Gehl SL3640, SL3840 & SL4240 Skid-Steer Loader Service Manual 917170 - PDF DOWNLOAD

917170

Revision A 01/06

®

SL3640, SL3840 and SL4240 Skid-Steer Loaders

Form No.

Service Manual

INTRODUCTION With correct maintenance and proper use, Gehl skid-steer loaders will give years of dependable service. This service manual is intended to be a guide in the assembly and disassembly, installation and removal, adjustment and testing, troubleshooting and replacement of components that together make up the Gehl SL3640/3840/4240 family of skid-steer loaders.

In many of the procedures found within, the installation steps are the exact opposite of the removal steps and vice versa, and therefore, the opposite procedure is not written. Instead, a note to reverse the procedure will be stated. This reduces redundancy and excessive pages in the manual. In cases though, where the assembly and disassembly or removal and installation procedures differ and additional steps or safety concerns are paramount, the entire reverse procedure will be written out to include the new information.

The Table of Contents and Index can be used to make the procedure you need to find an easier process. Also, there are black tabs extending off the pages highlighting the chapters for those who prefer to thumb through the manual. Many schematics, photographs, and line art drawings are used to help perform the necessary repairs, tests, or adjustments that the SL3640/3840/4240 skid-steer loaders need to keep them in good running condition.

If you have any additional questions, please contact your authorized Gehl dealer or call the Gehl Service Department for assistance.

Gehl is a registered trademark of the Gehl Company.

SL3640/3840/4240

TABLE OF CