................................................................................. 50.2 litres (13.3 gallons)
Capacity - Reservoir........................................................................................................... 32.4 litres (7.1 gallons)
Specifications .................................................................................... Case Akcela No. 1 Engine Oil SAE 10W30
CHAIN COMPARTMENTS
Capacity - Each Side ............................................................................................................ 5.7 litres (6.0 quarts)
Specifications ................................................................................... Case Akcela No. 1 Engine Oil, SAE 10W30
BATTERY
Quantity .............................................................................................................................................. As required
Specifications ................................................................................................................................. Distilled water
GREASE FITTINGS
Quantity .............................................................................................................................................. As required
Attachments (If equipped) ..................................................................................................... Quantity as required
Specifications .............................................................................................................. Case molydisulfide grease
ENGINE CRANKCASE OIL (410 and 420 MACHINES)
Capacity - with filter change .................................................................................................. 8.7 litres (9.2 quarts)
Capacity - without filter change ................................................................................................ 8.5 litres (9 quarts)
Specifications ..................................................... Case Akcela No. 1 Engine Oil SAE 10W-30 (API service CH-4)
.................................................................................... (See Oil Viscosity/Temperature Ranges Chart on page 4)
ENGINE CRANKCASE OIL (430 and 440 MACHINES)
Capacity - with filter change ................................................................................................. 12 litres (12.7 quarts)
Specifications ..................................................... Case Akcela No. 1 Engine Oil SAE 10W-30 (API service CH-4)
.................................................................................... (See Oil Viscosity/Temperature Ranges Chart on page 4)
ENVIRONMENT
Before you service this machine and dispose of oil, fluids and lubricants, always remember the environment. Do
not put oil or fluids into the ground or into containers that can leak. Check with your local environmental, recycling
center or your Case dealer for correct disposal information.

1001-4
ENGINE LUBRICATION
Engine Oil Selection See the chart below for recommended viscosity at
ambient temperature ranges.
Case Akcela No. 1 Engine Oil is recommended for
use in your Case Engine. Case Akcela Engine Oil will NOTE: Do not put Performance Additives or other oil
lubricate your engine correctly under all operating additive products in the engine crankcase. The oil
conditions. change intervals given in the operating manual are
. according to tests with Case lubricants.
Oil Viscosity/Temperature Ranges
BS99N019

1001-5
DIESEL FUEL SYSTEM

Use No. 2 diesel fuel in the engine of this machine. Fuel Storage
The use of other fuels can cause the loss of engine
power and high fuel consumption. If you keep fuel in storage for a period of time, you
can get foreign material or water in the fuel storage
In very cold temperatures, a mixture of No. 1 and No. tank. Many engine problems are caused by water in
2 diesel fuels is temporarily permitted. See the the fuel.
following:
Keep the fuel storage tank outside and keep the fuel
NOTE: See your fuel dealer for winter fuel as cool as possible. Remove water from the storage
requirements in your area. If the temperature of the container at regular periods of time.
fuel lowers below the cloud point (wax appearance
point), wax crystals in the fuel will restrict the fuel Fill the fuel tank at the end of the daily operating
filter and cause the engine to loose power or not period to prevent condensation in the fuel tank.
start.
The diesel fuel used in this machine must meet the
specifications below, “Specifications for Acceptable
No. 2 Diesel Fuel” or Specification D975-81 of the
American Society for Testing and Materials.
Specifications for Acceptable No. 2 Diesel Fuel

API Gravity, Minimum ............................................................................................................................................ 34
Flash Point, Minimum .......................................................................................................................... 60° C (140° F)
Cloud Point (wax appearance point), Maximum ................................................................................... -20° C (-5° F)
Pour Point, Maximum .......................................................................................................................... -26° C (-15° F)
Distillation Temperature, 90% Point .............................................................................282 to 338° C (540 to 640° F)
Viscosity, at 38° C (100° F)
Centistokes ............................................................................................................................................ 2.0 to 4.3
Saybolt Seconds Universal ...................................................................................................................... 32 to 40
Cetane Number, Minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)
Water and Sediment, by Volume, Maximum .............................................................................................. 0.5 of 1%
Sulphur, by Weight, Maximum .....................................................................................................................0.5 of 1%
Copper Strip Corrosion, Maximum ................................................................................................................... No. 2
Ash, by Weight, Maximum .......................................................................................................................... 0.1 of 1%

1001-6
NOTES

1002
Section
1002
STANDARD TORQUE SPECIFICATIONS
CNH AMERICA LLC

© 2005 CNH America LLC
Racine, WI 53404 U.S.A. Bur 7-52931 September, 1998
1002-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE ...................................................................................................... 3
Grade 5 Bolts, Nuts, and Studs .................................................................................................................................. 3
Grade 8 Bolts, Nuts, and Studs .................................................................................................................................. 3
TORQUE SPECIFICATIONS - METRIC HARDWARE ........................................................................................................ 4

Grade 8.8 Bolts, Nuts, and Studs ................................................................................................................................ 4
Grade 12.9 Bolts, Nuts, and Studs .............................................................................................................................. 4
Grade 10.9 Bolts, Nuts, and Studs .............................................................................................................................. 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ........................................................................................... 5

37 Degree Flare Fitting ............................................................................................................................................. 5
Straight Threads with O-ring ...................................................................................................................................... 5
Split Flange Mounting Bolts ....................................................................................................................................... 6
O-Ring Face Seal End .............................................................................................................................................. 6
O-Ring Boss End
Fitting or Lock Nut .................................................................................................................................................... 6
Pipe fittings ............................................................................................................................................................. 7
Bur 7-52931 Issued 9-98 Printed in U.S.A

Template Name: SM_2_col Alt= to hide template information
Template Date: 1997_01_13 Alt+ to display template information
1002-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques
are not given. These torques apply to fasteners with Grade 8 Bolts, Nuts, and Studs
both UNC and UNF threads as received from
suppliers dry, or when lubricated with engine oil. Not
applicable if special graphities, Molydisulfide
greases, or other extreme pressure lubricants are Newton Pound-
used. Size metres Inches
1/4 inch 15 to 16 130 to 145
Grade 5 Bolts, Nuts, and Studs
5/16 inch 30 to 34 268 to 301
3/8 inch 54 to 60 474 to 534
Pound-
Newton Pound- Feet
Size metres Inches 7/16 inch 86 to 97 63 to 71
1/4 inch 10 to 12 91 to 103 1/2 inch 132 to 149 96 to 110
Pound- 3/4 inch 480 to 515 340 to 380
Feet
7/8 inch 745 to 835 550 to 615
7/16 inch 61 to 69 45 to 51
1.0 inch 1120 to 1280 825 to 925
1/2 inch 94 to 104 68 to 76
1-1/8 inch 1585 to 1785 1170 to 1315
9/16 inch 132 to 149 98 to 110
1-1/4 inch 2215 to 2235 1650 to 1855
5/8 inch 183 to 210 138 to 155
1-3/8 inch 2930 to 3295 2160 to 2430
3/4 inch 325 to 370 242 to 270
1-1/2 inch 3895 to 4375 2870 to 3225
7/8 inch 530 to 595 390 to 435
NOTE: Use thick nuts with Grade 8 bolts.
1.0 inch 790 to 890 585 to 655
1-1/8 inch 980 to 1100 725 to 805
1-1/4 inch 1385 to 1555 1020 to 1145
1-3/8 inch 1810 to 2030 1335 to 1495
1-1/2 inch 2400 to 2700 1770 to 1990

1002-4
TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not
given. Grade 10.9 Bolts, Nuts, and Studs
These values apply to fasteners with both coarse and 10.9
fine threads as received from supplier, plated or
unplated, or when lubricated with engine oil. These
Newton Pound-
values do not apply if graphite or Molydisulfide
Size metres Inches
grease or oil is used. Use of a click type torque
wrench, or better is required. M4 5 to 6 44 to 49
M5 8 to 9 71 to 79
M6 14 to 15 120 to 136
Grade 8.8 Bolts, Nuts, and Studs M8 33 to 37 293 to 329
Pound-
8.8 Feet
M10 65 to 74 48 to 54
Newton Pound- M12 114 to 128 85 to 94
Size metres Inches
M14 183 to 205 136 to 153
M4 3 to 4 31 to 35
M16 285 to 320 208 to 235
M5 5 to 6 49 to 55
M20 555 to 620 406 to 460
M6 10 to 11 84 to 94
M24 955 to 1075 705 to 790
M8 23 to 26 229 to 277
M30 1900 to 2140 1400 to 1580
M10 46 to 51 408 to 460
M36 3315 to 3730 2445 to 2750
Pound-
Feet
M12 80 to 90 59 to 66 Grade 12.9 Bolts, Nuts, and Studs
M14 128 to 145 94 to 106
M16 200 to 220 149 to 161 12.9
M20 400 to 450 293 to 330
M24 690 to 780 510 to 575
Usually the torque values specified for grade 10.9
M30 1375 to 1545 1010 to 1140 fasteners can be used satisfactorily on grade 12.9
M36 2400 to 2700 1770 to 1990 fasteners.

1002-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
37 Degree Flare Fitting

Nom. SAE
Dash Size Tube OD/Hose ID Thread Size Newton metres Pound-Inches
-2 5/16 - 24 8 to 9 72 to 84
-3 3/8 - 24 11 to 12 96 to 108
-4 6.4 mm (1/4 inch) 7/16 - 20 14 to 16 120 to 144
-5 7.9 mm (5/16 inch) 1/2 - 20 18 to 21 156 to 192
-6 9.5 mm (3/8 inch) 9/16 - 18 27 to 33 240 to 300
-8 12.7 mm (1/2 inch) 3/4 - 16 46 to 56 408 to 504
-10 15.9 mm (5/8 inch) 7/8 - 14 77 to 85 684 to 756
Pound-Feet
-12 19.0 mm (3/4 inch) 1-1/16 - 12 107 to 119 79 to 88
-14 22.2 mm (7/8 inch) 1-3/16 - 12 127 to 140 94 to 103
-16 25.4 mm (1.0 inch) 1-5/16 - 12 131 to 156 97 to 117
-20 31.8 mm (1-1/4 inch) 1-5/8 - 12 197 to 223 145 to 165
-24 38.1 mm (1-1/2 inch) 1-7/8 - 12 312 to 338 230 to 250
Straight Threads with O-ring

Nom. SAE
Dash Size Tube OD/Hose ID Thread Size Newton metres Pound-Inches
-2 5/16 - 24 8 to 9 72 to 84
-3 3/8 - 24 11 to 12 96 to 108
-4 6.4 mm (1/4 inch) 7/16-20 20 to 25 180 to 228
-5 7.9 mm (5/16 inch) 1/2-20 27 to 33 240 to 300
-6 9.5 mm (3/8 inch) 9/16-18 43 to 54 384 to 480
-8 12.7 mm (1/2 inch) 3/4-16 73 to 90 648 to 804
Pound-Feet
-10 15.9 mm (5/8 inch) 7/8-14 100 to 124 74 to 92
-12 19.0 mm (3/4 inch) 1-1/16-12 138 to 173 102 to 128
-14 22.2 mm (7/8 inch) 1-3/16-12 173 to 216 128 to 160
-16 25.4 mm (1.0 inch) 1-5/16-12 203 to 253 150 to 187
-20 31.8 mm (1-1/4 inch) 1-5/8-12 308 to 357 227 to 264
-24 38.1 mm (1-1/2 inch) 1-7/8-12 492 to 542 363 to 400

1002-6
Split Flange Mounting Bolts

Size Newton metres Pound-Inches
5/16-18 20 to 27 180 to 240
3/8-16 27 to 34 240 to 300
7/16-14 47 to 61 420 to 540
Pound-Feet
1/2-13 74 to 88 55 to 65
5/8-11 190 to 203 140 to 150
O-Ring Boss End

O-Ring Face Seal End Fitting or Lock Nut
Nom. SAE Newton Newton
Dash Size Tube OD Thread Size metres Pound-Inches Thread Size metres Pound-Inches
-4 6.4 mm 9/16-18 23 to 26 204 to 228
(1/4 inch)
-6 9.5 mm 11/16-16 34 to 40 300 to 348 9/16-18 48 to 54 432 to 480
(3/8 inch)
-8 12.7 mm 13/16-16 52 to 57 456 to 504 3/4-16 70 to 78 612 to 684
(1/2 inch) Pound-Feet
-10 15.9 mm 1-14 81 to 90 720 to 792 7/8-14 102 to 114 75 to 84
(5/8 inch) Pound-Feet
-12 19.0 mm 1-3/16-12 117 to 128 86 to 94 1-1/16-12 142 to 160 105 to 117
(3/4 inch)
-16 25.4 mm 1-7/16-12 152 to 174 112 to 128 1-5/16-12 237 to 254 175 to 187
(1.0 inch)
-20 31.8 mm 1-11/16-12 179 to 201 132 to 148
(1-1/4 inch)
-24 38.1 mm 2-12 213 to 235 157 to 173
(1-1/2 inch)

1002-7
Pipe fittings
Nom. SAE
Dash Size Thread Size TFFT (Turns For Finger Tight)
-2 1/8 - 27 2.0 - 3.0
-3 1/8 - 27 2.0 - 3.0
-4 1/8 - 27 2.0 - 3.0
-5 1/8 - 27 2.0 - 3.0
-6 1/4 - 18 1.5 - 3.0
-8 3/8 - 18 2.0 - 3.0
-10 1/2 - 14 2.0 - 3.0
-12 3/4 - 14 2.0 - 3.0
-14 3/4 - 14 2.0 - 3.0
-16 1 - 11 1/2 1.5 - 2.5
-20 1 1/4 - 11 1/2 1.5 - 2.5
-24 1 1/2 - 11 1/2 1.5 - 2.5
-32 2 - 11 1/2 1.5 - 2.5
NOTE: Apply sealant/lubricant to male pipe threads. The first two threads should be left uncovered to avoid
system contamination. Screw pipe fitting into female pipe port to the finger tight position. Wrench tighten fitting to
the appropriate turns from finger tight (TFFT) shown in table above, making sure the tube end of an elbow or tee
fitting is aligned to receive incoming tube or hose fitting.

1002-8

Section
1003
1003
METRIC CONVERSION CHART
CNH AMERICA LLC

© 2005 CNH America LLC
Racine, WI 53404 U.S.A. Bur 7-52950 June, 1997
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS ............................................................................................................................................. 3
Metric to U.S. .......................................................................................................................................................... 3
U.S. to Metric ......................................................................................................................................................... 4
Bur 7-52950 Issued 6-97 Printed in U.S.A

1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
Area: sq. meter 10.763 91 square foot

hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch

meter 3.280 840 foot
kilometer 0.621 371 mile
Mass: kilogram 2.204 622 pound
Mass/Area: kilogram/hectare 0.000 466 ton/acre
Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.
Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.
Power: kilowatt 1.341 02 horsepower
Pressure: kilopascal 0.145 038 lb/sq. inch

bar 14.50385 lb/sq. inch
Temperature: degree C 1.8 x C +32 degree F
Torque: newton meter 8.850 748 lb/inch

newton meter 0.737 562 lb/foot
Velocity: kilometer/hr. 0.621 371 miles/hr.

Volume: cubic centimeter 0.061 024 cubic inch
cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
litre 1.056 814 quart (US liquid)
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

litre/min. 0.219 969 gallon/min. (Imperial)

1003-4
U.S. to Metric
MULTIPLY BY TO OBTAIN
Area: square foot 0.092 903 square meter

acre 0.404 686 hectare
Force: ounce force 0.278 014 newton
pound force 4.448 222 newton
Length: inch 25.4 * millimeter

foot 0.304 8 * meter
mile 1.609 344 * kilometer
Mass: pound 0.453 592 kilogram

ounce 28.35 gram
Mass/Area: ton/acre 2241 702 kilogram/hectare
Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr
Mass/Volume: lb/cubic yd. 0.593 276 kg/cubic meter
Power: horsepower 0.745 700 kilowatt
Pressure: lbs/sq. in. 6.894 757 kilopascal

lbs/sq. in. 0.069 bar
lbs/sq. in. 0.070 303 kg/sq. cm
Temperature: degree F 1.8 F - 32 degree C
Torque: pound/inch 0.112 985 newton meter

pound/foot 1.355 818 newton meter
Velocity: miles/hr. 1.609 344 * kilometer/hr.

Volume: cubic inch 16.387 06 cubic centimeter
cubic foot 0.028 317 cubic meter
cubic yard 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallons (Imperial) 4.546 092 litre
Volume/Time: gallon/min. 3.785 412 litre/min.
* = exact

SECTION INDEX
ENGINE

Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000
For Engine Repair, see the Engine Service Manual

CNH AMERICA LLC
2000
Section
2000
ENGINE AND RADIATOR REMOVAL AND

INSTALLATION

2000-2
TABLE OF CONTENTS
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2000-3
RADIATOR
Removal STEP 6
NOTE: Photos may be slightly different from the
machine you are repairing. The procedure is the
same.
NOTE: Put caps on all fittings and plugs in all
disconnected hoses.
1
STEP 1
Park the machine on a level surface.
STEP 2
Lift the hood and open the rear access door on the BD05A024
machine. If equipped with a heater, open the heater coolant
valve.
STEP 3
Turn the ignition switch and the master disconnect STEP 7
switch (if equipped) to the OFF position. Install a hose on the drain valve (16) and drain the
radiator (1) into a clean container that holds
STEP 4 approximately 17 litres (4.5 gallons).
Disconnect the negative battery cable from the
battery. STEP 8
If equipped with a heater, close the heater coolant
STEP 5 valve (1).
STEP 9
15
5 3
2
BD04C007
Slowly loosen the radiator cap (15). Disconnect the

overflow hose (5) from the radiator neck. BD05A026
If the machine is equipped with a High Flow Oil

NOTE: Refer to illustration on page 5. Cooler (1), release the latch (2) on the lower left side
of the oil cooler and swing the oil cooler away from
the radiator. Remove mounting bolts (3) from the
hinge and remove the oil cooler (1) from the radiator
mounting location. Secure the oil cooler away from
the radiator.

2000-4
STEP 10 STEP 12
5 1
BD04C026 BD04K036
Release the latch on the top of the radiator and tip Move the radiator (1) away from the upper radiator
the radiator out from the mounting location. hose (6) and lower radiator hose (5). Remove the
radiator (1) from the machine.
STEP 11
BD04C007
BD05A025
Loosen the clamps (7) on the lower radiator hose

(10) and clamps (7) on the upper radiator hose (8).
Remove the upper radiator hose (8) and the lower
radiator hose (10) from the radiator (1).
NOTE: Refer to illustration on page 5.

2000-5
15
16
BS04M094
1. RADIATOR 9. CLAMP
2. CUSHION 10. LOWER RADIATOR HOSE
3. BOLT 11. SEAL
4. UPPER FRAME ASSEMBLY 12. LOWER FRAME ASSEMBLY
5. COOLANT RECOVERY HOSE 13. NUT
6. COOLANT RECOVERY BOTTLE 14. LOCK WASHER
7. CLAMP 15. RADIATOR CAP
8. UPPER RADIATOR HOSE 16. DRAIN VALVE
410 AND 420 RADIATOR MOUNTING

2000-6
BS04M095
1. FAN BLADE 7. CAP SCREW
2. SPACER 8. LOCK WASHER
3. LOCK WASHER 9. WASHER
4. CAP SCREW 10. FAN GUARD
5. SHROUD 11. OIL COOLER
6. BOLT
410 AND 420 FAN MOUNTING

2000-7
Installation
STEP 13
Installation of the radiator is the reverse procedure of
removal.
STEP 14
After the radiator has been installed, fill the cooling
system. See Section 1001 for the correct coolant
mixture and quantity.
STEP 15
Start and run the engine until it reaches operating
temperature and check for any leaks. Stop the
engine. After the engine has cooled, check the level
of the cooling system and add coolant as required.

2000-8
ENGINE
Removal STEP 6
STEP 1
Remove the radiator from the machine.
STEP 2
Install plugs and caps on all disconnected hoses and 1 2 3 1
fittings.
STEP 3
Tag all electrical connection for identification during
assembly.
STEP 4 BD05A028
Disconnect the electrical connectors from the rear tail

1 lamps (1) on both sides of the rear access door.
Disconnect the electrical connectors from the rear
worklight (2). Disconnect the electrical connectors
from the backup alarm (3). Remove mounting
hardware from the wiring harness (4) and remove the
harness (4) from the rear access door.
STEP 7
BD05B048
If equipped with a heater, disconnect the heater

hoses (1) from the engine.
1
STEP 5
Lift the rear hood and open the rear access door.
BD05A028
Connect acceptable lifting equipment to the rear

access door. Remove the pivot bolt (1) and lift the
rear access door and remove from the machine.

2000-9
STEP 8 STEP 11
BD05A029 BD05B050
1. CYLINDER PIVOT BOLT 1. AIR RESTRICTION INDICATOR SWITCH
Remove the nut from cylinder pivot bolt (1) on the Disconnect the electrical connector for the air
hood end of the cylinder. restriction indicator switch (1).
STEP 9 STEP 12
2 3
1
2
BD05A066 BD05B049
Remove the plastic clip (2) from the hood pivot shaft. Loosen the clamps (1) on the outlet hose (2).
Slide the hood to the left and remove the hood from Remove the outlet hose (2) from the intake and air
the hood pivot shaft on both sides of the machine. filter assembly (3).
Remove the hood from the machine.
NOTE: Torque clamps (1) 3 to 4 Nm (25 to 35
pound-inches) during assembly.
STEP 10
Push the hood to the right hand side of the machine NOTE: Refer to illustration on page 14 and 15.
and remove the left hand side of the hood from the
pivot pin. Remove the hood from the machine. STEP 13
Loosen and remove the mounting bolts and washers
from the air filter housing mounting bracket.
STEP 14
Remove the air cleaner and bracket from the
machine.

2000-10
STEP 15 STEP 21
Remove the bolts and washers that fasten the front
muffler support rods (5 and 8) and the rear muffler
support rods (14 and 16) to the engine.
NOTE: Torque bolts 23 to 26 Nm (204 to 228
pound-inches) during assembly.
STEP 16
Loosen and remove the bolts and washers that
fasten the muffler to the exhaust manifold.
1
NOTE: Torque the bolts 51 to 61 Nm (38 to 45
pound-feet) during assembly.
Refer to illustration on page 16 and 17. BD05B050
1. ALTERNATOR WIRES
STEP 17 Disconnect the wires from the alternator.

Remove the muffler from the engine.
STEP 22
STEP 18
Remove the cap screws (7), washers (8), fan blade
(1), from the engine. Loosen and remove cap screws
(4), washers (3) and spacer (2) from the engine.
STEP 19
2
1
BD05B049
Remove the throttle linkage (1) from the fuel injection

pump and the linkage (2) to the throttle control lever.
STEP 23
1 2 Disconnect the wire for the engine coolant
temperature switch and the engine oil pressure
BD05B050
switch.
1. STARTER WIRES
2. WIRE HARNESS CLAMP
Disconnect the wires (1) from the starter and from

the alternator (2). Loosen and remove the bolts and
wire harness clamp (2) from the engine.
STEP 20
Loosen and remove the bolts that fastens the ground
wires to the engine. Keep all ground wires together.

2000-11
STEP 24 STEP 28
1
2
BD05B049 BD01C188
Disconnect the wire connector for the fuel injection

Disconnect the fuel lines (1) from the engine.
pump solenoid.
Remove the bolts from the clamps (2) and remove
the fuel lines (1) from the engine.
STEP 25
Loosen and remove the bolts that fasten the wire STEP 29
harness to the right side of the machine.
STEP 26
Move the all of the wiring harness out of the way.
1 3
STEP 27
2 1
BD05B049
Loosen and remove the mounting bolts (1) which

fasten the throttle linkage assembly (2) to the engine.
Remove the linkage assembly (2) from the engine.
fasten the cover (4) to the engine. Remove the cover
BD01C219
(4).
Close the fuel shut off valve.

2000-12
STEP 30 STEP 34
Use lifting equipment and remove the engine from
the chassis.
NOTE: During assembly apply Molykote GN to the
pump drive joint splines before assembly.
2
Installation
1 STEP 35
Installation of the engine is the reverse procedure of
3 removal.
BD05B049
STEP 36
fasten the pump drive joint (2) to the flywheel (3). After the engine and radiator have been installed,
Remove the pump drive joint (2) from the flywheel refill the engine cooling system. Refill the engine
(3). crankcase with engine oil. See Section 1001 for the
correct type and quantity of engine coolant and
NOTE: Tighten pump drive joint bolts to a torque of engine oil.
94 to 106 Nm (68 to 78 pound-feet) during assembly.
STEP 37
STEP 31 Start and run the engine at low idle until the engine
reaches operating temperature and check for any
leaks. Stop the engine. After the engine has cooled,
check the level of the coolant in the cooling system.
Add coolant as required. Check the oil level in the
engine crankcase. Add engine oil as required.
BD05B049
Connect acceptable lifting equipment to the engine

lifting eyes at the front and rear of the engine.
STEP 32
Remove the bolt, washers, and nut from the rear
engine mount (2).
STEP 33
Remove the bolts, washers, and nut from the front
engine mounts (1).

2000-13
3 4
3
1
BS04N063
1. FRONT ENGINE MOUNTS 5. PUMP DRIVE JOINT
2. REAR ENGINE MOUNT 6. ENGINE OIL DIPSTICK
3. THROTTLE LEVER 7. ENGINE OIL DIPSTICK MOUNTING BRACKET
4. THROTTLE LINKAGE
ENGINE MOUNTING

2000-14
BS04M104
1. AIR CLEANER BODY 7. CLAMP
2. PRIMARY FILTER ELEMENT 8. CAP SCREW
3. SECONDARY FILTER ELEMENT 9. WASHER
4. COVER 10. NOT SHOWN
5. DUST VALVE 11. PLUG
6. OUTLET HOSE
410 AIR FILTER ASSEMBLY

2000-15
BS04M103
1. AIR CLEANER BODY 7. OUTLET HOSE
2. PRIMARY FILTER ELEMENT 8. CAP SCREW
3. SECONDARY FILTER ELEMENT 9. WASHER
4. COVER 10. CLAMP
5. DUST VALVE 11. PLUG
6. CLAMP
420 AIR FILTER ASSEMBLY

2000-16
BS04M097
1. MUFFLER 11. SPACER
2. CAP SCREW 12. CAP SCREW
3. LOCK WASHER 13. GASKET
4. NUT 14. SUPPORT ROD
5. SUPPORT ROD 15. CAP SCREW
6. CAP SCREW 16. SUPPORT ROD
7. LOCK WASHER 17. CLAMP
8. SUPPORT ROD 18. EXHAUST TUBE
10. SPACER 20. EXHAUST MANIFOLD
410 MUFFLER ASSEMBLY

2000-17
BS04M098
1. MUFFLER 10. SPACER
2. CAP SCREW 11. SPACER
3. LOCK WASHER 12. CAP SCREW
4. NUT 13. GASKET
5. SUPPORT ROD 14. SUPPORT ROD
7. LOCK WASHER 16. SUPPORT ROD
8. SUPPORT ROD 17. CLAMP
9. CAP SCREW 18. EXHAUST TUBE
420 MUFFLER ASSEMBLY

2000-18
NOTES

SECTION INDEX
FUEL SYSTEM

For Fuel System Repair, See the Engine Service Manual

CNH AMERICA LLC
SECTION INDEX
ELECTRICAL SYSTEM

Electrical Specifications and Troubleshooting and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4005
Starter and Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4006

CNH AMERICA LLC
4001
Section
4001
ELECTRICAL SYSTEM SPECIFICATIONS,

TROUBLESHOOTING, AND SCHEMATICS

4001-2
TABLE OF CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Circuit Diagram Legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ELECTRICAL SCHEMATIC FRAME 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL SCHEMATIC FRAME 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CONNECTORS
SCHEMATIC FRAME 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connector 4 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connector 7 Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connector 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connector 8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Connector 9 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Connector 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Connector 52A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
CONNECTORS
SCHEMATIC FRAME 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connector 14 Main Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connector 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connector 64 Options Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
CONNECTORS
SCHEMATIC FRAME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connector 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
CONNECTORS
SCHEMATIC FRAME 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connector 8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connector 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connector 18 Interlock Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Connector 23 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Connector 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Connector 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4001-3
Connector 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connector 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connector 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connector 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connector 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connector 127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connector 127A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CONNECTORS
SCHEMATIC FRAME 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Connector 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Connector 8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Connector 23 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Connector 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Connector 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Connector 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Connector 52A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
CONNECTORS
SCHEMATIC FRAME 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connector 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connector 8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connector 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connector 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connector 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Connector 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Connector 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Connector 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
CONNECTORS
SCHEMATIC FRAME 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Connector 39 (Grey) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
CONNECTORS
SCHEMATIC FRAME 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Connector 50A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Connector 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Connector 51A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connector 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connector 65A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connector 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connector 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Connector 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Connector 140A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Connector 141 Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
CONNECTORS
SCHEMATIC FRAME 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connector 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connector 70A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connector 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connector 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connector 81B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connector 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connector 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connector 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connector 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connector 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CONNECTORS
SCHEMATIC FRAME 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connector 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CONNECTORS

4001-4
SCHEMATIC FRAME 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connector 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connector 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
CONNECTORS
SCHEMATIC FRAME 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connector 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connector 71A (Euro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
CONNECTORS
SCHEMATIC FRAME 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connector 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connector 70A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connector 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connector 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connector 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connector 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Connector 115A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
CONNECTORS
SCHEMATIC FRAME 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Connector 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Connector 117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Connector 117A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Connector 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Connector 171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Connector 174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connector 175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connector 176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
CONNECTORS
SCHEMATIC FRAME 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connector 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connector 66A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Connector 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Connector 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CONNECTORS
SCHEMATIC FRAME 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Connector 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Connector 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Connector 138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Connector 138A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Connector 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Connector 150A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
CONNECTORS
SCHEMATIC FRAME 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Connector 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Connector 127B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Connector 127C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Connector 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Connector 129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Connector 130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
CONNECTORS
SCHEMATIC FRAME 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Connector 66B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Connector 66C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Connector 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Connector 275 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Connector 276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
CONNECTORS
SCHEMATIC FRAME 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

4001-5
Connector 86B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Connector 226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Connector 227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Connector 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Connector 229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Connector 230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
CONNECTORS
SCHEMATIC FRAME 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Connector 50C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Connector 50D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Connector 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
CONNECTORS
SCHEMATIC FRAME 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Connector 71B (Euro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Connector 71C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Connector 190 (Euro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
CONNECTORS
SCHEMATIC FRAME 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connector 79B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connector 79C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connector 79D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connector 85A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connector 85D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connector 123B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connector 123C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connector 123D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
CONNECTORS
SCHEMATIC FRAME 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Connector 39F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Connector 39G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Connector 39H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Connector 49H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Connector 77H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Electronic Instrument CONSOLE (EIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Electronic Instrument PANEL (EIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Electronic Instrument Cluster (EIC) Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Special Feature Choices: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Detailed Description of Setup Items: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
TROUBLESHOOTING
ELECTRONIC INSTRUMENT CLUSTER (EIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

4001-6

4001-7
GENERAL INFORMATION
Wire Identification
625A W 3.0
Circuit Diagram Legends
Wire Size
Earth connection terminal
Wire Color
Wire Number
WIRE SIZE IN MM WIRE SIZE IN STANDARD

Intersection of two wires with connecting points 0.8 MM 2.0 MM 18 - GAUGE 14 - GAUGE
1.0 MM 5.0 MM 16 - GAUGE 10 - GAUGE
Fuses
Intersection of two wires without connecting points
Options Primary
Fuse Block Fuse Block
Diode 9 13
5 1
Indicates frame continued on 6 2 14
10
7 3
9
8 4
11 15 17
Indicates component number
6
12 16
Bulb or lamp
Color Abbreviations
87457332
1. LIGHTS
B---Black LG--Light Green T---Tan 2. WIPER (IF EQUIPPED)
BR-Brown O---Orange V---Violet 3. INTERLOCK/INSTRUMENT CLUSTER
G---Gray P---Pink W---White 4. HORN/BACKUP ALARM
LB-Light Blue R---Red Y---Yellow 5. FRONT ELECTRIC/ACCESSORY
6. HEATER/AIR CONDITIONING (IF EQUIPPED)
7. HAZARD/HIGH FLOW (IF EQUIPPED)
8. HYDRAULIC COUPLER/BEACON (IF EQUIPPED)
9. INTERLOCK RELAY
10. MAIN POWER RELAY
11. STARTER RELAY
12. N/A
13. ACCESSORY POWER RELAY
14. AUXILIARY INTERLOCK / FUEL SHUTOFF RELAY
15. AUXILIARY INTERLOCK / STARTER RELAY
16. WORK LIGHT / ROAD LIGHT RELAY
17. HAZARD FLASHER

4001-8
TROUBLESHOOTING
1 Battery
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a multimeter for the following tests.
2 Alternator
Check Points Reading Possible Cause of Bad Readings
Terminal for wire 120A to ground 12 volts Check wire 120A between the alternator and the starter battery terminal.
Also check the starter (3).
NOTE: Turn the ignition switch to the RUN position.
Terminal for wire 121A to ground Approximately Check the circuit from the alternator through the 50 ohm resistor to the fuse
1.1 volts block (11) Frame 2. Also check the 50 ohm resistor and the fuse block (11)
Frame 2.
NOTE: Start the engine.
Terminal for wire 124A to ground Voltage varies Bad alternator.

with engine RPM
3 Starter Motor and Solenoid

Battery terminal of starter to ground 12 volts Check the battery cable to the positive post of the battery.
NOTE: Have another person hold the ignition switch to the START position.
Terminal for wire 625D to ground 12 volts Check the circuit between the starter and starting relay. Also check the
starting relay (5).
NOTE: If the readings are good, the starter motor and solenoid should be bench tested.
5 Starting Relay
Terminal for wire 178A to ground Continuity Bad ground circuit.
Terminal for wire 170A to ground 12 volts Check the circuit between the starter relay and the 40 ampere circuit
breaker. Also check the 40 ampere circuit breaker and the buss bar.
NOTE: Make sure all electrical switches except the ignition switch are in the OFF position. Have another person hold the ignition switch
in the START position.
Terminal for wire 622D to ground 12 volts Check the circuit between the starter relay and the ignition switch (7). Also
check the ignition switch (7).
Terminal for wire 625A to ground 12 volts Bad starter relay.

4001-9
7 Ignition Switch
Terminal for wire 130D to ground 12 volts Check the circuit between the ignition switch and the 15 amp circuit
breaker. Also check the 15 ampere circuit breaker.
NOTE: Remove the Instrument Cluster from the right side A post. Uncouple the 26 pin connector from the Instrument Cluster. Uncouple
the 4 pin connector from the Key Switch. Turn the ignition switch to the ON position.
Check between the BAT terminal and the Continuity Bad ignition switch.
IGN terminal of the ignition switch
ACC terminal of the ignition switch
NOTE: Have another person hold the ignition switch to the START position.
START terminal of the ignition switch
IGN terminal of the ignition switch

4001-10
1. BATTERY 5. STARTER RELAY

2. ALTERNATOR 6. RESISTOR (50 OHM)
3. STARTER AND SOLENOID 7. IGNITION SWITCH
4. CIRCUIT BREAKERS
ELECTRICAL SCHEMATIC FRAME 1

4001-11
8 Main Power Relay
Terminal for wire 178B to ground Continuity Bad ground circuit.
Terminal for wire 190A to ground 12 volts Check the circuit between the main power relay and the 40 ampere circuit
breaker in the buss bar. Also check the 40 ampere circuit breaker and the
buss bar.
Terminal for wire 131C to ground 12 volts Check the circuit between the main power relay and the ignition switch (7)
Frame 1. Also check the ignition switch (7) Frame 1. Also check the reverse
polarity diode (10).
Terminal for wire 136A to ground 12 volts Bad main power relay.
Terminal for wire 137F to ground 12 volts Check the circuit between the main fuse block and the main power relay.
Also check the main power relay.
9 Options Power Relay

Terminal for wire 178AH to ground Continuity Bad ground circuit.
Terminal for wire 180A to ground 12 volts Check the circuit between the options power relay and the circuit breaker.
Also check the circuit breaker.
Terminal for wire 137D to ground 12 volts Check the circuit between the options power relay and the ignition switch
(7) Frame 1 “ACC” position. Also check the ignition switch (7) Frame 1.
Terminal for wire 138A to ground 12 volts Bad options power relay.
11 Primary Fuse Block

Terminal for wire 136A to ground 12 volts Bad main power relay (8).
Terminal for wire 137F to ground 12 volts Check the circuit between the fuse block and the main power relay (8). Also
check the main power relay (8).
Terminal for wire 780A to ground 12 volts Bad 20 ampere fuse or missing fuse.
Terminal for wire 830A and 610A to ground 12 volts Bad 25 ampere fuse or missing fuse.
Terminal for wires 890A and 895A to 12 volts Bad 10 ampere fuse or missing fuse.
ground
Terminal for wire 200H to ground 12 Volts Check the circuit between the fuse block and the ignition switch (5). Also
check the ignition switch (5).

4001-12
12 Options Fuse Block
Terminal for wire 138A to ground 12 volts Check the circuit between the options fuse block and the primary fuse block
(11). Also check the primary fuse block (11).
Terminal for wires 817A and 817F to 12 volts Bad 15 ampere fuse or missing fuse.
ground
Terminal for wires 751D and 751F to 12 volts Bad 10 ampere fuse or missing fuse.
ground
Terminal for wires 540B and 540C to 12 volts Bad 10 ampere fuse or missing fuse.
ground

4001-13
8. MAIN POWER RELAY 11. PRIMARY FUSE BLOCK

9. OPTIONS POWER RELAY 12. OPTIONS FUSE BLOCK
10. DIODE (REVERSE POLARITY)

4001-14
15 Fuel Hold In Solenoid
Between the housing of the solenoid and Continuity Bad ground connection.
ground
NOTE: Turn the key switch to the RUN position. Have someone sit in the operators seat with the seat bar in the down position.
Terminal for wire IVC3 to ground 12 volts Check the circuit between the fuel hold in solenoid and the interlock relay
(18) Frame 5. Also check the interlock relay (18) Frame 5.

4001-15
13. NOT USED 15. FUEL HOLD-IN SOLENOID

14. FUEL PUMP

4001-16
16. COIL 17. GLOW PLUGS


4001-17
18 Interlock Relay
Terminal for wire 178E to ground Continuity Bad ground circuit.
NOTE: Turn the key switch to the RUN position. Have someone sit in the operators seat with the seat bar in the down position.
Terminal for wire 300B to ground 12 volts Check the circuit between the interlock relay and the 15 ampere fuse in the
primary fuse block (11) Frame 2. Also check the 15 ampere fuse and the
fuse block (11) Frame 2.
Terminal for wire 303D to ground 12 volts Check the circuit between the interlock relay and the seat bar switch. Also
check the seat bar switch. Also check the instrument cluster.
Terminal for wire 311B to ground 12 volts Bad interlock relay.
19 Seat Switch
NOTE: Remove the Instrument Cluster from the right side A post. Uncouple the 26 pin connector from the Instrument Cluster. Sit in the
operators seat.
Pin 12 on the 26 pin wiring harness connec- Approximately Check the 15 ampere fuse in the primary fuse block (11) Frame 2. Check
tor to ground 12 volts the seat switch. Check fro wiring continuity from the pin 12 pin of the instru-
ment cluster connector to the 15 amp fuse. Also check the 30 pin connector
cavity C1.
20 Seat Bar Switch

Terminal for wire 178E to ground Continuity Bad ground connection through wire.
NOTE: Remove the Instrument Cluster from the right side A post. Have another person sit in the operators seat and move the seat bar
down to the operating position. Turn the ignition switch to the RUN position. Visually observe the flashing LED next to the loader enable
button. Have another person push and release the button.
Terminal 12 of the instrument cluster con- Approximately Ensure continuity from the 15 amp fuse in the buss bar, through the seat
nector. 12 volts switch to the instrument cluster connector pin 12.
Terminal for wire 311B at the interlock relay Approximately Check the 15 amp fuse in the primary fuse block (11) Frame 2.
to ground. 12 volts
Terminal for wire 303D at the coil of the
interlock relay (terminal 86) to ground.
Instrument cluster 26 pin connector pin 14.
Loader valve solenoid wire 311F. Approximately Check the circuit from the loader valve solenoids to wire 3311B at the relay
12 volts contact to ground.
Check the interlock relay. Check the circuit fro wire 300B from the interlock
relay terminal 30 to the 15 amp fuse in the primary fuse block (11) Frame 2.

4001-18
22 and 23 Loader Valve Solenoids
Terminal for wire 178K to ground Continuity Bad ground circuit.
Terminal for wire 178BD to ground Continuity Bad ground circuit.
NOTE: Turn the ignition switch to the RUN position. Have someone sit in the operators seat with the seat bar in the down position.
Ensure that the cab door (if installed) is closed and latched.
Terminal for wire 311G to ground 12 volts Check the circuit between the loader valve solenoid and the cab door
switch (48) Frame 10. Also check the cab door switch (48) Frame 10
NOTE: If the front door option is not installed, check the diode installed in
the front door interlock connector in the cab harness.
Terminal for wire 311H to ground 12 volts Check the circuit between the loader valve solenoid and splice 14.
NOTE: If the readings are ok, check with a screwdriver to see whether the solenoid magnetizes when energized. If not, replace the sole-
noid. If the solenoid magnetizes, the problem may be in the hydraulic system.
24 Brake Release Solenoid

NOTE: Disconnect the connector from the brake solenoid. Have someone sit in the seat with the seat bar in the down position. Turn the
ignition switch to the RUN position.
Instrument cluster pin 8 or terminal for wire Approximately 0 Bad instrument cluster output.
258B to ground. volts
Terminal for wire 178CJ to ground Continuity Bad solenoid ground.
Push and release the park brake button on Approximately Bad instrument cluster output.
the instrument cluster. 12 volts
Instrument cluster pin 8 or terminal for wire
258B to ground.
Reconnect the connector to the brake sole- Approximately Check the circuit for wire 258B to the instrument cluster.
noid. 12 volts
Terminal for wire 258B at the brake sole-
noid to ground

4001-19
18. INTERLOCK RELAY 22. LOADER VALVE SOLENOID

19. SEAT SWITCH 23. LOADER VALVE SOLENOID
20. SEAT BAR SWITCH 24. BRAKE RELEASE/TANDEM PUMP NEUTRAL OVERRRIDE
21. NOT USED SOLENOID
25. OPTION NOT AVAILABLE 410 AND 420

4001-20
Instrument Cluster
NOTE: See Troubleshooting Electronic Instrument Cluster (EIC) in this Section.
27 Hydraulic Filter Pressure Switch

Check between the housing of the Continuity Bad ground connection between the hydraulic filter pressure switch and
hydraulic filter pressure switch and the fil- the filter housing.
ter housing.
Check between switch housing and Continuity Bad ground connection between filter housing and frame.
engine ground.
Terminal for wire 261A to ground Approximately Check the circuit between the hydraulic filter pressure switch and the
12 volts instrument cluster. Also check the instrument cluster.
If the readings are good, replace the hydraulic filter pressure switch.
28 Hydraulic Oil Temperature Sender

Disconnect the connector from the For tempera- Temperature of oil outside of range indicated.
hydraulic oil temperature sender and use tures greater Bad sender.
a voltmeter set to read resistance. than 60o F the
Measure the resistance from the sender sender resis-
terminal to the machine frame. tance should
measure
between 4300
ohms 60o F
and 180 ohms
212o F.
Reconnect the connector to the hydraulic For tempera- Temperature of oil outside of range indicated.
oil temperature sender. tures greater Bad sender.
Remove the instrument cluster and dis- than 60o F the bad wiring to the sender.
connect the 26 pin connector from the sender resis-
instrument cluster. tance should
Measure the resistance from terminal 2 to measure
terminal 20 of the 26 pin connector in the between 4300
wiring harness. ohms 60o F
and 180 ohms
212o F.

4001-21
29 Engine Coolant Temperature Sender
Disconnect the connector from the For tempera- Temperature of oil outside of range indicated.
engine coolant temperature sender and tures greater Bad sender.
use a voltmeter set to read resistance. than 60o F the
Measure the resistance from the sender sender resis-
terminal to the machine frame. tance should
measure
between 4300
ohms 60o F
and 180 ohms
212o F.
Reconnect the connector from the engine For tempera- Temperature of oil outside of range indicated.
coolant temperature sender. tures greater Bad sender.
Remove the instrument cluster and dis- than 60o F the Bad wiring to sender.
connect the 26 pin connector from the sender resis-
instrument cluster. tance should
Measure the resistance from terminal 25 measure
to terminal 20 of the 26 pin connector in between 4300
the wiring harness. ohms 60o F
and 180 ohms
212o F.
30 Air Filter Restriction Switch

Terminal for wire 178G to ground. Continuity Bad ground circuit.
Terminal for wire 266C to ground Approximately Check the circuit between the air filter restriction switch and the instru-
12 volts ment cluster connector pin 16.
Also check the instrument cluster.
Remove the switch from the air filter and Continuity Bad switch.
apply 64m bar vacuum to the port.
31 Fuel Level Sender

NOTE: Check the level of fuel in the fuel tank.
Check between the housing of the fuel Continuity Bad ground connection inside the fuel level sender.
level sender and the engine block.
NOTE: Disconnect the connector for wire 234A from the fuel sender.
Terminal for wire 234A to ground Approximately Check for continuity between the fuel level sender and the instrument
12 volts cluster pin 1. Also check the instrument.
When the tank is full the resistance should be 80 ohms or less.
If the tank is empty, the resistance should be 180 ohms or greater. If the
ohmmeter readings are not correct, replace the fuel level sender.

4001-22
32 Engine Oil Pressure Switch
Check between the housing of the engine Continuity Bad sensor internal ground connection between the engine oil pressure
oil pressure switch and the engine block. switch and the engine block.
NOTE: Turn the ignition switch to the RUN position. Disconnect the connector from the engine oil pressure switch.
Terminal for wire 255C to ground Approximately Check the circuit between the engine oil pressure switch and the instru-
12 volts ment cluster. Also check the instrument cluster.
NOTE: Connect the connector to the engine oil pressure switch. Turn the ignition switch to the RUN position. Engine should not be
running.
Terminal for wire 255C to ground Approximately Bad engine oil pressure switch.
0 volts
NOTE: Start and run the engine at low idle.
Terminal for wire 255C to ground Approximately Engine oil pressure less than 70 kPa (10 psi).
12 volts

4001-23
26. NOT USED 30. AIR FILTER RESTRICTION SWITCH

27. HYDRAULIC FILTER PRESSURE SWITCH 31. FUEL SENDER
28. HYDRAULIC OIL TEMPERATURE SENDER 32. ENGINE OIL PRESSURE SWITCH
29. ENGINE COOLANT TEMPERATURE SENDER 33. CHARGE PRESSURE SWITCH

4001-24
Work/Road Light Switch
NOTE: See Troubleshooting Electronic Instrument Cluster (EIC) in this Section.
37 Left Front Work Lamp

Terminal for wire 178X to ground Continuity Bad ground circuit.
Bulb Good Bad bulb.
NOTE: Turn the ignition switch to the RUN position. Push and release the work/road light switch i on the instrument cluster.
Terminal for wire 783F to ground 12 volts Check the circuit between the left front work lamp and the work/road light
switch. Also check the work/road light switch.
38 Right Front Work Lamp

Terminal for wire 178R to ground Continuity Bad ground circuit.
Bulb Good Bad bulb.
NOTE: Turn the ignition switch to the RUN position. Push and release the work/road light switch i on the instrument cluster.
Terminal for wire 783G to ground 12 volts Check the circuit between the right front work lamp and the work/road
light switch. Also check the work/road light switch.
39 Rear Work Lamp

Terminal for wire 178F to ground Continuity Bad ground circuit.
Bulb Good Bad bulb.
NOTE: Turn the ignition switch to the RUN position. Push and release the work lamp button on the instrument cluster.
Terminal for wire 784A to ground 12 volts Check the circuit between the rear work lamp and light relay No. 2. Also
check light relay No. 1.
Also check the instrument cluster.
40 Left Rear Indicator Lamp

Terminal for wire 178L to ground Approximately Bad ground circuit

12 volts
Bulb Good Bad bulb.
NOTE: Turn the ignition switch to the RUN position. Push and release the light button on the instrument cluster.
Terminal for wire 706B to ground 12 volts Check the circuit between the rear positional lamp lamps and the light
relay No. 2.
Also check the light relay No. 2.

4001-25
41 Right Rear Indicator Lamp
Terminal for wire 178W to ground Approximately Bad ground circuit

12 volts
Bulb Good Bad bulb.
NOTE: Turn the ignition switch to the RUN position. Push and release the light button on the instrument cluster.
Terminal for wire 706C to ground 12 volts Check the circuit between the rear positional lamp lamps and the light
relay No. 2.
Also check the light relay No. 2.

4001-26
34. DIODE 38. RIGHT FRONT WORKLIGHT

35. LIGHT RELAY NO. 1 39. REAR WORKLIGHT
36. LIGHT RELAY NO.2 40. LEFT REAR INDICATOR LAMP
37. LEFT FRONT WORKLIGHT 41. RIGHT REAR INDICATOR LAMP

4001-27
44 Horn
Terminal for wire 178M to ground Continuity Bad ground circuit.
NOTE: Turn the ignition switch to the RUN position. Have another person hold down the horn switch.
Terminal for wire 892A to ground 12 volts Check the circuit between the horn and the horn switch (92) Frame
25. Also check the horn switch (92) Frame 25.
NOTE: If the readings are good and the horn does not work, replace the horn.

4001-28
44. HORN

4001-29
45 Backup Alarm Switch (Left)
NOTE: Place the Skid Steer Loader on acceptable supports so that all four wheels are off the ground. Disconnect the electrical con-
nector from backup alarm switch (Left). Turn the ignition switch to the RUN position.
Check between the switch terminal for Approximately Check the circuit between backup alarm switch terminal 42 and the
wire 895A to ground 12 volts 10 ampere fuse in the primary fuse block (11) Frame 2. Also check
the 10 ampere fuse and the primary fuse block (11) Frame 2.
Check between opposite ends of wire Continuity Bad circuit between backup alarm switches.
895B.
Check between the terminals of each Open Bad backup alarm switch (Left).
individual backup alarm switch.
Start the engine and run at low idle. Continuity Bad backup alarm switch (Left).
Have another person move the control
levers to the REVERSE position.
Check between the terminals of each
untidily backup alarm switch.
46 Backup Alarm Switch (Right)

nector from backup alarm switch (Right). Turn the ignition switch to the RUN position.
Check between the switch terminal for Approximately Check the circuit between backup alarm switch terminal 42 and the
wire 895A to ground 12 volts 10 ampere fuse in the primary fuse block (11) Frame 2. Also check
the 10 ampere fuse and the primary fuse block (11) Frame 2.
Check between opposite ends of wire Continuity Bad circuit between backup alarm switches.
895B.
Check between the terminals of each Open Bad backup alarm switch (Right).
Start the engine and run at low idle. Continuity Bad backup alarm switch (Right).
Have another person move the control
levers to the REVERSE position.
Check between the terminals of each

4001-30
47 Backup Alarm
nector from backup alarm switch (Left). Turn the ignition switch to the RUN position. Have another person move the control handles to
the REVERSE position.
Terminal for wire 178N to ground. Continuity Bad ground circuit.
Check between the backup alarm and the Approximately Bad backup alarm.
terminal for wire 897A to ground 12 volts
NOTE: If the readings are good but the backup alarm doesn’t sound, replace the backup alarm.

4001-31
45. BACKUP ALARM SWITCH (LEFT) 47. BACKUP ALARM

46. BACKUP ALARM SWITCH (RIGHT)

4001-32
48 Cab Door Switch
NOTE: Disconnect the connector from the cab door switch. Cab door should be open.
Between the terminal for the white wire and Open Bad cab door switch.
the terminal for the black wire for the cab
door switch.
NOTE: Close and latch the cab door.
Between the terminal for the white wire and Continuity Bad cab door switch.
the terminal for the black wire for the cab
door switch.
NOTE: Have someone sit in the seat with the seat bar in the down position. Turn the ignition switch to the RUN position.
Terminal for wire 313G to ground 12 volts Check the circuit between the cab door switch and the loader lock out relay
(84) Frame 22. Also check the loader lock out relay (84) Frame 22.

4001-33
48. CAB DOOR SWITCH 48A. WIPER/WASHER SWITCH


4001-34
49 High Flow Switch
NOTE: Have someone sit in the seat with the seat bar in the down position. Turn the ignition switch to the RUN position.
Terminal for wire 751E to ground 12 volts Check the circuit between the high flow switch and the 10 amp fuse in the
options fuse block (12) Frame 2.
NOTE: Have another person hold the high flow switch in the FWD position.
Terminal for wire 535A to ground 12 volts Bad high flow switch or internal handle wiring. Disassemble handle and
check the circuit between the high flow switch and the connector. If OK,
replace the high flow switch.
52 Forward High Flow Solenoid

Terminal for wire 178DC to ground Continuity Bad ground circuit.
NOTE: Have someone sit in the seat with the seat bar in the down position. Turn the ignition switch to the RUN position. Have the other
person hold the high flow switch in the FWD position.
Terminal for wire 545B to ground 12 volts Check the circuit between the forward high flow solenoid and the high flow
switch (49). Also check the high flow switch (49).
53 Reverse High Flow Solenoid

Terminal for wire 178DD to ground Continuity Bad ground circuit.
NOTE: Have someone sit in the seat with the seat bar in the down position. Turn the ignition switch to the RUN position. Have the other
person hold the high flow switch in the REV position.
Terminal for wire 546CB to ground 12 volts Check the circuit between the reverse high flow solenoid and the high flow
switch (49). Also check the high flow switch (49).

4001-35
49. ELECTRO-HYDRAULIC HIGH FLOW SWITCH 52. FORWARD SOLENOID

50. DIODE 53. REVERSE SOLENOID
51. COMBINATION SOLENOID

4001-36
54 Ride Control Solenoid
Check between the housing of the ride Continuity Bad ground connection.
control solenoid and ground
NOTE: Turn the ignition switch to the RUN position. Have another person press and hold the ride control switch.
Terminal for wire 548B to ground 12 volts Check the circuit between the ride control solenoid and the ride control
switch (93) Frame 25. Also check the ride control switch (93) Frame 25.

4001-37
54. RIDE CONTROL SOLENOID


4001-38
55 Rotating Beacon Switch
Terminal for wire 540C to ground 12 volts Check the circuit between the rotating beacon switch and the 10
ampere fuse in the options fuse block (12) Frame 2. Also check the
10 ampere fuse and options fuse block (12) Frame 2.
Place the rotating beacon switch in the 12 volts Bad rotating beacon switch.
ON position. If the readings are correct and the indicator lamp on the rotating bea-
Terminal for wire 766A to ground con switch does not illuminate, proceed to the next test
Terminal for wire 178AJ to ground Continuity Bad ground circuit for rotating beacon switch indicator lamp. Bad rotating
beacon switch.
If the readings are correct and the indicator lamp on the rotating bea-
con switch does not illuminate, replace the rotating beacon switch.
NOTE: If the readings were correct and the indicator lamp on the rotating beacon switch does not illuminate, replace the rotating bea-
con switch.
56 Rotating Beacon
Between the terminals of the lamp Good Bad bulb.
Terminal for wire 178Y to ground Continuity Bad ground circuit.
NOTE: Turn the ignition switch to the RUN position. Place the rotating beacon switch in the ON position.
Terminal for wire 766A to ground 12 volts Check the circuit between the rotating beacon and the rotating beacon
switch (55). Also check the rotating beacon switch (55).
NOTE: If the readings are good, replace the rotating beacon.

4001-39
55. ROTATING BEACON SWITCH 56. ROTATING BEACON


4001-40
Electrical Accessory Outlet (Optional)
Terminal for wire 178AD to ground Continuity Bad ground circuit.
NOTE: Turn the ignition switch to the ACC position.
Terminal for wire 817B to ground 12 volts Check the circuit between the accessory outlet and the 10 ampere fuse in
the options fuse block (12) Frame 2. Also check the 10 ampere fuse and
the options fuse block (12) Frame 2.
NOTE: If the readings are good, replace the electric accessory socket.

4001-41

4001-42
57 Hydraulic Coupler Switch
NOTE: Turn the ignition switch to the ON position.
Terminal for wire 178BF to ground Continuity Bad ground circuit.
Terminal for wire 540A to ground 12 volts Check the circuit between the hydraulic coupler switch and the 10
ampere fuse in the options fuse block (12) Frame 2. Also check the 10
ampere fuse and the options fuse block (12) Frame 2.
NOTE: Have another person hold the hydraulic coupler switch in the UNLATCH position.
Terminal for wire 547A to ground 12 volts Bad hydraulic coupler switch.
NOTE: Have another person hold the hydraulic coupler switch in the LATCH position.
Terminal for wire 547A to ground 0 volts Bad hydraulic coupler switch.
59 Hydraulic Coupler Release Solenoid

Terminal for wire 178BB to ground Continuity Bad ground circuit.
NOTE: Turn the ignition switch to the ON position. Have another person hold the hydraulic coupler switch in the UNLATCH position.
Terminal for wire 547 to ground 12 volts Check the circuit between the hydraulic coupler release solenoid (59)
and the hydraulic coupler switch (57). Also check the hydraulic coupler
switch (57).
If the readings are good, replace the hydraulic coupler release solenoid
(59).
NOTE: If the readings are ok, check with a screwdriver to see whether the solenoid magnetizes when energized. If not, replace the
solenoid. If the solenoid magnetizes, the problem may be in the hydraulic system.

4001-43
57. HYDRAULIC COUPLER SWITCH 59. HYDRAULIC COUPLER RELEASE SOLENOID

58. DIODE

4001-44
Dome Lamp with Switch
Bulb Continuity Bad bulb.
Terminal for wire 178Z to ground Continuity Bad ground circuit.
Terminal for wire 540G to ground Approxi- Check the circuit between the dome lamp and the ignition switch (7)
mately 12 Frame 1. Also check the ignition switch (7) Frame 1.
volts
NOTE: If the readings are good, replace the dome lamp.
62 Fan Speed Switch

Terminal for wire ET000H to ground 12 volts Check the circuit between the heater blower switch and the 20 ampere
fuse in the primary fuse block (11) Frame 2. Also check the 20 ampere
fuse and the primary fuse block (11) Frame 2.
NOTE: Place the fan speed switch in the LOW position.
Terminal for wire ET003C to ground 12 volts Bad fan speed switch.
NOTE: Place the fan speed switch in the MEDIUM position.
NOTE: Place the fan speed switch in the HIGH position.
NOTE: If the readings are bad, replace the fan speed switch.

4001-45
61. HEAT CONTROL SWITCH 65. OPTION NOT AVAILABLE 410 AND 420
62. FAN SPEED SWITCH 66. OPTION NOT AVAILABLE 410 AND 420
63. BLOWER MOTOR 67. OPTION NOT AVAILABLE 410 AND 420
64. OPTION NOT AVAILABLE 410 AND 420

4001-46

4001-47

4001-48
70 Starting Interlock Relay
Terminal for wire 178DF to ground Continuity Bad ground circuit.
NOTE: Turn the ignition switch to the ON position. Have someone sit in the operators seat with the seat bar in the down position.
Terminal for wire 622D to ground Approxi- Check the circuit between the starting interlock relay and the ignition
mately 12 switch (7) Frame 1. Also check the ignition switch (7) Frame 1.
volts
Terminal for wire 624A to ground Approxi- Check the circuit between the starting interlock relay and the instrument
mately 12 cluster pin 26. Also check the instrument cluster pin 26.
volts
Terminal for wires 320A and 320B to Approxi- Bad starting interlock relay.
ground mately 12
volts

4001-49
69. AUXILIARY HYDRAULIC NEUTRAL SWITCH 71. FUEL SOLENOID RELAY

70. STARTING INTERLOCK RELAY 72. DIODE

4001-50
73. HAZARD SWITCH 75. DIODE PACK

74. FLASHER MODULE

4001-51
60. LEFT FRONT HEADLAMP 78. RIGHT FRONT TURNLIGHT

68. RIGHT FRONT HEADLIGHT 80. LEFT FRONT POSITION LIGHT
76. LEFT REAR TURNLIGHT 81. RIGHT FRONT POSITION LIGHT
77. RIGHT REAR TURNLIGHT 82. LICENSE PLATE LIGHT
78. LEFT FRONT TURNLIGHT 83. RESISTOR

4001-52
BC04M092-22
84. LOADER LOCKOUT SWITCH (OPTIONAL)

4001-53
BC04M092-23
85. NOT USED 87. RIGHT BRAKE LIGHT SWITCH (EURO)
86. LEFT BRAKE LIGHT SWITCH (EURO) 88. BRAKE LIGHT SWITCH TIMER RELAY (EURO)

4001-54
90 Turn Signal Switch
Terminal for wire 540AA to ground Approximately Check the circuit between the turn signal switch and the 10 amp fuse in the
12 volts options fuse block (12) Frame 2. Also check the 10 amp fuse in the options
fuse block (12) Frame 2.
Place the turn signal switch in the LEFT Approximately Bad turn signal switch.
turn position. 12 volts Replace turn signal switch.
Terminal for wire 757AA to ground.
Place the turn signal switch in the RIGHT Approximately Bad turn signal switch.
turn position. 12 volts Replace turn signal switch.
Terminal for wire 756AA to ground.
91 Attachment Hydraulic Switch

NOTE: Have another person sit in the operators seat. Pull the seat bar down to the operating position. Turn the ignition switch to the ON
position.
Push and release the hydraulic attachment Approximately Check the circuit for wire 311AB or 311BC or 311BD to the instrument clus-
switch. 12 volts ter connector pin 26.
Terminal for wire 311AB or 311BC or Also check the instrument cluster.
311BD to ground
Disconnect connector 123B or 123C or Approximately Bad hydraulic attachment switch.

123D. 12 volts
Have another person hold the switch in the
FORWARD flow position.
Terminal for wire 545AB or 545AC or
545AD to ground.
Have another person hold the switch in the Approximately Bad hydraulic attachment switch.
REVERSE flow position. 12 volts
Terminal for wire 546AB or 546AC or
546AD to ground.
98 Attachment Hydraulic Forward Flow “ON” Switch

NOTE: Have another person sit in the operators seat. Pull the seat bar down to the operating position. Turn the ignition switch to the ON
position.
Push and release the hydraulic attachment Approximately Check the circuit for wire 311CB or 311CC or 311CD to the instrument clus-
forward flow “ON” switch. 12 volts ter connector pin 26.
Terminal for wire 311CB or 311CC or Also check the instrument cluster.
311CD to ground
Place the hydraulic attachment forward flow Approximately Bad hydraulic attachment forward flow “ON” switch.
“ON” switch in the FORWARD position. 12 volts
Terminal for wire 545BB or 545BC or
545BD to ground.

4001-55
89. TWO (2) SPEED SWITCH 91. ATTACHMENT HYDRAULIC SWITCH

90. TURN SIGNAL SWITCH 98. ATTACHMENT HYDRAULIC FORWARD FLOW “ON”
SWITCH

4001-56
92 Horn Switch
NOTE: Disconnect the horn switch connector.
Measure the resistance across the termi- Open Bad horn switch.
nals of the switch.
Have another person push and hold the Continuity Bad horn switch.
horn button down.
Measure the resistance across the termi-
nals of the switch.
NOTE: Reconnect the horn switch connector. Turn the ignition switch to the ON position.
Have another person push and hold the Approximately Check the circuit between the terminal for wire 892A and the horn button.
horn button down. 12 volts Check the circuit between the horn button and the 10 amp fuse in the pri-
Terminal for wire 892A at the horn. mary fuse block (11) Frame 2.
Also check the horn button.
Also check the 10 amp fuse in the primary fuse block (11) Frame 2.
94 Front Electric Control Switch No. 1

Terminal for wire 178BJ to ground Continuity Bad ground circuit.
Terminal for wire 003O to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and
the front electric control switch No. 1.
Also check the front electric control switch No. 1.
NOTE: Turn the ignition switch to the ON position. Place the front electric control switch No. 1 in the UP position.
Terminal for wire 001B to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and
NOTE: Turn the ignition switch to the ON position. Place the front electric control switch No. 1 in the DOWN position.
Terminal for wire 002D to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and

4001-57
Terminal for wire 004R to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and
Terminal for wire 005Y to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and

Terminal for wire 006P to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and
Terminal for wire 007T to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and

NOTE: Turn the ignition switch to the ON position. Place the front electric control switch No. 4 in the ON position.
Terminal for wire 008W to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and

4001-58
92. HORN SWITCH 95. FRONT ELECTRIC CONTROL SWITCH NO. 2

93. RIDE CONTROL SWITCH 96. FRONT ELECTRIC CONTROL SWITCH NO. 3
94. FRONT ELECTRIC CONTROL SWITCH NO. 1 97. FRONT ELECTRIC CONTROL SWITCH NO. 4

4001-59

4001-60
CONNECTORS Connector 7 Starter Relay

SCHEMATIC FRAME 1
Connector 4 Alternator
245731C1
Cavity Circuit ID Description
PAC_12186568 30 170A (R) 5.0 From 40 amp circuit

breaker to connector 7
Cavity Circuit ID Description pin 30
A 124A (R) 1.0 To connector 8A pin B4 85 178A (B) 2.0 From start relay to
ground
B 121B From Alternator to 50
ohm resistor 85 178B (B) 1.0 From start relay to main
power relay
86 622D (W) 1.0 To connector 127A pin B
87 625A (W) 3.0 From start relay to

starter solenoid
Connector 8
A1 130B (R) 2.0 From connector 9 pin C
B2 131B (R) 1.0 From connector 9 pin B
A3 137A (R) 3.0 From connector 9 pin D
B3 622B (W) 1.0 From connector 9 pin A
256357A1

4001-61
Connector 8A Connector 9 Ignition Switch
256356A1 PAC_12052856
Cavity Circuit ID Description Cavity Circuit ID Description
A1 130A (R) 2.0 From 15 amp circuit A 622B (W) 1.0 To connector 8 pin B3
breaker
B 131B (R) 1.0 To connector 8 pin B2
B2 131A (R) 1.0 To connector 25pin A
C 130D (R) 2.0 To connector 8 pin A1
A3 137C (R) 3.0 To primary fuse block
D 137B (R) 0.8 to instrument cluster pin
terminal 2
10 “ACC”
B3 622A (W) 1.0 From connector 127pin
D 137A (R) 3.0 To connector 8 pin A3
B
Connector 52
FRA54201016
8 137K (R) 1.0 To connector 21
9 121A (Y) 1.0 To connector 20
10 625A (W) 3.0 To connector 7 pin 85

4001-62
Connector 52A Connector 25
FRA54201009 CNH_STYLE_24
9 121B (Y) 1.0 From connector 4 pin B A 131A (R) 1.0 From connector 8A pin
B2
10 625D (W) 5.0 From connector 106
B 131C (R) 1.0 To connector 14 pin 86
CONNECTORS
SCHEMATIC FRAME 2 Connector 64 Options Power Relay
Connector 14 Main Power Relay
245731C1

245731C1
30 180A (R) 5.0 From 40 amp circuit

Cavity Circuit ID Description breaker
30 180A (R) 5.0 From 40 amp circuit 85 178H (B) 1.0 To ground
breaker
86 137D (R) 1.0 From connector 17A
85 178B (B) 1.0 To ground pin A
85 178E (B) 1.0 To ground 87 138A (R) 5.0 To options fuse block T3
86 131C (R) 1.0 To reverse polarity diode

connector 25 pin B
87 136A (R) 5.0 To primary fuse block T4

4001-63
CONNECTORS Connector 8
SCHEMATIC FRAME 3
Connector 60
1 IVC2 (B) 0.8 From splice
2 IVC4 (B) 0.8 To cold start advance

solenoid
256357A1

CONNECTORS
C1 311D (T) 1.0 To connector 50 pin B
SCHEMATIC FRAME 5
D2 300E (R) 1.0 To connector 23 pin 24
Connector 8A “IGN ON”
C2 303C (T) 0.5 To connector 59 pin A
D4 258C (T) 0.5 To connector 23 pin 8
J2 602B (W) 0.5 To connector 23 pin 5
D1 319A (T) 0.5 To connector 23 pin 26
H2 311C (T) 1.0 To connector 50 pin A
256356A1
C1 311F (T) 1.0 From splice 14
D2 300D (R) 1.0 From splice
C2 303D (T) 1.0 From connector 18 pin

86
D4 258B (T) 1.0 From connector 80 pin 1
J2 602A (W) 1.0 From connector 127 pin

A
D1 319B (T) 1.0 From connector 79 pin A
H2 311B (P) 1.0 From connector 18 pin

87

4001-64
Connector 18 Interlock Relay Connector 50
245731C1 CNH_STYLE_24
30 300B (R) 2.0 From splice A 311C (T) 1.0 From connector 8 pin H2
85 178E (B) 1.0 To ground B 311D (T) 1.0 From connector 8 pin J2
86 303D (T) 1.0 To connector 8A pin C2
87 311B (P) 1.0 To connector 8A pin H2
Connector 23 Instrument Cluster
AMP_3_1437290_8
12 323A (T) 0.5 From connector 58 pin B
14 313D (T) 0.8 To connector 59 pin A
8 258C (T) 0.5 To connector 8 pin D4
5 602B (W) 0.5 To connector 8 pin J2
26 319A (T) 0.5 To connector 8 pin D1
4 754A (P) 0.5 To connector 97A pin B

4001-65
Connector 57 Connector 59
256340A1 253294A1
A 178K (B) 1.0 To ground A 313D (T) 0.8 To connector 23 pin 14

seat bar switch
B 311G (T) 1.0 From splice 14
B 303C (T) 0.8 From connector 8 pin C2
Connector 58
Connector 79
253294A1‘
256340A1
A 130E (R) 0.8 From splice
A 319C (T) 1.0 From connector 8 pin D1
B 323A (T) 0.8 To connector 23 pin 12
B 565A (T) 1.0 From connector 48 pin B

4001-66
225316C1 256346A1
1 258B (T) 1.0 From connector 8A pin A 602A (W) 1.0 From connector 8A pin
D4 J2
2 178CJ (B) 1.0 To ground B 622A (W) 1.0 From connector 8A pin
B3
C 319D (T) 1.0 From splice
D 178CJ (B) 1.0 To ground
Connector 103
Connector 127A
256340A1
256346A1
A 178D (B) 1.0 To ground
A 602G (W) 1.0 To fuel hold-in solenoid
B 311H (T) 1.0 From splice 14
B 622D (W) 1.0 From start relay
connector 7 pin 86

4001-67
CONNECTORS Connector 8A
SCHEMATIC FRAME 6
Connector 8
256356A1
256357A1 D3 641A (W) 1.0 To grid heater relay
Cavity Circuit ID Description G2 261A (Y) 1.0 From hydraulic filter

pressure switch
D3 641B (W) 0.5 To connector 23 pin 7
G4 264A (Y) 1.0 From hydraulic oil
G2 261B (Y) 0.5 To connector 23 pin 15 temperature sender
G4 264B (Y) 0.5 To connector 23 pin 2 G1 257A (Y) 1.0 From engine coolant
temperature sender
G1 257B (Y) 0.5 To connector 23 pin 25
J1 266A (Y) 1.0 From air filter restriction
J1 266B (Y) 0.5 To connector 23 pin 16 switch
F1 234B (Y) 0.5 To connector 23 pin 1 F1 234A (Y) 1.0 From fuel sender
E4 255B (Y) 0.5 To connector 23 pin 18 E4 255A (Y) 1.0 From engine oil pressure
switch
G3 262A (Y) 0.5 To connector 23 pin 17
G3 262B (Y) 1.0 From charge pressure
B4 124B (R) 0.5 To connector 23 pin 19
switch
K1 200C (B/W) 0.5 To connector 23 pin 20
B4 124C (R) 1.0 From connector 52 pin 4
K1 200D (B/W) To ground

1.0

4001-68
Connector 23 Instrument Cluster Connector 29
AMP_3-1437290-8 291718A1
3 130C (R) 0.5 From splice 1 266C (Y) 1.0 To connector 52A pin 1
24 300H (R) 0.5 From splice (Key “ON”) 2 178G (B) 1.0 to ground
23 300G (R) 0.5 From splice (Key “ON”)
10 137B (R) 0.8 Form connector 9 pin D

(Key “ACC”)
Connector 30
21 781A (P) 0.5 To connector 8 pin H1
22 782A (P) 0.5 To connector 8 pin E1
7 641B (W) 0.5 To connector 8 pin D3
15 261B (Y) 0.5 To connector 8 pin G2
16 266B (Y) 0.5 To connector 8 pin J1
1 234B (Y) 0.5 To connector 8 pin F1 245482C1
18 255B (Y) 0.5 To connector 8 pin E4 Cavity Circuit ID Description
17 262A (Y) 0.5 To connector 8 pin G3 A 178CK (B) To ground

1.0
19 124B (R) 0.5 To connector 8 pin B4
B 262B (Y) 1.0 From connector 8A pin
20 200C (B/W) Clean ground G3
0.5

4001-69
Connector 52 Connector 52A
FRA_54201009 FRA_54201016
1 266A (Y) 1.0 From connector 8A pin 1 266C (Y) 1.0 From connector 29 pin 1
J1
2 255C (Y) 1.0 From connector 27 pin
2 255A (Y) 1.0 From connector 8A pin
E4 3 257C (Y) 1.0 From connector 26
3 257A (Y) 1.0 From connector 8A pin 4 124A (R) 1.0 From connector 4 pin A
G1 Alternator
4 124C (R) 1.0 From connector 8A pin

B4

4001-70
SCHEMATIC FRAME 7
Connector 8
256340A1
256357A1 A 178X (B) 1.0 To ground
Cavity Circuit ID Description B 783F (P) 1.0 From connector 8 pin A2
E1 782A (P) 0.5 From connector 23 pin

22
H1 781A (P) 0.5 From connector 23 pin

21 Connector 33
A2 783E (P) 2.0 To connector 32 pin A
Connector 8A
256340A1
A 784A (P) 1.0 From connector 93 pin

87A
B 178F To connector 38
256356A1
E1 782B (P) 0.8 To connector 96 pin 86
H1 781B (P) 0.8 From connector 99 pin A
A2 783D (P) 2.0 To connector 96 pin 87

4001-71
256340A1 245731C1
A 783G (P) 1.0 From splice 30 780A (R) 3.0 From primary fuse block
T1
B 178R (B) 1.0 To ground
85 178AU (B) To connector 93 pin 85
0.8
87 783A (P) 3.0 From connector 8A pin

A2
Connector 93
86 782B (P) 0.8 From connector 8A pin
E1
86 782C (P) 0.8 To connector 99 pin B
245731C1
85 178U (B) 0.8 To ground
87 706A (P) 3.0 To connector 102 pin 1
87A 784A (P) 2.0 To connector 101B
30 783B (P) 2.0 From splice
85 178U (B) 1.0 To ground
86 781C (P) 0.8 To connector 99 pin A

4001-72
Connector 99 CONNECTORS
SCHEMATIC FRAME 10
Connector 50A
CNH_STYLE_24
A 781B (P) 0.8 From connector 8A pin CNH_STYLE_24
E1
A 781C (P) 0.8 From connector 93 pin
86 A 313F (T) 1.0 From connector 140 pin
1
B 782C (P) 1.0 From connector 96 pin
86 B 313J (T) 1.0 From connector 140 pin
2
CONNECTORS
SCHEMATIC FRAME 8 Connector 51
Connector 39 (Grey)
225295C1

256340A1
A 313H (T) 1.0 From connector 140A
Cavity Circuit ID Description pin 2
A 890A (R) 1.0 From primary fuse block B 313G (T) 1.0 From connector 140A
T7 pin 1
B 892C (O) 1.0 To horn

4001-73
Connector 51A Connector 65A
225295C1 182069A1
A COM (B) 1.0 To door switch COM A 830C (R) 2.0 To connector 140 pin 5
Terminal
B 178WH (B) From connector 113 pin
B NO (W) 1.0 To door switch NO 1.0 1
Terminal
C NC (R) 1.0 To door switch NC

Terminal
Connector 112
Connector 65
239451A1
182069A1 2 837a (w) 1.0 To connector 141 pin B
Cavity Circuit ID Description 3 830F (R) 2.0 From connector 141 pin
8
A 830B (R) 3.0 From primary fuse block
T3 4 178WP (B) From connector 140A
1.0 pin 6
B 178T (B) 3.0 To ground

4001-74
1 2
AMP_480115_1 225350C1
1 178WH (B) From connector 65A pin 1 313G (T) 1.0 To connector 51 pin B
1.0 B
2 313H (T) 1.0 To connector 51 pin A
1 178G (B) 1.0 From connector 140 pin
6 3 835A (O) 1.0 From connector 141 pin
7
2 835B (O) 1.0 To connector 140 pin 3
5 830D (R) 2.0 From connector 141 pin
3
6 178WP (B) To connector 112 pin 4

1.0
Connector 140
Connector 141 Wiper/Washer

Switch
3 830E (R) 1.0 To connector 141 pin 8
3 830D (R) 2.0 To connector 140A pin 5

225351C1
4 837A (W) 1.0 To connector 112 pin 2
Cavity Circuit ID Description 7 835A (O) 1.0 To connector 140A pin 3
1 313F (T) 1.0 To connector 50A pin A 8 830F (R) 2.0 To connector 112 pin 3
2 331J (T) 1.0 To connector 50A pin B 8 830E (R) 1.0 To connector 141 pin 3
3 835B (O) 1.0 To connector 113 pin 2
5 830C (R) 2.0 To connector 65A pin A
6 178WG (B) To connector 113 pin 1

1.0

4001-75
SCHEMATIC FRAME 11
Connector 70
245432C1
DE_HDP26-24-21S A 535A (T) 1.0 To connector 70 pin V
Cavity Circuit ID Description B 751E (R) 1.0 From options fuse block
T6
V 535A (T) 1.0 From connector 72 pin A
C 178CG (B) To ground
U 751E (R) 1.0 From connector 72 pin B 0.8
DE_HDP24-24-21P 225316A1
V 535B (T) 1.0 To connector 81 pin 2 1 178CF (B) To ground

1.0
U 751E (R) 1.0 From options fuse block
T6 2 535B (T) 1.0 To connector 70A pin V

4001-76
Connector 81B Connector 121
225315C1 291718A1
1 178DA (B) From splice 1 178DC (B) From splice

1.0 1.0
2 535D (T) 1.0 To connector 124 pin B 2 545B (T) 1.0 To connector 123 pin A
245482C1 291718A1
A 535C (T) 1.0 From connector 124 pin 1 178DD (B) To connector 124 pin A
B 1.0
B 178D (B) 1.0 From splice 2 546B (T) 1.0 From connector 123 pin
B

4001-77

SCHEMATIC FRAME 12
Connector 77
253294A1
A 545B (T) 1.0 To connector 121 pin 2 256340A1
B 546B (T) 1.0 To connector 122 pin 2 Cavity Circuit ID Description
B 548B (T) 1.0 To ride control solenoid
Connector 124
CONNECTORS
SCHEMATIC FRAME 13
Connector 67
CNH_STYLE-24
A 178DE (B) From connector 12 pin 1

1.0
245781C1
B 535D (T) 1.0 From connector 81B pin

2 Cavity Circuit ID Description
B 535C (T) 1.0 From connector 120 pin A 178AJ (B) To ground
A 0.8
E 540F (R) 1.0 To connector 70 pin A
E 540G (R) 1.0 From options fuse block

T8
D 766A (P) 1.0 To connector 68 pin B

4001-78
Connector 68 Connector 71A (Euro)
CNH_STYLE-24 877290R1
A 178AF (B) To ground B 817D (R) 1.0 From options fuse block
1.0 T2
A 178BZ (B) To connector 69 pin A A 178BZ (B) To ground

1.0 1.0
B 766A (P) 1.0 From connector 67 pin D

(rotating beacon switch)
CONNECTORS
SCHEMATIC FRAME 15
CONNECTORS
SCHEMATIC FRAME 14 Connector 70
Connector 71
DE_HDP26-24-21S

877291R1
S 540A (R) 1.0 From connector 75 pin A
C 547A (T) 1.0 From connector 75 pin B
B 817B (R) 1.0 From options fuse block
T2
A 178AD (B) To ground

1.0

4001-79
DE_HDP24-24-21P 245432C1
S 540B (R) 1.0 From options fuse block D 178BF (B) To ground
T8 0.8
C 547B (T) 1.0 From connector 115 pin A 547A (T) 1.0 To connector 70 pin C
A
B 540A (R) 1.0 To connector 70 pin S
Connector 73
Connector 76
CNH_STYLE-24
225316C1

A 178BB (B) From connector 76 pin 2
0.8 1 547E (B) 0.8 From connector 73 pin B
B 547E (B) 0.8 From connector 76 pin 1 2 178BB (B) To connector 73 pin A
0.8
A 178BA (B) From connector 115A
1.0 pin B
B 547D (T) 0.8 To connector 115A pin A

4001-80

SCHEMATIC FRAME 16
Connector 69
256340A1
A 547B (T) 1.0 From connector 70A pin CNH_STYLE-24
C
B 178AF (B) To ground
1.0 A 178BZ (B) To connector 68 pin A
1.0
B 540G (R) 1.0 From connector 67 pin E
Connector 115A
Connector 117
256341A1

877291R1
A 547D (T) 1.0 From connector 73 pin B

B 178BA (B) To connector 73 pin A
1.0 A 178CE (B) To ground
2.0
B 540G (R) 1.0 From connector 67 pin E

4001-81
A ET000B (R) To connector 176 pin A B ET001C (R) From connector 170 pin
0.8 0.8 3
A ET000A (B) To connector 174 pin D B ET001A (R) From connector 117A
2.0 2.0 pin B
B ET001A (R) To connector 171 pin B C ET007A (R) To connector 172 pin A
2.0 1.0
B ET001B (R) To connector 176 pin C L ET003A (P) To connector 174 pin E
0.8 2.0
M ET004A (Y) To connector 174 pin B

2.0
H ET005A (O) To connector 174 pin C

Connector 170 2.0
1 ET000E (B) From connector 172 pin

0.8 B
2 ET006A (Y) To connector 176 pin B

0.8
3 ET001C (R) To connector 171 pin B

0.8

4001-82
E ET003A (P) From connector 171 pin A ET000B (R) To connector 117A pin A
2.0 L 0.8
B ET004A (Y) From connector 171 pin B ET006A (Y) From connector 170 pin
2.0 M 0.8 2
C ET005A (O) From connector 171 pin C ET001B (R) From connector 117A
2.0 H 0.8 pin B
D ET000C (B) From connector 17A pin

1.0 A
A ET008A (LB) From connector 172 pin

1.0 B CONNECTORS
F ET009A (LB) From air conditioner
SCHEMATIC FRAME 17
1.0 pressure switch
Connector 66
Connector 175
E ET003C (P) To connector 179 blower

2.0 motor
B ET004C (Y) To connector 178 blower

2.0 motor
256351A1
C ET005C (O) To connector 177 blower

2.0 motor Cavity Circuit ID Description
D ET000H (B) From connector 180 A 757B (P) 1.0 To connector 85 pin A
2.0 blower motor
B 751G (R) 1.0 To connector 85 pin B
A ET008C (LB) To connector 181
C 756B (P) 1.0 To connector 85 pin C
1.0 thermostat
F ET009C (LB) From connector 182

1.0 thermostat

4001-83
256350A1 256345A1
A 757A (P) 1.0 To connector 86 pin A A 757B (P) 1.0 To connector 85A pin A
option A or connector
B 751F (R) 1.0 From options fuse block 85D pin A option D
T6
B 751G (R) 1.0 To connector 85A pin B
C 756A (P) 1.0 To connector 86 pin C option A or connector
85D pin B option D
D 759A (P) 1.0 From connector 70A pin
L C 756B (P) 1.0 To connector 85A pin C
option A or connector
E 758B (P) 1.0 To connector 70A pin K 85D pin C option D
F 754C (P) 1.0 To connector 70A pin N
H 178AN (B) To ground

1.0
Connector 86
256345A1
A 757A (P) 1.0 To connector 86B pin A
B 178AG (B) To ground

1.0
C 756A (P) 1.0 To connector 86B pin C

4001-84

SCHEMATIC FRAME 18
Connector 49
225233C1
225320C1 E 001B (B) 1.0 From connector 138 pin

1
F 002B (DB From connector 138 pin
1 001A (B) 1.0 To connector 138A pin 1 1.0 2
2 002A (DB) To connector 138A pin 2 K 817J (O) 2.0 From connector 138 pin
1.0 3
3 003D (O) 1.0 To connector 138A pin 3 G 004B (R) 1.0 From connector 138 pin
4
4 004A (R) 1.0 To connector 138A pin 4
H 005B (Y) 1.0 From connector 138 pin
5 005A (Y) 1.0 To connector 138A pin 5 5
6 006A (P) 1.0 To connector 138A pin 6 C 006B (P) 1.0 From connector 138 pin
6
7 007A (T) 1.0 To connector 138A pin 7
D 007B (T) 1.0 From connector 138 pin
8 008A (W) 1.0 To connector 138A pin 8
7
J 008B (W) 1.0 From connector 138 pin

8
B 178JH (B) From connector 138 pin

2.0 9

4001-85
225389C1 225388C1
1 001B (B) 1.0 To connector 107 pin E 1 001A (B) 1.0 From connector 49 pin 1
2 002B (DB To connector 107 pin F 2 002A (DB From connector 49 pin 2
1.0 1.0
3 817J (O) 2.0 To connector 107 pin K 3 817H (O) 2.0 From connector 49 pin 3
4 004B (R) 1.0 To connector 107 pin G 4 004A (R) 1.0 From connector 49 pin 4
5 005B (Y) 1.0 To connector 107 pin H 5 005A (Y) 1.0 From connector 49 pin 5
6 006B (P) 1.0 To connector 107 pin C 6 006A (P) 1.0 From connector 49 pin 6
7 007B (T) 1.0 To connector 107 pin D 7 007A (T) 1.0 From connector 49 pin 7
8 008B (W) 1.0 To connector 107 pin J 8 008A (W) 1.0 From connector 49 pin 8
9 178JH (B) To connector 107 pin B 9 178HJ (B) To ground

2.0 2.0

4001-86

SCHEMATIC FRAME 19
Connector 125
182069A1
A 817F (R) 2.0 From options fuse block 245731C1
T2
B 178BJ (B) To ground
2.0 85 178DF (B) From connector 127B
1.0 pin D
85 178DG (B) From connector 128 pin

1.0 85
Connector 150A 86 320B (LB) From connector 129 pin

1.0 A
30 622D (W) To connector 127B pin B

1.0
86 320A (LB) To connector 130 pin B

1.0
87 624A (DB) To connector 127B pin B

1.0
182069A1
A 817G (O) From splice 15
B 178HJ (B) To connector 138A pin 9

2.0

4001-87
Connector 127B Connector 128
256347A1 245731C1
A 602D (W) From connector 128 pin 85 178 DG (B) From connector 125 pin
1.0 30 1.0 85
B 622D (W) From connector 125 pin 86 319F (T) 1.0 From connector 129 pin
1.0 30 B
C 319E (T) 1.0 From connector 129 pin 30 602F (W) 1.0 From splice
B
87 604A (W) 1.0 To connector 127C pin A
D 178DF (B) From connector 125 pin
1.0 85
Connector 129
Connector 127C
CNH_STYLE_30
256346A1 Cavity Circuit ID Description
Cavity Circuit ID Description A 320B (LB) From connector 125 pin

1.0 86
A 604A (W) 1.0 From connector 128 pin
87 B 319E (T) 1.0 To connector 127B pin C
B 624A (DB) From connector 125 pin B 319F (T) 1.0 To connector 128 pin 86
1.0 87

4001-88
Connector 130 Connector 66C
256341A1 256351A1
B 320A (LB) To connector 125 pin 86 B 751FA (R) From connector 275 pin
1.0 1.0 86
A 602E (W) 1.0 From splice C 756FA (P) From connector 66B pin
1.0 C
E 758FA (P) From connector 276 pin

1.0 B
CONNECTORS H 178FA (B) From connector 275 pin

SCHEMATIC FRAME 20 1.0 85
A 757FA (P) From connector 66B pin

Connector 66B 1.0 A
D 759FB (P) From splice F1

1.0
F 754FA (P) To connector 276 pin E

1.0
256350A1
A 757FB (P) From splice F3

1.0
B 759FA (P) From splice F1

1.0
C 756FB (P) From splice F2

1.0

4001-89
245781C1 245488C1
A 178AL (B) To ground A 756FC (P) From splice F2

0.8 1.0
D 758A (P) 1.0 To connector 70 pin K C 757FC (P) From splice F3

1.0
E 759A (P) 1.0 To connector 70 pin L
E 754FA (P) To connector 66C pin F
1.0
B 758FA (P) To connector 66C pin E

1.0
Connector 275
D 756FD (P) From splice F2
1.0
F 757FD (P) From splice F3

1.0
245731C1
85 178FA (B) To connector 66C pin H

1.0
86 751FA (R) To connector 66C pin B

1.0
87 759FC (P) To connector 66C pin D

1.0

4001-90

SCHEMATIC FRAME 21
Connector 86B
225326C1
256344A1 1 178TB (B) From splice T1

1.0
2 706TB (P) From splice T3
C 757TC (P) To connector 227 pin 4 1.0
1.0
3 701TA (P) To connector 250A
B 178TE (B) To connector 227 pin 1 1.0
1.0
4 756TB (P) From splice T1
A 756TC (P) From splice T1 1.0
1.0

4001-91
225326C1 277905A1
1 178TG (B) From splice T6 2 178TA (B) From splice T5

1.0 1.0
2 706TF (P) From splice T4 1 706TH (P) From splice T3

1.0 1.0
3 701TB (P) From connector 250A 3 756TA (P) From splice T1

1.0 1.0
4 757TB (P) From splice T2 4 706TA (P) To connector 228 pin 1

1.0 1.0

4001-92

SCHEMATIC FRAME 22
Connector 50C
277905A1
2 178TH (B) From splice T7 CNH_STYLE_24
1.0
4 706TG (P) To connector 229 pin 1
1.0 A 12B (T) 1.0 To connector 229 pin E
3 757TA (P) From splice T2 B 13A (T) 1.0 To connector 50D pin B
1.0
1 706TJ (P) From splice T4

1.0
Connector 50D
Connector 230
CNH_STYLE_24
245482C1
A 13B (T) 1.0 From connector 1189 pin
F
B 13A (T) 1.0 To connector 50C pin B
A 706TC (P) From connector 102B
1.0
B 178TC (B) From splice T5

1.0

4001-93
Connector 119 Connector 71C
245781C1 877290R1
E 12B (T) 1.0 To connector 50C pin A A 178EA (B) From connector 190 pin
1.0 85
F 13B (T) 1.0 To connector 50D pin A
A 178EB (B) From connector 71B pin
1.0 A
B 700A (P) 1.0 To right brake light

switch
CONNECTORS
SCHEMATIC FRAME 23 B 700B (P) 1.0 To connector 71B pin B
Connector 71B (Euro)
Connector 190 (Euro)
872291R1

245731C1
A 178EB (B) From connector 71C pin
1.0 A Cavity Circuit ID Description
B 700B (P) 1.0 From connector 71C pin 86 702A (P) 1.0 To connector 250
B
87 701A (P) 1.0 To left brake light switch
85 178EA (B) To connector 71C pi n A

1.0

4001-94
CONNECTORS Connector 79D

SCHEMATIC FRAME 24
Connector 79B
256341A1
256341A1 B 565AD (T) To 2 speed switch

0.8 (option D)
A 311AD (R) To attachment hydraulic
A 311AB (R) To attachment hydraulic 1.0 forward flow “ON” switch
1.0 forward flow “ON” switch (option D)
(option B)
Connector 85A
Connector 79C
256344A1
256341A1

C 756AA (LB) From turn signal switch
B 565AC (T) To 2 speed switch 0.8 (option A)
1.0 (option D)
B 540AA (O) To turn signal switch
A 311AC (R) To attachment hydraulic 0.8 (option A)
1.0 forward flow “ON” switch
(option D) A 757AA (Y) From turn signal switch
0.8 (option A)

4001-95
Connector 85D Connector 123C
256344A1 256294A1
A 757AD (Y) From turn signal switch A 545AC(Y) From attachment

1.0 (option D) 1.0 hydraulic switch (option
C)
B 540AD (O) To turn signal switch
0.8 (option D) B 546AC (LB) From attachment
1.0 hydraulic switch (option
C 756AD (LB) From turn signal switch C)
0.8 (option D)
Connector 123D
Connector 123B
256294A1
256294A1

A 545AD(Y) From attachment
B 545AB (Y) From attachment 1.0 hydraulic switch (option
1.0 hydraulic switch (option D)
B)
B 546AD (LB) From attachment
A 546AB (LB) From attachment 1.0 hydraulic switch (option
1.0 hydraulic switch (option D)
B)

4001-96
CONNECTORS Connector 39H

SCHEMATIC FRAME 25
Connector 39F
253294A1
253294A1 A 890AH (R) From horn switch (option

1.0 H)
B 892AH (V) From horn switch (option
A 890AF (R) From horn switch (option 1.0 H)
1.0 F)
B 892AF (V) From horn switch (option

1.0 F)
Connector 39G
253294A1
A 890AG (R) From horn switch (option

1.0 G)
B 892AG (V) From horn switch (option

1.0 G)

4001-97
Connector 49H Connector 77H
DEU_DT06-8S 256341A1-
1 001(B) 0.8 From front electric B 548AH (V) From ride control switch
control switch No. 1 1.0 (option H)
(option H)
2 002 (DB) 0.8 From front electric

control switch No. 1
(option H)
3 003 (0) 0.8 To front electric control

switch No. 1 (option H)
4 004 (R) 0.8 From front electric

(option H)
5 005 (Y) 0.8 From front electric

(option H)
6 006 (P) 0.8 From front electric

(option H)
7 007 (T) 0.8 From front electric

(option H)
8 008 (W) 0.8 From front electric

(option H)

4001-98
ELECTRONIC INSTRUMENT CONSOLE (EIC)
BD05A089
1. KEY SWITCH 2. INSTRUMENT (EIC) PANEL
SWITCH PANEL
1
2 4
3 5
6
7
8
BD04N043
1. TEMPERATURE CONTROL
2. BLOWER FAN SWITCH
3. AIR CONDITIONING SWITCH (IF EQUIPPED)
4. BLANK FOR SWITCH
5. HYDRAULIC COUPLER SWITCH (IF EQUIPPED)
6. ROTATING BEACON SWITCH LOCATION (IF EQUIPPED)
7. HAZARD FLASHER SWITCH LOCATION (IF EQUIPPED)
8. HIGH/LOW HYDRAULIC CONTROL SWITCH (IF
EQUIPPED)

4001-99
ELECTRONIC INSTRUMENT PANEL (EIC)
1
2 14
11 15
12 10
13 3
4 5
8 6
7
9
BD05A089
1. SEAT BELT INDICATOR LAMP
2. ENGINE OIL PRESSURE INDICATOR LAMP AND ALARM
3. PARK BRAKE INDICATOR LAMP
4. FUEL GUAGE
5. HOURMETER
6. ROAD LAMP SWITCH
7. AUXILIARY HYDRAULIC INTERLOCK OVERRIDE SWITCH
8. WORK LAMP SWITCH
9. PARK BRAKE “ON/OFF” SWITCH
10. HYDRAULIC OIL FILTER WARNING LAMP
11. COOLANT TEMPERATURE WARNING LAMP AND ALARM
12. ENGINE AIR FILTER WARNING LAMP
13. ENGINE PREHEATER LAMP (IF EQUIPPED)
14. CHARGE PRESSURE WARNING LAMP
15. HYDRAULIC FLUID TEMPERATURE WARNING LAMP

4001-100
ELECTRONIC INSTRUMENT CLUSTER (EIC) OPERATING INSTRUCTIONS

The EIC monitors and controls certain loader A. (6) Work lights (ON/OFF)
functions and engine parameters. When a monitored B. (8) Road lights (ON/OFF)
parameter limit is exceeded, the EIC issues audible
and visual warnings to the operator. C. (9) Parking brake (SET/RELEASE)
D. (7) Auxiliary hydraulic interlock override.
Monitored functions and parameters:
1. Operator (in/out seat) – lighted indicator Push Button Functional Description:
2. Operator seat restraint bar (up/down), – lighted Work lights and road lights – toggles the state of
indicator (same as lighted indicator in (1). the lights indicated by an associated LED. Only
3. Engine oil pressure (high/low) – lighted indicator. works when the ignition key is ON.
4. Hydraulic charge pressure (high/low) – lighted Parking brake – for machines with hydraulically
indicator. actuated brake, this button toggles the state of the
5. Hydraulic oil temperature (high/low) – lighted parking brake. A back lighted symbol displays the
indicator. state of the brake. At power up, loader motion,
hydraulic flow to attachments and movement of the
6. Engine coolant temperature (high/low) – lighted
boom and bucket are inhibited until this button is
indicator.
pushed. At power up only, a flashing LED near this
7. Hydraulic oil filter condition (free/restricted) – push button prompts the operator to release the
lighted indicator. brake to begin operation. This function only works
8. Engine air filter condition (free/restricted) – when the ignition key is ON.
lighted indicator. Auxiliary hydraulic override – if pressed, the light
9. Parking brake state (ON/OFF) – lighted indicator. next to the switch will turn on for thirty seconds.
10. Engine preheat state (ON/OFF) – lighted Within that period of time, an operator may leave the
indicator. seat without interruption to attachment hydraulic flow.
This feature is turned off or reset while the operator is
11. Battery voltage (over/under) – displayed in place in the seat and (1) the operator again pushes the
of engine hours when out of limits high/low. button during the thirty seconds (2) automatically
12. Engine hours (accumulated to tenth hour) – after thirty seconds or (3) leaves to operate the
character display. attachment and then sits back down in the seat at
13. Fuel level – eight element vertical bar graph. some later time. When the operator returns to the
seat after using an implement for an extended period
Controlled Functions: of time, the brake button must be pushed again to
1. Hydraulic interlock solenoid output – inhibits enable the loader hydraulic system and turn off the
boom/bucket movement when operator out of brake. The override feature is primarily used to
seat or the seat restraint bar is in the raised support attachments such as a backhoe or other
position. out-of-cab operated implements.
2. Hydraulic brake output – prevents loader motion
when the operator is out of the seat, or the seat
restraint bar is in the raised position.
3. Grid heat output (if equipped) – applies power to
the grid heater relay for an interval of time
determined by the temperature of the engine
coolant each time the ignition key is turned from
off to on.
4. Hydraulic auxiliary override – enables a
continuous hydraulic flow to attachments when
an operator leaves the seat to operate an
attachment. If not pushed, provides a safety
interlock during operator entry/exit of the loader.
Additionally, a four push-button operator selector
area located on the EIC provides the following
functions during normal operation:

4001-101
Restraint System: The EIC contains logic to ensure 3. Road light: Used to view in succession all of the
operator safety. The EIC continually monitors the values that an item can have. When changing
seat switch and the seat restraint bar switch. If, engine hours, this button increments a flashing
during operation, any of these restraint devices digit value in a circular manner from 0 – 9.
indicates to the EIC that the operator has left the seat 4. Work light: Used to navigate to the next menu
or is about to leave the seat, the EIC will inhibit item. When changing engine hours, this button
hydraulic flow to the boom and bucket and will set the causes the flashing emphasis to move to the
brake. next digit to the right.
Additionally, if the operator has not pressed the
auxiliary hydraulic override push button, flow will be 5. Auxiliary override: This button functions as an
halted to attachments via hydraulic solenoid interlock unconditional setup exit without save from any
or automatic engine shut down provided that the location in the menu. When this button is
auxiliary control is displaced from neutral. pushed, the EIC will turn off. If the operator is in
the seat, the EIC will immediately power up
To prevent annoying attachment flow interruption normally. None of any changed information will
and hydraulic brake activation due to be saved unless that information was first saved
operator-induced seat switch bounce, the EIC using the parking brake button and then verified.
implements a short seat switch time delay prior to
6. To Exit the Setup Menu: (1) Leave the loader.
halting auxiliary flow.
After three seconds the EIC will automatically
The EIC will power up when an operator sits in the
power down, (2) place the ignition key in either
seat. This enables viewing of fuel level and engine
the ACC or the ON position or (3) push and
hours without use of the ignition key. If the operator is
release the auxiliary override button.
in the seat for more than thirty seconds and the
ignition key is not turned on, the EIC will turn itself
off.
EIC Special Functions (Setup Menu):
Special machine setup features are available via the
operator push button selector area. The EIC will
display the word “SETUP” as a first menu item visual
“anchor” message.The choices available are:
A. (1) Select engine type: (for correct cold engine
preheat profile)
B. (2) Select brake type: hydraulic or no brake
C. (3) Display EIC software revision level.
D. (5) Modify engine hours: (coded entry
required).
Push Button Definitions:

1. Any button: Any button may be depressed and
held for six seconds to enter the setup mode.
The seat must be unoccupied and the ignition
key off during this time, but the operator may sit
in the seat after the setup mode is entered.
2. Parking brake: Provides for editing the values
that a setup menu item (engine type, brake type,
engine hours) can have. When a value has been
changed, this button is also used to save the
value in memory. Verification of the saved value
is automatic. The display will blank and go dark.
Then, after a short delay time, the value will be
retrieved from memory and shown again in the
display. After this visual verification, the word
“SETUP” will again appear in the display.

4001-102
Special Feature Choices: Changing Engine Hours:

1. Display/select engine type. ATTENTION: You must contact your CNH
2. Display/change brake type. Technical Services Adviser to obtain the UNLOCK
CODE before the Engine Hourmeter can be
3. Display/change engine hours are the only values changed.
that may be modified.
To change engine hours (item 4), press and release
NOTE: For the following three descriptions, it is the work light push button four times until the word
assumed that the operator has already placed the “HOUR” is displayed. Then, push and release the
instrument cluster in the SETUP mode and is sitting park brake push button. The word “UNLOCK” will be
in the seat. The word “SETUP” appears in the text displayed for two seconds to prompt that an
display. unlocking code must be entered to change engine
hours. After the two second delay, the display will
Detailed Description of Setup prompt for the entry of a four-digit code. The leftmost
Items: digit after the prompt “>” will flash, indicating a digit
that can be changed. Using the road light push
button to change the digit value and the work light
Selecting an Engine Preheat Profile:
push button to select the next digit, enter the
To select an engine preheat profile (item 1), press unlocking code.
and release the work light push button one time. The Push and release the park brake push button to
word “ENGIN” will be displayed. Then, push and accept this unlocking code. Currently stored engine
release the park brake push button. The engine type hour value will be retrieved and displayed and the
“CASE” (for Case brand) or “ISM” will be displayed leftmost digit will flash. Using the same technique
depending on the profile currently stored in the EIC. outlined above, enter the desired engine hour value.
Push and release the road light push button to switch Push and release the park brake push button to store
between the engine types. When the desired engine the new engine hour value. After visual verification,
type is displayed, push and release the park brake the word “SETUP” will again appear in the display.
push button to store the new selection. After visual Exit the Setup Menu using one of the three methods
verification, the word “SETUP” will again appear in described above.
the display.
Changing Brake Type:

To select a brake type (item 2), press and release the
work light push button two times. The word “BRAKE”
will be displayed. Then, push and release the park
brake push button. The brake type “HYDRL” (for
hydraulic) “NOBRK” (for no brake – to adjust drive
neutral) or “MANUL” (for manual) will be displayed
depending on the type currently stored in the EIC.
Push and release the road light push button to switch
between the brake types. When the desired type is
displayed, push and release the park brake push
button to store the new selection. After visual
verification, the word “SETUP” will again appear in
the display.

4001-103
TROUBLESHOOTING
ELECTRONIC INSTRUMENT CLUSTER (EIC)
PROBLEM POSSIBLE CAUSE CORRECTION
EIC board will not light up when Faulty seat switch. Replace switch
operator sits in the seat.
No battery voltage to seat switch. Blown 5 amp fuse electronic bat-

tery in engine panel, replace fuse.
Open in power wire from 5 amp
fuse from supply, check and/or
replace battery.
No battery voltage to 5 amp fuse
from supply, check and/or replace
battery.
Blown 5 amp fuse (electronic bat-

Replace fuse.
tery) in engine panel.
No battery voltage from seat switch Open in power wire from seat
to EIC board. switch to EIC board, repair open
wire.
Poor or no connection at EIC
board, repair connection.
Battery voltage from seat switch to If battery voltage from seat to

EIC board. board is OK, replace the EIC.
EIC backlighting is dim. Brightness variations due to produc- None -- overlay decal material
tion differences between models variations cause differences in
and/or EIC board changes. brightness.
Backlights dim when the loader None -- EIC board circuitry auto-
worklights are activated. matically dims the backlighting
when then worklights are on, to
reduce the glare at night.

4001-104
EIC will not read correct Engine Incorrect engine configuration. Correct the engine configuration.
RPM, and varies more than ± 50
RPM.
No AC voltage at tachometer termi- Repair alternator.

nal at alternator.
Loose or corroded connection at

Repair connection.
tachometer terminal at alternator.
No AC voltage at EIC board from Open in wire from alternator to

alternator. EIC board, repair connection.
AC voltage from alternator to EIC Repair loose or corroded connec-

board. tion at EIC board.
Wire connection from alternator to If OK, replace EIC.

EIC board.
EIC will not unlock boom and Seat restraint bar not in operating Lower the restraint bar to the oper-
bucket spool locks. position (down). ating position (down).
No battery voltage from seat Open in power wire from seat

restraint bar switch to EIC. restraint bar switch, repair open.
No battery voltage from EIC to spool Open in power wire from EIC to
lock solenoids. solenoids, repair open.
Battery voltage to lock solenoids. If OK, check inoperative sole-

noids, check solenoid coils and
repair or replace.

4001-105
Engine will not start and/or run. Incorrect Engine configuration. Correct configuration.
(EIC)
No battery voltage to start relay. Open in power wire from key

switch “START” to relay, or
through seat/seat restraint bar cir-
cuits to relay, repair open.
No battery voltage from EIC to fuel Open in power wire from EIC to
solenoid. fuel solenoid, repair open.
Inoperative start interlock relay. Repair or replace.
Fuel solenoid inoperative. Repair or replace.
Inoperative Engine preheat system. Incorrect Engine configuration,

correct configuration.
No power to Engine preheater. Manifold heater preheat relay or

wire open, repair or replace.
Inoperative manifold heater. Replace manifold heater.
Engine turns over, but will not Check 7.5 amp fuse in cab fuse
No power to fuel solenoid.
start. block.
Check interlock fuel solenoid
relay.
If equipped with auxiliary override
switch, make sure switch is in neu-
tral position.
No power to starter, no power to key Check key switch, seat switch,

Engine will not turn over.
switch. start interlock relay, battery.
Check 5 amp fuse in engine fuse
panel.
Check 15 amp fuse in engine fuse
panel.
Engine will start and run but boom No power to control valve lockout Check for power at spool lockout
and bucket will not move. solenoids. solenoids.
Check 15 amp fuse in cab fuse
block.
Replace EIC.
EIC will not read monitored cir-

Incorrect engine configuration. Correct engine configuration.
cuits.
Open or short in wire from sensor to Repair open/short.

EIC.
Faulty sender or sensor. Repair/replace sender or sensor.

4001-106
NOTES

Section
4005
BATTERY
4005
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright © 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 7-51310 Issued May, 1996
4005-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
NONSPILL CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHARGING GUIDE FOR BATTERIES OTHER THAN
MAINTENANCE FREE BATTIERES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4005-3
SAFETY RULES
WARNING: Never try to charge the battery if WARNING: If the battery(ies) in this machine
the electrolyte is frozen. must have nonspill caps, do not operate the
47-3A machine if the nonspill caps do not work
correctly, or if the nonspill caps are not in
WARNING: Never cause sparks to occur or place.
smoke near batteries that are charging or
48-99A
have been recently charged.
13-8A WARNING: Battery acid causes severe
burns. Batteries contain sulfuric acid. Avoid
WARNING: Disconnect the ground cable contact with skin, eyes, or clothing. Antidote:
first when the battery cables are EXTERNAL - Flush with water. INTERNAL -
disconnected from the battery. Connect the Drink large quantities of water or milk. Follow
ground cable last when the battery cables are with milk of magnesia, beaten egg, or
connected to the battery. vegetable oil. Call physician immediately.
47-55A
EYES: Flush with water for 15 minutes and
WARNING: Some batteries have a get prompt medical attention.
ventilation tube. If there is battery acid in the Batteries produce explosive gases. Keep
ventilation tube, this battery acid can be sparks, flame, and cigarettes away. Ventilate
released when the battery is turned upside when charging or using in an enclosed area.
down. If you turn the battery upside down, Always shield eyes when working near
make sure that the end of the ventilation tube batteries. Keep out of reach of children.
is away from you and away from any other D-47-53
people in the area. Battery acid can cause
severe burns.
48-57B
MAINTENANCE
Electrolyte Level If the level of the electrolyte is low, add distilled water
or other clean water until the electrolyte is just below
If the battery is a maintenance free battery, check the the cell opening. Do not add more water than is
level of the electrolyte every 1000 hours of operation n e e d e d . To o m u c h w a t e r c a n c a u s e b a d
or six months, whichever occurs first. For all other performance, a short service life, and corrosion
batteries, check the level of the electrolyte every 250 around the battery.
hours of operation.
NOTE: Add water only. DO NOT add electrolyte.
NOTE: A maintenance free battery will have the
words Maintenance Free on the decal on the top of Inspecting and Cleaning a Battery
the battery. If the center part of the decal has been
removed for access to the battery caps, it is possible If damage causes an electrolyte leak, replace the
that the words Maintenance Free have been battery.
removed from the decal.
If the battery in your machine has nonspill caps, see
Check the level of the electrolyte more often during No nsp ill C ap s on pa ge 40 05 -4 a nd ch eck th e
hot weather. The use of a large amount of water by condition of the nonspill caps. See Specifications in
th e batte ry can b e caused b y high ba ttery Section 4002 to find if the battery in your machine
temperature or a voltage regulator setting that is too must have nonspill caps.
high. Keep the electrolyte level above the top of the
Inspect the battery at regular intervals for dirt,
plates in the battery at all times to prevent damage to
corrosion, and damage. Electrolyte and dirt on the
the battery.
top of the battery can cause the battery to discharge
NOTE: On maintenance free batteries it is by making a passage for the current to flow.
necessary to remove the center part of the decal for
access to the battery caps. Do not discard the center
part of the decal. Install the center part of the decal
after the battery caps have been installed.

4005-4
If the battery must be cleaned, remove the battery Install the battery in the machine and make sure the
from the battery carrier and clean the battery, cable fasteners are tight. Apply Case Battery Saver and
terminals, and the battery carrier. When available, Cleaner or Urethane Seal Coat to the cable terminals
use Case Battery Saver and cleaner according to the to prevent corrosion. See the Parts Counter Catalog.
instructions on the container. Case Battery Saver DO NOT apply grease.
and Cleaner also helps prevent corrosion. If Case
Battery Saver and Cleaner is not available, use
baking soda and water as a cleaner. DO NOT permit
any type of cleaner to enter the cells of the battery.
NONSPILL CAPS
See Specifications in Section 4002 to find if the The nonspill caps have a valve with a stem made of
battery(ies) in your machine must have nonspill caps. lead and rubber. When the nonspill cap is turned
upside down, the weight of the lead holds the rubber
WARNING: If the battery(ies) in this machine stem against the breather hole, preventing the loss of
must have nonspill caps, do not operate the electrolyte.
machine if the nonspill caps do not work
correctly, or if the nonspill caps are not in If the breather hole and valve are closed by foreign
place. material, pressure in the battery can become high
48-99A
enough to break the case of the battery. Always
check the breather hole for foreign material when you
Do not operate the machine if the nonspill caps do
check the electrolyte level. If there is foreign material
not work correctly or if the nonspill caps are not in
over the breather hole, turn the nonspill cap upside
place. Nonspill caps prevent electrolyte leakage
down and clean the nonspill cap. Move the nonspill
which can cause personal injury and damage to the
cap up and down rapidly. You must be able to hear
machine if the machine turns over in an accident.
the valve, wash the nonspill cap and loosen the
valve. Move the nonspill cap up and down rapidly to
remove the water.
When you remove a nonspill cap, check the condition
of the rubber gasket. If the rubber gasket is gone or
is damaged, install a new nonspill cap.
Missing or broken nonspill caps MUST be replaced
with new nonspill caps. DO NOT use any other type
of cap to replace nonspill cap.
When you install a new battery, the new battery
MUST have nonspill caps. You can use the nonspill
caps from the old battery if the nonspill caps are in
B800305M good condition.
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the
battery.
Visual Checks
1. Make sure the cable connections are clean and 4. If you added water to the battery, the battery
tight. Clean foreign material from the top of the must be charged for 15 minutes at 15 to 25
battery. amperes to mix the water with the electrolyte.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See page 4005-4.
4005-5
Specific Gravity Check 4. Make a record of the corrected specific gravity

reading for each cell.
A hydrometer is used to check the specific gravity
(weight) of the electrolyte. The specific gravity is an 5. If the difference between the high reading and
indication of the level of charge for each cell. the low reading is.050 or more, charge the
battery and check the specific gravity again. If
Hydrometers are made to show the correct specific after charging, the difference is still .050 or more,
gravity when the temperature of the electrolyte is install a new battery.
80°F (26.7°C).
6. The corrected specific gravity reading shows the
When you check the specific gravity, you must know level of charge for the cell. The level of charge
the temperature of the electrolyte. If your hydrometer must be at least 75% in each of the cells. In
does not have a thermometer, get a thermometer to maintenance free batteries the level of charge is
che ck th e temp eratu re of the ele ctrolyte . Th e at least 75% if the corrected specific gravity
thermometer must indicate a high temperature of at reading is 1.240 or higher. In all other batteries
least 120°F (52°C). the level of charge is at least 75% if the corrected
1. Remove enough electrolyte from a cell so that specific gravity reading is 1.230 or higher.
the float is free in the tube. 7. If the difference between the high reading and
NOTE: If the specific gravity cannot be checked the low reading is less then .050, and the level of
without first adding water to the cell, the battery must charge is at least 75% in all of the cells, do the
be charged for 15 minutes at 15 to 25 amperes to Capacity (Load) Test.
mix the water with the electrolyte. Then check the 8. If the difference between the high reading and
specific gravity. the low reading is less than .050, but the level of
2. Read the float. charge is less than 75% in any of the cells,
charge the battery and check the specific gravity
3. Read the thermometer. If the reading is above again. If after charging:
80°F (26.7°×C) add specific gravity points to the
reading for specific gravity. If the reading is below A. The level of charge is less than 75% in any of
80°F (26.7°×C) subtract specific gravity points the cells, discard the battery.
from the reading for specific gravity. See the B. The level of charge is at least 75% in all of the
following illustration and add or subtract specific cells, do the Capacity (Load) Test.
gravity points as needed.
Capacity (Load) Test
1 2
This test can be done using a variable load tester.
Co n n ec t t he t es t e q uip me n t a cc o rd ing to th e
instructions of the manufacturer of the equipment.
1. The level of charge of the battery must be at
least 75%. Do the Specific Gravity Check in this
section.
2. Prepare the tester (Sun Electric VAT-33 shown)
for the test.
A. Select the voltmeter range that will measure 1
to 18 volts.
B. Make sure the load control knob is in the OFF
position.
C. Select the ammeter range that will measure 0
to 1000 amperes.
790863A
D. Move the volt lead switch to the INT. position.

1. TEMPERATURE IN ° F
2. TEMPERATURE IN ° C 3. Connect the tester to the battery as shown.
SPECIFIC GRAVITY CHART

4005-6
6. Find the correct load for this test in Specifications
1 in Section 4002.
NOTE: The correct load is half of the cold cranking
amperes at 0°F (-17°C).
2 7. Turn the load control knob until the ammeter

indicates the specified load. Keep the load for 15
seconds and read the voltmeter. Turn the load
control knob to OFF.
8. Compare the test reading and the temperature of
the electrolyte to the chart below.
Temperature of . . . . . . . . . . . . . . . Minimum Voltage
electrolyte
70° F (21° C) and above . . . . . . . . . . . . . . . . . . . 9.6
60° F (16° C) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
50° F (10° C) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
40° F (4° C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
790499
30° F (-1° C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
20° F (-7° C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
1. LOAD CONTROL KNOB 2. AMMETER CLAMP
10° F (-12° C) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
NOTE: Never apply a load for longer than 15 0° F (-18° C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
seconds. After each 15 seconds, turn the load control A. If the test result is equal to or more than the
knob to OFF for at least one minute. voltage shown, the battery is in good
4. Apply a 15 ampere load to the battery for 15 condition.
seconds. Wait at least three minutes before B. If the test result is less than the voltage
continuing with the test. shown, discard the battery.
5. Check and make a record of the temperature of
the electrolyte.
CHARGING A BATTERY
The charging rate must be decreased if:
WARNING: Never try to charge the battery if
the electrolyte is frozen. 1. Too much gas causes the electrolyte to flow from
47-3A
the cells.
Before you charge the battery, check the level of the 2. The temperature of the electrolyte rises above
electrolyte. 125°F (52°C).
It is difficult to give an exact charging rate because of NOTE: For the best charge, use the slow charging
the following variable conditions: (1) temperature of rates.
the electrolyte, (2) level of charge, and (3) condition
The battery is fully charged when, over a three hour
of the battery. Use the charging guide for the correct
period at a low charging rate, no cell is giving too
charging rate and time.
much gas, and the specific gravity does not change.
See Specifications in Section 4002 for the reserve
capacity of the battery in this machine.

4005-7
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES

Recommended Rate * and Time for Fully Discharged Battery
Battery Capacity - See
Reserve Capacity under
Specifications Slow Charge Fast Charge
80 Minutes or Less 10 Hours at 5 Amperes 2.5 Hours at 20 Amperes
5 Hours at 10 Amperes 1.5 Hours at 30 Amperes
Above 80 to 125 Minutes 15 Hours at 5 Amperes 3.75 Hours at 20 Amperes
7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes
Above 125 to 170 Minutes 20 Hours at 5 Amperes 5 Hours at 20 Amperes
10 Hours at 10 Amperes 2 Hours of 50 Amperes
15 Hours at 10 Amperes 3 Hours at 50 Amperes
* Initial rate for standard taper charger.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed to get access to the battery caps, it is possible the words
Maintenance Free will have been removed from the decal.

4005-8
CHARGING GUIDE FOR BATTERIES OTHER THAN

MAINTENANCE FREE BATTIERES
Recommended Rate * and Time for Fully Discharged Battery
Battery Capacity - See
Reserve Capacity under
Specifications Slow Charge Fast Charge
80 Minutes or Less 10 Hours at 5 Amperes 2.5 Hours at 20 Amperes
5 Hours at 10 Amperes 1.5 Hours at 30 Amperes
7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes
Above 125 to 170 Minutes 20 Hours at 5 Amperes 5 Hours at 20 Amperes
10 Hours at 10 Amperes 2 Hours of 50 Amperes
15 Hours at 10 Amperes 3 Hours at 50 Amperes
Above 250 Minutes 24 Hours at 10 Amperes 6 Hours at 40 Amperes
4 Hours at 60 Amperes
* Initial rate for standard taper charger.
PREPARING A DRY CHARGED BATTERY FOR USE

1. Remove the caps from the battery. 4. Connect a battery charger to the battery.
2. Fill each cell to the top of the separators with 5. Charge the battery at 30 amperes until the
ele ctro ly te . Th is will p er mit the vo lu me of s p e cif ic g ra v it y is 1 .2 5 0 o r m o r e a n d t h e
electrolyte to increase when heated by charging temperature of the electrolyte is at least 60°F
the battery. (15.5°C).
3. Install the caps on the battery. If the battery in 6. If necessary, fill each cell with electrolyte until the
your machine must have nonspill caps, install the electrolyte is just below split ring at the bottom of
nonspill caps. See Specifications in Section 4002 the cell opening.
to find if the battery in your machine must have
nonspill caps.

Section
4006
STARTER AND STARTER SOLENOID
4006

Racine, WI 53404 U.S.A. Bur 7-53091 Issued June, 1997 (Revised February, 2005)
4006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
NO-LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brushes and Brush Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Field Coil Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
STARTER SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Starter Solenoid Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Bur 7-53091 Revised 2-05 Printed in U.S.A.

4006-3
SPECIFICATIONS
Manufacturer .................................................................................................................................................. Denso
Denso part number ................................................................................................................................428000-3140
CNH part number ............................................................................................................................. SBA185086530
No-Load Test at 80° F (26.7° C)
Volts ................................................................................................................................................................... 12
Rating .......................................................................................................................................................... 2.7 KW
LUBRICATION
Interval ....................................... When the starter is disassembled or each time the engine is removed for repairs
Lubricant
Molykote-GN ........................................................................................ Use on shaft at pinion end of starter drive
Case multipurpose grease ....................................................... Use on bearings, gears, idler gear shaft and spring.
NO-LOAD TEST
General Information B. Select the 18 to 40 volt range.
1. The No-Load Test is done with the starter C. Move the volt lead switch to the EXT. position.
removed from the engine. D. Turn the load control to the OFF position.
2. Check to see if you can pull the gear on the
starter drive out of the starter drive housing.
3. Check to see if the starter drive can be turned.
Pull the gear on the starter drive out of the starter
drive housing. Turn the gear to turn the starter
drive and the armature.
4. If the starter drive cannot be turned, disassemble
the starter and make repairs as needed. Then do
the No-Load Test.
Test Equipment
The No-Load Test can be done using a Sun Electric B795328M
VAT-33 Tester, an equivalent tester, or separate 2. Fasten the starter in a vise or use another
pieces of test equipment. method to prevent the starter from moving. This
A hand held tachometer is needed to measure the must be done to prevent personal injury.
speed of the armature shaft. 3. Connect the positive battery cable to the battery
A remote starter button is needed to actuate the terminal on the starter solenoid and the negative
starter. battery cable to the mounting flange of the
starter.
A fully charged 12 volt battery is needed to supply
the electricity to turn the starter.
Test Procedure
The illustrations in this procedure show the use of the
Sun Electric VAT-33 tester. Other test equipment can
be used. Connect the test equipment according to
this procedure and the manufacturer’s instructions.
1. If the VAT-33 tester is being used:
A. Select the 0 to 100 ampere range.

4006-4
1 3
2 2
B831432J
1. 1. RED VOLTMETER LEAD
B831430J
1. 1. POSITIVE BATTERY CABLE 2. 2. MOTOR TERMINAL
2. 2. BATTERY TERMINAL
6. Connect the black voltmeter lead to the mounting
3. 3. NEGATIVE BATTERY CABLE
flange on the starter.
4. Connect the positive load cable to the positive
post of the battery. Connect the negative load
cable to the negative post.
1
1
2
B831433J
1. 1. BLACK VOLTMETER LEAD
7. Fasten the ammeter clamp around the positive

battery cable so that the tip of the arrow is toward
B831431J the starter.
1. 1. POSITIVE LOAD CABLE
2. 2. NEGATIVE LOAD CABLE
5. Connect the red voltmeter lead to the motor

terminal on the starter solenoid.

4006-5
4 3
2
B831434J
1. 1. AMMETER CLAMP
8. Connect the leads from the remote starter button

to the Battery and Switch terminals. 5
B831436J
1. 1. REMOTE STARTER BUTTON
2. 2. LOAD CONTROL
3. 3. VOLTMETER
4. 4. AMMETER
5. 5. HAND HELD TACHOMETER
10. Look at the ammeter and record the amperage.

11. Use a hand held tachometer check and record
the armature shaft speed.
12. Release the remote starter button and turn the
load control to the OFF position.
1 2
Understanding No-Load Test Results
1. If the current draw and the armature shaft speed
3
B831435J are within the ranges listed in Specifications, the
1. 1. REMOTE STARTER BUTTON starter is good.
2. 2. BATTERY TERMINAL
3. 3. SWITCH TERMINAL 2. Low armature shaft speed and high current draw
are indications of too much friction. Possible
IMPORTANT: Steps 9, 10, and 11 must be done causes for excessive friction are:
rapidly. Do not load the battery for more than 15
seconds at one time. After the battery has been A. Tight, dirty, or worn bearings.
loaded for 15 seconds, let the starter cool for 60
B. A bent armature shaft.
seconds.
C. Loose pole shoes (pole shoes make contact
9. Actuate the remote starter button and turn the with the armature).
load control until the voltmeter indicates 11 volts.

4006-6
D. A short circuit in the armature coil. B. An open armature coil. Disassemble the
Disassemble the starter. Use an armature starter and check for burned commutator bars.
tester to test the armature. Use the Use an armature tester to test the armature.
instructions included with the armature tester. Use the instructions included with the
armature tester.
E. Damaged field coil. Do the test on page 12.
C. Brushes not making good contact with the
3. If the armature does not rotate and the current
commutator bars. Check for high insulation
draw is high, possible causes are:
between the commutator bars, broken brush
A. Field terminal making contact with the field springs, or worn brushes.
frame. Inspect the insulators for the field
5. Low armature shaft speed and low current draw
terminal.
are indications of:
B. Damaged field coil. Do the tests on page 12.
A. Dirt or corrosion on connections.
C. Damaged bearings.
B. Damaged wiring.
4. If the armature does not rotate and the current
C. Dirty commutator bars.
draw is zero, possible causes are:
D. All causes in step 4.
A. An open field armature circuit. Disassemble
the starter and inspect the field coil 6. High armature shaft speed and high current draw
connections. are indications of a short circuit in the field coil. It
is difficult to find a short circuit in a field coil.
Install a new field coil. Do the No-Load Test
again to check for improvement in the operation
of the starter.
DISASSEMBLY
STEP 1 STEP 3
Pull back the boot on the motor terminal, loosen and remove
the nut and lock washer.
STEP 2
B330733M
Loosen and remove the cap screws.
B330732M
Loosen and remove the screws that hold the cover.

4006-7
STEP 4 STEP 8
B330735M B330739M
Remove the cover. Remove the armature.
STEP 5 STEP 9
B330736M B330740M
Hold the spring away from one of the brushes Fasten the starter solenoid in a vise and loosen and
connected to the field coil and remove the brush from remove the screws that hold the starter drive
the brush holder. Repeat this step for the other brush housing.
connected to the field coil.
STEP 10
STEP 6
B330741M
B330737M Remove the starter drive housing from the starter

Remove the brush holder. solenoid.
STEP 7
Remove the field frame assembly.

4006-8
STEP 11 STEP 15
B330743M B330703M
Push down the starter drive housing as shown to Remove the idler gear.
loosen and remove the starter drive.
STEP 16
STEP 12
B330704M
B330744M Remove the bearing cage.

Remove the steel ball from the starter drive. If
necessary, use a magnet. STEP 17
STEP 13
Remove the O-ring from the groove in the starter
drive housing.
STEP 14
B330705M
Remove the thrust washer.
B330702M
Remove the spring.

4006-9
STEP 18 STEP 21
B330706M B330709M
Loosen and remove the screws that hold the cover. Remove the plunger.
STEP 19 STEP 22
If necessary, use a hammer to loosen the cover.
STEP 20
B330710M
If necessary, remove the gasket from the cover.
B330708M
Remove the cover.
INSPECTION
All parts except the starter drive must be cleaned 3. Use a spring scale to check the tension of the
using mineral spirits and a brush or cloth. Use a brush springs. Pull the brush spring up until the
clean, dry cloth to clean the starter drive. brush spring is just above the brush holder. The
scale indication must be between 1.8 and 4.1 kg
Brushes and Brush Springs (4 and 9 pounds). If a brush spring is not as
specified, use a new brush spring when the
1. If the length of the brush fastened to the brush starter is assembled.
holder is less than 11 mm (7/16 inch), a new
brush holder assembly must be used when the Brush Holder
starter is assembled.
1. 1. Hold the leads of an ohmmeter against the
2. If the length of a brush fastened to the field coil is
frame and the brush holders that have insulation
less than 11 mm (7/16 inch), a new field frame
between the brush holder and frame.
assembly must be used when the starter is
assembled.

4006-10
B313142M B313141M
2. If there is an indication of a complete circuit, 5. If the depth of the groove between the
install a new brush holder. commutator bars is less than 0.2 mm (0.008
inch), cut the insulation between the commutator
Armature bars to a depth of 0.4 to 0.8 mm (1/64 to 1/32
inch). Use sandpaper to remove the rough edges
1. Test the armature on an armature tester. Use the from the commutator bars.
equipment manufacturer’s instructions.
6. Check the bearings on the armature for free
2. Put the armature on vee-blocks as shown and rotation, rough balls, and damage to the inner
check the runout of the armature with a dial race or outer race. If a bearing is to be replaced,
indicator. The runout must not be more than 0.05 use a press and acceptable tools to remove and
mm (0.002 inch). install the bearings.
Field Coil Test

1. Hold the leads of an ohmmeter against one of
the brushes and the field frame. The needle of
the ohmmeter must not move.
B313141M
3. If necessary, put the armature in a lathe and

remove enough material from the commutator to
make the runout less than 0.05 mm (0.002 inch).
4. Measure the diameter of the commutator. If the
diameter is less than 35 mm (1.38 inch), install a
B610614M
new armature.
2. If the needle of the ohmmeter moved, install a
new field frame assembly.
3. Hold the leads of the ohmmeter against one of
the brushes and the end of the cable. The needle
of the ohmmeter must move.

4006-11
B610616M
4. If the needle of the ohmmeter did not move,

install a new field frame assembly.

4006-12
5 18 20
17
13
19
2
21
5
22 3
10
23
22
24
11
17
14
16
11 15
10
12
11 14
7
13
8
6
1
4
BS05B254
1. SCREW 7. STEEL BALL 13. DRAIN BUSHING 19. FIELD FRAME
2. SPRING STARTER 8. SPRING 14. NUT 20. CAP SCREW
3. CAP SCREW 9. BEARING CAGE 15. PLUNGER 21. BRUSH HOLDER
4. STARTER DRIVE HOUSING 10. PINION 16. GASKET 22. BEARING
5. O-RING 11. STARTER SOLENOID ASSEMBLY 17. COVER 23. ARMATURE
6. STARTER DRIVE 12. ROLLER 18. SCREW 24. CLAMP
STARTER AND STARTER SOLENOID EXPLODED VIEW

4006-13
ASSEMBLY
STEP 23 STEP 27
Install the plunger in the starter solenoid.
STEP 24
B330714M
Install the bearings in the bearing cage.
B330711M STEP 28
If necessary, install a new gasket in the cover.
STEP 25
B330715M
Lubricate the bearings and teeth of the idler gear with

the grease specified on page 3.
B330708M
Install the cover. STEP 29
STEP 26
B330834M
Install the thrust washer.

B330712M
Install and tighten the screws.

4006-14
STEP 30 STEP 33
B330704M B330838M
Install the bearing cage as shown. Install a new O-ring in the groove in the starter drive housing.
Lubricate the O-ring.
STEP 31
STEP 34
B330703‘M
Install the idler gear. B330841M
Lubricate the open bearing on the starter drive with the grease
STEP 32 specified on page 3.
STEP 35
B330837M
Install the spring.

B330802M
Insert the starter drive into the starter drive housing.

4006-15
STEP 36 STEP 39
B330803M B330805M
Push down on the starter drive housing to push the Install a lock washer, flat washer, and O-ring on the
starter drive all the way into the starter drive housing. screws that hold the starter drive housing to the
starter solenoid. Lubricate the O-rings.
STEP 37
STEP 40
B330804M
Put a small amount of grease in the hole in the B330807M
starter drive and install the steel ball in the hole. Install the screws in the starter drive housing.
STEP 38 STEP 41
B330741M B330740M
Assemble the starter drive housing and starter Fasten the starter solenoid in the vise and tighten the
solenoid. screws that hold the starter drive housing.

4006-16
STEP 42 STEP 45
B330739M B330809M
Install the armature. Install the brush holder.
STEP 43 STEP 46
B330738M B330810M
Install the field frame assembly. Put the springs on top of the brushes connected to
the brush holder.
STEP 44
STEP 47
B330808M
Use the springs to hold the brushes in the brush B330811M
holder as shown. Install the brushes that are connected to the field coil.

4006-17
STEP 48 STEP 51
B330812M B330815M
Use a cap screw to align the brush holder with the Install and tighten the screws that hold the brush
field frame assembly. holder.
STEP 49 STEP 52
B330813M B330816M
Move the brush holder so that the brush holder is Install a lock washer, flat washer, and O-ring on the
even with the end of the armature. cap screws. Lubricate the O-rings.
STEP 50 STEP 53
B330814M B330818M
Install and align the cover with the brush holder. Install and tighten the cap screws.

4006-18
STEP 54 STEP 55
Pull the boot over the motor terminal.
B330731M
Install the cable, lock washer, and nut on the motor

terminal. Tighten the nut.
STARTER SOLENOID TEST

This test will check the condition of the pull-in 3. Connect a jumper wire to the battery terminal
winding and the hold-in winding in the starter and the switch terminal in the starter solenoid
solenoid. housing. The jumper wire must be made from
No. 10 or larger wire.
The jumper cable connected to the starter mounting
flange and the motor terminal must have a common 4. Connect the jumper cable with the common
connection at the negative battery post. connection to the starter mounting flange and the
motor terminal in the starter solenoid housing.
Starter Solenoid Test Procedure NOTE: Steps 5 and 7 must be done in a maximum
1. Remove the rubber boot from the motor terminal. of 15 seconds to prevent damage to the pull-in
Remove the nut and lock washer from the motor winding and the hold-in winding.
terminal. Then remove the wire from the motor 5. Connect the jumper cable with the common
terminal. connection to the negative battery post. The
2. Connect a jumper cable to the positive battery pinion gear on the starter drive must come all the
post of a fully charged 12 volt battery. Connect way out rapidly and with force.
the other end of the jumper cable to the battery 6. If the pinion gear did not come out rapidly and
terminal in the starter solenoid housing. with force, the pull-in winding is damaged. The
complete starter solenoid housing assembly
2 must be replaced.
7. Disconnect the jumper cable from the motor
terminal in the starter solenoid housing. The
pinion gear on the starter drive must not move
3 1 toward the starter drive housing.
5 8. If the pinion gear started to move toward the
4 starter drive housing, the hold-in winding is
damaged. The complete starter solenoid housing
assembly must be replaced.
B831438R
1. 12 VOLT BATTERY
2. STARTER
3. BATTERY TERMINAL
4. SWITCH TERMINAL
5. MOTOR TERMINAL

SECTION INDEX
POWER TRAIN

Hydrostatic System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
Removal and Installation of Hydrostatic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002
Drive Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6003
Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Drive Motors (Eaton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005
Single Speed Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005
Sprockets, Chains, and Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011

CNH AMERICA LLC
6001
Section
6001
HYDROSTATIC SYSTEM TROUBLESHOOTING

6001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHECKS TO DO BEFORE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDROSTATIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
One Transmission (Right or Left) Works Correctly and the Other Does Not . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Machine Does Not Have Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HYDROSTATIC SYSTEM TROUBLESHOOTING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Check 1- Checking Charge Pressure/Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Check 2 - Checking Circuit Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6001-3
SPECIFICATIONS
Hydrostatic Pump
Manufacturer ..............................................................................................................................Sauer/Sundstrand
Type ........................................................................................................................................Tandem axial piston
Model ..................................................................................................................................................................46
Displacement (410 and 420 Machines).......................................................................................... 46 cc (2.81 in3)
Displacement (430 and 440 Machines)....................................................................................... 34.7 cc (2.12 in3)
Pump Control Style ....................................................................................................................................... Servo
System Relief Pressure (forward and reverse) ....................................................................29,992 kPa (4350 psi)
Charge Oil Source.............................................................................................Integral charge pump gerotor type
Charge Pump Displacement ............................................................................................................ 23 cc (1.4 in3)
Charge Pressure (minimum at full throttle)............................................................... 2482 kPa (24.8 bar) (360 psi)
Charge Flow (410 and 420 Machines) (approximate, depends on motor and pump leakage) ...............................
.............................................................................................................................................72.3 L/min (19.1 gpm)
Charge Flow (430 and 440 Machines) (approximate, depends on motor and pump leakage) ...............................
................................................................................................................................................56 L/min (14.8 gpm)
Pump Flow at Rated Engine RPM (410 and 420 Machines).................................................109 L/min (28.9 gpm)
Pump Flow at Rated Engine RPM (430 and 440 Machines).................................................113 L/min (29.8 gpm)
Pump RPM/Engine RPM Ratio ..........................................................................................................................1:1
Hydrostatic Drive Motors (410 Machines)
Manufacturer .............................................................................................................................................. Rexroth
Type ...................................................................................................................................................Radial Piston
Model ..........................................................................................................................................................MCR03
Displacement
Maximum ................................................................................................................................. 400 cc (24.4 in3)
Minimum .......................................................................................................................................................N/A
Speed at High Idle Minus 50 Engine RPM ...............................................................................................260 RPM
Low Range Torque
At Relief Pressure and 86% Efficiency ........................................................................... 1719 Nm (1267.8 lb/ft)
Shuttle Oil Flow Per Motor ...............................................................................................................................N/A)
Hydrostatic Drive Motors (420 Machines)
Manufacturer ................................................................................................................................................. Eaton
Type ............................................................................................................................................................Geroler
Model ............................................................................................................................................................ VIS40
Displacement
Maximum ................................................................................................................................. 503 cc (30.7 in3)
Minimum .......................................................................................................................................................N/A
Speed at High Idle Minus 50 Engine RPM ...............................................................................................260 RPM
Low Range Torque
At Relief Pressure and 86% Efficiency .............................................................................. 1928 Nm (1422 lb/ft)
Hydrostatic Drive Motors (430 and 440 Machines)
Manufacturer .............................................................................................................................................. Rexroth
Type ...................................................................................................................................................Radial Piston
Model ..........................................................................................................................................................MCR05
Displacement
Maximum (Single Speed)......................................................................................................... 470 cc (28.7 in3)
Maximum (Optional Two Speed) ............................................................................................. 282 cc (17.2 in3)
Speed at High Idle Minus 50 Engine RPM (Single Speed)..................................................................238 RPM
Speed at High Idle Minus 50 Engine RPM (Optional Two Speed).......................................................397 RPM
Low Range Torque
At Relief Pressure and 90% Efficiency ........................................................................... 2019 Nm (1489.1 lb/ft)
High Range Torque
At Relief Pressure and 90% Efficiency .......................................................................... 1211.6 Nm (893.6 lb/ft)

6001-4
SPECIAL TOOLS
The troubleshooting and adjustment procedures in
this section can be performed using common
mechanic’s tools and the CAS-1804 Pressure Test
Kit.
B009638M
CAS-1804 PRESSURE TEST KIT

6001-5
SAFETY RULES
WARNING: Operate the Skid Steer controls from the WARNING: DO NOT LEAVE THE OPERATOR’S
operator’s seat only. SEAT WITH THE ENGINE RUNNING.
WARNING: When servicing the with the engine WARNING: If the Skid Steer lift arms are raised,
running, have another person help you. Follow the ALWAYS engage the loader support strut and lower
instructions in this manual or the operator’s manual. the lift arm to contact the support strut before you
service the machine.
CHECKS TO DO BEFORE TROUBLESHOOTING.

1. Check the oil level, type, and grade in the 5. Check that the tires are correct for the
hydraulic reservoir. See Section 1001 for correct application and surface, same size, and correctly
hydraulic oil. inflated. See operator’s manual for inflation
pressure.
2. Check hydraulic oil filter condition and change as
necessary. See Operators Manual for procedure. 6. Flotation tires are designed for dirt, when used
on concrete surfaces they can cause resistance
3. Check control linkage for correct operation. See
when steering.
Section 9001 for adjustment.
7. Check for correct balance and counter weights
4. Check drive chain tension. See Section 9001 for
for attachments and machine application.
adjustment procedures.
NOTE: This is a Skid Steer. More weight is to be
carried by one pair of tires (front or rear) depending
on the application or portion of the duty cycle. This
allows the tires with the lighter load to skid easily
when turning.

6001-6
HYDROSTATIC SYSTEM TROUBLESHOOTING
One Transmission (Right or Left) Machine Does Not Have Enough

Works Correctly and the Other Power
Does Not 1. Check full throttle and rated engine speeds.
1. Check to see that the direction control levers are A. Is there still a problem? No: Troubleshooting
adjusted correctly. See section 9001. complete. Yes: Go to Step 2.
A. Is there still a problem? No: Troubleshooting 2. Full throttle engine speed is good, rated engine
complete. Yes: Go to Step 2. speed is low. Problem in engine or fuel system.
2. Check for charge pressure at the servo bypass Repair as required.
valve fitting while in neutral. A. Is there still a problem? No: Troubleshooting
A. Charge pressure OK? Stroke the control lever. complete. Yes: Go to Step 3.
A 20psi or greater drop indicates a leaky 3. Do Check 1 - Checking Charge Pressure. Also
servo. check for damaged parts. Adjust pressure
B. Is there still a problem? No: Troubleshooting setting.
complete. Yes: Go to Step 3. A. Is there still a problem? No: Troubleshooting
3. Check the pressure setting of the circuit relief complete. Yes: Go to Step 4.
valve for the transmission with the problem. 4. Disassemble and inspect the hydrostatic pump
A. Do Check 2 - Checking Circuit Relief Valve and hydrostatic drive motors. Repair as required.
Pressure.
B. Is there still a problem? No: Troubleshooting
complete. Yes: Go to Step 4.
4. There is too much leakage in the hydrostatic
system. Disassemble and inspect the piston
pump and drive.

6001-7
HYDROSTATIC SYSTEM TROUBLESHOOTING CHECKS
Check 1- Checking Charge 5. If the pressure is correct go to step 7. If the

pressure is not correct loosen the cap on the
Pressure/Flow hydraulic reservoir. Remove the plug, shim(s),
IMPORTANT: For the following test the machine spring, and poppet for the charge relief valve.
MUST be raised up on supports until the tires are See figure below.
above the floor. This is a safety procedure if the
CHARGE RELIEF VALVE
parking brake latch pins fail to hold.
NOTE: You will need two people to perform this test.
The ROPS canopy must be raised to gain access to
the hydrostatic pumps. In order to start the engine,
someone will need to lower the seat bar to the
operating position and press on the seat to close the
seat switch.
1. Connect a 4,137 kPa (41 bar) (600 psi) pressure
gauge to test port 1, see next figure.
2. If the hydraulic oil is not at operating temperature
run the engine at full throttle and hold the bucket
control lever in the ROLLBACK position for 30 ENGINE
seconds. Then return the bucket control lever to GM98H002
NEUTRAL for 15 seconds. Repeat this cycle until CHARGE RELIEF VALVE LOCATION
the temperature of the oil is at least 52 ° C
6. Inspect the parts of the charge relief valve. If the
(125°F).
parts are good, add shim(s) from the shim kit and
3. Continue to run the engine at full throttle. Read repeat steps 1 through 4 until the pressure is
the pressure gauge and record the Charge correct.
Pressure reading. Stop the engine.
7. After you get the correct charge pressure in
NEUTRAL, do the following steps:
TEST PORT 1
IMPORTANT: For the following test the machine
MUST be raised up on supports until the tires are
above the floor. This is a safety procedure if the
parking brake latch pins fail to hold.
A. Start and run the engine at low idle. With the
parking brake activated (ROPS canopy
raised), slowly move the direction control
levers into FORWARD until the pins for the
parking brake latch engage each brake
sprocket.
B. Increase the engine speed to full throttle.
ENGINE
Slowly move one of the direction control
HI01E019 levers FORWARD to load the hydraulic piston
TEST PORT LOCATION pumps without decreasing the engine speed.
4. The pressure must be a minimum of 2,482 kPa Repeat for the other control lever.
(24.8 bar) (360 psi) at full throttle. C. Read the pressure gauge. The pressure must
be within 138 kPa (1.5 bar) (20 psi) of the
pressure in step 3.
D. Repeat Steps B and C with the direction
control levers in REVERSE.

6001-8
Check 2 - Checking Circuit Relief 3. Run the engine at low idle. Raise the seat bar
and slowly move the direction control levers into
Valve Pressure FORWARD until the pins for the parking brake
IMPORTANT: For the following test the machine latch engage each drive sprocket.
MUST be raised up on supports until the tires are 4. Increase the engine speed to full throttle. Move
above the floor. This is a safety procedure if the the control lever for the circuit being tested one
parking brake latch pins fail to hold. half the distance of full travel and watch the
NOTE: You will need two people to perform this test. pressure gauge. When the pressure gauge stops
The ROPS canopy must be raised to gain access to increasing, read the pressure gauge and move
the hydrostatic pumps. In order to start the engine, the control lever to NEUTRAL.
someone will need to lower the seat bar to the 5. The correct pressure is the gauge reading minus
operating position and press on the seat to close the the charge pressure. If the pressure is not
seat switch. correct, use a new circuit relief valve. You can
1. Connect a 690 bar (10,000 psi) pressure gauge temporarily repair a forward circuit by
to the test port. See the figure below. interchanging a functioning reverse circuit relief
valve with the forward circuit relief valve. See the
RH MOTOR LH MOTOR figure below.
REVERSE FORWARD
TEST PORT TEST PORT
RH REVERSE LH FORWARD
CIRCUIT RELIEF CIRCUIT RELIEF
RH MOTOR LH MOTOR
FORWARD REVERSE
ENGINE TEST PORT TEST PORT
HI01E019
RH FORWARD LH REVERSE
ENGINE CIRCUIT RELIEF CIRCUIT RELIEF
RH AND LH MOTOR TEST PORT LOCATIONS
HI01E019
2. If the hydraulic oil is not at operating temperature
CIRCUIT RELIEF VALVE LOCATIONS
run the engine at full throttle and hold the bucket
control lever in the ROLLBACK position for 30
seconds. Then return the bucket control lever to
NEUTRAL for 15 seconds. Repeat this cycle until
the temperature of the oil is at least 52 ° C
(125°F).

6001-9
NOTE: 2
THIS ILLUSTRATION SHOWS
A TYPICAL HYDROSTATIC
PUMP. AL L VALVES AND
INLETS ARE AS SHOWN.
1
HI01E018
1. BYPASS/TOW VALVE
2. CHARGE PUMP INLET
HYDROSTATIC TANDEM AXIAL PISTON PUMP

6001-10
NOTES

6002
Section
6002
REMOVAL AND INSTALLATION OF

HYDROSTATIC COMPONENTS
CNH AMERICA LLC

700 State Street Copyright © 2005 CNH America LLC
Racine, WI 53404 U.S.A. Printed in U.S.A.
Bur 6-79530 Issued February, 2005
6002-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TANDEM (HYDROSTATIC) PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
410 HYDRAULIC (DRIVE) MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
420 HYDRAULIC (DRIVE) MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6002-3
TORQUE SPECIFICATIONS
Tandem Pump to Bracket Mounting Bolts
(Apply Locktite 243 to the Threads)...................................................................110 to 122 Nm (80 to 90 pound-feet)
Tandem Pump Mounting Bracket to Chassis Mounting Bolts
(Apply Locktite 243 to the Threads).......................................................................54 to 60 Nm (40 to 44 pound-feet)
410 Hydraulic Drive Motor Mounting Bolts ...................................... 56 Nm (40 pound-feet) plus Turn Additional 65°
420 Hydraulic Drive Motor Mounting Bolts
(Apply Locktite 243 to the Threads)............................................... 122 Nm (90 pound-feet) plus Turn Additional 60°

6002-4
TANDEM (HYDROSTATIC) PUMP
Removal STEP 7
Disconnect all the electrical connections from the
STEP 1 tandem pump.
Remove the cap from the hydraulic reservoir.
STEP 8
STEP 2 Remove the nuts, washers, and control linkages from
Connect a vacuum pump to the hydraulic reservoir. the tandem pump.
STEP 3 STEP 9
Start the vacuum pump. Connect acceptable lifting equipment to the tandem
pump.
STEP 4
STEP 10
BD05C001
BD05C001
Tag and disconnect all hoses from the tandem pump. Loosen and remove the set screw in the pump drive
Install plugs in the hoses and caps on the fittings. joint.
STEP 5 STEP 11
BD05A085
BD05C001
Remove the access plate for the gear pump. Tag and
Remove the bolts and washers from the tandem
disconnect all hoses from the gear pump. Install
pump mounting flange.
plugs in the hoses and caps on the fittings.
STEP 6
Stop the vacuum pump.

6002-5
STEP 12 Installation
STEP 1
Connect acceptable lifting equipment to the tandem
pump. Use the lifting equipment and move the
tandem pump into the mounting location.
STEP 2
BD05C001
Loosen and remove the mounting bolts from the front

tandem pump mounting bracket.
STEP 13
Move the tandem pump away from the engine and
disengage the pump drive shaft from the pump drive
joint. BD05C001
Move the tandem pump towards the engine. Engage

STEP 14 the splines of the pump drive joint with the splines on
Remove the tandem pump from the machine. the pump drive shaft.
STEP 3
BD05C001
Apply Loctite No. 243 to the threads of the front

tandem pump bracket mounting bolts and install the
mounting bolts. Tighten the mounting bolts to a
torque of 54 to 60 Nm (40 to 44 pound-feet).

6002-6
STEP 4 STEP 10
BD05C001 BD05A085
Apply Loctite No. 243 to the threads and install the 4 Remove the plugs from the hoses and caps from the
tandem pump mounting bolts and washers and nuts fittings. Connect and tighten all hoses to the fittings
into the tandem pump mounting bracket. Tighten the on the gear pump. Install the access plate for the
mounting bolts to a torque of 54 to 60 Nm (40 to 44 gear pump. Install and tighten the mounting bolts for
pound-feet). the access cover.
STEP 5 STEP 11
Install and tighten the set screw in the pump drive Stop the vacuum pump. Disconnect the vacuum
joint. pump from the hydraulic reservoir. Install the cap on
the reservoir.
STEP 6
Connect all the electrical connections to the tandem STEP 12
pump Clean up any hydraulic fluid from equipment or floor.
STEP 7 STEP 13
Install the control linkages washers, and nuts to the Start and run the engine at low idle for 2 to 5 minutes
tandem pump. and check for any leaks.
STEP 8 STEP 14
Start the vacuum pump. Stop the engine.
STEP 9 STEP 15
Check the level of the oil in the hydraulic reservoir.
Add hydraulic oil as required. See Section 1001 for
the correct hydraulic oil specifications.
STEP 16
Install the cap on the hydraulic reservoir.
BD05C001
Remove the caps from the fittings and plugs from the
hoses. Connect and tighten all of the hoses to the
fittings on the tandem pump.

6002-7
3
1
BS04N063
1. BOLTS 3. BELL HOUSING
2. PUMP DRIVE JOINT 4. FLYWHEEL
DRIVE COUPLING INSTALLATION

6002-8
410 HYDRAULIC (DRIVE) MOTOR
Removal STEP 4
NOTE: Photos may not be the same as the machine
you are repairing, the procedure is the same.
STEP 5
NOTE: It may be necessary to disconnect hydraulic Connect a vacuum pump to the hydraulic reservoir.
hoses from the tandem pump, or remove the tandem
pump from the machine, to remove the hydraulic
STEP 6
drive motors from the machine. See page 4 for the
procedure to remove the tandem pump from the Start the vacuum pump.
machine.
STEP 7
STEP 1
1 2
BD05A087
BD01C103
Tag and disconnect all of the hydraulic hoses and
Remove the bolts (1) and washers from the chain hydraulic lines from the drive motor / brake
tank cover (2). Remove the chain tank cover (2) from assembly. Install plugs in the hoses and caps on the
the machine. fittings.
STEP 2 STEP 8
Stop the vacuum pump.
1 3 STEP 9
1 Attach acceptable lifting equipment to the drive
motor.
2 STEP 10
BD01F305
Loosen the flange nuts (3) on the front and rear axle
housings. Slide the axle housings towards the drive
sprocket (2) to allow slack in the drive chains.
Remove the drive chains (1) from the drive sprocket
(2).
STEP 3 BD05A086
Place a shop towel under the hydraulic drive motor / Loosen and remove the mounting bolts from the
brake assembly. drive motor mounting flange which fasten the drive
motor / brake assembly to the chassis. Remove the
drive motor / brake assembly from the chassis.
6002-9
Installation STEP 15
If the tandem pump was removed, install the tandem
STEP 11 pump.
Use acceptable lifting equipment and install the drive
motor / brake assembly into the chassis mounting STEP 16
location. Stop the vacuum pump. Disconnect the vacuum
pump from the reservoir. Install the cap on the
STEP 12 hydraulic reservoir.
STEP 17
1
1
BD05A086
Install the mounting bolts and nuts into the drive

motor mounting flange. Tighten the nuts to a torque BD01F305
of 122 Nm (90 pound-feet) plus turn additional 60° . Install the drive chains (1) onto the drive sprocket (2).
STEP 13 STEP 18
Start the vacuum pump. See Section 6007 for the procedure to adjust the
drive chain tension.
STEP 14
STEP 19
Adjust the drive chain tension.
STEP 20
BDO5A087
hoses. Install and tighten all of the hoses and
hydraulic lines on the drive motor.
BD01C258
Remove the old sealant and apply new RTV sealant

between the gasket, cover, and the chassis. Install
the chain tank cover and the bolts onto the chassis.
Tighten the bolts to a torque of 125 to 150 Nm (93 to
112 pound-feet).

6002-10
STEP 21 STEP 22
Clean up any hydraulic oil from the equipment or the
floor.
STEP 23
Start and run the engine at low idle for 2 to 5 minutes
and check for any leaks.
STEP 24
Disengage the park brake and move the machine in
order to remove any air from the hydrostatic system.
BD01C268 STEP 25
If the wheels were removed, install the wheels and Stop the engine.
the wheel nuts.
For machines equipped with Stamped Center STEP 26
Wheels with tapered type lug nuts, tighten wheel nuts
to a torque of 135 to 163 Nm (100 to 120
pound-feet).
For machines equipped with Solid Center Wheels
with flange type lug nuts, tighten wheel nuts to a
torque of 224 to 265 Nm (165 to 195 pound-feet). STEP 27

6002-11
1
2
4
3
BS05C069
1. HYDROSTATIC PUMP 4. GEAR PUMP
2. DRIVE MOTOR 5. FILTER ASSEMBLY
3. BRAKE VALVE
410 HYDROSTATIC DRIVE SYSTEM

6002-12
420 HYDRAULIC (DRIVE) MOTOR
Removal STEP 4
NOTE: Photos may not be the same as the machine
you are repairing, the procedure is the same.
STEP 5
NOTE: It may be necessary to disconnect hydraulic Connect a vacuum pump to the hydraulic reservoir.
hoses from the tandem pump, or remove the tandem
pump from the machine, to remove the hydraulic STEP 6
drive motors from the machine. See page 4 for the Start the vacuum pump.
procedure to remove the tandem pump from the
machine. STEP 7
STEP 1
1 2
BS05C072
Tag and disconnect all of the hydraulic hoses and
BD01C103 hydraulic lines from the drive motor / brake
Remove the bolts (1) and washers from the chain assembly. Install plugs in the hoses and caps on the
tank cover (2). Remove the chain tank cover (2) from fittings.
the machine.
STEP 8
STEP 2 Stop the vacuum pump.
STEP 9
1 3 Attach acceptable lifting equipment to the drive
1 motor.
STEP 10
2
BD01F305
Loosen the flange nuts (3) on the front and rear axle
housings. Slide the axle housings towards the drive
sprocket (2) to allow slack in the drive chains.
Remove the drive chains (1) from the drive sprocket
(2).
BS05C072
STEP 3 From inside the chain tank, loosen and remove the
Place a shop towel under the hydraulic drive motor / mounting bolts from the drive motor mounting flange
brake assembly. which fasten the drive motor / brake assembly to the
chassis. Remove the drive motor / brake assembly
from the chassis.

6002-13
Installation STEP 15
If the tandem pump was removed, install the tandem
STEP 11 pump.
Use acceptable lifting equipment and install the drive
motor / brake assembly into the chassis mounting STEP 16
location. Stop the vacuum pump. Disconnect the vacuum
pump from the reservoir. Install the cap on the
STEP 12 hydraulic reservoir.
STEP 17
1
1
BS05C072
Install the mounting bolts and nuts inside the chain

tank into the drive motor mounting flange. Tighten BD01F305
the bolts to a torque of 122 Nm (90 pound-feet) plus Install the drive chains (1) onto the drive sprocket (2).
turn additional 60° .
STEP 18
STEP 13 See Section 6007 for the procedure to adjust the
Start the vacuum pump. drive chain tension.
STEP 14 STEP 19
Adjust the drive chain tension.
STEP 20
BS05C072
hoses. Install and tighten all of the hoses and
hydraulic lines on the drive motor. BD01C258
Remove the old sealant and apply new RTV sealant

between the gasket, cover, and the chassis. Install
the chain tank cover and the bolts onto the chassis.
Tighten the bolts to a torque of 125 to 150 Nm (93 to
112 pound-feet).

6002-14
STEP 21 STEP 22
Clean up any hydraulic oil from the equipment or the
floor.
STEP 23
Start and run the engine at low idle for 2 to 5 minutes
and check for any leaks.
STEP 24
Disengage the park brake and move the machine in
order to remove any air from the hydrostatic system.
BD01C268 STEP 25
If the wheels were removed, install the wheels and Stop the engine.
the wheel nuts.
For machines equipped with Stamped Center STEP 26
Wheels with tapered type lug nuts, tighten wheel nuts
to a torque of 135 to 163 Nm (100 to 120
pound-feet).
For machines equipped with Solid Center Wheels
with flange type lug nuts, tighten wheel nuts to a
torque of 224 to 265 Nm (165 to 195 pound-feet). STEP 27

6002-15
4 3
BS05C071
1. HYDROSTATIC PUMP 4. GEAR PUMP
2. DRIVE MOTOR 5. FILTER ASSEMBLY
3. BRAKE VALVE
420 HYDROSTATIC DRIVE SYSTEM

6002-16
NOTES

Section
6003
6003
DRIVE COUPLER

6003-2
TABLE OF CONTENTS
DRIVE COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

6003-3
Bolts for Pump Drive Joint ...................................................................................94 to 106 Nm (69 to 78 pound-feet)

6003-4
DRIVE COUPLER
Disassembly Inspection
1. Tilt the ROPS canopy forward according to the 1. Inspect the pump drive joint (2) for cracks or any
instructions in Section 9004. other damage. Inspect the splines on the pump
drive joint (2) for wear or any other damage. Use
2. Loosen and remove the bolts (1) and washers new parts as required.
from the pump drive joint (2).
3. Remove the pump drive joint (2) from the engine.
4. Slide the pump drive joint (2) off of the pump
drive shaft and remove the pump drive joint (2)
from the pump shaft.

6003-5
3 1
1
BS04N063
1. BOLTS 3. BELL HOUSING

2. PUMP DRIVE JOINT 4. FLYWHEEL
EXPLODED VIEW OF DRIVE COUPLER

6003-6
Assembly
1. Apply Molycote GN tp the pump drive joint (2)
splines. Engage the pump drive joint (2) splines
onto the splines of the pump shaft. Slide the
pump drive joint (2) onto the pump drive shaft.
2. Install the pump drive joint (2) onto the flywheel
(4). Install the mounting bolts (1) into the pump
drive joint (2). Tighten the bolts (1) to a torque of
94 to 106 Nm (69 to 78 pound-feet).
3. Lower the ROPS canopy according to the

instructions in Section 9004.
4. Start and run the engine at low idle and check for
oil leaks.
5. Stop the engine and check the oil level in the
hydraulic reservoir. If the level is low, add only
the specified oil to the hydraulic reservoir. See
Section 1001.

Section
6004
6004
PISTON PUMP
CNH AMERICA LLC Copyright © 2003 CNH America LLC.

6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SEPARATING THE PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ASSEMBLING THE PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassembly, Inspection, and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6004-3
SPECIFICATIONS
Manufacturer ..................................................................................................................................Sauer Sundstrand
Type............................................................................................................................................Tandem Axial Piston
Model Number .........................................................................................................................................................46
Approximate Weight .....................................................................................................................59 kg (130 pounds)
SPECIAL TORQUES
Bolts that hold pumps together............................................................................91 to 111 Nm (67 to 82 pound-feet)
Orifice ............................................................................................................... 0.9 to 1.3 Nm (8 to 12 pound-inches)
Bypass valve .................................................................................................... 9 to 13 Nm (84 to 120 pound-inches)
Bolts for servo piston covers .......................................................................... 11 to 15 Nm (96 to 132 pound-inches)
3/8 inch Special bolts for cover..............................................................................53 to 64 Nm (39 to 47 pound-feet)
7/16 inch Special bolts for cover..........................................................................81 to 100 Nm (60 to 74 pound-feet)
GENERAL INFORMATION
Some types of failures will require the disassembly of NOTE: The following steps use photographs of a
the tandem pump for cleaning and inspection. If there typical tandem pump only as a general guide. When
is a failure in the drive motors or tandem pump, disassembling and assembling the rear pump refer to
disassemble both the rear and front pumps, the drive illustrations on pages 15, 16, 17. When
motors, and all hoses between the pumps and drive disassembling and assembling the front pump refer
motors. See Section 8002 for information about to illustrations on pages 18, 19, 20.
cleaning the hydrostatic system.
SEPARATING THE PUMPS

STEP 1 STEP 2
BD01H182 BD01H183
Remove the bolts (10) that fasten the pumps Remove the nut (11) and bracket from the stud (12).
together, see the illustration on page 20.
NOTE: During assembly, tighten the bolts (10) to 91
to 111 Nm (67 to 82 pound-feet).

6004-4
STEP 3 STEP 4
39
37
38
BD01H185
BD01H184
Separate the pumps. Replace the o-rings (37 and 38) and back-up ring
(39), see the illustration on page 15.
ASSEMBLING THE PUMPS

Assemb le the pu mps in the reverse order o f
separating the pumps.
NOTE: Follow all special torque instructions.
REAR PUMP
Disassembly STEP 6
STEP 5
36
BD01H187
Remove the coupling (31) and pin (32).

BD01H186
Remove the cover (35), see the illustration on page

15. Note the position of the cover and the pin (36) for
use during assembly.

6004-5
STEP 7 STEP 10
BD01H188 BD01H190
Remove the inner gear (33). Remove the special bolts (6 and 7) from the cover
(9).
STEP 8
STEP 11
BD01H189
Remove the outer gear (34). BD01H191
Remove the cover (9), gasket (29), and shaft (5).

STEP 9
STEP 12
BD01H192
Remove the bolt stud. BD01H193
Remove the swash plate (13).

6004-6
STEP 13 STEP 16
BD01H194 BD01H197
Remove the pistons (16) and retainer (17). Remove the wear plate (27)
STEP 14 STEP 17
BD01H195 BD01H198
Remove the guide (18). Be careful not to lose the three pins (20) in the
cylinder block (21). Do not try to disassemble the
STEP 15 cylinder block (21).
STEP 18
BD01H196
Remove the cylinder block (21).

BD01H199
Remove the gasket (29).

6004-7
STEP 19 STEP 22
BD01H200 B518727
Remove the snap ring (2) from the seal (1). Press the shaft (5) out of the cover (9). Inspect the
bearing on the shft. Replace if neccessary.
STEP 20
STEP 23
B5182721
Fasten the cover (9) in a vise with soft jaws. Use a B518840
prybar to remove the seal (1). Inspect the bearings (4) on the cover (9). If the yellow
surface has worn through to the dark base, use new
STEP 21 bearings.
STEP 24
B518724
Remove the snap ring (3).

BD01H201
Remove the screws (3) from the cover (6), see the
illustration on page 16.

6004-8
STEP 25 STEP 28
BD01H202 BD01H230
Pull the piston (18) from the housing. Measure the distance from the end of the special bolt
(15) to the cover (6). Record the measurement.
STEP 26
STEP 29
Turn the cover (6) off of the special bolt (15).
STEP 30
BD01H203
Remove and discard the gasket (7). 10
STEP 27
BD01H231
Fasten the piston (18) in the vise with soft jaws. Hold
the adjusting nut (10) and loosen the jam nut (9).
STEP 31
BD01H229
Prevent the special bolt (15) from turning and remove

the special nut (2).
BD01H232
Hold the special bolt (15) and tighten the adjusting

nut (10) to push the outer spring guide (11) away
from the retaining ring (8).

6004-9
STEP 32 STEP 35
31 16
31
16
BD01H233 BD01H235
Remove the retaining ring (8). The retaining ring (8) Remove and discard the piston rings (16, 31), and
will be difficult to remove. O-rings (17) from the piston (18).
STEP 33 STEP 36
BD01H234 BD01H204
Remove the spring assembly (12). Remove the screws (3) from the cover (19).
STEP 34 STEP 37
14
12
11
10
9
BD01H236 BD01H205
Remove the jam nut (9) and adjusting nut (10). Remove the cover (19) and gasket (7).
Separate the outer spring guide (11), spring (12),
sleeve (13), and inner spring guide (14).

6004-10
STEP 38 STEP 41
BD01H206 BD01H209
Make a mark to show the position of the stop bracket Remove the lock nut (20) and washer (21) from the
(23). spool (27).
STEP 39 STEP 42
25
26
27
BD01H207 BD01H213
Remove the bolts. Remove the spool assembly (27) Remove and discard the backup ring (25) and o-ring
from the housing. (26) from the spool (27).
STEP 40 STEP 43
30
29
28
BD01H209 BD01H214
Remove the sleeve (30) from the housing. Remove and discard the backup ring (28) and o-ring
(29) from the sleeve (30).

6004-11
STEP 44 STEP 47
BD01H215 BD01H217
Remove the hex plug (22) and shims (20) for the Remove the valve poppet (18).
charge pressure relief valve, refer to illustration on
page 17. STEP 48
STEP 45
BD01H218
Make a mark on one of the circuit relief-check valves

BD01H227 (2).
Remove the shims (20) from the hex plug (22). Do
not lose the shims. STEP 49
STEP 46
BD01H219
Remove the hex plug (2) for the circuit relief-check

BD01H216 valve.
Remove the spring (19).

6004-12
STEP 50 STEP 53
BD01H220 BD01H223
Remove the spring (5). Remove the bypass valve (17).
STEP 51 STEP 54
16
15
BD01H221 BD01H228
Remove the circuit relief-check valve (4). Remove and discard the o-ring (15) and backup ring
(16).
STEP 52
BD01H222
Loosen the bypass valve (17).

6004-13
STEP 55 STEP 58
BD01H225 B313327
Measure the thickness of each shoe. If the

measurements are not equal to within 0.02 mm
(0.001 inch), use a new cylinder assembly.
STEP 59
Inspect the face of the cylinder block (21) for wear,
scoring, and other damage. Use a new cylinder
assembly as necessary.
STEP 60
Inspect the cylinder bores for wear, scoring, and
other damage. Use new cylinder assembly as
BD01H226 necessary.
Remove the 90° elbow then the plug (7).
STEP 61
Inspection Lubricate the pistons and cylinder bores with clean
oil.
STEP 56
Clean all parts in cleaning solvent. STEP 62
Check the fit of the pistons (16) in the bores. The
STEP 57 piston (16) must move freely with minimum
clearance. Use a new cylinder assembly as
necessary.
STEP 63
Inspect the bronze surface of the wear plate (27).
Use a new wear plate (27) as necessary.
STEP 64
Inspect the parts of the charging pump for wear and
damage. Use a new pump as necessary.
STEP 65
B313202 Measure the gear tip clearance between the inner
Measure the free travel between the shoes and the gear (33) and outer gear (34). Clearance must not be
pistons (16), see the illustration on page 15. If all the more than 0.13 mm (0.005 inch).
measurements are not equal to within 0.13 mm
(0.005 inch), use a new cylinder assembly.

6004-14
STEP 66 STEP 68
Measure the width of the inner gear (33) and the Inspect the shaft (5) for damage to the splines and
outer gear (34). The width of each gear must be wear at the seal (1) surfaces.
equal to within 0.05 to 0.06 mm (0.002 to 0.003 inch).
STEP 69
STEP 67 Inspect the bearings (4, 11, and 28). Replace any
Inspect the pistons (16) for wear and damage. use damaged bearings.
new parts as necessary.
STEP 70
Inspect the circular relief valve seats in the housings.

6004-15
36
34
32
38
30
39
35
26
25 29
24 33
23 31
14 18
15
19 8 22
28
10
27
20 21
17
16
4 13
11
9
3
1 7
5 6
37
12
2
BS98F144
1. SEAL 9. COVER 17. RETAINER 25. SPRING SEAT 33. GEAR
2. SNAP RING 10. ROLL PIN 18. GUIDE 26. RING 34. GEAR HOUSING
3. SNAP RING 11. BALL BEARING 19. RETAINING RING 27. PLATE 35. COVER
4. JOURNAL BEARING 12. SNAP RING 20. PIN 28. NEEDLE BEARING 36. PIN
5. SHAFT 13. PLATE 21. CYLINDER BLOCK 29. GASKET 37. O-RING
6. SPECIAL BOLT 14. GUIDE 22. PIN 30. HOUSING 38. O-RING
7. SPECIAL BOLT 15. PIN 23. WASHER 31. COUPLING 39. BACK-UP RING
8. ROLL PIN 16. PISTON 24. SPRING 32. PIN
REAR PUMP CYLINDER, BEARINGS, SHAFT, AND PLATES

6004-16
20
4 21
5 6 22
7
2
8 10 23
9
11
24
3 12
25
26
27
30 28
13 29
18 1
14
15
7
19
17
16 5
31 4
3
BS01H247
1. TANDEM PUMP 8. RETAINING RING 15. SPECIAL BOLT 22. LEVER 29. O-RING
2. SPECIAL NUT 9. NUT 16. RING 23. BRACKET 30. SLEEVE
3. SCREW 10. NUT 17. O-RING 24. GUIDE 31. RING
4. HEX PLUG 11. GUIDE 18. PISTON 25. BACKUP RING
5. O-RING 12. SPRING 19. COVER 26. O-RING
6. COVER 13. GUIDE 20. NUT 27. SPOOL
7. GASKET 14. GUIDE 21. LOCK WASHER 28. BACKUP RING
REAR PUMP PISTON, COVERS, AND BRACKET

6004-17
BS03D066
1. HOUSING 7. PLUG 13. BOLT 19. SPRING
2. PLUG 8. HEX PLUG 14. SEAL 20. SHIM KIT
3. O-RING 9. O-RING 15. O-RING 21. O-RING
4. RELIEF VALVE 10. HEX PLUG 16. BACKUP RING 22. HEX PLUG
5. SPRING 11. O-RING 17. BY-PASS VALVE 23. PLUG
6. PLUG 12. ADAPTER 18. VALVE POPPET 24. O-RING
REAR PUMP VALVES, PLUGS, AND ADAPTER

6004-18
21
23
24
26 25
27
29
28
31
30
2
1
3
14 11
12
22 5
15
17
18 6
19 7
4 10
9
13
20 16
BS98F143
1. SEAL 9. COVER 17. RETAINER 25. SPRING SEAT
2. PLATE 10. ROLL PIN 18. GUIDE 26. RING
3. SNAP RING 11. BALL BEARING 19. RETAINING RING 27. PLATE
4. JOURNAL BEARING 12. SNAP RING 20. PIN 28. NEEDLE BEARING
5. SHAFT 13. PLATE 21. CYLINDER BLOCK 29. GASKET
6. SPECIAL BOLT 14. RETAINER 22. PIN 30. BOLT
7. SPECIAL BOLT 15. PIN 23. WASHER 31. ROLL PIN
8. ROLL PIN 16. PISTON 24. SPRING
FRONT PUMP CYLINDER, BEARINGS, SHAFT, AND PLATES

6004-19
3
2 20
6
4 7
21
8 10 22
9 11
5
12 23
24
25
26
27
28
13 18 29
14 30
15
1
17 7 19
16 3
31
5
4
BS98F141
1. TANDEM PUMP 8. RETAINING RING 15. SPECIAL BOLT 22. LEVER 29. O-RING
2. SPECIAL NUT 9. NUT 16. RING 23. BRACKET 30. SLEEVE
3. SCREW 10. NUT 17. O-RING 24. GUIDE 31. RING
4. HEX PLUG 11. GUIDE 18. PISTON 25. BACKUP RING
5. O-RING 12. SPRING 19. COVER 26. O-RING
6. COVER 13. GUIDE 20. NUT 27. SPOOL
7. GASKET 14. GUIDE 21. LOCK WASHER 28. BACKUP RING
FRONT PUMP PISTON, COVERS, AND BRACKET

6004-20
14
6
3 8
4 7
9
8
9 10
2
5 11
17 16
15 5
12
19
18 4
13 1 3
2
9
8
BS98F139
1. HOUSING 6. PLUG 11. NUT 16. BACK-UP RING
2. PLUG 7. PLUG 12. STUD 17. BY-PASS VALVE
3. O-RING 8. HEX PLUG 13. O-RING 18. PLUG
4. RELIEF VALVE 9. O-RING 14. PLUG 19. O-RING
5. O-RING 10. BOLT 15. O-RING
FRONT PUMP VALVES AND PLUGS

6004-21
Assembly STEP 74
STEP 71
BD01H222
Tighten the bypass valve (17) to 9 to 13 Nm (84 to

BD01H225
120 pound-inches).
Install and tighten the plug (7) 0.9 to 1.3 Nm (8 to 12
pound-inches), see the illustration on page 17. Then STEP 75
install the 90° elbow.
STEP 72
15 16
B9109025
17 Install the circuit relief-check valve (4).
B9109027
Install a new backup ring (16) and o-ring (15) on the

bypass valve (17).
STEP 73
BD01H220
Install the spring (5).
BD01H223
Install the bypass valve (17).

6004-22
STEP 76 STEP 79
BD01H219 BD01H215
Install and tighten the plug (2) to a torque of 115 to Install the shims (20) into the plug and install the hex
230 Nm (85 to 170 pound-feet). plug (22) for the charge pressure relief valve.
STEP 77 STEP 80
29
28
30
B9109024 BD01H214
Install the valve poppet (18). Install a new o-ring (29) and backup ring (28) on the
sleeve (30), see the illustration on page 16.
STEP 78
STEP 81
26 25
27
BD01H216
Install the spring (19). BD01H213
Install a new o-ring (26) and backup ring (25) on the

spool (27).

6004-23
STEP 82 STEP 85
BD01H211 BD01H208
Install the spool (27). Refer to the alignment mark Lubricate the spool (27) and install into the sleeve
made during disassembly. (30).
STEP 83 STEP 86
BD01H210 BD01H207
Install the washer (21) and nut (20) on the spool (27). Make sure the marks are in alignment and tighten the
bolts.
STEP 84
STEP 87
14
12
11
15
9 10
BD01H209
Lubricate the sleeve (30). Install the sleeve. Make BD01H236
sure the notch in the end of the sleeve is in alignment Assemble the special bolt (15), inner spring guide
with the notch in the body of the pump. (14), sleeve (13), spring (12), outer spring guide (11),
adjusting nut (10), and jam nut (9).

6004-24
STEP 88 STEP 91
BD01H237 BD01H238
Tighten the adjusting nut (10) to begin compression Hold the special bolt (15) and tighten the adjusting
of the spring (12). nut (10) until the outer spring guide (11) is below the
groove for the retaining ring (8).
STEP 89
STEP 92
16 31
16
31
BD01H235
BD01H239
Install new rings (31, 16) and o-rings (17) on the
Install the retaining ring (8).
piston (18).
STEP 93
STEP 90
BD01H232
BD01H234
Loosen the special bolt (15) just enough so the
Fasten the piston (18) in the vise with soft jaws.
spring (12) and adjusting nut (10) are not loose.
Install the spring assembly (12).

6004-25
STEP 94 STEP 97
BD01H241 BD01H244
Hold the adjusting nut (10) and special bolt (15). Turn the cover (6) onto the special bolt (15) until the
Tighten the jam nut (9). Recheck the special bolt and measurement is equal to the measurement in step 28
spring (12) to make sure the spring is not loose. of Disassembly.
STEP 95 STEP 98
BD01H242 BD01H245
Lubricate the piston (18) with clean oil. Install the When the measurement is correct, install and tighten
piston (18). the screws (3) to 11 to 15 Nm (96 to 132
pound-inches).
STEP 96
STEP 99
BD01H243
Push the piston (18) into the housing. Install a new BD01H246
gasket (7). Install the cover (6). Hold the special bolt (15) and install the special nut
(2). Install the special nut with sealing surface
inward.

6004-26
STEP 100 STEP 102
BD01H204 B518843
Install the cover (19) with a new gasket (7). Tighten If the ball bearing (11) for the shaft (5) has been
the screws (3) to 11 to 15 Nm (96 to 132 replaced, install the snap rings (12).
pound-inches).
STEP 103
STEP 101
B518730
B518838 Press the ball bearing (11) and shaft (5) into the
If necessary, install new bearings (4) on the cover cover (9).
(9), refer to illustration on page 15. Make sure the
holes in the bearings (4) engage the roll pins (10) in STEP 104
the cover (9).
NOTE: If a new cover (9) is being used, install new roll

pins (10) so the tops of the roll pins are 2.3 to 2.8 mm
(0.090 to 0.110 inch) above the face of the cover.
B518944
Install the snap ring (3) in the groove just above the
ball bearing (11).

6004-27
STEP 105 STEP 108
B518904 BD01H198
Lubricate the lip of the seal (1) with clean oil. Make sure the three pins (20) are installed in the
Carefully press the new seal (1), with the lip down, cylinder block (21).
into the cover (9).
STEP 109
STEP 106
BD01H247
BD01H200 Pull the pin retaining collar (19) up to the top of the
Install the other snap ring (2). splines.
STEP 107 STEP 110
26
BD01H197 BD01H196
Install the wear plate (26) with the bronze surface up. Install the cylinder block (21) into the pump.
Make sure the notch in the wear plate engages the
roll pin. Lubricate the wear plate (26) with clean oil.

6004-28
STEP 111 STEP 113
BD01H248 BD01H250
Install the guide (18) on the pins (20).
STEP 112
BD01H251
Lubricate the pistons (16) with clean oil. Install the

pistons (16) into the retainer (17) and cylinder block
BD01H249 one at a time. Make sure the guide (18) is still in
Install the retainer (17) on the guide. position on the three pins (20).
STEP 114
B518618
If a new swash plate (13) or pin (15) is being used,

press the pin (15) so that the end of the pin is 8.4 to
8.9 mm (0.33 to 0.35 inch) above the surface of the
swash plate (13). The slot in the pin (15) must be
toward the center of the swash plate (13).

6004-29
STEP 115 STEP 118
14
B519113 B9109118
Install the retainer (14) on the other pin (22) of the Carefully install the cover (9) and shaft (5). Rotate
swash plate (13). the shaft (5) to align the support and cylinder block.
STEP 116 STEP 119
BD01H193 BD01H190
Install the swash plate(13). The pin (15) must engage Install the special bolts (7 and 6). Use the bolts to
the slot in the body of the control valve and the evenly draw the cover (9) to the housing (30).
retainer (14) must engage the groove in the piston. Tighten the 3/8 inch special bolt to a torque of 53 to
64 Nm (39 to 47 pound-feet). Tighten the 7/16 inch
STEP 117 special bolts to a torque of 81 to 100 Nm (60 to 74
pound-feet).
STEP 120
B9109117
Install a new gasket (28).
BD01H189
Install the gear housing (33) in the cover (34).

6004-30
STEP 121 STEP 123
35
BD01H188 BD01H186
Install the inner gear (32). Lubricate the cover (34) with clean oil. Install the
cover (34) so that the pin (35) engages the hole at
STEP 122 the top of the housing.
STEP 124
Adjust the controls and piston for NEUTRAL.
BD01H187
Install the coupling (30). Make sure the pin (31) in the
coupling (30) engages the slot in the inner gear (32).
FRONT PUMP
Disassembly, Inspection, and

Assembly
Disassembly, inspection, and assembly of the front
pump is the same as the rear pump except for the
shaft and end cover. Repeat steps as necessary for
the front pump, refer to the illustration on page 18 in
place of the illustration on page 15, the illustration on
page 19 in place of the illustration on page 16, and
the illustration on page 20 in place of the illustration
on page 17.

Section
6005
DRIVE MOTORS (EATON)

WITH SPRING APPLIED - HYDRAULIC RELEASE
6005
BRAKES
CNH AMERICA LLC. Copyright © 2005 CNH America LLC

6005-2
TABLE OF CONTENTS
DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6005-3
DRIVE MOTOR
Disassembly STEP 4
NOTE: The following photos may not match your
machine, the procedure is the same.
STEP 1
BD01M052
Remove the end cover.
STEP 5
BD01M049
Mark all points of separation.
STEP 2
BD01M053
Remove the dash pot and spring from the valve

plate.
BD01M050 STEP 6
Loosen the bolts on the end cover.
STEP 3
Set the motor on blocks or in a vise with soft jaws.
Then remove the bolts.
BD01M054
Remove the valve plate.

6005-4
STEP 7 STEP 10
BD01M055
Remove the geroter assembly. Be careful not to BD01M058
loose the two small check balls in the bottom of the Remove the drive shaft.
geroter star.
STEP 11
STEP 8
BD01M059
BD01M056 Remove and discard the seal and back-up ring.

Remove the outer thrust plate.
STEP 12
STEP 9
BD01M060
Remove the O-ring from the flange.

BD01M057
Remove the inner thrust plate.

6005-5
STEP 13 STEP 16
BD01M061 BD01M066
Remove the seal from the flange. Remove the inner O-ring from the valve plate.
STEP 14 STEP 17
BD01M068
BD01M067
Remove the seal from the geroter housing. Remove the seal from the outer thrust plate.
STEP 15 STEP 18
BD01M062
BD01M065
Remove the outer seal from the valve plate. Remove the plug from the end cover.

6005-6
STEP 19 STEP 21
2
3
BD01M063
4
Remove the dash pot, spring, and poppet from the BS01M204
cover. 1. PLUG 2. SPRING 3. SHIM(S) 4. POPPET 5. O-RING

Remove the plug (1), spring (2), shim(s) (3), and
STEP 20 poppet (4) from the end cover.
BD01M064
Turn the cover on its side and remove the poppet

and shuttle piston.

6005-7
24
28
25
27 3 28
26
4
5
6
7 6
5
2 4
18
8
17
9
21
20 10
12
19 16 22
15
21
11 13
14
23
BS01M202
1. BOLT 8. VALVE PLATE 15. O-RING 22. FLANGE
2. END COVER 9. GEROTER ASSEMBLY 16. SEAL 23. SEAL
3. PLUG 10. OUTER THRUST PLATE 17. SEAL 24. PLUG
4. DASH POT 11. INNER THRUST PLATE 18. SEAL 25. SPRING
5. SPRING 12. DRIVE SHAFT 19. O-RING 26. SHIM
6. POPPET 13. BACKUP RING 20. SEAL 27. POPPET
7. SHUTTLE PISTON 14. O-RING 21. CHECK BALL 28. O-RING
DRIVE MOTOR

6005-8
Assembly STEP 25
STEP 22
BD01M068
Install a new seal onto the outer thrust plate.

BD01M061
Install the outer square cut seal on the flange. STEP 26
STEP 23
BD01M057
Install the inner thrust plate on the flange.

BD01M060
Install a new O-ring on the flange. STEP 27
STEP 24
BD01M056
Install the outer thrust plate on the flange.

BD01M059
Install the O-ring and backup ring on the flange with

the backup ring on top.

6005-9
STEP 28 STEP 31
BD01M058 BD01M065
Install the drive shaft into the output shaft. Install a new seal onto the valve plate.
STEP 29 STEP 32
BD01M067 BD01M066
Install a new seal onto the geroter housing. Install a new O-ring onto the valve plate.
STEP 30 STEP 33
BD01M055 BD01M054
Install the geroter assembly onto the shaft. Make Install the valve plate.
sure the two small check balls do not fall out.

6005-10
STEP 34 STEP 37
BD01M064 BD01M063
Install the shuttle piston and poppet into the end Install the poppet, spring, dash pot, and plug into the
cover. Use grease to hold them in place. end cover.
STEP 35 STEP 38
Install the spring and dash pot into the cover. Use
grease to hold them in place.
STEP 36
BD01M051
Install the plug on the cover.
STEP 39
BD01M050
Install the end cover and secure it with the bolts.

Torque bolts to 108 Nm (80 pound-feet).
1
2
3
4
BS01M204
1. PLUG 2. SPRING 3. SHIM(S) 4. POPPET 5. O-RING

Install the poppet (4), spring (2), shim(s) (3), and plug
(1) into the end cover.

Section
6005
SINGLE SPEED DRIVE MOTOR
6005

6005-2
TABLE OF CONTENTS
SINGLE SPEED DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6005-3
SINGLE SPEED DRIVE MOTOR
Disassembly STEP 4
STEP 1
BD04E005
Remove the gasket.

BD04E002
Make reference marks on the motor case for correct STEP 5

alignment during assembly.
STEP 2
BD04E006
Remove the disc spring.
BD04E002 STEP 6
Loosen and remove the socket head cap screws
alternately, one turn at a time from the cover plate.
STEP 3
BD04E008
Use compressed air in the port to force the piston up

for removal.
BD04E004
Remove the cover plate.

6005-4
STEP 7 STEP 10
BD04E009 BD04E014
Remove the piston. Use a soft hammer to loosen the brake housing.
STEP 8 STEP 11
BD04E010 BD04E015
Remove the O-ring. Remove the brake housing from the motor case.
STEP 9 STEP 12
BD04E011 BD04E016
Loosen and remove the socket head cap screws and Remove the brake discs and shims as one unit from
washers from the brake housing. the shaft.

6005-5
STEP 13 STEP 16
BD04E017 BD04E022
Remove the O-ring. Remove the flushing valve spool, 2 springs, and
washer from the valve port. Make a record of the
STEP 14 parts assembly for us e du ring the assembly
procedure.
STEP 17
BD04E020
Loosen the plug for the flushing spool valve.
STEP 15 BD04E023
Loosen the plug for the flushing valve poppet.
STEP 18
BD04E021
Remove the flushing spool valve plug.
BD04E024
Remove the plug from the port.

6005-6
STEP 19 STEP 22
BD04E025 BD04E029
Remove the spring and the flushing poppet. Remove the rear motor case.
STEP 20 STEP 23
BD04E026 BD04E030
Loosen the socket head cap screws. Remove the seal from the rear case.
STEP 21 STEP 24
BD04E028 BD04E042
Remove the socket head cap screws. Drop the rear case assembly from approximately
80mm onto a wooden or plastic surface. This will
release the distributor from the rear case.

6005-7
STEP 25 STEP 28
BD04E031 BD04E034
Remove the distributor from the rear case. Remove the seal from the front case.
STEP 26 STEP 29
BD04E032 BD04E035
Make a record of the number of springs and the stop Remove the cylinder block from the front case.
pin location in the distributor for use during the
assembly procedure. STEP 30
STEP 27
BD04E041
Place the front case assembly in the press. Use

BD04E033 acceptable tools and remove the split ring from the
Remove the cam from the front case. shaft.

6005-8
STEP 31 STEP 34
BD04E063 BD04E068
Use acceptable tools and press the shaft out of the If required, use acceptable tools and press the inner
front case. bearing cup from the front case.
STEP 32 Inspection
1. Clean all parts in cleaning solvent. Use a lint free
cloth or air dry all of the parts.
NOTE: The parts must be clean and free
contamination before assembly.
2. Inspect the bearings and cups for any damage.
Use new parts as required. Bearings and cups
must be installed as a set.
3. Inspect the shaft for any wear or damage. Use
new parts as required.
4. Inspect the cam, rollers and pistons for any wear
or damage. Use new parts as required.
BD04E065
5. Inspect the distributor for any wear or damage.
Use acceptable tools and press the seal out of the Use new parts as required.
front case.
6. Inspect the spool, springs, and poppet of the
flushing valve for any wear or damage. Use new
STEP 33
parts as required.
7. Inspect the brake discs and shims for any wear
or damage. Use new parts as required.
8. Replace all seals and O-rings as required. Use
clean hydraulic oil to lubricate all seals and
O-rings before installation.
BD04E066
If required, use acceptable tools and press the outer

bearing cup from the front case.

6005-9
Assembly STEP 41
Use acceptable tools and press the inner bearing
STEP 35 onto the shaft and into the inner bearing cup. Press
the bearing into the cup to a preload of 5 tonnes
(5000 kg). Rotate the front case during this
procedure. Allow the assembly to cool.
STEP 42
BD04E061
If removed, install a new outer bearing cup in the

front case.
STEP 36
BD04E059
Place special tool 380001893 onto the shaft. Using a

press and apply a preload 2 tonnes (2000 kg) to the
inner bearing.
STEP 43
BD04E067
If removed, install a new inner bearing cup in the

front case.
STEP 37
Lubricate a new shaft seal with clean hydraulic oil.
BD04E039
Use acceptable tools and install the new shaft seal
Use acceptable tools and install the split ring onto the
onto the shaft.
shaft.
STEP 38
Place the shaft in a press. Use acceptable tools and
warm the outer bearing. Use acceptable tools and
press the outer bearing onto the shaft.
STEP 39
Cover the splines on the shaft with tape to protect the
seal. Install the shaft into the front case. Remove the
tape from the splines.
STEP 40
Use acceptable tools and warm the inner bearing.

6005-10
STEP 44 STEP 47
Release the preload from the bearing and remove
the front case assembly from the press.
STEP 48
Check the shaft to make sure it rotates in the front
case assembly.
STEP 49
BD04E038
With the preload still applied, use acceptable tools

and measure the gap between the split ring and the
bearing.
STEP 45
BD04E035
Install the cylinder block onto the shaft.
STEP 50
BD04E040
Use acceptable tools and remove the split ring. Install

a shim with a thickness of 0.005 to 0.2 mm (0.002 to
0.008 inches) greater than the measured gap
between the split ring and the bearing surface.
STEP 46
BD04E034
Lubricate the seal with clean hydraulic oil. Install the

seal on the front case.
BD04E039
Install the split ring on the shaft.

6005-11
STEP 51 STEP 54
BD04E033 BD04E030
Install the cam on the cylinder block. Be sure to align Lubricate the seal with clean hydraulic oil. Install the
the cam with the alignment mark on the front case. seal on the rear case.
STEP 52 STEP 55
BD04E032 BD04E029
Install the springs and the stop pin in the distributor. Use the marks made during disassembly and install
the rear case onto the cam.
STEP 53
STEP 56
BD04E031
Lubricate the seals on the distributor with clean BD04E028
hydraulic oil. Install the distributor into the rear case. Apply Loctite 243 to the threads and install the socket
Be careful not to dislodge the springs while installing head cap screws into the rear case.
the distributor into the rear case. Make sure to the
stop pin is aligned with the hole in the rear case. Tap
the distributor with a soft hammer until it is seated in
the rear case.
6005-12
STEP 57 STEP 60
BD04E027 BD04E022
Tighten the socket head cap screws alternately from Lubricate the springs and flushing spool with clean
side to side to a torque of 117 to 122 Nm (86 to 90 hydraulic oil. Install the 2 springs, washer, and
pound feet). flushing spool into the valve port.
STEP 58 STEP 61
BD04E025 BD04E020
Lubricate the spring and flushing poppet with clean Lubricate the O-ring on the plug with clean hydraulic
hydraulic oil. Install the spring and flushing poppet oil. Install and tighten the plug.
into the port.
STEP 62
STEP 59
BD04E017
BD04E023 Lubricate the O-ring with clean hydraulic oil. Install

Lubricate the O-ring on the plug with clean hydraulic the O-ring on the brake housing.
oil. Install and tighten the plug.

6005-13
STEP 63 STEP 66
BD04E016 BD04E012
Lubricate with the brake discs and shims with clean Tighten the socket head cap screws alternately from
hydraulic oil. Install the brake discs and shims as one side to side to a torque of 70 to 77 Nm (52 to 57
unit on the shaft. Make sure all of the tabs on the pound feet).
brakes discs are aligned.
STEP 67
STEP 64
BD04E010
BD04E015 Lubricate the seal with clean hydraulic oil. Install the
Install the brake housing on the rear motor case. seal in the brake housing.
STEP 65 STEP 68
BD04E013 BD04E009
Apply Locktite 243 to the threads and install the Lubricate the seals on the piston with clean hydraulic
socket head cap screws into the brake housing. oil and install the piston into the brake housing.

6005-14
STEP 69 STEP 71
BD04E006 BD04E004
Install the disc spring on top of the piston. Install the cover plate onto the brake housing.
STEP 70 STEP 72
BD04E005 BD04E003
Install the gasket on the brake housing. Install the socket head cap screws into the cover
plate. Tighten the socket head cap screws alternately
from side to side to a torque of 14 to 16 Nm (10 to 12
pound feet).

Section
6007
SPROCKETS, CHAINS, AND AXLE ASSEMBLIES
6007

6007-2
TABLE OF CONTENTS
ADJUSTING THE DEFLECTION OF THE CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL AND INSTALLATION OF AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Axle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6007-3
Nuts for Axle Housings ..................................................................................223 to 265 Nm (165 to 195 pound-feet)
Wheel Nuts (Stamped Center Wheels with Tapered Type Lug Nuts) ...........135 to 163 Nm (100 to 120 pound-feet)
Wheel Nuts (Solid Center Wheels with Flange Type Lug Nuts) ....................224 to 265 Nm (165 to 195 pound-feet)
Bolts for Chain Tank ........................................................................................101 to 113 Nm (93 to 112 pound-feet)
Bolts for Drive Sprockets ...............................................................................247 to 320 Nm (185 to 235 pound-feet)
(All threads are to be clean and free of rust, dirt and oil. Apply Loctite 243 to the first 10 to 15 threads of the cap
screw)
NOTE: Be sure to recheck the wheel nuts every two hours until the wheel nuts remain tight. See Operations
Manual.

6007-4
ADJUSTING THE DEFLECTION OF THE CHAINS

1. Lower the loader bucket or attachment to the 12. When the chain deflection (8) is correct, 3.0 to
ground. 12.0 mm (0.12 to 0.50 inch, tighten the axle
mounting nuts (2) to a torque of 7 Nm (5
2. Use a jack or hoist to lift the machine off of the
pound-feet).
ground. Place approved jack strands under the
machine. Loosen and remove the wheel nuts (1) 13. Repeat the previous steps for the remaining
and wheels. See illustration on page 5. drive chains (3).
3. Clean the area around both chain tank inspection 14. Following adjustment of all drive chains (3), start
covers. Loosen and remove the (6) inspection the engine and run at low idle.
cover retaining bolts and special flat washers.
15. Move the drive control levers all of the way
4. Remove the inspection cover and gasket. Check forward for 5 seconds and stop the engine.
the gasket for damage and replace if necessary.
16. Check the deflection of all four drive chains. The
5. Start the machine. drive chains (3) are correctly adjusted if the
deflection is 3.0 to 12.0 mm (0.12 to 0.50 inch).
6. Push both steering control levers all the way
forward for 5 seconds. 17. If necessary, tighten or loosen the drive chains to
get the correct deflection.
7. Stop the engine.
18. Tighten the axle housing mounting nuts (2) to a
8. Check the deflection of the chains (3) on the
torque of 223 to 2654 Nm (165 to 190
slack side (8). The slack side is on top of the
pound-feet).
front chain and on the bottom of the rear chain
when traveling forward. Estimate the amount of 19. Apply RTV sealant between the gasket cover
deflection by moving the chain up and down. If and chassis and install the inspection cover.
deflection is more than 40 mm (1.5 inch) for one
20. Tighten the inspection cover retaining bolts to a
chain, adjust the deflection of all four chains.
torque of 101 to 113 Nm (75 to 83 pound-feet).
NOTE: The deflection of the chains can not be
21. Install the four wheels and tighten the wheel
measured with accuracy.
nuts.
9. Loosen the axle housing (9) and mounting nuts For machines equipped with Stamped Center
(2), so the axle is free to move. Wheels with tapered type lug nuts, tighten wheel
nuts (1) to a torque of 135 to 163 Nm (100 to 120
10. Insert a pry bar against the adjusting spud and
pound-feet).
axle housing (9).
For machines equipped with Solid Center
11. Pry against the axle housing (9) until it stops Wheels with flange type lug nuts, tighten wheel
moving. Tighten one or two axle mounting nuts nuts (1) to a torque of 224 to 265 Nm (165 to 195
(2) to hold the axle housing (9) in place and pound-feet).
check the chain deflection (8)
NOTE: Be sure to check the wheel nuts (2) every 2
hours until the nuts remain tight.
22. Remove the approved jack stands and lower the
machine to the ground.

6007-5
5 8
6
8
5 9
Rear Axle
3
8
9 3 7
6 5
10
8
Front Axle
2
3
1
4
1 2
9
BT96M075
1. WHEEL NUTS 6. CAP SCREW (DRIVEN SPROCKET)
2. AXLE HOUSING NUTS 7. WASHER
3. ROLLER CHAIN 8. CENTER OF SLACK SIDE OF CHAIN
4. DRIVE SPROCKET 9. AXLE HOUSING
5. DRIVEN SPROCKET 10. O-RING
ILLUSTRATION OF SPROCKETS, CHAINS, AND AXLE ASSEMBLIES

6007-6
REMOVAL AND INSTALLATION OF AXLES
Removal Installation
1. Raise the machine off the floor and place 1. Install the sprocket (5) on the axle assembly (9).
approved jack stands under the machine.
NOTE: Be sure to note the direction of installation,
2. Loosen and remove the wheel nuts (1) and refer to IMPORTANT under step 11 of removal.
wheels. See illustration on page 7.
2. Install the chain (3) on the sprocket (5) and align
3. Loosen and remove the chain tank inspection sprocket (5) with the axle opening in the chassis.
cover retaining bolts and washers.
3. Install a new O-ring (10) on axle assembly (9).
4. Remove the cover and the gasket. Check the
4. Align the splines on the axle assembly (9) with
gasket for damage and replace if necessary.
the splines in sprocket (5) and install axle
5. Loosen the flange nuts (2) that hold the axle assemblies (9) and flange nuts (2) on the
housings (9) enough to allow the axle housings chassis.
(9) to move, refer to the illustration on page 7.
5. Install bolt (5) and washer (7) in the axle
6. Insert a pry bar against the adjusting spud and assembly (9) through the opening on the inside
the axle housing (9). of the chassis. Be sure to install washer (7) with
the recess area on the washer towards the axle.
7. Pry against the axle housing (9) until the chain
(3) is loose enough to remove from the drive 6. Tighten bolt (4) to a torque of 247 to 320 Nm
sprocket (4). (185 to 235 pound-feet). Install the rubber plugs
in the chassis.
8. Remove the 4 rubber plugs inside the chassis to
gain access to the bolt (6). Remove bolt (4) and 7. Adjust the deflection of the chains, refer to
washers (7). ADJUSTING DEFLECTION OF THE CHAINS in
this section.
9. Remove the flange nuts (2) and axle assembly
(9) from the chassis. 8. Install inspection cover and gasket. Tighten
inspection cover retaining bolts to a torque of
10. Remove the O-ring (10) and discard.
101 to 113 Nm (75 to 83 pound-feet).
11. Remove the chain (8) from the sprocket (5).
9. Install wheels and wheel nuts (1).
IMPORTANT: Be sure to note the location of the
10. For machines equipped with Stamped Center
sprockets. Both sprockets are interchangeable but
Wheels with tapered type lug nuts, tighten wheel
face opposite directions.
pound-feet).
For machines equipped with Solid Center
Wheels with flange type lug nuts, tighten wheel
pound-feet).
11. Remove supports and lower machine to the
ground.

6007-7
5 8
6
8
5 9
Rear Axle
3
8
9 3 7
6 5
10
8
Front Axle
2
3
1
4
1 2
9
BT96M075
1. WHEEL NUTS 6. CAP SCREW (DRIVEN SPROCKET)
2. AXLE HOUSING NUTS 7. WASHER
3. ROLLER CHAIN 8. CENTER OF SLACK SIDE OF CHAIN
4. DRIVE SPROCKET 9. AXLE HOUSING
5. DRIVEN SPROCKET 10. O-RING
EXPLODED VIEW OF DRIVELINE

6007-8
Axle Disassembly STEP 3
STEP 1
BK96ZK022
Install an acceptable puller on the outer bearing cup.

BP96K019
Put the axle housing in a press for removal of the STEP 4

axle.
STEP 2
BP96K023
Turn the axle housing over so that the puller is down.

Install an acceptable driver on the puller and press
BP96K020
the outer bearing cup out of the axle housing.
Press the axle out of the inner bearing and remove
the axle housing from the axle. Remove the inner
bearing from the axle housing.

6007-9
STEP 5 STEP 7
BP96K024 BP96K028
Remove the outer plastic grease disc from the axle Turn axle housing over so that the puller is down.
housing. Install an acceptable driver on the puller and press
the inner bearing cup out of the axle housing.
STEP 6
STEP 8
BP96K027
Turn the axle housing over and install an acceptable

BP96K030
puller on the inner bearing cup.
Install an acceptable puller on the outer bearing and
pull the bearing from the first press fit area of the
axle. Slide the bearing upward to the second press fit
area.

6007-10
STEP 9 Inspection
1. Use cleaning solvent to clean the bearings. Make
sure all grease is removed from the bearings.
2. Remove the grease from the bore of the axle
housing.
3. Inspect the rollers of each bearing for flat areas,
pitting, scoring, or other damage. If you find any
damage, install a new bearing and cup.
4. Inspect each bearing cup for flat areas, pitting,
scoring, or other damage. If you find any
damage, install a new bearing and cup.
BP96K031
NOTE: If a bearing or bearing cup is to be replaced,
Remove the outer bearing from the second press fit
replace both parts at the same time.
area of the axle.
5. Check for wear, cracks or damage to the splines
on the axle. If any damage is found, replace the
STEP 10 axle shaft.
NOTE: Use a new outer axle seal and plastic grease
disc during assembly of the axle housing.
BP96K032
Remove the outer seal from the axle.

6007-11
7
7
3
3
5
6 4
4 2
BC00H048
1. AXLE SHAFT 5. AXLE SEAL
2. AXLE HOUSING 6. PLASTIC GREASE DISC
3. BEARING 7. AXLE SEAL DETAIL
4. BEARING CUP
CROSS SECTION OF AXLE ASSEMBLY

6007-12
6
7
8
7
6
5 4
3
2
BT00G044
1. AXLE HOUSING 5. SEAL
2. AXLE SHAFT 6. BEARING
3. SEAL GUARD 7. BEARING CUP
4. ’STUD 8. PLASTIC GREASE DISC
EXPLODED VIEW OF AXLE ASSEMBLY

6007-13
Axle Assembly STEP 14
STEP 11
BP96K035
Start the outer bearing cup into the axle housing.

BP96K033
Start the inner bearing cup into the axle housing. STEP 15
STEP 12
BP96K036
Use an acceptable driver to press the bearing cup

BP96K034
into the axle housing. Press the cup until it is seated
Use an acceptable driver to press the bearing cup against the axle housing shoulder.
into the axle housing. Press the cup until it is seated
against the axle housing shoulder. STEP 16
STEP 13
BP96K037
Use No. 2 lithium wheel bearing grease to fill the

BP96K024
bearings.
Turn the axle housing over and install the outer
plastic grease disc into the axle housing.

6007-14
STEP 17 STEP 20
BP96K038 BP96K041
Fill the area between the outer grease disc and seal Use an acceptable driver to press the outer seal into
with grease. the housing. Press the seal into the axle housing until
the seal is seated against the shoulder. When
STEP 18 properly installed, the outer face of the seal may be
flush or slightly below the axle housing.
STEP 21
BP96K039
Install the bearing into the outer bearing cup.
STEP 19 BP96K042
Start the axle into the outer bearing. Be careful not to

damage the lips on the outer seal during this step.
Install a driver on the flange and press the axle
through the first press fit area of the axle.
NOTE: Be sure to support the axle while pressing.
Once the axle presses past the first press fit area the
axle will drop to the second press fit area and may
damage the seal.
BP96K040
Lubricate the lips of a new seal with No. 2 lithium

grease and start the seal into the housing.

6007-15
STEP 22 STEP 24
BP96K043 BP96K046
Press the axle through the second press fit area. Use an acceptable driver to press the inner bearing
Press the axle until it is seated against the outer onto the axle. Press the bearing until it is seated in
bearing. the cup.
STEP 23
BP96K045
Install the inner bearing onto the axle.

6007-16
NOTES

6011
Section
6011
WHEELS AND TIRES

CNH AMERICA LLC All rights reserved.
6011-2
TABLE OF CONTENTS
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inflating the Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6011-3
WHEELS AND TIRES
Tire Pressure
Check the air pressure and the condition of the tires every 50 hours of operation.
10 x 16.5 .......................................................................................................................275 to 265 kPa (40 to 50 psi)
12 x 16.5..................................................................................................................... 241 to 310 kPa (35 to 45 psi))
13 X 16.5 .......................................................................................................................206 to 275 kPa (30 to 40 psi)
15.50 X 16.5 ..................................................................................................................172 to 341 kPa (25 to 35 psi)
Inflating the Tire Wheel Nut Torque

Always have a qualified tire mechanic service the If the machine is new or you have just installed the
tires and rims on this machine. It is recommended wheels, check the wheel nuts every 2 hours until the
that you have this mechanic inflate the tires. To nuts remain tight.
prevent accidents, always use a restraining device
If the machine is equipped with stamped center
(tire inflation cage), correct equipment, and correct
wheels, the lug nuts will be tapered type lug nuts.
procedure. Explosive separation of the tire can cause
Tighten each lug nut to a torque of 135 to 163 Nm
serious injury.
(100 to 120 pound-feet).
If the tire has lost all the pressure or service to the
If the machine is equipped with solid center wheels,
tire or rim is required, do the following:
the lug nuts will be flange type lug nuts. Tighten each
1. Before you add air, have the tire correctly lug nut to a torque of 224 to 265 Nm (165 to 195
installed on the machine or put the tire in a pound-feet).
restraining device (tire inflation cage).
2. Use an air hose with remote shut-off valve and a
self-locking air chuck.
3. Stand behind the tread of the tire and make sure
all persons are away from the side of the tire
before you start to add air.
4. Inflate the tire to the recommended air pressure.
DO NOT inflate the tire more than the
recommended pressure.
BP96N057
NOTE: When tires are installed, make sure that the

tread is in the same direction. See the photo above

6011-4
NOTES

SECTION INDEX
BRAKES

Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7002
410 Brakes - Spring Applied - Hydraulic Release . . . . . . . . . . . (Refer to Section 6005 - Single Speed Drive Motor)
420 Brakes - Spring Applied - Hydraulic Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004

CNH AMERICA LLC
7002
Section
7002
REMOVAL AND INSTALLATION OF

PARK BRAKE COMPONENTS

7002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
410 PARK BRAKES (SPRING APPLIED - HYDRAULIC RELEASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
420 PARK BRAKES (SPRING APPLIED - HYDRAULIC RELEASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

7002-3
SPECIFICATIONS
410 Brake System
Type .................................................................................................Wet Disk, Spring Applied, Hydraulic Release
Release Pressure - Maximum - Fully Disengaged ..................... 1100 to 1500 kPa (11 to 15 bar) (160 to 217 psi)
420 Brake System
Type .................................................................................................Wet Disk, Spring Applied, Hydraulic Release
Release Pressure - Maximum - Fully Disengaged ................................................... 2760 kPa (27.6 bar) (400 psi)
Safety Rules
WARNING: Raised equipment or machine movement without an operator can cause injury or death.
! Before you service this machine, do the following:
1. Park the machine on a level surface,
2. Support or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground (if equipped).
3. If the loader arms are raised for serviceability, remove the attachment prior to raising the loader arms,
then engage the lock pin or strut.
4. Apply the parking brake.
5. Stop the engine.
6. Block the machine (wheels, tracks, etc.) to prevent machine movement.
84-108

7002-4
410 PARK BRAKES (SPRING APPLIED - HYDRAULIC RELEASE)
1. Refer to Section 6005 Single Speed Drive Motor 1. Refer to Section 6005 Single Speed Drive Motor
for removal of the park brake components which for installation of the park brake components
are part of the drive motor assembly. Follow the which are part of the drive motor assembly.
steps for removal of the park brake components. Follow the steps for installation of the park brake
components.

7002-5
420 PARK BRAKES (SPRING APPLIED - HYDRAULIC RELEASE)
1. Refer to Section 7004 420 Brakes 1. Refer to Section 7004 420 Brakes
Spring Applied - Hydraulic Release for removal Spring Applied - Hydraulic Release for
of the park brake components which are part of installation of the park brake components which
the drive motor assembly. Follow the steps for are part of the drive motor assembly. Follow the
removal of the park brake components. steps for installation of the park brake
components.

7002-6
BRAKE SOLENOID VALVE
1. Place a shop towel under the brake solenoid 1. Install the brake solenoid valve (1) in the chassis
valve(1). mounting location.
2. Remove the cap from the hydraulic reservoir. 2. Install the mounting bolts (4) which fasten the
brake solenoid valve (1) to the chassis. Tighten
3. Connect a vacuum pump to the hydraulic
the mounting bolts (4).
reservoir.
3. Connect the wiring harness (2) to the brake
4. Start the vacuum pump.
solenoid valve (1).
5. Tag and disconnect all of the hoses (3) from the
fittings on the brake solenoid valve (1).
5. Remove the plugs in the hoses and caps from
6. Install plugs in the hoses and caps on the fittings.
the fittings.
7. Stop the vacuum pump.
6. Connect all of the hoses (3) to the fittings on the
8. Disconnect the wiring harness (2) from the brake brake solenoid valve (1).
solenoid valve (1).
7. Stop the vacuum pump. Disconnect the vacuum
9. Loosen and remove the mounting bolts (4) which pump from the hydraulic reservoir. Install the cap
fasten the brake solenoid valve (1) to the on the hydraulic reservoir.
chassis.
8. Clean up any hydraulic fluid from equipment or
10. Remove the brake solenoid valve (1) from the floor.
chassis mounting location.
9. Start and run the engine at low idle. Engage and
disengage the park brakes several times.
10. Stop the engine.
11. Check for oil leakage.
12. Check the level of the oil in the hydraulic
reservoir. Add oil as required. Install the cap on
the hydraulic reservoir.

7002-7
2
1
7 1
3
3
6
BS05C070
1. BRAKE SOLENOID VALVE 5. TO MANIFOLD VALVE
2. WIRING HARNESS 6. RIGHT HAND BRAKE LINE
3. HYDRAULIC HOSE 7. LEFT HAND BRAKE LINE
4. MOUNTING BOLTS
410 BRAKE SOLENOID VALVE INSTALLATION

7002-8
2
2
3 1
4
5
6
3
BS05B102
1. BRAKE SOLENOID VALVE 5. MANIFOLD VALVE
2. WIRING HARNESS 6. RIGHT HAND BRAKE LINE
3. HYDRAULIC HOSE 7. LEFT HAND BRAKE LINE
4. MOUNTING BOLTS
420 BRAKE SOLENOID VALVE INSTALLATION

Section
7004
7004
420 BRAKES
SPRING APPLIED - HYDRAULIC RELEASE

7004-2
TABLE OF CONTENTS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7004-3
DISASSEMBLY
STEP 1 STEP 3
BDOOM166 BD00M167
Make an alignment mark on the sprocket housing, Loosen and remove the four bolts.
friction housing, and the motor flange.
NOTE: Motor flange is under spring load, use
caution while releasing the tension on the press.
STEP 2
STEP 4
BD00M165
Place the brake assembly on a press and apply just

BD00M169
enough tension to hold the brake assembly in
Remove the drive motor from the friction housing.
position.
STEP 5
BD00M170
Remove the friction housing from the sprocket

housing.

7004-4
STEP 6 STEP 9
BD00M177 BD00M172
Remove and discard the outer O-ring. Remove the seven stator plates and six lining
assemblies.
STEP 7
STEP 10
BD00M178
Remove and discard the inner O-ring. BD00M173
Turn the brake over and remove and discard the snap
STEP 8 ring.
STEP 11
BD00M171
Remove the friction shim(s).

BD00M187
Press the shaft out of the sprocket housing.

NOTE: Opposite end of the shaft will need to be
supported, once the shaft presses through the press
fit area, the shaft will fall freely.

7004-5
STEP 12 STEP 15
BD00M188 BD00M180
Remove the bearing cone from the friction housing. Remove the piston.
STEP 13 STEP 16
BD00M176 BD00M185
1. BEARING CONE Remove and discard the outer O-ring from the piston.
It is not necessary to press the bearing cone from the
shaft unless the bearing assembly is to be replaced. STEP 17
STEP 14
BD00M186
Remove and discard the inner O-ring from the piston.

BD00M179
To remove the piston apply compressed air of no

more than 1.0 bar (15 psi) to the hydraulic port of the
sprocket housing.

7004-6
STEP 18 STEP 20
BD00M181 BD00M183
Remove the disc spring. 1. BEARING CUP

It is not necessary to remove the bearing cup unless
STEP 19 the bearing assembly is to be replaced.
STEP 21
BD00M182
Remove and discard the seal.

BD00M184
1. BEARING CUP
It is not necessary to remove the bearing cup unless
the bearing assembly is to be replaced.

7004-7
20
4
24 11 3
20
6 8
21 12
14 15
5
9
22
17 23
16
13
10
2
18
19
1
BS00J128
1. SHAFT 7. STATOR PLATE 13. O-RING 19. BEARING CONE

2. SPROCKET HOUSING 8. LINING ASSEMBLY 14. O-RING 20. BOLT
3. FRICTION HOUSING 9. DISC SPRING 15. O-RING 21. SNAP RING
4. MOTOR FLANGE 10. QUAD SEAL 16. BEARING CUP 22. PORT PLUG
5. PISTON 11. O-RING 17. BEARING CONE 23. SHAFT PLUG
6. FRICTION SHIM 12. O-RING 18. BEARING CUP 24. SHAFT END SEAL
420 BRAKE ILLUSTRATION

7004-8
ASSEMBLY
STEP 22 STEP 24
BD00M184 BD00M176
1. BEARING CUP 1. BEARING CONE

If the bearing cup (1) was removed, press a new If the bearing cone (1) was removed, press a new
bearing cup into the sprocket housing. bearing cone onto the shaft until it rests against the
shaft flange.
NOTE: Apply 8 896 to 22 240 N (2000 to 5000
pound- force) to press bearing cup into place.
STEP 25
STEP 23
1 1
BD00M189
BD00M183
1. SHAFT PLUG
1. BEARING CUP
If the shaft plug (1) was removed, or if replacing the
If the bearing cup (1) was removed, press a new shaft, press the shaft plug (1) into the shaft 110.8
bearing cup into the sprocket housing. mm +/-..25mm (4.363 +/- 0.010 inch) from the motor
NOTE: Apply 8 896 to 22 240 N (2000 to 5000 flange mounting face. 35 584 N (8000 pound-force)
pound-force) to press bearing cup into place. maximum.

7004-9
STEP 26 STEP 28
BD00M182 BD00M197
1. SEAL Install the sprocket housing onto the shaft. Place the
assembly on the press as shown and press the
Lubricate a new seal (1) with clean SAE 10W30 oil.
bearing cone into place.
Install the seal into the groove of the sprocket
housing. NOTE: Make sure when installing the sprocket
housing onto the shaft that you avoid damaging the
STEP 27 seal.
STEP 29
2
1 2
1
3
BD00M188
1. BEARING CONE
2. SPROCKET HOUSING BD00M198
3. PISTON 1. SNAP RING GROOVE
Install the bearing cone (1) into the sprocket housing 2. BEARING CONE
(2). Measure the gap between the bearing cone (2) and
NOTE: This photo is for reference only. The piston is the snap ring groove (1) to determine the appropriate
installed in step 33. size snap ring to install.
IMPORTANT: It is critical that the sharp (non-rolled)
side of the snap ring is opposite of the bearing cone.

7004-10
STEP 30 STEP 32
BD00M174 BD00M185
Install the snap ring. Lubricate a new outer O-ring with clean SAE 10W30
oil and install in the groove of the piston.
STEP 31
STEP 33
BD00M186
Lubricate a new inner O-ring with clean SAE10W30 BD00M199
oil and install in the groove of the piston. Install the disc spring into the sprocket housing.

7004-11
STEP 34 STEP 37
BD00M200 BD00M177
Lubricate the piston bore of the sprocket housing Lubricate the new outer O-ring for the friction housing
with a thin film of SAE 10W30 oil. Insert the piston with clean SAE 10W30 oil. Install a new outer O-ring
into the sprocket housing being careful not to on the nose of the friction housing.
damage the O-rings.
STEP 38
STEP 35
BDOOM170
BD00M201 Install the friction housing onto the sprocket housing.

Press the piston into place using 4 448 N (1000
pound-force) maximum. STEP 39
STEP 36
BD00M204
Place the assembly in a press and press the friction

BD00M178 housing into place, making sure the alignment
Lubricate the new inner O-ring for the friction housing marks, made during disassembly, are aligned.
with clean SAE 10W30 oil. Install a new inner O-ring
in the groove of the friction housing.

7004-12
STEP 40 STEP 44
Soak the stator plates and the lining assemblies in
clean SAE 10W30 oil before assembly.
STEP 41
BD00M204
Press the friction stack with 11 120 N (2500

pound-force) to completely compress the spring.
BD00M206 STEP 45
Install a stator plate.
1
STEP 42 2
BD00M207
1. FRICTION HOUSING
2. STATOR PLATE
BD00M205
Install a lining assembly. Measure the distance from the top face of the friction
housing (1) to the top stator plate (2).
STEP 43
Repeat steps 41 and 42 until all six lining assemblies
and seven stator plates are installed.

7004-13
STEP 46 STEP 49
BDOOM208 BD00M169
1. SHIMS Install the motor flange onto the friction housing,

making sure that the alignment marks made during
If the measurement taken in step 22 is between 7.26 disassembly are aligned.
to 7.75 mm (0.286 to 0.305 inch), it will not be NOTE: Special care is needed to insure the O-ring
necessary to install any shims (1). If the and the seal are not misaligned or damaged.
measurement was more than 7.75 mm (0.305 inch)
install the necessary amount of shim(s) to reach the STEP 50
correct distance.
STEP 47
lubricate O-ring (11) with clean SAE 10W30 oil and
install onto the nose of the motor flange (4). Refer to
illustration on page 7 of this section.
STEP 48
Install a new seal (24) into the seal groove of the
motor flange (4). Refer to illustration on page 7 of this
section.
BDOOM168
Install the four bolts into the motor flange. Tighten the
four bolts to a torque of 298 to 339 Nm (220 to 250
pound-feet).

7004-14
NOTES

SECTION INDEX
HYDRAULICS

Hydraulic System Troubleshooting and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001
Cleaning the Hydraulic System and Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8003
Gear Pump (Equipment and High Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8004
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8006
Flat Faced Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007
Accumulator for Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8013

CNH AMERICA LLC
8001
Section
8001
HYDRAULIC SYSTEM TROUBLESHOOTING AND

SCHEMATICS

8001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PRESSURE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Loader Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TESTING CIRCUIT RELIEF VALVES WITH A HAND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLOWMETER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Test No. 1 - Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Test No. 2 - Loader Circuits and Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 SPOOL LOADER CONTROL VALVE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
METRIC MEASURE CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
U.S. MEASURE CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
410 HYDRAULIC SCHEMATIC FRAME 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8001-3
SPECIFICATIONS
Hydraulic Pump
Manufacturer ...................................................................................................................................Sauer-Danfoss
Type ................................................................................................................................................................Gear
Displacement Per Revolution ...................................................................................................... 25.4 cc (1.55 in3)
410 Machines
Flow at Engine Rated RPM at 96% Volumetric Efficiency ................................................ 68.3 litres/min (18 gpm)
Flow at Engine Rated RPM at 100% Volumetric Efficiency ........................................... 73.7 litres/min (19.5 gpm)
420 Machines
Flow at Engine Rated RPM at 96% Volumetric Efficiency ............................................. 70.8 litres/min (18.7 gpm)
Loader Control Valve
Manufacturer .................................................................................................................................................Husco
Type .......................................................................... 3 Spool, Open Center, Series Parallel / with Power Beyond
Main Relief Pressure ................................................................ 21,000 ± 345 kPa (210 ± 3.5 bar) (3000 ± 50 psi)
Port Relief Pressure Settings
Port B1 Std. ................................................................................................... 22 995 kPa 230 bar (3335 psi)
Port A2 Std. (Shut Off Plug) (Optional) ................................................................. 25 993 kPa 260 bar (3770 psi)
Port B2 Anti-Cavitation Valve (Optional) ............................................................... 22 995 kPa 230 bar (3335 psi)
Spool Functions
No.1 (Out) .......................................................................................................................................................... Up
No.1 (In) .........................................................................................................................................................Down
No.1 (Detent)...................................................................................................................................................Float
No.2 (In) .................................................................................................................................................... Rollback
No.2 (Out) ..................................................................................................................................................... Dump
Return Filter Bypass Pressure ....................................................................................... 345 kPa, 3.4 bar (50 psi)
Cycle Times With Rated Load In Bucket
Loader Raising Time (410 Machines) ................................................................................................. 4.2 seconds
Loader Raising Time (420 Machines) ................................................................................................. 4.0 seconds
Loader Lowering Time (Power Down) (410 Machines) .................................................................... 2.55 seconds
Loader Lowering Time (Power Down) (420 Machines) ...................................................................... 2.4 seconds
Bucket Dump Time (410 Machines) .................................................................................................... 2.0 seconds
Bucket Dump Time (420 Machines) .................................................................................................... 1.9 seconds
Optional High Flow (420 Machines)
Hydraulic Pump
Manufacturer ...................................................................................................................................Sauer-Danfoss
Type ................................................................................................................................................................Gear
Model ........................................................................................................................................................ Series D
Displacement Per Revolution ...................................................................................................... 17.2 cc (1.05 in3)
System
System Relief Valve Pressure................................................................................ 20 690 kPa 207 bar (3001 psi)
Theoretical System
Hydraulic Flow at Rated Speed, 2000 psi and 100% Volumetric Efficiency.................... 124 litres/min (32.7 gpm)
Measured Flow at 2000 RPM and Maximum Flow....................................................... 113.5 litres/min (30.0 gpm)

8001-4
SPECIAL TOOLS
B785789M B877895
OEM-1239 (CAS-10280) FLOWMETER CAS-100900 HAND PUMP
B797157M B009638M
CAS-1808 FLOWMETER FITTING KIT CAS-1804 PRESSURE TEST FITTING KIT

8001-5
PRESSURE CHECKS
Loader Main Relief 3. Use a pressure gauge with a capacity of at least

276 bar (4000 psi). Connect the pressure gauge
NOTE: Flat face couplers are not included with the to one of the auxiliary hydraulic couplers on the
CAS-1808 Flowmeter Fitting Kit or the CAS-1804 left hand loader arm.
Pressure Test Fitting Kit. The part numbers for the
auxiliary hydraulic couplers are 87417308 (male 4. Run the engine at full throttle. Actuate the
coupler) and 393394A1 (female coupler). auxiliary hydraulic flow control pedal to
pressurize the hydraulic line which has the
1. Park the machine on a level surface. Lower the pressure gauge. Record the indication on the
loader bucket to the floor. pressure gauge. Then return the auxiliary
2. The oil must be at operating temperature. To hydraulic flow control pedal to the Neutral
heat the oil, do the following steps: position and decrease the engine speed to low
idle. Stop the engine.
A. With the engine running at full throttle, hold
the bucket control lever in the ROLLBACK 5. Compare the indication with the specification on
position for 10 seconds. page 3. If the indication is not correct, see page 9
and 10 for the location of the main relief valve.
B. Put the bucket control lever in the NEUTRAL Adjust the main relief valve. Then do the
position for 10 seconds. pressure check again to make sure that the
C. Repeat steps A and B until the temperature of setting is correct.
the oil is 52° C (125° F) or the side of the
reservoir is very warm.
TESTING CIRCUIT RELIEF VALVES WITH A HAND PUMP

1. Park the machine on a level surface. 9. Operate the hand pump to fill the hose of the
hand pump with oil. Then tighten the
2. Lower all attachments to the floor.
connections.
3. Stop the engine.
10. Operate the hand pump and read the pressure
4. Move the control levers in all directions to gauge. Record the highest indication. Check the
release any circuit pressure. pressure several times to make sure that the
indications are correct.
5. The best way to connect the hand pump is
directly to the control valve. Disconnect the tube 11. Compare the indication with the specification on
from the port of the control valve and connect the page 3. If the indication is not correct, replace the
hand pump to the port. By connecting directly to circuit relief valve.
the control valve, you avoid the possibility of a
NOTE: The circuit relief valves for the loader circuit
bad reading because of cylinder movement.
are not adjustable and must be replaced if they do
6. Remove all dirt and grease from the connecting not meet the specification.
point.
12. Repeat this test after installing a new circuit relief
7. Connect the hose of the hand pump to the valve.
connecting point, but do not tighten the
connection.
8. Make sure that the hand pump is filled with oil.
The temperature of the oil must be at least 21° C
(70° F).

8001-6
FLOWMETER TESTS
7. Make sure that the pressure valve is opened
WARNING: Two persons are required to completely. Adjust the engine speed to 2200
! perform the flowmeter tests for safety to r/min (rpm) and read the flow gauge. Write the
avoid possible injury. One person must be indication on line 1 on the check sheet.
seated in the operators seat with the Seat 8. Slowly close the pressure valve on the flowmeter
Bar down when the engine is running. The until the pressure gauge indicates 97 bar (1400
second person is to control the flowmeter psi). Keep the engine running at 2200 r/min
and take the readings. CSM118 (rpm). Read the flow gauge and write the
indication on line 2 on the check sheet.
General Information 9. Slowly close the pressure valve on the flowmeter

until the pressure gauge indicates 124 bar (1800
The flowmeter measures the volume, pressure, and psi). Keep the engine running at 2200 r/min
temperature of the hydraulic oil as the hydraulic oil (rpm). Read the flow gauge and write the
flows through the flowmeter. indication on line 3 on the check sheet.
Test No. 1 will indicate whether or not there are 10. Slowly close the pressure valve on the flowmeter
problems in the line between the reservoir and the until the pressure gauge indicates 152 bar (2000
gear pump and whether or not the gear pump is psi). Keep the engine running at 2200 r/min
working within acceptable standards of efficiency. (rpm). Read the flow gauge and write the
Test No. 2 will indicate whether or not there are indication on line 4 on the check sheet.
problems in the loader hydraulic circuits. 11. Open the pressure valve completely. Decrease
There is a check sheet at the end of this section. You the engine speed to low idle and stop the engine.
can make copies of the check sheet to record the test
results. Understanding the Results
NOTE: Use an accurate tachometer to adjust and 1. If the output at minimum pressure was less than
maintain engine speeds during these tests. the specification for Gear Pump Flow to Loader
(Machine in Neutral) shown on page 3, the
Test No. 1 - Gear Pump problem can be a restriction between the
reservoir and the gear pump, or the problem can
1. Park the machine on a level surface. Lower the be a badly worn or damaged gear pump.
loader bucket to the floor. Stop the engine.
2. If the output at minimum pressure was more than
2. Disconnect the hose from the fitting at Test Point the specification on page 3, there are no
1 (pressure port). Install a plug in the hose. problems between the reservoir and the gear
Connect the flowmeter inlet hose to the pressure pump. However, the gear pump can be worn or
port fitting. damaged and still have good flow at minimum
pressure.
3. Put the flowmeter outlet hose into the hydraulic
reservoir. Use wire to fasten the flowmeter outlet 3. Loss of output at 152 bar (2200 psi) indicates
hose below the surface of the hydraulic oil. that the gear pump is worn or damaged. To
determine the efficiency of the gear pump, divide
4. Make sure that the oil level in the hydraulic
the flow indication from line 4 by the flow
reservoir is correct.
indication from line 1. This answer multiplied by
5. Make sure that the pressure valve of the 100 is the percent efficiency of the gear pump. If
flowmeter is opened completely. the efficiency of the gear pump is less than 75%,
repair or replace the gear pump. If the efficiency
6. The oil must be at operating temperature. If the
of the gear pump is more than 75%, the pump is
oil is not at operating temperature, run the
good.
engine at full throttle and close the pressure
valve of the flowmeter until the pressure gauge NOTE: The flow at the other pressures will be used
indicates 103 bar (1500 psi). Continue to run the in the remaining tests.
engine at full throttle until the temperature of the
oil is 52° C (125° F). Then open the pressure
valve completely.

8001-7
Test No. 2 - Loader Circuits and 10. Start the engine and run the engine at 2200 r/min
(rpm).
Main Relief Valve
11. Hold the bucket control lever in the ROLLBACK
1. Park the machine on a level surface. Lower the position and close the pressure valve on the
loader bucket to the floor. Stop the engine. flowmeter until the pressure gauge indicates 124
2. Disconnect the flowmeter inlet hose from the bar (1800 psi). Adjust the engine speed to keep
elbow at Test Point 1. Remove the plug which the engine running at 2200 r/min (rpm). Read the
you installed in the hose to the loader control flow gauge and write the indication on line 7 on
valve (Test No. 1 - step 2) and reconnect the the check sheet.
hose to the Tee fitting. Connect the flowmeter 12. Hold the bucket control lever in the DUMP
inlet hose to the tee. Leave the flowmeter outlet position and adjust the pressure valve on the
hose in the hydraulic reservoir as in Test No. 1 - flowmeter until the pressure gauge indicates 124
Gear Pump. bar (1800 psi). Adjust the engine speed to keep
3. Make sure that the oil level in the hydraulic the engine running at 2200 r/min (rpm). Read the
reservoir is correct. flow gauge and write the indication on line 8 on
4. The oil must be at operating temperature. If the the check sheet.
oil is not at operating temperature, run the 13. Hold the lift control lever in the LIFT position and
engine at full throttle. Hold the auxiliary hydraulic adjust the pressure valve on the flowmeter until
flow control pedal in the ON position and close the pressure gauge indicates 124 bar (1800 psi).
the pressure valve of the flowmeter until the Adjust the engine speed to keep the engine
pressure gauge indicates 103 bar (1500 psi). running at 2200 r/min (rpm). Read the flow
Continue to run the engine at full throttle until the gauge and write the indication on line 9 on the
temperature of the oil is 52° C (125° F). check sheet.
5. Continue to hold the auxiliary hydraulic flow 14. Hold the lift control lever in the LOWER position
control pedal in the ON position. Continue to run and adjust the pressure valve on the flowmeter
the engine at full throttle. Slowly close the until the pressure gauge indicates 124 bar (1800
pressure valve. As the pressure increases, the psi). Adjust the engine speed to keep the engine
flow indication will decrease slowly. As you running at 2200 r/min (rpm). Read the flow
continue to close the pressure valve, you will gauge and write the indication on line 10 on the
reach a point at which the flow indication begins check sheet.
to decrease rapidly. This is the point at which the
main relief valve starts to open. Read the Auxiliary Circuits
pressure gauge and write the indication on line 5 NOTE: Both of the loader control valve spools must
on the check sheet. be in the NEUTRAL position during the following test.
6. Continue to close the pressure valve until the NOTE: If the auxiliary hydraulic circuit is connected
indication of the flow gauge is zero. This is the to an attachment using a hydraulic motor, this flow
point at which the main relief valve is completely test does not apply.
open. Read the pressure gauge and write the
indication on line 6 on the check sheet. 15. Push down one side of the auxiliary hydraulic
flow control pedal and adjust the pressure valve
7. Open the pressure valve completely. Decrease on the flowmeter until the pressure gauge
the engine speed to low idle and stop the engine. indicates 124 bar (1800 psi). Adjust the engine
8. If the pressure setting of the main relief valve is speed to keep the engine running at 2200 r/min
not as specified on page 3, try to adjust the main (rpm). Read the flow gauge and write the
relief valve. See page 9 and 10 for the location of indication on line 11 of the check sheet.
the main relief valve. If the main relief valve 16. Push down the opposite side of the auxiliary
cannot be adjusted to the correct setting, you hydraulic flow control pedal and adjust the
must replace the main relief valve. pressure valve on the flowmeter until the
9. If you adjusted, repaired, or replaced the main pressure gauge indicates 124 bar (1800 psi).
relief valve, repeat steps 5 through 7. Adjust the engine speed to keep the engine
If the completely open pressure (step 6) is as running at 2200 r/min (rpm). Read the flow
specified, but the pressure at which the main relief gauge and write the indication on line 12 of the
valve begins to open (step 5) is 183 bar (2400 psi) or check sheet.
less, the main relief valve is damaged and must be 17. Open the pressure valve completely. Decrease
replaced before you do further testing. the engine speed to low idle and stop the engine.

8001-8
Understanding the Results 21. Leakage in the lift circuits can be caused by any
of the following problems:
18. If the flow indication for a circuit was
approximately the same as the flow indication at A. Damaged or worn packing in one or both of
the same pressure in Test No. 1, the circuit is the lift cylinders.
good. B. Damaged or worn spool or spool bore in the
19. If the flow indication for a circuit was more than loader control valve.
3.8 L/min (one gpm) less than the flow indication C. Defective circuit relief valves.
at the same pressure in Test No. 1, there is
D. Inadequate control spool travel.
leakage in that circuit.
22. Leakage in the auxiliary circuits can be caused
20. Leakage in the bucket circuits can be caused by
by any of the following problems:
any of the following problems:
A. Inadequate control spool travel.
A. Damaged or worn packing in one or both of
the bucket cylinders. B. Damaged or worn packing in one or both of
the cylinders.
B. Damaged or worn spool or spool bore in the
loader control valve. C. Damaged or worn spool or spool bore in the
loader control valve.
C. Self-leveling valve (if equipped) is sticking or
has worn spools. 23. If the flow indication for every circuit tested was
more than 3.8 L/min (one gpm) less than the flow
D. Defective circuit relief valves.
indication at the same pressure in Test No. 1,
E. Inadequate control spool travel. there is leakage at a point common to the entire
system. A probable cause is a damaged or worn
main relief valve or seals.

8001-9
11
10
7 8
5 9
6
6
4
2 6 3
1
BS05A075
1. LIFT SPOOL 7. TILT CYLINDERS
2. TILT SPOOL 8. LIFT CYLINDERS
3. AUXILIARY SPOOL 9. AUXILIARY OUTLETS
4. MAIN RELIEF VALVE 10. OIL COOLER
5. CIRCUIT RELIEF VALVE 11. OIL COOLER BYPASS VALVE
6. CHECK VALVE
3 SPOOL LOADER CONTROL VALVE SCHEMATIC

8001-10
5
8 9
10
4
7
6
6
3
1 2
11
BS05A082
1. LIFT SPOOL 7. AUXILIARY SPOOL SWITCH
2. TILT SPOOL 8. SHUTOFF PLUG
3. AUXILIARY SPOOL 9. ANTI CAVITATION VALVE (IF EQUIPPED)
4. MAIN RELIEF VALVE 10. SPRING
5. CIRCUIT RELIEF VALVE 11. POPPET
6. SPOOL LOCKOUT SOLENOID
LOADER CONTROL VALVE

8001-11
METRIC MEASURE CHECK SHEET

Owner ________________________________________________ Date __________ Hours________________
Model _________________________________________ Product Identification Number __________________
Oil Temperature: At start of test ______ ° C. At end of test ______ ° C.
Test No. 1 - Gear Pump

1. _________ L/min at min. pressure at 2200 r/min 3. _________ L/min at 124 bar at 2200 r/min
2. _________ L/min at 97 bar at 2200 r/min 4. _________ L/min at 152 bar at 2200 r/min
The efficiency of the gear pump is line 4 divided by line 1.
Test No. 2 - Loader Circuits and Main Relief Valve

5. Main relief valve begins to open at ________ bar 9. Lift ______________________ L/min at 124 bar
6. Main relief valve completely open at _______ bar 10. Lower ____________________ L/min at 124 bar
7. Rollback __________________ L/min at 124 bar 11. Auxiliary __________________ L/min at 124 bar
8. Dump ____________________ L/min at 124 bar 12. Auxiliary __________________ L/min at 124 bar
U.S. MEASURE CHECK SHEET

Owner ________________________________________________ Date __________ Hours________________
Model _________________________________________ Product Identification Number __________________
Oil Temperature: At start of test ______ ° F. At end of test ______ ° F.
Test No. 1 - Gear Pump

1. _________ gpm at min. pressure at 2000 rpm 3. _________ gpm at 1800 psi at 2000 rpm
2. _________ gpm at 1400 psi at 2000 rpm 4. _________ gpm at 2200 psi at 2000 rpm
The efficiency of the gear pump is line 4 divided by line 1.
Test No. 2 - Loader Circuits and Main Relief Valve

5. Main relief valve begins to open at ________ psi 12. Auxiliary __________________ gpm at 1800 psi
6. Main relief valve completely open at _______ psi
7. Rollback __________________ gpm at 1800 psi
8. Dump ____________________ gpm at 1800 psi
9. Lift _______________________ gpm at 1800 psi
10. Lower ____________________ gpm at 1800 psi
11. Auxiliary __________________ gpm at 1800 psi
8001-12
1. LEFT PISTON PUMP 12. RIGHT BRAKE

2. RIGHT PISTON PUMP 13. FLUSHING VALVE
3. CHARGE PUMP 14. BRAKE SOLENOID VALVE
4. HYDROSTATIC PUMP 15. CHARGE PRESSURE SWITCH
5. CIRCUIT RELIEF VALVE 16. ORIFICE
6. TOW VALVE 17. HYDRAULIC RESERVOIR
7. CHECK VALVE 18. DRAIN MANIFOLD
8. HYDRAULIC GEAR PUMP 21. BACKUP ALARM SWITCH PORTS
9. LEFT DRIVE MOTOR 22. BRAKE LIGHT SWITCH PORTS
10. RIGHT DRIVE MOTOR 25. MAIN RELIEF VALVE
11. LEFT BRAKE 44. 100 MESH SCREEN
410 HYDRAULIC SCHEMATIC FRAME 1

8001-13
5. RELIEF VALVE 26. LOADER CONTROL VALVE

16. ORIFICE 27. TILT SPOOL
19. OIL COOLER 28. LIFT SPOOL
20. OIL COOLER BYPASS VALVE 29. AUXILIARY SPOOL
23. TILT CYLINDER 30. AUXILIARY OUTLETS
24. LIFT CYLINDER

8001-14
5. CIRCUIT RELIEF VALVE 30. AUXILIARY OUTLETS

16. ORIFICE 37. NOT USED
26. LOADER CONTROL VALVE 38. NOT USED
27. TILT SPOOL 39. NOT USED
28. LIFT SPOOL 40. ATTACHMENT CASE DRAIN
29. AUXILIARY SPOOL 45. ACCUMULATOR

8001-15
40. ATTACHMENT CASE DRAIN 42. HYDRAULIC COUPLER CYLINDER

41. HYDRAULIC COUPLER CONTROL VALVE 46. CHECK VALVE

8001-16
43. SECONDARY AUXILIARY CONTROL VALVE


8001-17
47. SELF LEVEL VALVE


8001-18
45. ACCUMULATOR 48. RIDE CONTROL SOLENOID VALVE


8001-19
NOTES

8001-20
1. LEFT PISTON PUMP 12. RIGHT BRAKE

2. RIGHT PISTON PUMP 13. FLUSHING VALVE
3. CHARGE PUMP 14. BRAKE SOLENOID VALVE
4. HYDROSTATIC PUMP 15. CHARGE PRESSURE SWITCH
5. CIRCUIT RELIEF VALVE 16. ORIFICE
6. TOW VALVE 17. HYDRAULIC RESERVOIR
7. CHECK VALVE 18. DRAIN MANIFOLD
8. HYDRAULIC GEAR PUMP 21. BACKUP ALARM SWITCH PORTS
9. LEFT DRIVE MOTOR 22. BRAKE LIGHT SWITCH PORTS
10. RIGHT DRIVE MOTOR 25. MAIN RELIEF VALVE
11. LEFT BRAKE 44. 100 MESH SCREEN

8001-21
5. RELIEF VALVE 26. LOADER CONTROL VALVE

16. ORIFICE 27. TILT SPOOL
19. OIL COOLER 28. LIFT SPOOL
20. OIL COOLER BYPASS VALVE 29. AUXILIARY SPOOL
23. TILT CYLINDER 30. AUXILIARY OUTLETS
24. LIFT CYLINDER

8001-22
5. CIRCUIT RELIEF VALVE 30. AUXILIARY OUTLETS

16. ORIFICE 37. HIGH FLOW PUMP
26. LOADER CONTROL VALVE 38. HIGH FLOW OIL COOLER
27. TILT SPOOL 39. HIGH FLOW CONTROL VALVE
28. LIFT SPOOL 40. ATTACHMENT CASE DRAIN
29. AUXILIARY SPOOL 45. ACCUMULATOR

8001-23
40. ATTACHMENT CASE DRAIN 42. HYDRAULIC COUPLER CYLINDER

41. HYDRAULIC COUPLER CONTROL VALVE 46. CHECK VALVE

8001-24
43. SECONDARY AUXILIARY CONTROL VALVE


8001-25
47. SELF LEVEL VALVE


8001-26
45. ACCUMULATOR 48. RIDE CONTROL SOLENOID VALVE


8002
Section
8002
CLEANING THE HYDRAULIC SYSTEM AND THE

HYDROSTATIC SYSTEM
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-45290 September, 2001
8002-2
TABLE OF CONTENTS
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING THE HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLEANING HOSES, TUBES, AND FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

8002-3
GENERAL INFORMATION
Contamination in the hydraulic system or hydrostatic 3. When you connect dirty hydraulic couplers.
system is a majo r cau se of mal fu ncti on of
4. From normal wear of the components.
components. Contamination is any foreign material in
the hydraulic oil. Contamination can ente r the 5. From damaged components.
hydraulic and hydrostatic system in any of the
The best way to remove contamination from the
following ways:
hydraulic system is to use the portable filter. See
1. When you drain the hydraulic oil or disconnect a Cleaning the Hydraulic System beginning on page 4.
line.
The best way to remove contamination from the
2. When you disassemble hydraulic or hydrostatic hydrostatic system is to disassemble the components
components. and clean the system. See Cleaning the Hydrostatic
System on page 6.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic 4. Components wear rapidly.
and visible. Microscopic contamination occurs when
Visible contamination is foreign material that can be
v e r y f in e p a r t ic le s o f f o r e i g n m a t e r ia l a r e i n
found by sight, touch, or odor. Visible contamination
suspension in the hydraulic oil. These particles are
c a n c a u s e a s u d d e n f a ilu r e o f a c o m p o n e n t.
too small to see or feel. Mircroscopic contamination
Examples of visible contamination include the
can be found by the identification of the problems
following:
that the microscopic contamination causes, or by
testing in a laboratory. Examples of problems caused 1. Particles of metal or dirt in the oil.
by microscopic contamination include the following:
2. Air in the oil.
1. Cylinder rod seals leak.
3. Odor of burned oil.
2. Control valve spools do not return to neutral.
4. Water in the oil.
3. The hydraulic system has a high operating
temperature.
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter shown on page 2 by A. Check the maintenance schedule for the
doing the following steps: machine to learn whether or not the hydraulic
oil must be changed. If necessary, change the
A. Remove all the hydraulic oil from the inlet and
hydraulic oil. See the Operators Manual for
outlet hoses for the portable filter.
instructions.
B. Remove the filter element from the portable
B. Do steps 6 through 36.
filter.
4. If the contamination is visible, do the following
C. Remove all hydraulic oil from the portable
steps:
filter.
A. Change the hydraulic oil. See the Operators
D. Clean the inside of the housing for the filter
Manual for instructions.
element.
B. Do steps 5 through 36.
E. Install a new filter element in the portable filter.
5. Check the amount of contamination in the
2. Determine whether the contamination is
hydraulic system by doing the following steps:
m i c r o s c o p i c o r v i s i b l e . S e e Ty p e s o f
Contamination of page 3. A. Disassemble one cylinder in each circuit.
Check for damage to the seals, scoring of the
3. If the contamination is microscopic, do the
cylinder walls, etc. Repair the cylinders as
following:
necessary.

8002-4
B. If, in your judgment damage to the cylinders B. Hold the bucket control lever in the
was caused by severe contamination and is ROLLBACK position for 30 seconds.
not the result of normal wear, it is necessary
C. Return the bucket control lever to NEUTRAL
to remove, clean, and repair all valves, pumps,
for 15 seconds.
lines, cylinders, etc. in the hydraulic system.
To clean the lines, see Cle aning Hoses, D. Repeat steps 19B and 19C until the oil is at
Tubes, and Fittings on page 6. operating temperature.
6. Remove the cap from the reservoir. 20. With the engine running at full throttle and the
portable filter running, completely extend and
7. Connect a vacuum pump to the reservoir.
retract the lift cylinders and the bucket cylinders.
8. Start the vacuum pump. Continue to operate the cylinders two times, one
after the other, for 30 minutes.
9. The reservoir is on the left hand side of the
machine. Loosen and remove the drain plug from 21. Decrease the engine speed to low idle.
the bottom of the reservoir.
22. Continue to run the portable filter for 10 minutes.
10. Find the valve in the fitting kit. Install the valve During this time, move the hose up and down in
into the drain plug hole. Make sure that the valve the reservoir to help mix the oil in the reservoir.
is closed.
23. Stop the portable filter.
12. Connect the inlet hose of the portable filter to the
25. Remove the hose from the reservoir.
valve.
26. Connect the vacuum pump to the reservoir.
13. Disconnect the vacuum pump.
27. Close the valve in the bottom of the reservoir.
14. Put the return hose of the portable filter into the
reservoir. 28. Disconnect the inlet hose from the valve.
15. Open the valve in the bottom of the reservoir. 29. Start the vacuum pump.
16. Move the switch for the portable filter to the ON 30. Loosen and remove the valve.
position.
31. Install and tighten the drain plug.
17. Start and run the engine at half throttle.
18. Run the portable filter for 10 minutes with the
33. Disconnect the vacuum pump from the reservoir.
engine running at half throttle.
34. Install a new hydraulic oil filter on the machine.
19. Do the following to heat the oil to operating
temperature: 35. Check the level of oil in the reservoir and add oil
as required.
A. Increase the engine speed to full throttle.
36. Install the cap.
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at half throttle. 4. Change the hydraulic filter. See the Operators
2. Operate the control levers to retract all cylinder
rods. 5. You will be disconnecting the hydraulic lines from
the cy lind er s in th e ne xt ste p . Befo re yo u
disconnect any hydraulic lines, make sure that
WARNING: If retracting the cylinder rods
the attachments will not fall. Put supports under
causes the attachment to be raised, block
the attachments as required. Move all control
the attachment in place before proceeding to
levers in both directions to relieve any circuit
the next step.
pressure.
39-4
3. Change the hydraulic oil. See the Operators


8002-5
6. Disconnect the hydraulic lines from the closed 11. Start and run the engine at low idle.
ends and the rod ends of all cylinders.
12. Move the control levers to extend the rods of all
NOTE: Check the hydraulic oil level frequently while cylinders. While the rods are being extended,
you do steps 7 and 8. Have another person hold a hydraulic oil will be pushed from the rod ends of
container under the hydraulic lines while you do step the cylinders.
8.
7. Start and run the engine at low idle.
14. Connect the hydraulic lines to the rod ends of the
8. Move each control lever in both directions until cylinders.
clean hydraulic oil flows from each hydraulic line.
15. Check the hydraulic oil level. Add hydraulic oil as
9. Stop the engine. required.
10. Connect the hydraulic lines to the closed ends of
the cylinders.
CLEANING THE HYDROSTATIC SYSTEM

The hy dro sta tic s ystem is a clo sed loo p. An y 3. Clean all hoses and tubes in the hydrostatic
contamination in the hydrostatic system will stay in system. See Cleaning Hoses, Tubes, and Fittings
the closed loop. If a component, hose, or tube in the on this page.
hydrostatic system is removed for any reason, you
4. Change the hydrostatic filter. See the Operators
must clean the hydrostatic system. If any
c o n t a m i n a t io n is le ft in t h e c lo s e d lo o p , th e
contamination will damage the components in the 5. See Section 6002 and install the piston pumps
hydrostatic system. and motors.
1. See Section 6002. Remove the piston pumps 6. Make sure the hydraulic system is clean so that
and motors. the charge pump w ill not cause new
contamination in the closed loop. Clean the
2. Disassemble, clean, and inspect the piston
hydraulic system as required.
pumps and motors. See Section 6004 for piston
pumps and 6005 for the motors.
CLEANING HOSES, TUBES, AND FITTINGS

It is recommended that hoses, tubes, and fittings be 5. Use compressed air to dry the inside of each
clea n ed w ith a ste am clea n er an d dr ye d w ith part. Dry the parts from both ends to make sure
compressed air. Use the following procedure: that all water has been removed.
1. Fasten the parts to a rack in a position as nearly 6. Install caps or plugs in the ends of each hose,
vertical as possible. This will allow the water to tube, or fitting as soon as the parts are dry. This
drain as you flush the parts. will prevent entry of airborne contaminants.
Remove the caps or plugs from a part only when
2. Clean the exterior surfaces of the parts
the part is in position in the machine and you are
thoroughly.
ready to make the connection.
3. Clean the interior surfaces of the parts. Use hot
water with a soap solution first. Then use clean
hot water to rinse.
NOTE: If the steam cleaner does not have a soap
injection system, spray an oil solvent into the parts.
This will dissolve the oil film that holds contaminants
inside the parts. Then use clean hot water to rinse.
4. Fasten the parts to the rack so that the parts can
be flushed from the opposite ends. Repeat steps
2 and 3.

8002-6
NOTES

Section
8003
8003
REMOVAL AND INSTALLATION OF HYDRAULIC
COMPONENTS

8003-2
TABLE OF CONTENTS
GEAR (EQUIPMENT) PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC FILTER BASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HIGH FLOW PUMP (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HIGH FLOW VALVE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HIGH FLOW ACCUMULATOR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECONDARY FRONT AUXILIARY HYDRAULICS CONTROL VALVE
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RIDE CONTROL ACCUMULATOR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RIDE CONTROL SOLENOID VALVE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SOLENOID VALVE FOR HYDRAULIC COUPLER
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CHECK VALVE FOR HYDRAULIC COUPLER
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
HYDRAULIC OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
HIGH FLOW OIL COOLER (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SELF LEVELING VALVE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

8003-3
GEAR (EQUIPMENT) PUMP
1. Loosen and remove the bolts from the cover on 13. Hold the gear pump (2) against the tandem
the kick plate (1). pump mounting location, refer to the photo
below. Rotate the gear pump shaft until it aligns
2. Place a shop towel under the gear pump (2).
with the coupling splines.
3. Remove the cap from the hydraulic reservoir.
14. Apply Loctite 243 to the flange bolts (3). Install
4. Connect a vacuum pump to the hydraulic washers (4) and flange bolts (3), and tighten
reservoir. flange bolts (3).
5. Start the vacuum pump. 15. Start the vacuum pump.
6. Tag and disconnect the hose from the fitting at 16. Connect the hoses to the suction port (5) and
the suction port (5) of the gear pump (2). pressure port(s) side (6) of the gear pump (2).
7. Install a plug in the hose and a cap on the fitting. 17. Stop the vacuum pump. Disconnect the vacuum
pump from the hydraulic reservoir. Install the cap
8. Tag and disconnect the hose from the pressure
on the hydraulic reservoir.
port(s) (6) of the gear pump (2).
9. Install a plug in the hose(s) and a cap on the
floor.
fitting(s).
11. Remove the flange bolts (3) and washers (4),
refer to the photo below. 21. Check for oil leakage.
12. Remove the gear pump (2) from the tandem 22. Check the level of the oil in the hydraulic
pump mounting location. reservoir. Add oil as required.
23. Install the cap on the hydraulic reservoir.
24. Install the cover plate on the plate (1) and tighten
the mounting bolts.
1 3 4
3 4
6
5
6
2
BD05A085
GEAR PUMP MOUNTING

8003-4
LOADER CONTROL VALVE
1. Install the loader control valve (1) in the chassis
mounting location.
2. Install the mounting bolts which fasten the loader
control valve (1) to the chassis. Tighten the
1 mounting bolts.
3. Install the hydraulic override cable to the loader
control valve (1).
4. Install all of the control linkage to the loader
control valve (1).
5. Connect the electrical connectors to the loader
BD05B009 control valve (1).
1. Remove the cap from the hydraulic reservoir. 6. Start the vacuum pump.
2. Connect a vacuum pump to the hydraulic 7. Remove the plugs from the fittings and caps from
reservoir. the connections.
3. Start the vacuum pump. 8. Install all of the hydraulic lines and hoses to the
4. Tag and disconnect all of the hydraulic lines and correct connections on the loader control valve
hoses that are connected to the loader control (1). Tighten all of the hydraulic connections.
valve (1). 9. Stop the vacuum pump.
5. Install plugs in the fittings and caps on the 10. Remove the vacuum pump from the hydraulic
connections. reservoir. Install the cap on the reservoir.
6. Stop the vacuum pump. 11. Clean up any hydraulic fluid from equipment or
7. Tag and disconnect the electrical connectors floor.
from the loader control valve (1). 12. Start and run the engine at low idle.
8. Disconnect all of the control linkage from the 13. Operate the loader controls to completely extend
loader control valve (1). and retract the lift and tilt cylinders in order to
remove any air from the hydraulic system.
9. Disconnect the hydraulic override cable from the
loader control valve (1). 14. Lower the loader arm to the floor.
10. Loosen and remove the mounting bolts which
fasten the loader control valve (1) to the chassis. 16. Check for oil leakage.
11. Remove the loader control valve (1) from the 17. Check the level of the oil in the hydraulic
chassis mounting location. reservoir. Add oil as required.

8003-5
1 6
5
3 2
BS05B066
1. LOADER CONTROL VALVE 4. LIFT SPOOL
2. LIFT CYLINDER 5. TILT SPOOL
3. TILT CYLINDER 6. AUXILIARY SPOOL
LOADER CONTROL VALVE HYDRAULIC INSTALLATION

8003-6
HYDRAULIC FILTER BASE ASSEMBLY
1. Place a shop towel under the hydraulic filter. 1. Install the hydraulic filter, washers, and bolts to
the bracket.
2. Install the electrical connection to the hydraulic
filter indicator switch assembly.
reservoir.
4. Connect all hoses to the hydraulic filter.
5. Tag and disconnect all hoses from the hydraulic
filter. 5. Stop the vacuum pump. Disconnect the vacuum
6. Install plugs in the hoses and caps on the fittings.
7. Tag and disconnect electrical connection from
the hydraulic filter indicator switch assembly.
floor.
8. Remove the bolts, washers, and hydraulic filter
from the bracket.
8. Operate the loader controls to completely extend
and retract the lift and tilt cylinders to remove any
air from the hydraulic system.
Inspection
9. Lower the loader bucket to the floor.
1. Inspect the hydraulic filter head and indicator
switch assembly for damage. Replace all 10. Stop the engine.
damaged parts. 11. Check for oil leakage.
2. Inspect the hydraulic filter mounting bracket for 12. Check the level of the oil in the hydraulic
corrosion or damage. Replace all damaged reservoir. Add oil as required.
parts.

8003-7
BS04M122
1. BRACKET 8. NUT
2. BOLT 9. LOCK WASHER
3. LOCK NUT 10. O-RING
4. BOLT 11. O-RING
5. WASHER 12. INDICATOR
6. FILTER HEAD 13. FILTER ELEMENT
7. WASHER
HYDRAULIC FILTER BASE ASSEMBLY

8003-8
HIGH FLOW PUMP (IF EQUIPPED)
1. Loosen and remove the bolts from the cover on 13. Hold the High Flow pump (2) against the tandem
the kick plate (1). pump mounting location, refer to the photo
below. Rotate the High Flow pump shaft until it
2. Place a shop towel under the High Flow pump
aligns with the coupling splines.
(2).
14. Apply Loctite 243 to the flange bolts (3). Install
washers (4) and flange bolts (3), and tighten
4. Connect a vacuum pump to the hydraulic flange bolts (3).
reservoir.
16. Connect the hoses to the suction port (5) and
6. Tag and disconnect the hose from the fitting at pressure port(s) side (6) of the High Flow pump
the suction port (5) of the High Flow pump (2). (2).
7. Install a plug in the hose and a cap on the fitting. 17. Stop the vacuum pump. Disconnect the vacuum
8. Tag and disconnect the hose from the pressure
port(s) (6) of the High Flow pump (2).
9. Install a plug in the hose(s) and a cap on the
floor.
fitting(s).
11. Remove the flange bolts (3) and washers (4),
refer to the photo below. 21. Check for oil leakage.
12. Remove the High Flow pump (2) from the 22. Check the level of the oil in the hydraulic
tandem pump mounting location. reservoir. Add oil as required.
24. Install the cover plate on the plate (1) and tighten
the mounting bolts.
1 3 4
3 4
6
5
6
2
BD05A085
HIGH FLOW PUMP

8003-9
HIGH FLOW VALVE (IF EQUIPPED)
1. Install the high flow valve (1) into the chassis
mounting location.
2. Install and tighten the high flow valve mounting
bolts.
3. Reconnect the electrical harness to the high flow
valve (1) solenoid valve.
1
5. Remove the plugs in the fittings and a caps from
the connections.
6. Connect all of the hydraulic connections on high
BD05B009
1. HIGH FLOW VALVE flow valve (1). Tighten all of the hydraulic
connections.
1. Place a shop towel under the high flow valve (1).
8. Disconnect the vacuum pump from the hydraulic
3. Connect a vacuum pump to the hydraulic reservoir. Install the cap on the hydraulic
reservoir. reservoir.
4. Start the vacuum pump. 9. Clean up any hydraulic fluid from equipment or
5. Tag and disconnect all of the hydraulic floor.
connections on high flow valve (1). 10. Start and run the engine at low idle.
6. Install a plugs in the fittings and a caps on the 11. Engage the high flow hydraulics.
connections.
8. Disconnect the electrical harness from the high
flow valve (1) solenoid valve. 14. Check the level of the oil in the hydraulic
reservoir. Add oil as required.
9. Loosen and remove the high flow valve mounting
bolts. 15. Install the cap on the hydraulic reservoir.
10. Remove the high flow valve (1) from the chassis
mounting location.

8003-10
HIGH FLOW ACCUMULATOR (IF EQUIPPED)
1. Install the high flow accumulator (1) in the
WARNING: DO NOT attempt to chassis mounting location.
disassemble any accumulator until the
nitrogen charge is properly discharged. 2. Install the mounting bolts which fasten the high
SM386\ flow accumulator (1) to the chassis. Tighten the
SM386\
mounting bolts.
IMPORTANT: Follow the procedure for Discharging
an Accumulator in Section 8013 before attempting to 3. Start the vacuum pump.
remove the accumulator from the machine. 4. Remove the plug in the fitting and a cap on the
connection.
1 5. Install the hydraulic connection to high flow

accumulator (1). Tighten the connection.
reservoir. Install the cap on the hydraulic
reservoir.
8. Follow the procedure in Section 8013 for
Charging the Accumulator With Dry Nitrogen.
BD05B010
1. HIGH FLOW ACCUMULATOR
10. Engage the high flow hydraulics.
1. Place a shop towel under the high flow
accumulator (1).
13. Check the level of the oil in the hydraulic
3. Connect a vacuum pump to the hydraulic reservoir. Add oil as required.
reservoir.
5. Tag and disconnect the hydraulic connection to
high flow accumulator (1).
6. Install a plug in the fitting and a cap on the
connection.
8. Loosen and remove the mounting bolts which
fasten the high flow accumulator (1) to the
chassis.
9. Remove the high flow accumulator (1) from the

8003-11
2
3
BS05C073
1. LOADER CONTROL VALVE 3. HIGH FLOW ACCUMULATOR
2. HIGH FLOW VALVE 4. RETURN OIL MANIFOLD
HIGH FLOW COMPONENTS (IF EQUIPPED)

8003-12
SECONDARY FRONT AUXILIARY HYDRAULICS CONTROL VALVE

(IF EQUIPPED)
1. Remove the floorplate from the machine. 1. Install the control valve (1) into the chassis
2. Place a shop towel under the control valve (1). mounting location.
3. Remove the cap from the hydraulic reservoir. 2. Install and tighten the control valve mounting
bolts (3).
reservoir. 3. Start the vacuum pump.
5. Start the vacuum pump. 4. Remove the plugs in the fittings and a caps from
the connections.
5. Connect all of the hydraulic connections on
2 control valve (1). Tighten all of the hydraulic
connections.
3 6. Stop the vacuum pump.
1
3
reservoir.
floor.
BS05C081 9. Start and run the engine at low idle.
6. Tag and disconnect all of the hydraulic
10. Engage the secondary front auxiliary hydraulics.
connections on control valve (1).
7. Install a plugs in the fittings and a caps on the
connections. 12. Check for oil leakage.
8. Stop the vacuum pump. 13. Check the level of the oil in the hydraulic
reservoir. Add oil as required.
9. Remove the clip from the pin and remove the pin
from the clevis (2). 14. Install the cap on the hydraulic reservoir.
10. Loosen and remove the control valve mounting
bolts (3).
11. Remove the control valve (1) from the chassis
mounting location.

8003-13
3
2
BS05C082
1. CONTROL VALVE 3. COUPLERS
2. PEDAL
SECONDARY FRONT AUXILIARY HYDRAULICS (IF EQUIPPED)

8003-14
RIDE CONTROL ACCUMULATOR (IF EQUIPPED)
WARNING: DO NOT attempt to STEP 1
nitrogen charge is properly discharged.
SM386\
IMPORTANT: Follow the procedure for Discharging

an Accumulator in Section 8013 before attempting to
remove the accumulator from the machine.
2
STEP 1
Remove the cap from the hydraulic reservoir. 1
Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump.
BD05B012
STEP 2 Install the accumulator into the chassis mounting
location. Secure the clamps (1) around the
accumulator (2) and tighten the clamps (1).
1 STEP 2
STEP 3
2 1
BD05B012
Loosen and remove the hydraulic hose connection

(1) from the accumulator (2). Install a plug in the
hose and a cap on the fitting. Stop the vacuum pump.
STEP 3
2
BD05B012
Remove the plug from the hose and the cap from the
fitting. Install the hydraulic hose connection (1) to the
accumulator (2). Tighten the hydraulic connection
2 (1). Stop the vacuum pump and remove the vacuum
pump from the hydraulic reservoir. Install the cap on
the hydraulic reservoir.
1
STEP 4
Follow the procedure in Section 8013 for Charging
BD05B012 the Accumulator With Dry Nitrogen.
Loosen and remove the 2 clamps (1) which mount
the accumulator (2) to the chassis. Remove the STEP 5
accumulator (2) from the chassis.
Start the engine and run at low idle. Check for leaks.
Stop the engine and check the hydraulic oil level in
the reservoir. Add hydraulic oil as required. Install the
cap on the reservoir.

8003-15
RIDE CONTROL SOLENOID VALVE (IF EQUIPPED)
Removal STEP 4
STEP 1
STEP 2
1 BD05B011
Loosen and remove the mounting bolts from the

solenoid valve. Remove the valve from the machine.
BD05B011
Tag and loosen and remove the hydraulic

connections from the solenoid valve (1). Place a cap
on the fittings and plugs in the hoses. Stop the
vacuum pump.
STEP 3
BD05B011
Disconnect the electrical harness to the solenoid

valve.

8003-16
Installation STEP 3
STEP 1
BD05B011
Start the vacuum pump. Remove the caps from the

BD05B011
fitting and the plugs from the hoses. Connect the
Install the solenoid valve (1) into the mounting hydraulic hoses to the solenoid valve (1) and tighten
location. Install the mounting bolts into the solenoid the connections. Stop the vacuum pump and remove
valve (1) and tighten the mounting bolts. the vacuum pump from the hydraulic reservoir. Install
the cap on the hydraulic reservoir.
STEP 2
STEP 4
BD05B011
Connect the electrical harness to the solenoid valve.

8003-17
4
1
BS05B088
1. ACCUMULATOR 3. LOADER CONTROL VALVE
2. SOLENOID VALVE 4. MANIFOLD VALVE
RIDE CONTROL HYDRAULIC INSTALLATION

8003-18
SOLENOID VALVE FOR HYDRAULIC COUPLER

(IF EQUIPPED)
Removal STEP 4
STEP 1
Start the vacuum pump. 1
2
STEP 2
1 BD05B013
Loosen and remove the mounting bolts (2) from the

solenoid valve (1). Remove the solenoid valve (1)
from the machine.
BD05B013
Disconnect the electrical harness to the solenoid

valve (1).
STEP 3
BD05B013
Tag and disconnect all of the hydraulic hoses

connected to the solenoid valve (1). Install caps on
the fittings and plugs in the hoses. Stop the vacuum
pump.

8003-19
Installation STEP 3
STEP 1
1
2
BD05B013
Connect the electrical harness to the solenoid valve

BD05B013
(1) electrical connection.
Install the solenoid valve into the mounting location.
Install the mounting bolts (2) into the solenoid valve STEP 4
(1) and tighten the mounting bolts (2). Start the engine and run at low idle. Check for leaks.
STEP 2 the reservoir. Add hydraulic oil as required. Install the
BD05B013

fittings and the plugs from the hoses. Install the
hydraulic hoses to the correct fitting locations.
Tighten all of the hydraulic connections. Stop the
vacuum pump and remove the vacuum pump from
the hydraulic reservoir. Install the cap on the
hydraulic reservoir.

8003-20
CHECK VALVE FOR HYDRAULIC COUPLER

(IF EQUIPPED)
STEP 1
2 1
STEP 2
1
BD05B014
Install the check valve (1) into the mounting location.

Install and tighten the mounting bolts (2).
STEP 4
BD05B014
Tag and disconnect all of the hydraulic hoses

connected to the check valve (1). Install caps on the
fittings and plugs in the hoses. Stop the vacuum 1
pump.
STEP 3
BD05B014
2 1
fittings and plugs from the hoses. Install and tighten
all of the hydraulic hoses connected to the check
valve (1).
STEP 5
Stop the vacuum pump. Remove the vacuum pump
BD05B014 from the hydraulic reservoir. Install the cap on the
Loosen and remove the mounting bolts (2) from the hydraulic reservoir.
check valve (1). Remove the check valve (1) from the
machine. STEP 6

8003-21
HYDRAULIC OIL COOLER
Removal STEP 6
NOTE: Photos may be slightly different from the
machine you are repairing. The procedure is the
same.
disconnected hoses.
STEP 1 1
STEP 2
machine.
If equipped with a heater, open the heater coolant
valve (1).
STEP 3
Turn the ignition switch and the master disconnect STEP 7
switch (if equipped) to the OFF position.
Install a hose on the drain valve and drain the
radiator into a clean container that holds
STEP 4 approximately 17 litres (4.5 gallons).
battery. STEP 8
If equipped with a heater, close the heater coolant
STEP 5 valve.
1 2 STEP 9
3
1
BD04C007
Slowly loosen the radiator cap (1). Disconnect the

overflow hose (2) from the radiator neck.
BD05A026
If the machine is equipped with a High Flow Oil

Cooler (1), release the latch (2) on the lower left side
of the oil cooler and swing the oil cooler away from
the radiator. Remove mounting bolts (3) from the
hinge and remove the oil cooler (1) from the radiator
mounting location. Secure the oil cooler away from
the radiator.

8003-22
STEP 10 STEP 12
BD04C026 BD04K036
Release the latch on the top of the radiator and tip Move the radiator away from the upper radiator hose
the radiator out from the mounting location. and lower radiator hose. Remove the radiator from
the machine.
STEP 11
STEP 13
1 Remove the cap from the hydraulic reservoir.
STEP 14
1
3
BD04C007
2
BD04K036
Loosen and remove the upper (1) and lower (2)

1 hydraulic lines from the oil cooler (3). Place plugs in
the lines and caps on the fittings. Stop the vacuum
pump.
BD05A025
Loosen the clamps (1) on the lower radiator hose

and clamps (1) on the upper radiator hose. Remove
the upper radiator hose and the lower radiator hose
from the radiator.

8003-23
STEP 15 Installation
1
STEP 1
Installation of the oil cooler is the reverse procedure
1 of Removal.
STEP 2
After the oil cooler and radiator have been installed
1 fill the cooling system. See Section 1001 for the
correct coolant mixture and quantity.
2 STEP 3
BD04K036
Loosen and remove the mounting bolts which fasten Stop the engine and check the hydraulic oil level in
the oil cooler to the chassis. the reservoir. Add hydraulic oil as required. Install the
STEP 16
Remove the oil cooler from the chassis mounting STEP 4
location. After the engine has cooled, check the level of the
cooling system and add coolant as required.

8003-24
HIGH FLOW OIL COOLER (IF EQUIPPED)
Removal STEP 7
NOTE: Photos may be slightly different from the 3
machine you are repairing. The procedure is the 1
same.
disconnected hoses.
2
STEP 1
STEP 2
machine. Release the latch (2) on the lower left side of the high
flow oil cooler (1) and swing the high flow oil cooler
STEP 3 (1) away from the radiator. Remove mounting bolts
Turn the ignition switch and the master disconnect (3) from the hinge and remove the high flow oil cooler
switch (if equipped) to the OFF position. (1) from the radiator mounting location.
STEP 4 Installation
battery. STEP 1
Installation of the high flow oil cooler is the reverse
STEP 5 procedure of removal.
Connect a vacuum pump to the hydraulic reservoir. STEP 2
Start the vacuum pump. After the high flow oil cooler has been installed, start
the engine and run at low idle. Check for leaks. Stop
STEP 6 the engine and check the hydraulic oil level in the
reservoir. Add hydraulic oil as required. Install the
cap on the reservoir
1
BD05A025
Loosen and remove the upper (1) and lower (2)

hydraulic lines from the oil cooler (3). Place plugs in
the lines and caps on the fittings. Stop the vacuum
pump.

8003-25
SELF LEVELING VALVE (IF EQUIPPED)
1. Place a shop towel under the self leveling valve 1. Install the self leveling valve (1) into the chassis
(1). mounting location.
2. Remove the cap from the hydraulic reservoir. 2. Install and tighten the self leveling valve
mounting bolts.
reservoir. 3. Start the vacuum pump.
4. Start the vacuum pump. 4. Remove the plugs from the fittings and caps from
the connections.
5. Tag and disconnect all of the hydraulic
connections on self leveling valve (1). 5. Install all of the hydraulic connections to self
leveling valve (1). Tighten all the hydraulic
6. Install a plugs in the fittings and a caps on the
connections.
connections.
7. Remove the vacuum pump from the hydraulic
8. Loosen and remove the self leveling valve
mounting bolts.
reservoir.
9. Remove the self leveling valve (1) from the
8. Start the engine and run at low idle. Check for
leaks. Stop the engine and check the hydraulic
oil level in the reservoir. Add hydraulic oil as
required. Install the cap on the reservoir.

8003-26
2
1
BS05B101
1. SELF LEVELING VALVE 3. LOADER CONTROL VALVE
2. RELIEF VALVE
SELF LEVELING VALVE INSTALLATION

Section
8004
8004
GEAR PUMP (EQUIPMENT) AND (HIGH FLOW)

8004-2
TABLE OF CONTENTS
GEAR (EQUIPMENT) PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

8004-3
GEAR (EQUIPMENT) PUMP
Disassembly STEP 4
STEP 1
GD98J804
Remove the gear plate.

GD98J801
Put identification marks on the housing for use during STEP 5

assembly.
1
STEP 2
GD98J805
1. DOWEL PINS
Remove the dowel pins.

GD98J802
Loosen and remove the socket bolts and washers. STEP 6
STEP 3
GD98J806
Mark the gear teeth, that mesh, as shown. Two teeth

GD98J803
on one gear and one tooth on the other gear.
Remove the cover.

8004-4
STEP 7 STEP 10
GD98J807 GD98J810
Remove the drive shaft. Remove the wear plate from the body.
STEP 8 STEP 11
GD98J808 GD98J811
Remove the idler shaft. Remove and discard the seal ring from the cover.
STEP 9 STEP 12
GD98J809 GD98J812
Remove the wear plate from the cover. Remove and discard the seal ring from the body.

8004-5
STEP 13 STEP 16
GD98J813 GD98J816
Remove and discard the seal from the body. Inspect the drive and idler shafts for damage.
STEP 14 STEP 17
GD98J814 GD98J817
Remove and discard the seal from the body. Inspect the bearing sleeves of the drive and idler
shafts in the body and cover.
Inspection
STEP 18
STEP 15
GD98J818
GD98J815
Inspect the body and cover surfaces.
Inspect the brass surfaces of the wear plates.

8004-6
Assembly STEP 22
STEP 19
GD98J811
Lubricate and install a new seal ring in the cover.

GD98J814
Lubricate and install a new seal in the body. STEP 23
STEP 20
GD98J810
Install the wear plate in the body.

GD98J813
Lubricate and install a seal in the body. STEP 24
STEP 21
GD98J809
Install the wear plate in the cover.

GD98J812
Lubricate and install a new seal ring in the body.

8004-7
STEP 25 STEP 28
1
GD98J808 GD98J805
1. GUIDE DOWELS
Install the idler shaft.
Install the guide dowels.
STEP 26
STEP 29
GD98J807
Install the drive shaft. GD98J804
Install the gear plate.
STEP 27
STEP 30
GD98J806
Make sure that the meshed teeth marks, on the drive GD98J803
and idler shafts, are properly aligned. Put the cover in position on the body.

8004-8
STEP 31
GD98J802
Install washers and socket bolts and tighten socket

bolts to a torque of 34 Nm (301 pound-inches).

8004-9
3 10
2
11
10
8
3 9
4
9 5
8
2
7
4
1
BS05A088
1. SHAFT SEAL 7. SEAL
2. COVER 8. SEAL RING
3. GEAR PLATE 9. WEAR PLATE
4. DOWEL PIN 10. COVER
5. DRIVE SHAFT 11. SOCKET HEAD BOLT
6. IDLER SHAFT
GEAR PUMP (EQUIPMENT)

8004-10
3 10
2
11
10
8
3 9
4
9 5
8
2 7
4
1
BS05A089
1. SHAFT SEAL 7. SEAL
2. COVER 8. SEAL RING
3. GEAR PLATE 9. WEAR PLATE
4. DOWEL PIN 10. COVER
5. DRIVE SHAFT 1. SOCKET HEAD BOLT
6. IDLER SHAFT 2.
GEAR PUMP (HIGH FLOW)

Section
8006
CYLINDERS
8006

8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Retaining Screw - Tube to Gland Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LOADER LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOADER BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

8006-3
SPECIFICATIONS
Piston Bolt Torque
Loader Lift Cylinder .......................................................................................365 to 460 Nm (270 to 340 pound-feet)
Loader Bucket Cylinder .................................................................................585 to 720 Nm (432 to 531 pound-feet)
Packing Gland Torque
Loader Lift Cylinder ............................................................................................. 407 ± 68 Nm (300 ± 50 pound-feet)
Loader Bucket Cylinder ....................................................................................... 407 ± 68 Nm (300 ± 50 pound-feet)
SPECIAL TOOLS
1040L93
CAS-1456 GLAND WRENCH. NOT SHOWN IN USE.
GENERAL
Retaining Screw - Tube to Gland 3. When assembling new parts, tighten gland to
torque specified. Drill a hole 3.73 to 3.86 mm
Procedure (0.147 to 0.152 inch) diameter and 11 mm (7/16
1. When assembling original parts, align tube and inch) deep. Drill half in the tube and half in the
gland after tightening. gland. Make sure hole does not align within 12
mm (1/2 inch) of hole for gland wrench.
2. Install screw. If holes do not align, see step 3.

8006-4
LOADER LIFT CYLINDER
Disassembly 8. Inspect the gland end of the tube (1) for sharp
edges that may cut the gland O-ring (9). Remove
NOTE: Refer to illustration on page 5. sharp edges.
Clean the outside of the cylinder. If the hoses were
removed with the cylinder, remove the hoses from Assembly
the cylinder.
NOTE: If a new gland (15) is being installed, put the
1. Fasten the tube (1) in a vise or other holding part number of the cylinder on the new gland (15),
equipment. Be careful not to damage the tube. refer to the illustration on page 5.
2. Use a gland wrench to loosen the gland (15) in 1. Lubricate the rod (7) and the cylinder bore (1)
the tube (1). with hydraulic oil prior to assembly.
3. Pull the piston rod (7) straight out of the tube (1) 2. Lubricate a new seal (12) and install in the gland
to prevent damage to the tube. (15).
4. Fasten the piston rod (7) end in a vise. Place a 3. Lubricate a new seal (11) and install in the gland
padded support below the piston rod (7) near the (15).
piston (4) to prevent damage to the piston rod
4. Lubricate a new seal (10) and install in the gland
(7).
(15). The seal is to be installed so that the lips
5. Loosen and remove the nut (3) and the washer are toward the big end of the gland (15).
(2) that connects the piston (4) on the piston rod
5. Lubricate a new backup ring (8) and install in the
(7).
groove on the outside of the gland (15). Install
6. Remove the piston (4) from the piston rod (7). the backup ring (8) with the flat side toward the
large end if the gland (15).
7. Remove the seal (5) and wear ring (6) from the
piston (4). 6. Lubricate a new O-ring (9) and install in the
groove next to the backup ring (8) on the outside
8. Remove the O-ring (9), backup ring (8), and
of the gland (15). The O-ring (9) must be toward
seals (10,11,12) from the gland (15).
the small end of the gland (15).
Inspection 7. Fasten the piston rod (7) end in the vise.
1. Clean the piston (4), gland (16), piston rod (7), 8. Remove any marks and sharp edges on the
tube (1), washer (2), and nut (3) in cleaning chamfered end of the piston rod (7).
solvent, refer to the illustration on page 5. 9. Lubricate the bore of the gland (15) with clean
2. Discard the seals, wear rings and O-rings that hydraulic oil.
were removed from the piston (4) and gland (15). 10. Push the gland (15) onto the piston rod (7). If the
3. Inspect the inside of the tube (1) for deep gland (15) will not slide easily onto the piston rod
grooves or other damage. If there is damage to (7), use a soft hammer to drive the gland (15)
the tube (1), use new parts as required. onto the piston rod (7).
4. Inspect the piston rod (7) to make sure it is 11. Place a support below and near the end of the
straight. If the piston rod is damaged, use new piston rod (7). Use a shop cloth between the
parts as required. support and the piston rod (7) to prevent damage
to the piston rod.
5. Remove small scratches on the inside of the
tube (1) with emery cloth of medium grit. Use the 12. Install the piston (4) onto the end of the piston
emery cloth with a rotary motion. rod (7).
6. Inspect the bushings (16) in the piston rod end 13. Install the washer (2) onto the piston rod (7).
and the bushings (17) in the tube end. If the
bushing(s) are worn or damaged, use new parts
as required.
7. Inspect the gland (15) for rust or corrosion. Clean
and remove rust or corrosion from the gland (15).
Use new parts as required.
8006-5
8 5 6
15
9 4 2
10 11 12
3
13 13
14
16 17
7
1
BD01J190
1. TUBE 7. PISTON ROD 13. GREASE FITTING

2. WASHER 8. BACKUP RING 14. ROD END
3. LOCK NUT 9. O-RING 15. GLAND
4. PISTON 10. SEAL 16. BUSHING
5. SEAL 11. SEAL 17. BUSHING
6. WEAR RING 12. SEAL
CROSS SECTION VIEW OF LIFT CYLINDER

8006-6
NOTE: Refer to illustration on page 7. 19. Push the tube (1) straight onto the piston (4).
14. Clean the threads on the end of the piston rod (7) 20. Start the tube (1) onto the piston rod (7)
using Loctite cleaning solvent. Allow to dry. Apply assembly. Push the tube (1) onto the piston rod
Loctite 242 to the piston rod threads, 1/4 inch (7) until the compression tool is clear of the
from the end of the piston rod. piston rod (7). Be careful not to damage the wear
ring (6) and the seal (5).
NOTE: Do not apply Loctite 242 to the first 1/4 inch
of the piston rod (3) threads. 21. When the piston (4) is in the smooth part of the
tube (1), start the gland (15) into the tube (1).
15. Install the nut (3) and tighten to 365 to 469 Nm
(270 to 346 pound-feet). A torque multiplier can 22. Lubricate the new O-ring (9) on the gland (15)
be used to tighten the nut. with clean hydraulic oil.
16. Lubricate a new wear ring (6) with clean 23. Tighten the gland (15) to 407 Nm ± 68 Nm (300
hydraulic oil and install in the end groove on the pound-feet ± 50 pound-feet).
outside of the piston (4).
24. If hoses were removed with the cylinder, install
17. Lubricate a new seal (5) with clean hydraulic oil new O-rings, if equipped, on the hose fittings.
and install in the center groove on the outside of Lubricate the new O-rings with clean hydraulic oil
the piston (4). and install the hoses.
18. Lubricate the inside of the tube (1) and the piston
(4) with clean hydraulic oil. Use a piston ring
compression tool to hold the new wear ring (6) in
place.

8006-7
8 5 6
15
9 4 2
10 11 12
3
13 13
14
16 17
7
1
BD01J190
1. TUBE 7. PISTON ROD 13. GREASE FITTING

2. WASHER 8. BACKUP RING 14. ROD END
3. LOCK NUT 9. O-RING 15. GLAND
4. PISTON 10. SEAL 16. BUSHING
5. SEAL 11. SEAL 17. BUSHING
6. WEAR RING 12. SEAL
CROSS SECTION VIEW OF LIFT CYLINDER

8006-8
LOADER BUCKET CYLINDER
Disassembly 7. Inspect the gland (14) for rust or corrosion. Clean

and remove rust or corrosion from the gland (14).
NOTE: Refer to illustration on page 9. Use new parts as required.
1. Clean the outside of the cylinder. If the hoses 8. Inspect the gland end of the tube (1) for sharp
were removed with the cylinder, remove the edges that may cut the gland O-ring (13).
hoses. Remove sharp edges.
2. Clamp the tube (1) in a vise or other holding
equipment. Be careful not to damage the tube. Assembly
3. Use a gland wrench to loosen the gland (14) NOTE: If a new gland (14) is being installed, put the
from the tube (1). part number of the cylinder on the new gland (14),
refer to the illustration on page 9.
4. Pull the piston rod (8) straight out of the tube (1)
to prevent damage to the tube. 1. Lubricate all components with hydraulic oil.
5. Clamp the piston rod end (12) in a vise. Place a 2. Lubricate seal (9) with clean hydraulic oil and
padded support below the piston rod (8) near the install in the gland (14).
piston (4) to prevent damage to the piston rod.
3. Lubricate seal (10) with clean hydraulic oil and
6. Loosen and remove the bolt (3) and the washer install in the gland (14). Install the seal is so that
(2) that connects the piston (4) to the piston rod the lips are toward the small end of the gland.
(8). Use a torque multiplier for the bolts that have
4. Lubricate a new wiper seal (11) with clean
a high torque value.
hydraulic oil and install in the gland (14). The
7. Remove the piston (4) from the piston rod (8). wiper lips must be toward the large end of the
gland.
8. Remove the wiper seal (11) and wear ring (7)
from the piston (4). 5. Lubricate a new backup ring (5) with clean
hydraulic oil and install in the groove on the
9. Remove the O-ring (13), backup ring (5), wiper
outside of the gland (14). Install the ring with the
seal (11), seal (10), and seal (9) from the gland.
flat side toward the large end if the gland.
Inspection 6. Lubricate a new O-ring (13) with clean hydraulic

oil and install in the groove next to the backup
1. Clean the piston (4), gland (14), piston rod (8), ring (5) on the outside of the gland (14).
tube (1), hardened washer (2), and bolt (3) in
cleaning solvent, refer to the illustration on page 7. Fasten the piston rod end (12) in the vise.
9. 8. Remove any marks and sharp edges on the
2. Discard the seals, wear rings and O-rings that chamfer at the end of the piston rod (8).
were removed from the piston (4) and gland (14). 9. Lubricate the bore of the gland (14) with clean
3. Illuminate the inside of the tube (1). Inspect the hydraulic oil.
inside of the tube (1) for deep grooves or other 10. Push the gland (14) onto the piston rod (8). If the
damage. If there is damage to the tube (1), use gland will not slide easily onto the piston rod (8),
new parts as required. a soft hammer may be used.
4. Inspect the piston rod (8) to make sure it is 11. Place a support below and near the end of the
straight. If the piston rod is damaged, use new piston rod (8). Use a shop cloth between the
parts as required. support and the piston rod to prevent damage to
5. Remove small scratches on the inside of the the piston rod.
tube (1) with emery cloth of medium grit. Use the 12. Install the piston (4) onto the end of the piston
emery cloth with a rotary motion. rod (8).
6. Inspect the bushings in the piston rod end (12) 13. Install the washer (2) onto the bolt (3).
and the bushings in the tube end. If the
bushing(s) are worn or damaged, use new parts
as required.

8006-9
14 4 6 7
5 13
11
2 3
10 9
12
15
8
1
BD01J189
1. TUBE 6. SEAL 11. WIPER SEAL
2. HARDENED WASHER 7. WEAR RING 12. PISTON ROD END
3. BOLT 8. PISTON ROD 13. O-RING
4. PISTON 9. SEAL 14. GLAND
5. BACKUP RING 10. SEAL 15. GREASE FITTING
CROSS SECTION VIEW OF BUCKET CYLINDER

8006-10
NOTE: Refer to illustration on page 9. 19. Lubricate the inside of the tube (1) and the piston
(4) with clean hydraulic oil. Use a piston ring
14. Clean the threads on the end of the piston rod (8)
compression tool to hold the new wear ring (7) in
and the threads of the bolt (3) using Loctite
place.
cleaning solvent. Allow all the parts to dry. Apply
Loctite 242 to the piston rod (8) threads, 1/4 inch 20. Push the tube (1) straight onto the piston (4).
from the open end of the piston rod (8). Apply 1/2
21. Start the tube (1) onto the piston rod (8)
inch of Loctite 242 on the piston rod (8) threads.
assembly. Push the tube (1) onto the piston rod
NOTE: Do not apply Loctite 242 to the first 1/4 inch (8) until the compression tool is pushed off the
of the piston rod (8) threads. piston rod (8). Be careful not to damage the wear
ring (7) and the seal (6).
15. Install the bolt (3).
22. When the piston (4) is in the smooth part of the
16. Torque the bolt to 365 to 469 Nm (270 to 346
tube (1), start the gland (14) into the tube (1).
pound-feet). A torque multiplier can be used to
tighten the bolt (3). 23. Lubricate the new O-ring (13) on the gland (14)
with clean hydraulic oil.
17. Lubricate a new seal (6) with clean hydraulic oil
and install in the center groove on the outside of 24. Tighten the gland (14) to 407 Nm ± 68 Nm (300
the piston (4). pound-feet ± 50 pound-feet).
18. Lubricate a new wear ring (7) with clean 25. If hoses were removed with the cylinder, install
hydraulic oil and install in the end groove on the new O-rings, if equipped, on the hose fittings.
opposite end of the piston (4). Lubricate the new O-rings with clean hydraulic oil
and install the hoses.

Section
8007
FLAT FACE QUICK COUPLERS
8007
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 7-54740 September, 2001
8007-2
TABLE OF CONTENTS
FEMALE COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
MALE COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 4

8007-3
FEMALE COUPLER
1 2 3 4
807L94
1. VALVE 3. BACKUP WASHER

2. INNER SLEEVE 4. SEAL
PARTS INCLUDED IN REPAIR KIT
1 2 3 4 5 6 7 8 Disassembly
1. Install the appropriate coupler repair tool shown
on page 3 into the coupler body. Fasten the
assembly in a vise so that the coupler repair tool
is held by the vise jaws.
2. Remove the fitting from the coupler body.
3. Push the inner sleeve toward the fitting so that
you can reach the valve. Then use locking pliers
to hold the valve head while you remove the cap
screw.
9 10 4. Remove and discard the valve, the inner sleeve,
808L94
1. OUTER SLEEVE 6. COUPLER BODY
the seal, and the backup washer.
2. INNER SLEEVE 7. SPRING 5. Use solvent to clean the remaining parts. Use
3. VALVE 8. CAP SCREW
4. BACKUP WASHER 9. COLLAR
compressed air to dry the parts.
5. SEAL 10. FITTING IMPORTANT: Do not get solvent on the new seals
FEMALE COUPLER
and valve. Make sure that the female coupler is
completely dry before you install the new parts.
1 2 3 4 5 6 7
Assembly
1. Install a new backup washer and a new seal on
the new inner sleeve. Use clean hydraulic oil to
lubricate the seal and the backup washer.
2. Apply Loctite 271 to the threads in the new valve.
Install the new valve, the new inner sleeve, and
the spring in the fitting.
3. Install the cap screw to fasten the valve to the
8 9 10 11 fitting. Tighten the cap screw to a torque of 7.9 to
809L94
9.0 Nm (70 to 80 pound inches).
1. VALVE 7. CAP SCREW
4. Install the coupler repair tool into the coupler
2. OUTER SLEEVE 8. COUPLER REPAIR TOOL
3. BACKUP WASHER 9. INNER SLEEVE body. Fasten the assembly in a vise so that the
4. SEAL 10. COLLAR coupler repair tool is held by the vise jaws.
5. COUPLER BODY 11. FITTING
6. SPRING 5. Make sure that the outer sleeve and spring are
installed in the coupler body.
FEMALE COUPLER WITH COUPLER REPAIR TOOL
INSTALLED

8007-4
6. Apply Loctite 271 to the external threads of the 8. Use the matching male coupler to test for correct
fitting. Install the fitting in the coupler body. function.
Tighten the fitting to a torque of 61 to 68 Nm (45
9. Use clean hydraulic oil to leak test the coupler
to 50 pound-feet).
assembly to a pressure of 138 bar (2000 psi).
7. Remove the coupler repair tool from the coupler
body.
MALE COUPLER
Disassembly
1 2 1. Use solvent to clean the parts of the male
coupler. Use compressed air to dry the parts.
2. Use a screwdriver to push the poppet in all the
way. Insert a piece of soft wire between the
pop pet an d th e cou ple r body. Release th e
poppet. The wire will hold the poppet open so
that the seal can be removed.
3. Use an acceptable tool to remove the seal from
the groove in the coupler body. Be careful so that
85L95 you do not scratch the groove.
1. SEAL 2. POPPET
4. Use solvent to clean the groove for the seal. Use
compressed air to dry the groove.
1
Assembly
IMPORTANT: Do not get solvent on the new seal.
Make sure that the coupler body is completely dry
3 before you install the new seal.
1. Fold the new seal into a heart shape and work
the seal into the groove. DO NOT use sharp
tools. After the seal is installed, use clean
hydraulic oil to lubricate the seal.
2. Use a screwdriver to push the poppet in all the
2 way. Remove the piece of soft wire. Release the
86L95 poppet.
1. SEAL 3. WIRE
2. POPPET 3. Use clean hydraulic oil to leak test the male
coupler to a pressure of 138 bar (2000 psi).

Section
8013
8013
ACCUMULATOR FOR RIDE CONTROL
Copyright © 2001 Case Corporation

CASE CORPORATION All rights reserved.
Racine, WI 53404 U.S.A. Bur 6-45550 Issued September, 2001
8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
DISCHARGING AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 8
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . ........... 10
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 11

8013-3
SPECIFICATIONS
Accumulator Charging Valve Cap Torque......................................................................................... 10 pound inches
Weight (Approximate) .................................................................................................................3.73 kg (8.2 pounds)
Fluid Capacity....................................................................................................................... 740 ml (45 cubic inches)
Maximum Operating Pressure ................................................................................................... 20700 kpa (3000 psi)
SPECIAL TOOLS
94L95
CAS - 10899 NITROGEN CHARGING KIT
This tool is first used on page 3.

8013-4
NOTES

8013-5
DISCHARGING AN ACCUMULATOR
5. Remove the guard and cap from the accumulator
WARNING: DO NOT attempt to charging stem.
6. Connect valve F to the stem on the accumulator.
nitrogen charge is properly discharged.
SM386 7. Turn the T-handle inward on valve F to engage
IMPORTANT: To help prevent equipment damage, the pin in the valve stem.
the low pressure gauge (valve C) MUST BE SHUT 8. Open valve D and check the charge pressure on
OFF during high pressure (150 psi/10 bar and above) gauge E.
applications.
9. To discharge the accumulator partially open
1. Use the CAS-10899 accumulator charging kit to valve B. The accumulator charge will bleed down
discharge the accumulator. the tool must be through the regulator.
disconnected from the nitrogen tank.
10. Once the accumulator is fully discharged
2. Close valves B, C and D. disconnect valve F from the accumulator stem.
3. Adjust the regulator A to the minimum pressure 11. The accumulator can now be disassembly.
setting by turning the knob counterclockwise.
4. Turn the T-handle on valve F fully out.
4
6 7
8
2 1
94L95
1. VALVE A 4. VALVE D 7. TO NITROGEN TANK

2. VALVE B 5. GAUGE E 8. TO ACCUMULATOR
3. VALVE C 6. VALVE F

8013-6
Disassembly 4. Remove the seals (4) and quad ring (5) from the
piston (3).
1. Fasten the accumulator tube (1) in a vise with
soft jaws. Be careful not to damage the tube (1). 5. Remove the O-rings (6) and if used, the backup
rings (7) from the glands (2 and14).
IMPORTANT: The gland with the gas valve must be
removed first. 6. Loosen and remove the cap screws (8) and
guard (9).
2. Loosen and remove the gland (2 and 14) from
each end of the tube. 7. Loosen and remove the gas valve assembly (10).
3. Use a rod and push the piston (3) out of the gas 8. Remove the O-ring (6), cap (11) and valve core
valve end of the tube (1). (12) from the body (13).
14
6 7
4
5
4
3
6 7
6
10 11 12 13
9
8
BS96H067
1. TUBE 5. QUAD RING 9. GUARD 13. BODY

2. GLAND WITH GAS VALVE 6. O-RING 10. GAS VALVE ASSEMBLY 14. GLAND WITOUT GAS VALVE
3. PISTON 7. BACKUP RING (IF USED) 11. CAP
4. SEAL 8. CAP SCREW 12. VALVE CORE

8013-7
Inspection 5. Inspect the glands (2 and 14) for rust. Clean and
remove the rust as required.
1. Discard parts removed from the gland (2 and 14)
and piston (3) 6. Inspect the piston (3) for damage or wear. If the
piston(3) is damaged or worn a new accumulator
2. Clean all parts in cleaning solvent. must be used.
3. Inspect the inside of the tube (1) for deep 7. Inspect the gland ends of the tube (1) for sharp
grooves and other damage . If there is any edges that will cause damage to the seals (4),
damage, a new accumulator must be used. quad ring (5), or O-rings (6). Remove any sharp
4. Remove small scratches on the piston (3), gland edges as required.
(2 and 14) or tube (1) with emery cloth of 400 or
finer grit. Use the emery cloth with a rotary
motion.

8013-8
Assembly 7. Lubricate the O-ring (6) and backup ring (7) with
clean oil and start the gland (2) into the tube (1).
1. Install new quad ring (5) on the piston (3).
8. Fasten the tube (1) in the vise and tighten the
2. Install a new seals (4) on each end of the piston gland (2).
(3).
9. Repeat steps 5 through 8 for the other end of the
3. Lubricate the bore of the tube (1) and the piston tube (1).
(3) with clean oil.
10. Install a new O-ring (6) on the body (13) of the
NOTE: The piston must be installed slowly to gas valve assembly (10).
prevent damage to the quad ring on the threads in
the tube. 11. Install the valve core (12) in the body (13).
4. Start the piston (3) into the gas valve end of the 12. Lubricate the O-ring (6) with clean oil and install
tube (1). A soft hammer and wood block may be and tighten the gas valve assembly (10) in the
used to drive the piston (3) farther into the tube gland (2).
(1). See the illustration below for correct piston 13. Install the cap (11).
(3) installation. Carefully drive the piston (3) at
least 2 inches (51 mm) into the tube (1). Keep 14. Charge the accumulator with dry nitrogen
pressure against the piston (3) when driving the according to the instructions on page 9 in this
piston (3) into the tube (1), to prevent damage to section. Install the guard (9) and cap screws (8).
the quad ring (5).
5. If used, install a new back ring (7) on the gland
(2). Make sure the backup ring (7) is installed as
shown in the illustration below.
6 7
To Threaded End of Gland
6. Install the O-ring (6) next to the backup ring (7)

as shown in the illustration above. If a backup
ring (7) is not used, install a O-ring in the groove
on the gland.

8013-9
1
14
4 3 4 2
8
9
10
11
12
13
6
6 7
6
7
5
BT96H068
1. TUBE 5. QUAD RING 9. GUARD 13. BODY

2. GLAND WITH GAS VALVE 6. O-RING 10. GAS VALVE ASSEMBLY 14. GLAND WITOUT GAS VALVE
3. PISTON 7. BACKUP RING (IF USED) 11. CAP
4. SEAL 8. CAP SCREW 12. VALVE CORE

8013-10
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

1. Make sure that the oil side of the accumulator is 2. Close valves (B and C) on the nitrogen charging
completely discharged by doing the following: kit.
A. Put the ride control switch in the ON position. 3. Turn the stem out of valve (F) until the stem
stops.
B. Lower the loader to the floor. Put the loader
control lever in the FLOAT position. 4. Remove the cap screws and guard from the
accumulator.
C. Stop the engine. Put the key switch in the ON
position. 5. Remove the cap from the valve stem on the
accumulator.
D. Move the loader control lever in all directions
to rele ase an y pressure in the hydrau lic 6. Connect valve (F) to the valve stem.
circuits. Put the loader control lever in the
7. Make sure that valve (D) is open.
FLOAT position.
8. Turn the stem into valve (F) and read the
E. Find the right and left solenoid valves for the
pressure on gauge E.
ride control system. Find the pin in the coil end
o f th e s o le no id . D e p re s s th e p in in t h e 9. The pressure must be 275 to 325 psi (1897 to
solenoid valves with a soft pin (such as a 2241 kPa, 19 to 23 bar). If the pressure is too
welding rod) to release any pressure in the low, charge the accumulator with dry nitrogen.
loader lift circuit.
F. Leave the ride control switch and key switch in
the ON position.
G. Leave the loader control lever in the FLOAT
position.
E
C
B
A
D
94L95

8013-11
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

Check the pressure in the accumulator according to 5. If the pressure increases above 325 (2241 kPa,
the instructions in this section. Keep the nitrogen 23 bar), quickly open and close valve (D) and
charging kit connected to the accumulator. read gauge E. If the pressure is still too high,
close valve (A) (turn counterclockwise) a small
1. Close (turn counterclockwise) valve (A) and open
amount and quickly open and close valve (D).
valve (B). Close valves (C and D).
The pressure shown on gauge E is the charge
2. Turn the stem out of valve (F) until the stem stops pressure.
moving. Disconnect valve (F) from the valve stem
6. Connect valve (F) to the valve stem on the
on the accumulator.
accumulator. Turn the stem into valve F until the
3. Connect the nitrogen charging kit to a dry stem stops moving and open valve D to charge
nitrogen tank. the accumulator.
4. Slowly turn valve (A) clockwise and read gauge 7. After the accumulator stops charging, turn the
E until the pressure is 275 to 325 psi (1897 to stem out of valve (F) until the stem stops moving.
2241 kPa, 19 to 23 bar). Stop turning valve ( A).
8. Close valve (B) and disconnect the nitrogen
charging ki t from the va lve stem in the
accumulator.
9. Install the cap on the valve stem. Install the
guard and cap screws.
E
C
B
A
D
94L95

8013-12
NOTES

SECTION INDEX
MOUNTED EQUIPMENT

Pedals and Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9002
Attachment Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
ROPS Canopy, Seat, Seat Belts, and Operators Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9004
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006

CNH AMERICA LLC
9001
Section
9001
PEDALS AND LEVERS

9001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THROTTLE CONTROL lever ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hand Throttle Lever Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hand Throttle Adjustment (With Foot Throttle Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONTROLS ADJUSTMENT PROCEDURE - LOADER FUNCTIONS AND NEUTRAL POSITION . . . . . . . . . . . 7
Control Handle Fore and Aft Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Controls - Pump Shim Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Controls Adjustment - Dynamic Straight Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SEAT BAR HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AUXILIARY HYDRAULIC PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

9001-3
SPECIFICATIONS
Engine Speeds 410 and 420 Machines)
Low Idle ............................................................................................................................... 1050 ± 50 r/min (rpm)
High Idle-- No Load .............................................................................................................. 3050 ± 50 r/min (rpm)
Rated --Full Load .......................................................................................................................... 2900 r/min (rpm

9001-4
17
5
6
7
16 14
15
15
7
1
1
8
11
2
3
4
10
12 9
BS05B255
1. THROTTLE CONTROL LEVER 6. INJECTOR PUMP LEVER 11. THROTTLE PIVOT 16. FLYWHEEL COVER
2. NUT 7. BALL JOINT 12. THROTTLE PIVOT BOLT 17. SPRING
3. WASHER 8. JAM NUT 13. CAP SCREW
4. SPECIAL WASHER 9. FRICTION DISC 14. CRANK
5. THROTTLE ROD 10. RUBBER WASHER 15. CLAMP
HAND THROTTLE LEVER

9001-5
THROTTLE CONTROL LEVER ADJUSTMENT
Hand Throttle Lever Tension Hand Throttle Adjustment (With

Adjustment Foot Throttle Option)
1. The tension adjusting nut (2) for the throttle lever The adjustment procedure for the hand throttle with
(1) is to compress the rubber washer (10) to the foot throttle option is very similar to the procedure
cause a resistance to hold the throttle lever in the without the foot throttle.
position selected.
1. The tension adjusting nut (2) for the throttle lever
2. The tension adjusting nut (2) is not to be so tight (1) is to compress the rubber washer (10) to
the throttle lever is difficult to move. cause a resistance to hold the throttle lever in the
3. Remove any attachments from the loader lift position selected.
arms. 2. The tension adjusting nut (2) is not to be so tight
4. Refer to the operators manual for the correct the throttle lever is difficult to move.
procedure and tilt the ROPS for service. 3. Remove any attachments from the loader lift
5. The throttle control lever (1) may be in any arms.
working position during the adjustment 4. Refer to the operators manual for the correct
procedure. procedure and tilt the ROPS for service.
6. Measure the resistance that is required to move 5. Disconnect the foot throttle linkage from the
the throttle control lever (1) from the low idle to linkage controller so that the only input to the
high idle position.The effort required to move the controller is from the hand throttle.
throttle control lever (1) should be measured at
6. The throttle control lever (1) may be in any
the top of the throttle control lever (1).
working position during the adjustment
7. Loosen the jam nut (8). procedure.
8. Tighten or loosen the nut (2) until the force 7. Measure the resistance that is required to move
required to move the throttle control lever (1) is the throttle control lever (1) from the low idle to
50 ± 10 N. high idle position.The effort required to move the
9. When the effort required to move the throttle throttle control lever (1) should be measured at
control lever (1) is correct tighten the jam nut (8) the top of the throttle control lever (1).
against the nut (2). 8. Loosen the jam nut (8).
10. Lower the ROPS to the operating position. 9. Tighten or loosen the nut (2) until the force
required to move the throttle control lever (1) is
50 ± 10 N.
10. When the effort required to move the throttle
control lever (1) is correct tighten the jam nut (8)
against the nut (2).
11. Lower the ROPS to the operating position.
12. Depress and release the foot pedal to confirm
proper operation.

9001-6
4
6
2
5
10
11
12
1
14
13 3
BD05B256
1. BOLT 8. ROD
2. THROTTLE ROD EXTENSION 9. SPRING
3. WASHER 10. ROCKER ARM
4. WASHER 11. BEARING
5. SELF TAPPING SCREW 12. PIVOT SLEEVE
6. SLEEVE 13. BUSHING
7. FOOT THROTTLE PEDAL 14. SQUARE NUT
FOOT THROTTLE LEVER

9001-7
CONTROLS ADJUSTMENT PROCEDURE - LOADER FUNCTIONS AND

NEUTRAL POSITION
STEP 1 STEP 4
1 2
BD01J006
BD05B005
1. MEASUREMENT 735 ± 10 MM 1. DIMENSION FOR STANDARD CONTROL HANDLE (25 TO
40 MM)
Center of the seat bar must be 735 ± 10 mm from the 2. DIMENSION FOR DELUXE CONTROL HANDLE (LARGE
bottom surface of the front ROPS cross member HEAD) (15 TO 30 MM)
before making handle position adjustments. If Stroke the both control handles to the Full Forward
measurement is not within the specification, adjust position. With the control handles in any position and
the seat bar to the specifications. See the seat bar hands on the control handles, the control handles or
height adjustment procedure. hands must not contact the front ROPS post or any
front door component (if equipped). The clearance
STEP 2 between the ROPS post and the standard control
Stroke the handles to the Full Reverse position. In handle should be 25 to 40 mm. The clearance
any position the handles must not contact the seat between the ROPS post and the deluxe (large head)
bar. Set the left hand control at 6 to 20 mm clearance control handle should be 55 to 30 mm.
to the seat bar with the handle in the full reverse
If the machine is equipped with side windows there
stroke and in the float position.
should be 25 mm clearance between the control
handles and the side windows when the control
STEP 3 handles are in the locked down position with the seat
NEUTRAL: The front of the top of the handles must bar in the operating (down) position.
be inline with each other by 6 mm. Adjust the Right
Handle position relative to the Left handle.

9001-8
STEP 5 STEP 2
1 2
1
BD05B007 BD05B004
1. OUTER CONTROL ROD 1. STANDARD HANDLE DIMENSION 15 TO 35 MM
2. DELUXE HANDLE DIMENSION 5 TO 25 MM
Pull the control handle rubber boot up to access the
control linkage. Loosen the jam nuts on the outer
control rod (1) and turn the control rod (1) until the
STEP 3
proper measurement is obtained. Tighten the jam
nuts on the control rod (1). Repeat the same
procedu re fo r th e opposite control handle if
adjustment is required.
Control Handle Fore and Aft

Adjustment
1
STEP 1
BD05B006
1. FORE AND AFT POSITION CONTROL ROD
Pull the control handle rubber boot up to access the

control linkage. Loosen the jam nuts on the fore and
aft position control rod (1) and turn the control rod (1)
until the proper measurement is obtained. Tighten
the jam nuts on the control rod (1). Repeat the same
procedure for the opposite control handle if
adjustment is required.
BD05B003
Make sure the ROPS is in the operating position.

Place a 19.05 mm (0.75 inch) bar through the side
screen on the ROPS in the first row from the front
and five rows up from the bottom as indicated in the
photo above. Slide the bar towards the front of the
machine on both sides until it contacts the ROPS
post on each side of the ROPS as shown in the
photo above.

9001-9
Controls - Pump Shim Dimensions STEP 3

The controls should be initially set on the assembly
2 1
using the following shim dimensions. The shim
required for each machine should be used to set the
distance between the tandem pump Tee lever arm
and the pump stop. This should be done for full
forward and full reverse stroke on both the left and
right pumps. The straight tracking screws are the
means to set this gap dimension.
Model Pump Shim (mm) Shim in

Displacement
(in3/ rev
BD05B007
1. JAM NUT
410 2.3 0.90 0.035
2. STRAIGHT TRACKING SET SCREW
420 2.62 0.56 0.022 Pull the control handle rubber boot up to access the
control linkage. Loosen the jam nut (1) on the control
430/440 2.8 0.35 0.014 handle opposite the direction of turn and tighten the
set screw (2) until the machine tracks straight.
Example: If the machine turns to the right, adjust the
tracking set screw (2) on the left control handle.
Tighten the jam nut (1).
Controls Adjustment - Dynamic
STEP 4
Straight Tracking
Repeat step 3 for reverse direction tracking.
NOTE: During the Dynamic Straight Tracking
Adjustment procedure, the adjustments should be STEP 5
made with the hydraulic system at or above 120° F
Reinstall the control boot after adjustments are
and in the low speed range of machines equipped
complete.
with the two speed option
STEP 1
Install a bucket on the loader lift arms. Drive the
machine forward with both control handles against
the forward stops. The machine should not deviate
more than 6 feet width over 100 feet of forward
travel. If the machine does not meet this requirement
proceed with the following steps.
STEP 2
Drive the machine forward and determine which way
the machine turns.

9001-10
10
3
12
11
4 5 8
9
12
2
7
BS05B040
1. SEAT BAR LINKAGE 7. BRAKE CAM
2. LOADER LIFT LINKAGE 8. CRANK
3. LOADER TILT LINKAGE 9. LEFT LEVER ASSEMBLY
4. GROUND DRIVE LINKAGE 10. RIGHT LEVER ASSEMBLY
5. BRAKE CONTACT ROD 11. HYDRAULIC BYPASS CABLE
6. PIVOT 12. TRACKING SET SCREW
LOADER AND GROUND DRIVE CONTROL LINKAGE

9001-11
13
10
11
12
9
2
6 4 3
5
1
14 7
BS05B041
1. SEAT BAR LINKAGE 8. CRANK
2. LOADER LIFT LINKAGE 9. LEFT LEVER ASSEMBLY
3. LOADER TILT LINKAGE 10. RIGHT LEVER ASSEMBLY
4. GROUND DRIVE LINKAGE 11. HYDRAULIC BYPASS CABLE
5. BRAKE CONTACT ROD 12. SPRING
6. PIVOT 13. PIN
7. BRAKE CAM 14. SEAT BAR CONTROL ROD
LOADER AND GROUND DRIVE CONTROL LINKAGE

9001-12
SEAT BAR HEIGHT ADJUSTMENT
HS01E003
1. ADJUST TO 735 ± 10 MM (28.93 ± 0.40 IN) 3. LAP BAR
2. ADJUSTING SCREW 4. CROSSMEMBER
1. Measure the distance from the bottom of the 2. Loosen the nut on the adjusting screw (2) on
crossmember (4) of the ROPS frame to the flat each side of the frame and adjust the screw as
spot with the molded seat belt sign on the lap bar needed to obtain the correct measurement.
(3) when the lap bar is in the operating position. Tighten the nuts on the adjusting screws.
This distance (1) must be 735 ± 10 mm (28.93 ±
0.40 in).

9001-13
AUXILIARY HYDRAULIC PEDAL
7
3
8 1
2
2
4
1
1
5
2
BS05B060
1. AUXILIARY HYDRAULIC PEDAL 5. CLEVIS
2. AUXILIARY HYDRAULIC PEDAL LOCK LEVER 6. BRACKET
3. LOADER CONTROL VALVE 7. ELECTRICAL HARNESS
4. CONTROL CABLE 8. RELAY
NOTE: Make sure the auxiliary spool in the control valve is in the neutral position. Adjust the cable until the
auxiliary hydraulic pedal is in the horizontal position.

9001-14
NOTES

9002
Section
9002
LOADER

9002-2
TABLE OF CONTENTS
REPLACING THE CUTTING EDGE ON BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacing Welded Cutting Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacing Bolt-On Cutting Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WELD SPECIFICATIONS FOR BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL OF THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION OF THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION OF THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

9002-3
REPLACING THE CUTTING EDGE ON BUCKETS
Replacing Welded Cutting Edges 5. Position a new cutting edge on the bucket. Use
C-clamps to hold the cutting edge in proper
1. Raise the bucket to an acceptable height and position.
place supports to hold the bucket in position.
6. See page 4 for weld specifications for the bucket
2. Use carbon arc rod or an acetylene torch to being repaired. Use E7018 welding rod or
remove the welds that hold the cutting edge. Be equivalent welding wire.
careful not to distort the bucket while cutting the
welds. Replacing Bolt-On Cutting Edges
3. When removing the weld at the rear of the cutting
7. Raise the bucket to an acceptable height and
edge, do not cut through the bottom of the
place supports to hold the bucket in position.
bucket.
8. Remove the nuts, plow bolts, and cutting edge
from the bucket.
9. Install the new cutting edge, plow bolts and nuts
to the bucket.
BD01C061
1. CUTTING EDGE TO BE REMOVED
4. After the cutting edge has been removed, use a

grinder to remove any welds or extra metal on
the bucket that will prevent a new cutting edge
from fitting correctly.

9002-4
WELD SPECIFICATIONS FOR BUCKETS

Buckets
1. 86618349 4. 86618352 7. 86618353 10. 86618358 13. 86618361
2. 86618350 5. 86618363 8. 86618354 11. 86618359
3. 86618351 6. 86618364 9. 86618357 12. 86618360
1 2
3
BT97G325
3. 6 MM (1/4 INCH) GROOVE 6

1. 10 MM (3/8 INCH) FILLET
MM (1/4 INCH) FILLET
(WELD TWICE 1 ROOT PASS 1
(WELD TWICE -WRAP
COVER PASS)
ENDS)
2. 6 MM (1/4 INCH) FILLET (WELD
4 TIMES)
REMOVAL OF THE LOADER FRAME

NOTE: Refer to illustration on page 6. 8. Relieve any pressure from the hydraulic system
by turning the key switch to the “on” position and
1. Park the machine on a level surface.
move the hydraulic bypass control lever to the
2. Remove the bucket from the loader frame (1), bypass position and move the loader control
refer to Operators Manual. levers in both directions.
3. Clean any dirt and grease from the hydraulic 9. Tag all hydraulic lines and couplings for use
connections for the bucket and lift cylinders. during assembly procedure.
4. Claean any dirt and grease from the hydraulic 10. Loosen and remove all the hydraulic lines that
connections for the auxiliary hydraulic circuits at pass through both uprights of the chassis.
the rear of the machine.
11. Plug and cap the fittings and couplings to
5. Attach acceptable lifting slings to the loader arms minimize the loss of hydraulic oil and to prevent
(1) on each side of the loader frame towards the contamination from entering the hydraulic
rear of the machine. system.
6. Attach an acceptable lifting sling to the center of 12. Remove the rubber retaining rings (if equipped)
the tube between the loader arms (1). from the hydraulic couplings on each side of the
uprights and push the hydraulic couplings into
7. Attach the lifting slings to acceptable lifting
the center of the uprights.
equipment.

9002-5
13. Remove the snap ring (10), washer (11), and pin 15. Loosen and remove the bolt (5) and lock nut (6)
(7) from the loader frame (1). Use an acceptable from the right loader arm pivot pin (7). Use
support and attach the lift cylinder to the loader acceptable tools and remove the pivot pin (7).
frame.
16. Follow the procedure in step 14 to remove the
14. Follow the procedure in step 12 and remove the left loader arm pivot pin (7).
left side lift cylinder pivot pin (1).
17. Use lifting equipment and remove the loader
frame (1) from the chassis.

9002-6
2 5
7 14
14
14 13
6 14 14
13
14
1
7
4
5
7
9
3 7
4 5
6
4
12 11 10
8
3
8 4
BC01J007
1. LOADER ARM 6. NUT 11. WASHER
2. BUSHING 7. PIN 12. BUSHING
3. COVER (EUROPEAN) 8. CYLINDER ASSEMBLY 13. CYLINDER ASSEMBLY
4. CLAMP 9. STRUT 14. COVER
5. BOLT 10. RING
LOADER FRAME

9002-7
5
6
1
7
BC01J008
1. FRAME SUPPORT 3. PIN 5. PAD 7. RETAINING RING
2. LOADER FRAME 4. GROMMET 6. PIN
LOADER FRAME SUPPORT

9002-8
INSPECTION OF THE LOADER FRAME

NOTE: Refer to the illustration on page 6. 2. Inspect the pins (7) removed from the loader lift
frame (1) for wear, cracks, corrosion, and any
1. Inspect the loader frame (1) for cracks,
other damage. Use new parts as required.
corrosion, and any other damage. Use new parts
as required. 3. Inspect the loader lift pin bushings (2) for wear,
cracks, corrosion, and any other damage. Use
INSTALLATION OF THE LOADER FRAME

NOTE: Refer to illustration on page 6. 4. Install the bucket onto the loader frame (1).
1. Installation of the loader frame (1) is the reverse 5. After completing the loader installation, Check
of the removal procedure. the hydraulic oil reservoir level. Start the
machine and check for proper loader operation.
2. After lowering the loader frame (1) onto the
Check hydraulic lines for leaks.
chassis and install the loader lift cylinder pins (7).
3. Push the hydraulic couplings into the mounting
holes in the chassis uprights. Install the hydraulic
coupling retaining rings.

Section
9003
9003
ATTACHMENT COUPLER

9003-2
TABLE OF CONTENTS
ATTACHMENT COUPLER (MECHANICAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ATTACHMENT COUPLER (HYDRAULIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

9003-3
ATTACHMENT COUPLER (MECHANICAL)
Disassembly 5. Inspect the left handle (2) and the right handle
(3) for wear and damage. Use new parts as
NOTE: Refer to illustration on page 4. required.
1. Loosen and remove the nut (19), bolt (16),
washers (17 and 20), and spacer (18) from the Assembly
left and the right lower pins (21) on the coupler
1. Place the right handle (3) in a vise with soft jaws.
frame (1).
2. Install the pin (7) into the right handle (3).
2. Use acceptable tools and remove the left and the
right lower pins (21) from the coupler frame (1). 3. Place the bolt (6) into the pin (7) and install the
spring guide (8), spring (9) and pin (13) on the
bolt (6).
washers (17 and 20), and spacer (18) from the
left and right upper pins (23) of the coupler frame 4. Prevent pin (13) from turning and tighten the bolt
(1). (6).
4. Use acceptable tools and remove the left and 5. Install the latch pin (14) into the coupler frame
right upper pins (23) from the coupler frame (1). (1). Be sure the tapered side of the latch pin (14)
faces the coupler frame (1).
5. Remove the coupler frame (1) from the loader
arms. 6. Install the right handle (3) onto the coupler frame
(1). Install the pivot pin (10) into the right handle
6. Place the coupler frame (1) on a work bench.
(3) and coupler frame (1).
7. Remove the cotter pin (12) from pin (13) and
7. Install the retaining ring (15) onto the pivot pin
latch pin (14).
(10). Lift the handle (3) until the pin (13) will
8. Remove the retaining ring (15) from the right engage the latch pin (14).
handle pivot pin (10).Remove the pivot pin (10)
8. Install the cotter pin (12) through the latch pin
from the frame (1).
(14) and pin (13).
9. Lift the right handle (3) until the pin (13)
9. Repeat steps 1 through 8 for the left handle (2).
disengages the latch pin (14). Remove the right
handle (3) from the coupler frame (1). Remove 10. Install the coupler frame (1) onto the loader
the latch pin (14) from the coupler frame (1). arms.
10. Place the right handle (3) in a vise with soft jaws. 11. Install the left and right upper pins (23) into the
coupler frame (1).
11. Prevent the pin (13) from turning. Loosen and
remove the bolt (6) from the pin (13). Remove 12. Install the bolts (16), spacers (18), washers (17
the bolt (6), pin (13), spring (9), spring guide (8), and 20), and nuts (19) for the left and right upper
and pin (7) from the right handle (3). pins (23), Tighten the nuts (19).
12. Repeat steps 7 through 11 for the left handle (2). 13. Install the left and right lower pins (21) into the
coupler frame (1).
Inspection 14. Install the bolts (16), spacers (18), washers (17
1. Inspect the coupler frame (1) to be sure it is free and 20), and nuts (19) for the left and right lower
of cracks, corrosion, rust or any other damage. pins (21). Tighten the nuts (19).
2. Inspect the upper pins (23) and the lower pins
(21) for wear, cracks, corrosion or any other
damage. Use new parts as required.
3. Inspect the latch pins (14) for wear and damage.
4. Inspect the bolt (6), pin (13), spring (9), spring
guide (8), and pin (7) for wear and damage. Use

9003-4
15
3
6
2 7
8
22
10
11
13
1
12
14
23
5 19 20
21
16 17 18
4
4
BS05B028
1. COUPLER FRAME 7. PIN 13. PIN 19. LOCK NUT

2. LEFT HANDLE 8. SPRING GUIDE 14. LATCH PIN 20. WASHER
3. RIGHT HANDLE 9. SPRING 15. RETAINING RING 21. PIN
4. GREASE FITTING 10. HANDLE PIVOT PIN 16. BOLT 22. BUSHING/SPACER
5. WASHER 11. RETAINING RING 17. WASHER 23. PIN
6. BOLT 12. PIN 18. SPACER
EXPLODED VIEW OF MECHANICAL ATTACHMENT COUPLER

9003-5
ATTACHMENT COUPLER (HYDRAULIC)
Disassembly 3. Inspect the upper cylinder pins (24), cotter pins

(25), and flag rods (35) for wear, cracks, and
NOTE: Refer to illustrations on page 6 and 7. corrosion. Use new parts as required.
1. Loosen and remove the nuts (6), washers (5 and 4. Inspect the latch pins (20) for wear and damage.
7) and bolts (4) from the protective plate (2). Use new parts as required.
Remove the protective plate (2) from the coupler
frame (1). 5. Inspect the cylinders (27) for leaks, wear or any
other damage. Use new parts as required.
2. Loosen and remove the hydraulic hoses (62 and
63) from hoses (49 and 55). Assembly
3. Loosen and remove the hydraulic hoses (31, 34,
1. Install the latch pin (20) into the coupler frame
39, and 45) from the cylinders (27). Plug the
(1).
hoses and cap the fittings on the cylinders (27).
2. Put the cylinder (27) in place on the coupler
frame (1) and engage the cylinder (27) into the
washers (14 and 17), and spacer (15) from the
latch pin (20).
left and the right lower pins (12) of the coupler
frame (1). 3. Put the flag rod (35) into position on the bottom
of the cylinder (27).
5. Use acceptable tools and remove the left and
right lower pins (12) from the coupler frame (1). 4. Install the cotter pin (25) into the latch pin (20).
6. Loosen and remove the nut (16), bolt (13), 5. Install the pin (24) through the coupler frame (1)
washers (14 and 17), and spacer (15) from the and into the top of the cylinder (27).
left and right upper pins (23) of the coupler frame
6. Install the retaining ring (28) an the pin (24).
(1).
7. Repeat step 1 through 6 for the other cylinder
7. Use acceptable tools and remove the left and
(27).
right upper pins (23) from the coupler frame (1).
8. Install the coupler frame (1) onto the loader arm.
8. Remove the coupler frame (1) from the loader
arms. 9. Install the left and right upper pins (23) into the
coupler frame (1).
9. Place the coupler frame (1) on a work bench.
10. Install the bolts (13), spacers (15), washers (14
10. Remove the cotter pin (25) from the latch pin (20)
and 17), and nuts (16) for the left and right upper
and the flag rod (35) on the bottom of the
pins (23). Tighten the nuts (16).
cylinder (27).
11. Install the left and right lower pins (12) into the
11. Remove the retaining ring (28) from the pin (24)
coupler frame (1).
on the top of the cylinder (27). Remove the pin
(24) from the coupler frame (1). 12. Install the bolts (13), spacers (15), washers (14
and 17) and nuts (16) for the left and right lower
12. Remove the latch pin (20) from the cylinder (27)
pins (12). Tighten the nuts (16).
and frame (1).
13. Connect the hydraulic hoses to the cylinders
13. Remove the cylinder (27) from the coupler frame
(27).
(1).
14. Connect the hydraulic hoses (63 and 62) to the
14. Repeat step 10 through 13 for the other cylinder
hydraulic hoses (49 and 55).
(27).
15. Install the protective plate (2) onto the coupler
Inspection frame (1). Install and tighten the bolts (4),
washers (5 and 7), and nuts (6) which fasten the
1. Inspect the coupler frame (1) to be sure it is free protective plate (2) to the coupler frame (1).
of cracks, corrosion, rust or any other damage.
Use new parts as required. 16. Start the engine and run at low idle and check for
leaks.
2. Inspect the upper pins (23) and the lower pins
(12) for wear, cracks, corrosion or any other
damage. Use new parts as required.
9003-6
4
21 23
22 5 3
7
12
11
8 10
6
9
16
17
18 1
15
14
13
22
19 20
BC01J199
1. COUPLER FRAME 7. WASHER 13. BOLT 19. WASHER
2. PROTECTIVE PLATE 8. BOLT 14. WASHER 20. LATCH PIN
3. BRACKET 9. WASHER 15. SPACER 21. HEX SOCKET PLUG
4. BOLT 10. NUT 16. NUT 22. GREASE FITTING
5. WASHER 11. WASHER 17. WASHER 23. PIN
6. NUT 12. PIN 18. WASHER
EXPLODED VIEW OF HYDRAULIC ATTACHMENT COUPLER

9003-7
57
56
61 57 54
55
61
59 51
60 58
50
49 46
55 54 58 41
40 39
38
37
53 31
35
48
47 42
27
49
28 24 26
43 45
34
44
29 30
31
28 27
26
39 30 29
34
32
33 24
25
45
35
32
35 33
25
BC01J197
24. PIN 32. O-RING 40. ADAPTER 48. 90° ELBOW 55. STEP TO
25. COTTER PIN 33. 90° ELBOW 41. O-RING 49. STEP TO COUPLER HOSE
26. RETAINING RING 34. LH ROD END HOSE 42. O-RING COUPLER HOSE 56. NUT
27. COUPLER CYLINDER 35. FLAG ROD 43. WASHER 50. BOLT 57. WASHER
28. RETAINING RING 36. TEE 44. NUT 51. O-RING 58. 90° ELBOW
29. O-RING 37. 90° ELBOW 45. RH ROD END HOSE 52. O-RING 59. O-RING
30. ADAPTER 38. O-RING 46. CHECK VALVE 53. ADAPTER 60. LOCK NUT
31. LH BASE END HOSE 39. RH BASE END HOSE 47. O-RING 54. ADAPTER 61. BOLT
ATTACHMENT COUPLER SYSTEM HYDRAULICS

9003-8
46
27 27
1
20 20
62
46 46
BS05B029
1. COUPLER FRAME 46. CHECK VALVE
20. LATCH PIN 62. HYDRAULIC COUPLER VALVE
27. COUPLER CYLINDER
ATTACHMENT COUPLER SYSTEM HYDRAULICS

9003-9
3 2
BS05B030
1. WIRE HARNESS 4. SUPPLY HOSE
2. HOSE ASSEMBLY STEP TO COUPLER 5. CASE DRAIN HOSE
3. STEP PLATE 6. TEE
ATTACHMENT COUPLER HYDRAULIC SYSTEM

9003-10
NOTES

Section
9004
9004
ROPS CANOPY, SEAT, SEAT BELTS AND
OPERATORS COMPARTMENT

9004-2
TABLE OF CONTENTS
POSSIBLE DAMAGE TO THE ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND INSPECTION OF THE ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL OF THE ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION OF THE ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL OF THE REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION OF THE REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL OF THE SIDE WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION OF THE SIDE WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL OF TOP WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION OF TOP WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL OF THE DOOR FRAME WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION OF THE DOOR FRAME WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL OF THE FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION OF THE FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL OF THE NON-SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION OF THE SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION OF THE NON-SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL OF THE SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION OF THE SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION OF THE SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

9004-3
POSSIBLE DAMAGE TO THE ROPS CANOPY

If the machine has been rolled over or the ROPS After an accident, check for damage to the ROPS
canopy has been damaged (such as hitting an canopy, the operators seat, the seat belt, all
overhead object during transport), the ROPS canopy accessories, and wiring in the ROPS canopy. Before
shall be replaced in order to maintain maximum operating the machine again, all damaged parts must
protection. be replaced.
IMPORTANT: Do not weld or try to straighten a
ROPS canopy.
MAINTENANCE AND INSPECTION OF THE ROPS CANOPY
WARNING: Improper ROPS inspection or WARNING: Securely fasten your seat belt.
! maintenance can cause injury or death. Do
! Your machine is equipped with a ROPS cab,
the recommended ROPS inspection shown ROPS canopy or ROPS frame for your
in this manual. If you must replace the protection. The seat belt can help insure your
ROPS, ROPS parts, or ROPS mounting safety if it is used and maintained. Never
hardware, use only the replacement parts wear a seat belt loosely or with slack in the
shown in the Case parts catalog for this belt system. Never wear the belt in a twisted
machine. condition or pinched between the seat
SM029 structural members.
M437
After the first 20 hours of operation and after every

WARNING: Do not modify ROPS in any
! manner. Unauthorized modifications such as
500 hours of operation, do the following:
welding, drilling, cutting or adding 1. Check the operators seat and the mounting parts
attachments can weaken the structure and for the seat belt. Torque the seat belt mounting
reduce protection. Replace ROPS if bolts to 52 to 61 Nm (38 to 45 pound-feet). Use
subjected to roll-over or damage. Do not new parts as required.
attempt to repair. 2. Check for cracks, rust, or holes in the ROPS and
SM026 ROPS parts. Age, weather and accidents can
cause damage to the ROPS and ROPS parts. If
you have any doubt about the ROPS system,
s e e y ou r C a s e d e a l e r . U s e n e w pa r t s a s
WARNING: If you operate this machine
! without a ROPS and the machine rolls over,
required.
you can be injured or killed. Remove the
ROPS only for service or replacement. Do
not operate this machine with the ROPS
removed.
SM027
WARNING: Adding additional weight

! (attachments, etc). to the machine can cause
injury or death. Do not exceed the gross
weight printed on the ROPS label.
SM028

9004-4
REMOVAL OF THE ROPS CANOPY

NOTE: Refer to the illustration on page 5. IMPORTANT: Do not attempt to remove the gas strut
cylinder (1) mounting hardware with the ROPS in the
1. Park the unit on a level surface and remove the
lowered position.
bucket from the unit.
8. With the cab in the tilted position, remove the gas
2. Raise the loader arm and engage the loader arm
cylinder mounting bolt (2), washers (3), and lock
support strut.
nut (5) and gas strut cylinder (1).
3. Stop the engine and remove the key.
9. Remove the electrical harness clamp from under
4. Using a floor jack, raise the unit and place a the floor panel bolt. Loosen the retaining bolt in
suitable jack stand(s) under the unit. the cab harness connector and uncouple the
connector from the socket in the chassis.
5. Remove one of the tires/wheels from the unit.
This will be the side to which the ROPS pivot pin 10. Remove the wire harness retaining clip(s) from
(8) will be removed from. the canopy pivot pin (8).
6. Tilt the cab into the forward position. 11. Remove the lock rings (9) from the pivot pin (8).
7. Use the floor jack to raise the loader arm away 12. Place overhead lift chains or straps in the
from the chassis. It will be necessary to activate sidescreen cutouts (toward the rear of the
the manual override on the control valve to move cutouts) and remove any slack between the lift
the lift control lever to allow the arms to be and the ROPS.
raised. Raise the loader just high enough to be
13. Drive out the pivot pin (8) and lift the ROPS from
able to clear the ROPS pivot shaft (8) from the
the unit.
unit.
INSTALLATION OF THE ROPS CANOPY

1. Raise the ROPS over the chassis. Lower the 5. Insert the cab wire harness connector into the
ROPS until the pivot pin hole in the ROPS align socket in the chassis kick plate.
with the ROPS ears on the chassis.
6. Install the clamp and bolt into the floorplate.
2. Install the pivot pin (8) through the chassis ear
7. Install the gas strut cylinder (1), with the rod end
and ROPS pivot holes.
facing down, lock nut (5), washers (3), and bolt
3. Inspect the lock rings (9) and replace if (2).
necessary. Install both lock rings (9) in the pivot
8. Install the tire/wheel assembly and torque wheel
pin (8) ring grooves.
nuts to 135 to 163 Nm (100 to 120 pound-feet).
4. Insert the cab wire harness clips over the pivot Refer to Section 6011.
pin (8).
9. Lift the front of the unit with the floor jack and
remove the jack stand(s) from underneath.
Lower the unit to the ground.

9004-5
5 10
2 3 4
2 3 4 5
2 3 5 6
10 1
2 3 4 5
9
8
2 3 6 7
BS05B033
1. GAS STRUT CYLINDER 6. SPACER
2. BOLT 7. NUT
3. WASHER 8. PIVOT PIN
4. SPACER 9. LOCK RING
5. LOCK NUT 10. ACCESS PANEL
ROPS CANOPY - LATCH AND PIVOT

9004-6
3 1
10
6 18
8 16
6 9
17
5
13
6 9
4 6
16 6
6 14 15 7
11 12
10
6 14 15
16
11
BS05B034
1. FRAME 7. BOLT 13. ROPS TILT ASSIST CYLINDER
2. TRIM 8. HEAT SHIELD 14. BUSHING
3. PLUG 9. THUMB SCREW 15. LOCK RING
4. SPACER 10. SEAT BAR ASSIST CYLINDER 16. SEAT BAR
5. ACCESS PLATE 11. ADJUSTMENT BOLT 17. MANUAL BOX
6. WASHER 12. NUT 18. ROPS BOLT
ROPS CANOPY AND SEAT BAR

9004-7
REMOVAL OF THE REAR WINDOW

NOTE: Refer to illustration on page 7. 6. Remove the brackets (6) from the ROPS frame
(1).
1. Park the machine on a flat, level surface.
7. Inspect the brackets (3) for corrosion and
2. Remove the bolts (2) and knobs (8).
damage. Replace as needed.
3. Remove the retaining brackets (3).
8. Inspect the seal (4) for damage. Replace if
4. Remove the seal (4) and rear window (5). damaged.
5. Remove the bolts (9), washers (10), and flange 9. Inspect brackets (6) for corrosion or damage.
nuts (7) from the brackets (6). Replace as needed.
INSTALLATION OF THE REAR WINDOW

10. Install the brackets (6) on the ROPS frame. 13. Put the retaining brackets (3) in place on the rear
window (5).
11. Install the bolts (9), washers (10), and flange
nuts (7) that secure the brackets (6) to the ROPS 14. Install the knobs (8) and bolts (2) that secure the
frame (1). brackets (3).
12. Put the rear window (5) and seal (4) into place on 15. Fill the gaps between the window brackets and
the brackets (6). the ROPS with sikaflex.
10
8 1
6
10
7 9 10 4
7 9 10
3
6
11
3
BS05B037
1. ROPS FRAME 5. WINDOW 9. BOLT
2. BOLT 6. BRACKET 10. WASHER
3. RETAINING BRACKET 7. LOCK NUT 11. EMERGENCY EXIT DECAL
4. SEAL 8. KNOB
ROPS CANOPY - REAR WINDOW

9004-8
REMOVAL OF THE SIDE WINDOWS

NOTE: Refer to illustration on page 9. 4. The flocked rubber can be remove by lifting it
with a screwdriver midway between the glass
NOTE: Steps 1 through 4 are for removal of the
and the radius. and then pulling it out from under
glass for cleaning only.
the glass. This section of the flocked rubber
1. Close the side window (2). should only be removed from the bottom on the
glass.
2. Locate the midway point between the back of the
glass and the end of the glass frame. Begin 5. Remove the bolts (5) and jam nuts (6).
removing the flocked rubber from the glass
6. Remove the “outside window sub-assembly”.
channel by lifting it with a screwdriver.
Approximately 76 mm (3 inches) will be located 7. Remove the bolts (7) and jam nuts (8) from the
under the glass. Slide this portion out in order to window frame (2).
completely remove the flocked rubber back to
8. Remove the bolts (3) and jam nuts (4) from the
the plastic slide stop.
window frame (2).
3. Gently slide the glass to the full open position.
9. Remove the “inside window sub-assembly”.
About 76 mm (3 inches) of the flocked rubber
may also need to be removed from under the 10. Repeat procedure 1 through 9 for the other side.
front portion of the glass. This will allow the glass
11. Inspect the window frames, windows, and seals
to be lowered far enough into the channel so that
for damage. Replace as necessary.
the top of the glass can be tilted out of the frame.
INSTALLATION OF THE SIDE WINDOWS

12. Put the “inside window sub-assembly” in place 19. With the flocked rubber still removed from the
on the inside of the ROPS frame (9). glass, tilt and lower the bottom of the glass into
the rear portion of the open position. Lift up on
13. Install the bolts (3) and jam nuts (4). Tighten 2.26
the front of the glass while guiding it into the top
to 2.82 Nm (20 to 25 inch lbs).
channel. Slide the loose end of the flocked
14. Install the bolts (7) and jam nuts (8). Tighten rubber still remaining on the glass into the
bolts (7) 2.26 to 2.82 Nm (20 to 25 inch lbs). channel and under the glass. If necessary, coat
the end of the flocked rubber with soapy water.
15. Put the “outside window sub-assembly” in place
Smooth out the flocked rubber and make sure
on the ROPS (9).
the entire length is pressed into the channel.
16. Install the bolts (5) and jam nuts (6) on the
20. Slide the glass to the closed position and install
window frame (2). Tighten 1.13 to 1.36Nm (10 to
the rear piece of the flocked rubber in the same
12 inch lbs).
manner. Make sure both pieces of flocked rubber
17. Repeat steps 12 through 16 for the other side. fit together end to end under the glass.
18. Do steps 19 through 21 if the glass was removed 21. Repeat steps 19 through 20 for the other side.
for cleaning.

9004-9
6 8
5 7
5 6
8
7
10
10 3
4
9
2
3 1
4
6
5
7 3
8 5 6
4
7
8
BS05B038
1. LH WINDOW 6. JAM NUT
2. RH WINDOW 7. BOLT
3. BOLT 8. JAM NUT
4. JAM NUT 9. FRAME
5. BOLT 10. CLAMP
ROPS CANOPY - SIDE WINDOWS

9004-10
REMOVAL OF TOP WINDOW

NOTE: Refer to illustration on page 10. 3. Remove the seal (3) from the ROPS frame (7).
1. Remove the lock nuts (6), washers (5), and bolts 4. Inspect the seal (2) and window (1) for damage.
(4). Replace as necessary.
2. Remove the top window (1). 5. Inspect the seal (3) for damage. Replace if
needed.
INSTALLATION OF TOP WINDOW

6. Put the seal (3) in place on the ROPS frame (7). 8. Install the bolts (4), washers (5), and lock nuts
(6).
7. Put the top window (1) on the ROPS frame (7).
7
1 4
4 5
5
3
2 5
5
6
6
BC01K073
1. TOP WINDOW 3. SEAL 5. WASHER 7. FRAME

2. TOP SEAL 4. BOLT 6. LOCK NUT
ROPS CANOPY - TOP AND SIDE WINDOWS (IF EQUIPPED)

9004-11
NOTES

9004-12
REMOVAL OF THE DOOR FRAME WINDOW

NOTE: Refer to illustration on page 13. 2. Remove the window (4) and seal (3).
1. Remove the bolts (5), washers (6), and lock nut
(7) from the window (4).
INSTALLATION OF THE DOOR FRAME WINDOW

3. Put the seal (3) and window (4) in place on the 4. Install the bolts (5), washers (6), and lock nuts
bracket (43). (8).
REMOVAL OF THE FRONT DOOR

NOTE: Refer to illustration on page 13. 11. Remove the bracket (30).
1. Open the front door (1). 12. Remove the bolts (31), washers (32), and lock
nuts (33).
2. Remove the bolts (25) and lock nuts (23).
13. Remove the bolt (38), washers (39), and lock nut
3. Remove the bracket (24) from the ROPS
(40) on bracket (34).
canopy.
14. Remove the bracket (34) from the machine.
4. Remove the retaining ring (11).
15. Remove the bolts (35), washers (36), and lock
5. Remove the pin (10) from the hinge (9).
nuts (37).
6. Remove the front window (1) from the machine.
16. Remove the bolt (38), washers (39), and lock nut
7. Remove the bolts (15), washers (17), and lock (40) on bracket (41).
nuts (16).
17. Remove the bracket (41) from the machine.
8. Remove the bolts (18), washers (19), and lock
18. Inspect the brackets (30, 34, 41, 43) for
nuts (20).
corrosion or damage. Replace as needed.
9. Remove the bracket (43).
19. Inspect the seals (2, 3, 14, 22, 26) for damage.
10. Remove bolts (27), washers (28), and lock nuts Replace as needed.
(29).
INSTALLATION OF THE FRONT DOOR

1. Place the bracket (41) on the machine. 8. Install the bolts (18), washers (19), lock nuts
(20).
2. Install the bolt (38), washers (39), and lock nut
(40) on bracket (41). 9. Install the bolts (15), washers (17), and lock nuts
(16).
3. Install the bolts (35), washers (36), and lock nuts
(37). 10. Put the front door (1) in place on the machine
and install the pins (10) and retaining rings (11).
4. Put the bracket (34) in place and install the bolt
(38), washers (39), and lock nut (40). 11. Put the bracket (24) in place and install the bolts
(25) and lock nuts (23).
5. Install the bolts (31), washers (32), and lock nuts
(33).
6. Install bracket (30), bolts (27), washers (28), and
lock nuts (29).
7. Put the bracket (43), seal (14, 26), and seals (22)
in place on the machine.

9004-13
6 15
7 3
17 22
4 14
43 19 20
6
17
26 5
16 19
18
29
28
28 21
2
27 24
25 1
23 35
36 41
30 37
32 39 36
40 8
31 11
38 9
12
33 39 13 8
34 42
32 39 10
40
BS01H288
1. FRONT DOOR 12. FLANGE BOLT 23. FLANGE NUT 34. BRACKET
2. SEAL 13. FLANGE NUT 24. BRACKET 35. BOLT
3. SEAL 14. SEAL 25. BOLT 36. WASHER
4. WINDOW 15. BOLT 26. SEAL 37. LOCK NUT
5. BOLT 16. LOCK NUT 27. BOLT 38. BOLT
6. WASHER 17. WASHER 28. WASHER 39. WASHER
7. LOCK NUT 18. BOLT 29. LOCK NUT 40. LOCK NUT
8. WASHER 19. WASHER 30. BRACKET 41. BRACKET
9. HINGE 20. LOCK NUT 31. BOLT 42. GAS STRUT CYLINDER
10. PIN 21. BRACKET 32. WASHER 43. BRACKET
11. RETAINING RING 22. SEAL 33. LOCK NUT
ROPS CANOPY - FRONT DOOR (IF EQUIPPED)

9004-14
5
2
6
BC01H243
1. FRONT WINDOW (GLASS) 3. WIPER 5. SPACER
2. RESERVOIR 4. FLANGE NUT 6. SEAL
ROPS CANOPY - FRONT DOOR (GLASS)

9004-15
NOTES

9004-16
REMOVAL OF THE NON-SUSPENSION SEAT

NOTE: Refer to illustration on page 15. 8. Inspect the operator presence switch (2) and
harness (3) for damage. Replace all parts that
are damaged.
2. Raise the loader arm up and engage the lift arm
support strut.
3. Remove the two ROPS mounting bolts from the REMOVAL OF THE SEAT BELT
rear of the ROPS. 1. Remove bolts (4), lock nuts (7) and washers (6).
4. Tile the ROPS forward until the cab hold open 2. Remove the seat belts (5) from the mounts.
latch assembly is engaged.
3. Inspect the seat belt mounts for corrosion or
5. Remove lock nuts (9) from the non-suspension damage.
seat (1).
NOTE: Keep the seat belt clean. Use only soap and
6. Remove the non-suspension seat (1) from the water to wash the seat belt. Dye or other compounds
cab. can cause damage to the seat belt.
7. Inspect the non-suspension seat (1) mounts, on 4. Inspect the seat belts for damage. Replace all
the bottom of the seat, for corrosion or damage. parts that are damaged.
Replace all parts that are damaged.
INSTALLATION OF THE SEAT BELTS

1. Install the seat belts (5), bolts (4), washers (6), 2. Tighten the lock nuts (7) to 52 to 61 Nm (38 to 45
and lock nuts (7) to the mounts. pound-feet).
INSTALLATION OF THE NON-SUSPENSION SEAT

1. Install the non-suspension seat (1) in the cab. 2. Install the lock nuts (9) on the non-suspension
seat (1) mounts.

9004-17
4 1
5 2
6
7
7 6
5
4 3
BC01H247
1. SEAT 4. BOLT 7. LOCK NUT

2. SWITCH 5. SEAT BELT 8. SEAT PLATE
3. HARNESS 6. WASHER 9. LOCK NUT
NON - SUSPENSION SEAT MOUNTING (IF EQUIPPED)

9004-18
REMOVAL OF THE SUSPENSION SEAT

NOTE: Make sure that all suspension seat adjusters 9. Inspect the suspension seat mounts, on the
(angle, position, weight, and lumbar adjusters) bottom of the seat, for corrosion or damage.
function correctly before removing the suspension Replace all parts that are damaged.
seat.
10. Inspect the operator presence switch (2) and
NOTE: Refer to illustration on page 17. harness (3) for damage. Replace all parts that
are damaged.
4. Raise the loader arm up and engage lift arm
support strut. REMOVAL OF THE SEAT BELT
5. Remove the two ROPS mounting bolts from the 1. Remove bolts (4), lock nuts (7) and washers (6).
rear of the ROPS.
2. Remove the seat belts (5) from the mounts.
6. Tilt the ROPS forward until the cab hold open
latch assembly is engaged. 3. Inspect the seat belt mounts for corrosion or
damage.
7. Remove lock nuts (9) from the suspension seat
(1). NOTE: Keep the seat belt clean. Use only soap and
water to wash the seat belt. Dye or other compounds
8. Remove the suspension seat (1) from the cab. can cause damage to the seat belt.
4. Inspect the seat belts for damage. Replace all
parts that are damaged.
INSTALLATION OF THE SEAT BELTS

1. Install the seat belts (5), bolts (4), washers (6), 2. Tighten the lock nuts (7) to 52 to 61 Nm (38 to 45
and lock nuts (7) to the mounts. pound-feet).
INSTALLATION OF THE SUSPENSION SEAT

1. Install the non-suspension seat (1) in the cab. 2. Install the lock nuts (9) on the suspension seat
(1) mounts.

9004-19
4 2
5
5
6
7
5
7
3
6 5
4
BC01H246
1. SEAT 4. BOLT 7. LOCK NUT

2. SWITCH 5. SEAT BELT 8. SEAT PLATE
3. HARNESS 6. WASHER 9. LOCK NUTS
SUSPENSION SEAT MOUNTING (IF EQUIPPED)

9004-20
NOTES

Section
9006
HEATER
9006

9006-2
TABLE OF CONTENTS
DELUXE HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9006-3
DELUXE HEATER
Removal Inspection
1. Install a hose on the radiator drain valve and 1. Inspect the heater (1) for leaks or damage. Use
drain the radiator coolant into a clean container. new parts as required.
2. Open the shutoff valve (2). 2. Inspect the air ducts for cracks or damage. Use
3. Remove the fill cap on the radiator.
3. Inspect the supply hose (3) and return hose (4)
4. After the radiator is drained install the fill cap and
for cracks or damage. Use new parts as
close the drain valve.
required.
5. Close the heater shut-off valves (2).
4. Inspect the air filter to ensure its clean and free
6. Remove the rear window from the ROPS. of damage. Use new parts as required.
Installation
Installation of the heater assembly (1) is the reverse
procedure of removal. After the heater assembly (1)
has been installed follow the steps listed below.
5. Open the shut-off valve (2), remove the radiator
cap and fill the cooling system with clean
coolant. See Section 1001 for the correct coolant
type and quantity. Install the radiator cap on the
radiator and tighten the cap.
1
6. Start the engine and allow the engine to reach
BD05B015
1. ELECTRICAL HARNESS operating temperature. Check the heating
system for any leaks. Check the heater assembly
7. Loosen and remove the mounting screws on the
(1) for proper operation.
blower motor cover assembly. Remove the cover
and disconnect the electrical harness from the 7. Stop the engine. After the engine has cooled,
heater assembly (1). check the cooling system for proper coolant
level. Add coolant as required.
8. Remove the cover (5) from the heater assembly
(1).
IMPORTANT: Use care when removing the supply
and return hose(s) from the heater connection(s).
Twist the hose to break the seal between the hose
and the connection. If the seal cannot be broken it
may be necessary to cut the hose.
9. Loosen the clamps on the supply (3) and return
hose (4) at the heater core. Remove the supply
(3) and return hose (4) from the heater core.
10. Remove the rear mounting bolts (8) and washers
from the heater assembly (1).
11. Remove the upper mounting bolts (7) and
washers from the heater assembly (1).
12. Slide the heater assembly (1) towards the rear of
the machine and disconnect the heater assembly
(1) from the headliner (9). Remove the heater
assembly (1) from the machine.

9006-4
1
5
9
10
11
9
7
5
1
00
6
8
7
3 8
BS05B104
1. HEATER ASSEMBLY 7. UPPER MOUNTING BOLTS
2. SHUT-OFF VALVE 8. REAR MOUNTING BOLTS
3. SUPPLY HOSE 9. HEADLINER
4. RETURN HOSE 10. TEMPERATURE CONTROL
5. COVER 11. BLOWER SWITCH
6. CONTROL VALVE
DELUXE HEATER INSTALLATION

9006-5
7 8 4
5
3
2
6
BS05B105
1. HEATER CORE 5. COVER
2. BLOWER MOTOR ASSEMBLY 6. BLOWER MOTOR ASSEMBLY COVER
3. FILTER ELEMENT 7. SUPPLY TUBE
4. FILTER ELEMENT COVER 8. RETURN TUBE
DELUXE HEATER ASSEMBLY

9006-6
6 5
3 5
4 2
1
4
BS05B106
1. DUCT 5. LOUVER VENT
2. HEADLINER 6. DOME LIGHT
3. VENT 7. DOME LIGHT WIRING HARNESS
4. VENT HOUSING
HEATER HEADLINER ASSEMBLY

STARTING SYSTEM POWER DISTRIBUTION FUEL SUPPLY SYSTEM ENGINE PRE-HEAT SYSTEM SAFETY INTERLOCK SYSTEM INSTRUMENT CLUSTER STANDARD LAMPS HORN (OPTIONAL) BACK-UP ALARM (OPTIONAL) FRONT DOOR (OPTIONAL)
780A R-3.0 2
6 180A R-5.0 180A R-5.0 130C R-0.5 1
40A 782A P-0.5 6
190A R-5.0 190A R-5.0 300A R-2.0
50 2 300G R-0.5 300G R-0.5
137B R-0.8
WASHER
4 131A R-1.0 131A R-1.0 300B R-2.0 300E R-1.0 300H R-0.5 300H R-0.5 1 781A P-0.5 6 4 7
WIPER
40A 141
20 21 170A R-5.0 EMPTY 32

781A P-0.5
131C R-1.0
A B 25 86 30 18 7 A OFF ON ON
OCCUPIED 783E P-2.0 783F P-1.0
15A
20 B 37 48A
10 UP
137H R-1.0
137K R-1.0
130A R-2.0
121A Y-1.0
8 B1 E1 H1 A2
137D R-1.0
782A P-0.5
837A W-1.0
835A O-1.0
783G P-1.0
622D W-1.0 5
641A W-1.0 6
18
DOWN
59A 59
19 INSTRUMENT CLUSTER 7 8A B1 E1 H1 A2
120B R-8.0 BAT V+ (IN) 3
602G W-1.0 5 NC NC- R-1.0 C C
IGN ON (IN) 24
86 30 7 86 30 64 641A W-1.0
300D R-1.0
86 30 14
303D T-1.0
COM NO- W-1.0 B B 4 34
783D P-2.0
9 B A 58 IGN ON (IN) 23 3 8 141
781B P-0.8
NO COM- B-1.0 A A ACC ON / IGN OFF (IN) 10 A
160A R-8.0
8 52
1 18 85 87 87A 130E R-0.8 1 START (IN) 11 B 38
300E R-1.0
6
323A T-0.5
2.4 W 261A Y-1.0
830D R-2.0
830E R-1.0
830F R-2.0
6 52A ROAD LIGHTS (OUT) 21
7 9 8 10 52
7 9 8 10 52A
COIL
16 12 WORK LIGHTS (OUT) 22
8 8A
625A W-3.0
DOOR OPEN
641B W-0.5 D3 D3 24
178E B-1.0
PREHEAT (OUT) 7
178R B-1.0
178X B-1.0
602C W-1.0
817F R-2.0 DOOR CLOSED
5 18 8A 23 INSTRUMENT CLUSTER
HYD FILTER LAMP 15 261B Y-0.5 G2 G2
27 48 51A 51
625B W-3.0
15A HYD OIL TEMP LAMP 264B Y-0.5 G4 G4 264A Y-1.0

131E R-1.0
2
121C Y-1.0
7 85 87 87A 14 85 87 87A 64 85 87 87A

817A R-1.0 14 55 D2 D2 12 SEAT SWITCH (IN) ENGINE COOLANT TEMP LAMP 25 257B Y-0.5 G1 G1 257A Y-1.0 NC NC- R-1.0 C C
1 2
C2 C2 303C T-0.8 313D T-0.8 14 INTERLOCKV+ (OUT) AIR FILTER LAMP 16 266B Y-0.5 J1 J1 266A Y-1.0
P A B 99 COM NO- W-1.0 B B
1 101
178B B-1.0 178B B-1.0 138A R-5.0 3 4 820A R-2.0 16 258B T-1.0 D4 D4 258C T-0.5 8 PARK BRAKE (OUT) FUEL SENDER SIGNAL 1 234B Y-0.5 F1 F1 234A Y-1.0 2 101A NO COM- B-1.0 A A
10A 311B P-1.0 H2 H2 311C T-1.0 A A 5 FUEL SOLENOID (OUT) ENGINE OIL PRESS LAMP 18 255B Y-0.5 E4 E4 255A Y-1.0 21
178AH B-1.0
16
136A R-5.0
751F R-1.0 311F T-1.0 C1 C1 42
311D T-1.0 50J 311J T-1.0 262A Y-0.5
105 B A 137H R-1.0 137H R-1.0 17 B B 26 AUX HYD OVERRIDE (OUT) CHARGE PRESS LAMP 17 G3 G3
780A R-3.0
782C P-0.8
781C P-0.8
782B P-0.8
5 6 50
783C P-2.0
101B 1 102 1
2 L R 130A R-2.0 137C R-3.0 137C R-3.0
10A 602A W-1.0 J2 J2 602B W-0.5 13 23
34 P
895A O-1.0 2
131A R-1.0
178E B-1.0
751D R-1.0 319B T-1.0 D1 D1 319A T-0.5 6 33 895B O-1.0
17A A B 7 8 11 264A Y-1.0 890A R-1.0 8 8A
313G T-1.0
313H T-1.0
4 TURN INDICATOR A 2 43
B+ G
17 A B
540B R-1.0 15
8
8 8A B 39 45 K2 K2 830A R-3.0 2
P 622A W-1.0 5 754A P-0.5 B4 B4 124C R-1.0
17 21
4 A1 B2 A3 B3 8A
540C R-1.0 13 15 TACHOMETER 19 124B R-0.5 J3 J3 28
783B P-2.0
39
706D P-3.0
784B P-2.0
784A P-1.0
A1 B2 A3 B3 8 178CC B-1.0 127
643A R-8.0
9 F4 F4 A
124A R-1.0 602A W-1.0 A A 602G W-1.0
783A P-3.0
6 3 CLEAN GROUND 20 200C B/W-0.5 K1 K1 96 86 30 93 86 30 J4 J4 892C O-1.0 B 25
15
830B R-3.0
B B 44 178WH B-1.0
622B W-1.0
130B R-2.0
131B R-1.0
137A R-3.0
120A R-8.0 319D T-1.0 C C 622D W-1.0 1 23 1 2 3 4 5 52 8 8A 1 178WG B-1.0

895A O-1.0 P
9 D D 1 2 3 4 5 52A
35 36 897A O-1.0
2 835B 0-1.0
137E R-1.0
160A R-8.0 8 10A 7 127A 200D B/W-1.0 35
120B R-8.0
4 45 113
890A R-1.0 8 622A W-1.0 706B P-1.0
625B W-3.0
6 15A 5
1 46 140 140A
300A R-2.0 79 36 40 A 313F T-1.0 1 1 313G T-1.0
50A 4 130C R-0.5 6 4 25A 3
5
319C T-1.0 A
262B Y-1.0 124A R-1.0 1 40 B 313J T-1.0 2 2 313H T-1.0 112 112A
706A P-3.0
24 96 85 87 87A 93 85 87 87A
136A R-5.0 830A R-3.0 10 565A T-1.0 B 892A O-1.0 50A 3 3 835A O-1.0 1 1
130E R-0.8 5 2 20A 1 178M B-1.0 4 4 2 2
234A Y-1.0 257C Y-1.0
130D R-2.0
137F R-3.0 610A W-1.0 610A W-1.0 41 A A 830C R-2.0 5 5 830D R-2.0 830F R-2.0 3 3
178W B-1.0
706C P-1.0
178F B-1.0
120C R-8.0 2 258B T-1.0 897A O-1.0 B B 178WH B-1.0 6 6 178WP B-1.0 178WP B-1.0 4 4
178AU B-0.8
POS_CBL
61
780A R-3.0 7 311F T-1.0 255C Y-1.0 65 65A
137B R-0.8 6 14 2 1 80 A B 48 27 44 178N B-1.0
C B D A 9 11 17 31 28 266C Y-1.0 26 38 140B
M 22 57 1
B 311G T-1.0 CONNECT TO 140 2 313JP T-1.0
A
SPL14
24 25 37 41 WHEN DOOR IS 3
ACC B 2 P 4
IGN P V 1
REMOVED
A 5
1 3 ST
B 311H T-1.0
12 29 6
178E B-1.0
A 30
47
178BC B-1.0
178BD B-1.0
200D B/W-1.0
178CH B-1.0
178CJ B-1.0
103
178AH B-1.0
178AC B-1.0
178AE B-8.0
178CK B-1.0
178A B-2.0
178E B-1.0
178K B-1.0
178M B-1.0
178R B-1.0
178N B-1.0
178X B-1.0
178T B-3.0
23
178L B-2.0
178G B-1.0
178H B-1.0
178U B-0.8
7 33 30
32 29
NEG_CBL
FRAME 1 FRAME 2 FRAME 3 FRAME 4 FRAME 5 FRAME 6 FRAME 7 FRAME 8 FRAME 9 FRAME 10
BC04M092-01 BC04M092-02 BC04M092-03 BC04M092-04 BC04M092-05 BC04M092-06 BC04M092-07 BC04M092-08 BC04M092-09 BC04M092-10
HIGH FLOW ELECTRO-HYDRAULIC RIDE CONTROL (OPTIONAL) ROTATING BEACON (OPTIONAL) ELECTRICAL ACCESSORY OUTLET HYDRAULIC COUPLER DOME LIGHT/HEATER (OPTIONAL) TURN SIGNALS (OPTIONAL) LOADER ARM AUXILIARY ELECTRIC (OPTIONAL) AUXILIARY OVERIDE SYSTEM HAZARD SWITCH AND FLASHER HARNESS (OPTIONAL)
ATTACHMENT FLOW (OPTIONAL) (OPTIONAL) (OPTIONAL)
70 540G R-1.0
70A 70 13 69
535B T-1.0 V V 535A T-1.0 540A R-1.0 S S 540B R-1.0 2 B B
547A T-1.0 C C A A
TO DOME LAMP LIFT ARM CONNECTOR
751D R-1.0 U U 13 178Z B-1.0
49 T T
69A 107 E F K G H C D J B A L M N P
SPL
A 72 P P 66B 66C
604A W-1.0 #F3
70A A 757FB P-1.0 757FA P-1.0 A
70A
B 759FA P-1.0 751FA R-1.0 B
CONNECT TO 127 5 127B 127C 5 CONNECT TO 127A
C 756FB P-1.0 756FA P-1.0 C
178AF B-1.0 820B R-2.0 B B 820A R-2.0 SPL SPL
002B DB-1.0
178JH B-2.0
2 D 759FB P-1.0 D
008B W-1.0
17
004B R-1.0
001B B-1.0
006B P-1.0
817J O-2.0
005B Y-1.0
007B T-1.0
A A #F2 #F1
547B T-1.0 70 E 758FA P-1.0 E 17
B B CONNECT TO 66
B A 115
F 754FA P-1.0 F CONNECT TO 66A
B C 72 C C
B A 115A OFF G G
D D
751E R-1.0 178CG B-0.8 ON
H 178FA B-1.0 H
602D W-1.0
62 64
756FC P-1.0
757FC P-1.0
756FD P-1.0
757FD P-1.0
178BA B-1.0
758FA P-1.0
754FA P-1.0
547D T-1.0
56 ET001C R-0.8 L
RD
A
85
751D R-1.0 2 B M
BL 757B P-1.0 A
B A 68A B
BK 172 751G R-1.0 B 602F W-1.0
B A 68 C H C 24
3 2 170 756B P-1.0 C
1 2 3 4 5 6 7 8 9 10 11 12 138
SPOOL ENGAGED
SPOOL NEUTRAL
77 178BB B-0.8 171 171 172
622D W-1.0
602E W-1.0
319E T-1.0
766A P-1.0 1 2 3 4 5 6 7 8 9 10 11 12 138A 276 A B C D E F
A 548B T-1.0 B 547E B-0.8
1 2 81 24 A 26 71A ET007A R-1.0
B 55 D 67 A B 73
178HJ B-2.0
1 2 81B
817H O-2.0
ET006A Y-0.8
CONNECT B 817D R-1.0 1 2 76 61 75
ET001A R-2.0
123
178BZ B-1.0
A
74
ET000D B-1.0
ET000E B-0.8
TO 71
178DA B-1.0 66 86
275
TO ACCESSORY A A 757A P-1.0 A A
30
1 170 B B 751F R-1.0 B B 85 GRD
POWER OUTLET 21 178FA B-1.0
78 (EUROPE) 58 59 C C 756A P-1.0 C 150 130
751FA R-1.0
85
86 86 BATT
70A 70 E A 67 ET000E B-0.8

D
E
D
E
759A P-1.0
758B P-1.0
2 817F R-2.0 A A 69 320B LB-1.0 319F T-1.0 759FC P-1.0 87
87 LOAD
B B 87A
178DC B-1.0
178BD B-1.0
F A B 129
540C R-1.0 A A 540F R-1.0 F 754C P-1.0
178DD-1.0
545B T-1.0
546B T-1.0
751F R-1.0 150A

54 2
320A LB-1.0
ET000D B-1.0 G G 2
H H
540G R-1.0 49
178DE B-1.0
16 ET003A P-2.0 E E ET003C P-2.0
817G O-2.0
70A 66A
535D T-1.0
535C T-1.0
71 547A T-1.0 117 B B 759A P-1.0 20 008A W-1.0 8

ET001A R-2.0 ET004A Y-2.0 ET004C Y-2.0
A B 120 1 2 121 1 2 122
16 178Z B-1.0 2 817A R-1.0 R R 817B R-1.0
178AD B-1.0
B
A UNLATCH
B B ET001B R-0.8 ET005A O-2.0 C C ET005C O-2.0 007A T-1.0 7
6
72
A 75 A A ET000A B-2.0 ET000C B-1.0 D D ET000H B-2.0 006A P-1.0
LATCH
70 D 92
117A ET000B R-0.8 ET008A LB-1.0 A A 758B P-1.0 20 005A Y-1.0 5
4 25 86 30 125 86 30 128 17 758B P-1.0 70A 70
TO ACCESSORY ET009A LB-1.0 F F 004A R-1.0
POWER OUTLET 177 178 179 003D O-1.0 3
A B 124
(10 AMP MAXIMUM)
57 183
1
174 175
754C P-1.0 002A DB-1.0 2
K K
L L
758A P-1.0
759B P-1.0 73
21
ET0009C LB-1.0
ET008C LB-1.0
(NORTH AMERICA) 1 001A B-1.0 1
183A 70 71 17 759A P-1.0
184
ET010A LB-1.0
B D 75 SPL 15 E A 92
M
50 51 52 53 176 F E D C B A
65
540A R-1.0 VALVE CONNECTOR 125 85 87 87A 128 85 87 87A
ET011A LB-1.0
P 186
182
63 1
180 624A DB-1.0
178DF B-1.0
67 T
185 178DG B-1.0 604A W-1.0
178BCF B-1.0
178AG B-1.0
178AN B-1.0
178BF B-0.8
178AF B-1.0
178AL B-0.8
178CE B-20
178BJ B-2.0
178CG B-0.8
178AD B-1.0
178AJ B-0.8
178Y B-1.0
181
66
FRAME 11 FRAME 12 FRAME 13 FRAME 14 FRAME 15 FRAME 16 FRAME 17 FRAME 18 FRAME 19 FRAME 20
BC04M092-11 BC04M092-12 BC04M092-13 BC04M092-14 BC04M092-15 BC04M092-16 BC04M092-17 BC04M092-18 BC04M092-19 BC04M092-20
LIGHTING (OPTIONAL) LOADER LOCK OUT (OPTIONAL) EURO ON ROAD BRAKE LIGHTS LEFT-HAND HANDLE (OPTIONS) RIGHT-HAND HANDLE (OPTIONS) LEGEND
1. BATTERY 39. REAR WORKLIGHT 78. LEFT FRONT TURN LIGHT
70
754B P-1.0 N N 754C P-1.0 OPTION F OPTION G 2. ALTERNATOR 40. LEFT REAR INDICATOR LIGHT 79. RIGHT FRONT TURN LIGHT
17
70A OPTION A OPTION B 3. STARTER AND SOLENOID 41. RIGHT REAR INDICATOR LIGHT 80. LEFT FRONT POSITION LIGHT
97 85A 123B
A A C 756AA LB-0.8 A 545AB Y-1.0 545BB Y-0.8
4. CIRCUIT BREAKER 42. NOT USED 81. RIGHT FRONT POSITION LIGHT
754B P-1.0 B B 754A P-0.5 5 17
B 11 B 546AB LB-1.0 92 93 5. STARTER RELAY 43. NOT USED 82. LICENSE PLATE LIGHT
97A A 757AA Y-0.8 92 6. RESISTOR (50 OHMS) 44. HORN 83. RESISTOR
90 91 98
226
39G
7. IGNITION SWITCH 45. BACKUP ALARM SWITCH (LEFT) 84. LOADER LOCKOUT SWITCH
RIGHT
LEFT
76 890AG R-1.0 890BG R-0.8

FWD
A
REV
OFF
178TB B-1.0 1 1 B
8. MAIN POWER RELAY 46. BACKUP ALARM SWITCH (RIGHT) (OPTIONAL)
ON
8 B 892AG V-1.0
706TB P-1.0 2 2 R 39F
701TA P-1.0 3 3 DG 71B
A 890AF R-1.0
9. OPTIONS POWER RELAY 47. BACKUP ALARM 85. NOT USED
B 548AG V-1.0
756TB P-1.0 4
226A
4 LG
83 14
B
A
700B P-1.0
178EB B-1.0
8 B 892AF V-1.0 12 A 10. DIODE (REVERSE POLARITY) 48. CAB DOOR SWITCH 86. LEFT BRAKE LIGHT SWITCH
79B
CONNECTS 540AA O-0.8 B 311CB R-0.8
77G 11. PRIMARY FUSE BLOCK 48A. WIPER/WASHER SWITCH (EURO)
TO 71 5 A 311AB R-1.0
OPTION H 12. OPTIONS FUSE BLOCK 49. ELECTRO HYDRAULIC HIGH 87. RIGHT BRAKE LIGHT SWITCH
60 71C 700B P-1.0 GRD 4 13. NOT USED FLOW SWITCH (EURO)
B 700A P-1.0
86B 228 14 A 178EB B-1.0 OPTION C 14. FUEL PUMP 50. DIODE 88. BRAKE LIGHT TIMER RELAY
EXTEND RETRACT
C 757TC P-1.0 178TA B-1.0 2 2 B 78 CONNECTS 178EA B-1.0 (UP) (DWN) 15. FUEL HOLD-IN SOLENOID 51. COMBINATION SOLENOID (EURO)
B 178TE B-1.0 706TA P-1.0 TO 71A
17
A 756TC P-1.0 756TA P-1.0
4
3
4
3
R
LG
123C
92 93 FRT. ELECT
16. COIL 52. FORWARD SOLENOID 89. OPTION NOT AVAILABLE 410,420
A 545AC Y-1.0 545BC Y-0.8
SPL_T1 706TH P-1.0 1 1 RLB 80 11 B 546AC LB-1.0
CTRL SW. #1 17. GLOW PLUGS 53. REVERSE SOLENOID 90. TURN SIGNAL SWITCH
706TA P-1.0 228A 704A P-1.0 70
39H 18. INTERLOCK RELAY 54. RIDE CONTROL SOLENOID 91. ATTACHMENT HYDRAULIC
84 91 98 178AK B-3.0 E E 178AM B-3.0
19. SEAT SWITCH 55. ROTATING BEACON SWITCH SWITCH
F 119
8
A
B
890AH R-1.0
892AH V-1.0
890BH R-0.8 94 70A GRD 2
89
FWD
178TD B-1.0 20. SEAT BAR SWITCH 56. ROTATING BEACON 92. HORN SWITCH
86 87
REV
OFF
ON
SPL_T6 LOCKED FREE

SPL_T5
B 548AH V-1.0 21. NOT USED 57. HYDRAULIC COUPLER SWITCH 93. RIDE CONTROL SWITCH
P P 12 A
7 706TD P-3.0 706TC P-1.0 230 77H
EXTEND RETRACT
(UP) (DWN)
22. LOADER VALVE SOLENOID 58. DIODE 94. FRONT ELECTRIC CONTROL
SPL_T3
102B A A R 82 79C 8 23. LOADER VALVE SOLENOID 59. HYDRAULIC COUPLER RELEASE SWITCH No. 1
178AB B-3.0
SPL7
178TC B-1.0 B B B 119 E
B 565AC T-0.8 311BC R-0.8 311CC R-0.8 178V B-5.0 K3 K3 178S B-5.0
230A 5 A 311AC R-1.0 49H 24. BRAKE RELEASE/TANDEM PUMP SOLENOID 95. FRONT ELECTRIC CONTROL
1 001 B-0.8 8A SPL5
701A P-1.0 700A P-1.0 2 002 DB-0.8
FRT. ELECT
178CL B-1.0 178J B-2.0 NEUTRAL OVERRIDE SOLENOID 60. LEFT-HAND FRONT HEADLAMP SWITCH No. 2
CTRL SW. #2
25 701TA P-1.0
50C 50D 3 003 O-0.8 SPL12 GRD 1 25. OPTION NOT AVAILABLE 410,420 61. HEAT CONTROL SWITCH 96. FRONT ELECTRIC CONTROL
250A 701TB P-1.0 A 12B T-1.0 13B T-1.0 A 190 87 4 004 R-0.8
003A O-0.8 95 26. NOT USED 62. FAN SPEED SWITCH SWITCH No. 3
B 13A T-1.0 B 18
706TE P-2.0
5 005 Y-0.8
88
178CM B-2.0
178CN B-2.0
6 006 P-0.8 27. HYDRAULIC FILTER PRESSURE 63. BLOWER MOTOR 97. FRONT ELECTRIC CONTROL
757TC P-1.0
OPTION D SPL11
178TF B-1.0
7 007 T-0.8
T 85D 8 008 W-0.8 EXTEND RETRACT SWITCH 64. OPTION NOT AVAILABLE 410,420 SWITCH No. 4
68 C 756AD LB-0.8 (UP) (DWN)
28. HYDRAULIC OIL TEMPERATURE 65. OPTION NOT AVAILABLE 410,420 98. ATTACHMENT HYDRAULIC
B 540AD O-0.8 SPL25 SPL24
229 17
A 757AD Y-0.8 SENDER 66. OPTION NOT AVAILABLE 410,420 FORWARD FLOW "ON" SWITCH
SPL_T7 178TH B-1.0 2 2 B 79 190 85 86
706TG P-1.0 4 4 R 123D
FRT. ELECT
29. ENGINE COOLANT 67. OPTION NOT AVAILABLE 410,420
757TA P-1.0 3 3 LG START
250 A 545AD Y-1.0 545BD Y-0.8 CTRL SW. #3 TEMPERATURE SENDER 68. RIGHT-HAND FRONT HEADLAMP
SPL_T2 706TJ P-1.0 1 1 RLB 81 11 546AD LB-1.0 GRD
RIGHT
B
178EA B-1.0 702A P-1.0 003B O-0.8 96
LEFT
SPL_T4 706TG P-1.0 229A

21 30. AIR FILTER RESTRICTION 69. AUXILIARY HYDRAULIC NEUTRAL
91 98 SWITCH SPOOL SWITCH
227
89 31. FUEL SENDER 70. STARTING INTERLOCK RELAY
FWD
REV
OFF
ON
178TG B-1.0 1 1 B 77 ON OFF

32. ENGINE OIL PRESSURE SWITCH 71. FUEL SOLENOID RELAY
706TF P-1.0 2 2 R
200D B\W-1.0
701TB P-1.0 3 3 DG 33. CHARGE PRESSURE SWITCH 72. DIODE
178CH B-1.0
178CC B-1.0
178BD B-1.0
178BC B-1.0
178CK B-1.0
187AC B-1.0
178AH B-1.0
178CE B-2.0
178CG B-0.8
178AG B-1.0
178AN B-1.0
178AD B-1.0
178AF B-1.0
178BJ B-2.0
178BF B-0.8
178CJ B-1.0
178AL B-0.8
178AE B-8.0
178CF B-1.0
178AJ B-0.8
90
178U B-0.8
178H B-1.0
178N B-1.0
178M B-1.0
178X B-1.0
178K B-1.0
178A B-2.0
178G B-1.0
178R B-1.0
178Y B-1.0
178T B-3.0
178L B-2.0
757TB P-1.0
NEG CBL
4 4 LG
227A
83 79D FRT. ELECT 34. DIODE 73. HAZARD SWITCH
B 565AD T-0.8 311BD R-0.8 311CD R-0.8 CTRL SW. #4
5 A 311AD R-1.0 003C O-0.8 97 35. LIGHT RELAY No. 1 74. FLASHER MODULE
36. LIGHT RELAY No. 2 75. DIODE PACK
37. LEFT FRONT WORKLIGHT 76. LEFT REAR TURN LIGHT
FRAME 21 FRAME 22 FRAME 23 FRAME 24 FRAME 25 FRAME 26 38. RIGHT FRONT WORKLIGHT 77. RIGHT REAR TURN LIGHT
BC04M092-21 BC04M092-22 BC04M092-23 BC04M092-24 BC04M092-25 BC04M092-26
CIRCUIT DIAGRAM LEGEND WIRE IDENTIFICATION NOTES

702A P-1.0
INDICATES WIRE NUMBER ELECTRICAL SCHEMATIC
MALE FEMALE INDICATES WIRE SIZE
23
TERMINAL TERMINAL EXTERNAL
INTERNALLY
GROUNDED
WIRE COLOR
410 AND 420 SKID STEER
54 30 8 NUMBERS REFER TO THE GROUND Additional copies of this Hydraulic and Electrical Schematic can be ordered through Technical
COMPONENT B . . BLACK LB . LIGHT BLUE P . . PURPLE
SHOWS CIRCUIT SHOWS FRAME NUMBER AT THE Publications Distribution System. The part number is 6-78970
CROSSING CIRCUIT COMPONENT WIRE TAG CONNECTOR BOTTOM CENTER OF B/W BLACK/WHITE O . . ORANGE R . . RED
GROUND
NOT CONNECTED CONNECTED NUMBER NUMBER NUMBER EACH FRAME.
BC04M092-00
410 HYDRAULIC SYSTEM 410 LOADER CONTROL VALVE 410 EH VALVE 410 HYDRAULIC COUPLER (OPTION) 410 SECONDARY AUXILIARY (OPTION) 410 SELF-LEVEL (OPTION) 410 RIDE CONTROL (OPTION)
15
Pilot pressure line Pilot pressure line Pilot pressure line Pilot pressure line
Case drain line Case drain line Case drain line Case drain line
P
14 BRAKE
L15
K15 BRAKE 42
T K11
K7B K7A
K5 J5
18 20
K8
17 19
40 FC
44
G6 G7A G7B
J16 J15 J10 K8 46 E9
23 24 A B1 B2 47
H14 J9
H13 11 12 H9
B A L Z Z L B A
13 13 H5
P F7 G8 K11
AUXILIARY OUT 43
16 16 FC FC MC MC R6
30 45
V1 V2
G7B 16 C2 T
5 5 G5 R6 C1 P
G8 G6
G7A A B
MC FC
9 10 A B A B A B
22 INLET P C2 C1 48
F7 FC MC F5 R2
A B INLET CASE DRAIN C D
41 P. B. T
F5
16 30 5 K11
4
R5
A B A B A B R4 HPCO
1 2 E7 E7 K5
F9
6 5 5 8 R2 AUXILIARY 40
E1 E2
16 INLET
FC T P G5
R1 N N R1 5 26 AUX
F1 F2 INLET P
H5
R4 HPCO
45 K8
R1 R1
7 E9 E7
28 27 29 C12
AUXILIARY
3 6 INLET
26
7
25 21 28 27 29
FRAME 1 FRAME 2 FRAME 3 FRAME 4 FRAME 5 FRAME 6 FRAME 7
BC05A008-01 BC05A008-02 BC05A008-03 BC05A008-04 BC05A008-05 BC05A008-06 BC05A008-07
420 HYDRAULIC SYSTEM 420 LOADER CONTROL VALVE 420 EH VALVE AND HIGH FLOW (OPTION) 420 HYDRAULIC COUPLER (OPTION) 420 SECONDARY AUXILIARY (OPTION) 420 SELF-LEVEL (OPTION) 420 RIDE CONTROL (OPTION)
15
Pilot pressure line Pilot pressure line Pilot pressure line Pilot pressure line
Case drain line Case drain line Case drain line Case drain line
P
14 BRAKE
L15
K15 BRAKE F9 42
T K11
K7B K7A
18 20
K5 J5 38
E 37 K7B K7A
K8
P
17 19 SV1
39
40 FC
CV1
44 RV1
R3 G6 G7A G7B
J16 J15 J10
AUX T
K8 46 E9
23 24
J5 A B1 B2 47
H14 J9
H13 11 12 H9
B A L Z Z L B A
13 13 H5
P F7 G8 K11
AUXILIARY OUT 43
16 16 FC FC MC MC R6
30 45
V1 V2
G7B 16 C2 T
5 5 G5 R6 C1 P
G8 G6
G7A A B
MC FC
9 10 A B A B A B
22 INLET P C2 C1 48
F7 FC MC F5 R2
A B INLET CASE DRAIN C D
41 P. B. T
F5
16 30 5 K11
4
R5
A B A B A B R4 HPCO
1 2 E7 E7 K5
F9
6 5 5 8 R2 AUXILIARY 40
E1 E2
16 INLET
FC T P G5
R1 N N R1 5 26
AUX
F1 F2 INLET P
H5
R4 HPCO
45 K8
R1 R1
7 E9 E7
28 27 29 C12
AUXILIARY
3 6 INLET
26
7
25 21 28 27 29
FRAME 1 FRAME 2 FRAME 3 FRAME 4 FRAME 5 FRAME 6 FRAME 7
BC05A008-11 BC05A008-12 BC05A008-13 BC05A008-14 BC05A008-15 BC05A008-16 BC05A008-17
COMPONENT IDENTIFICATION
1. LEFT PISTON PUMP 40. ATTACHMENT CASE DRAIN

2. RIGHT PISTON PUMP 41. HYDRAULIC COUPLER CONTROL VALVE
3. CHARGE PUMP 42. HYDRAULIC COUPLER CYLINDER
4. HYDROSTATIC PUMP 43. SECONDARY AUXILIARY CONTROL VALVE
5. CIRCUIT RELIEF VALVE 44. 100 MESH SCREEN
6. TOW VALVE 45. ACCUMULATOR
7. CHECK VALVE 46. CHECK VALVE
8. HYDRAULIC PUMP 47. SELF-LEVEL VALVE
9. LEFT DRIVE MOTOR 48. RIDE CONTROL SOLENOID VALVE
10. RIGHT DRIVE MOTOR
11. LEFT BRAKE
12. RIGHT BRAKE
13. FLUSHING VALVE
14. BRAKE SOLENOID VALVE
15. CHARGE PRESSURE SWITCH
16. ORIFICE
17. HYDRAULIC RESERVOIR
18. DRAIN MANIFOLD
19. OIL COOLER
20. OIL COOLER BYPASS VALVE
21. BACKUP ALARM SWITCH PORTS
22. BRAKE LIGHT SWITCH PORTS
23. TILT CYLINDERS
24. LIFT CYLINDERS
25. MAIN RELIEF VALVE
26. LOADER CONTROL VALVE
27. TILT SPOOL
28. LIFT SPOOL
29. AUXILIARY SPOOL
30. AUXILIARY OUTLETS
31. NOT USED
32. NOT USED
33. NOT USED
34. NOT USED
35. NOT USED
36. NOT USED
37. HIGH FLOW PUMP
38. HIGH FLOW OIL COOLER
39. HIGH FLOW CONTROL VALVE
NOTES HYDRAULIC SYMBOLS

410 RELIEF VALVE PRESSURES
R1 = 4350 PSI (300 BAR)
420 RELIEF VALVE PRESSURES
R1 = 4060 PSI (280 BAR)
TEXT LEGEND
FC = FEMALE CONNECTOR PRESSURE HYDRAULIC SCHEMATIC
R2 = 3350 PSI (231 BAR) R2 = 3350 PSI (231 BAR) MC = MALE CONNECTOR PILOT PRESSURE 54 CHECK VALVE FILTER OR SCREEN 410 AND 420 SKID STEER
R3 = 3250 PSI (224 BAR) R3 = 3250 PSI (224 BAR) Additional copies of this Hydraulic and Electrical Schematic can be ordered through
R4 = 3050 PSI (210 BAR) R4 = 3050 PSI (210 BAR) CASE DRAIN COMPONENT SHOWS CIRCUIT SHOWS
NUMBER Technical Publications Distribution System. The part number is 6-78970
R5 = 2500 PSI (186 BAR) R5 = 2500 PSI (186 BAR) CROSSING CIRCUIT
COMPONENT RESTRICTOR
R6 = 1900 PSI (131 BAR) R6 = 1900 PSI (131 BAR) NOT CONNECTED CONNECTED OIL COOLER
BC05A008-00

51796-Case 410 420

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

51796-Case 410 420

Uploaded by

Copyright:

Available Formats

410/420 SKID STEER

Fuel Systems Tab 3

Power Train Tab 6

Copyright © 2005 CNH America LLC.

Mounted Equipment Tab 9

Bur 6-78990 Issued 2-05 Printed in U.S.A.

Section Title Section Number

Copyright © 2005 CNH America LLC

FLUIDS AND LUBRICANTS

CNH AMERICA LLC Copyright © 2005 CNH America LLC

Bur 6-79030 Issued 2-05 Printed in U.S.A.

CAPACITIES AND LUBRICANTS

Bur 6-79030 Issued 2-05 Printed in U.S.A.

Oil Viscosity/Temperature Ranges

Bur 6-79030 Issued 2-05 Printed in U.S.A.

DIESEL FUEL SYSTEM

Specifications for Acceptable No. 2 Diesel Fuel

Bur 6-79030 Issued 2-05 Printed in U.S.A.

Bur 6-79030 Issued 2-05 Printed in U.S.A.

STANDARD TORQUE SPECIFICATIONS

CNH AMERICA LLC

TORQUE SPECIFICATIONS - METRIC HARDWARE ........................................................................................................ 4

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ........................................................................................... 5

Bur 7-52931 Issued 9-98 Printed in U.S.A

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Bur 7-52931 Issued 9-98 Printed in U.S.A.

TORQUE SPECIFICATIONS - METRIC HARDWARE

Bur 7-52931 Issued 9-98 Printed in U.S.A.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fitting

Straight Threads with O-ring

Bur 7-52931 Issued 9-98 Printed in U.S.A.

Split Flange Mounting Bolts

O-Ring Boss End

Bur 7-52931 Issued 9-98 Printed in U.S.A.

Bur 7-52931 Issued 9-98 Printed in U.S.A.

Bur 7-52931 Issued 9-98 Printed in U.S.A.

CNH AMERICA LLC

Bur 7-52950 Issued 6-97 Printed in U.S.A

Area: sq. meter 10.763 91 square foot

Force: newton 3.596 942 ounce force

Length: millimeter 0.039 370 inch

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000 466 ton/acre

Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.

Power: kilowatt 1.341 02 horsepower

Pressure: kilopascal 0.145 038 lb/sq. inch

Temperature: degree C 1.8 x C +32 degree F

Torque: newton meter 8.850 748 lb/inch

Velocity: kilometer/hr. 0.621 371 miles/hr.

Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

Bur 7-52950 Issued 6-97 Printed in U.S.A.

Area: square foot 0.092 903 square meter

Length: inch 25.4 * millimeter

Mass: pound 0.453 592 kilogram

Mass/Area: ton/acre 2241 702 kilogram/hectare

Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr

Mass/Volume: lb/cubic yd. 0.593 276 kg/cubic meter

Power: horsepower 0.745 700 kilowatt

Pressure: lbs/sq. in. 6.894 757 kilopascal

Temperature: degree F 1.8 F - 32 degree C

Torque: pound/inch 0.112 985 newton meter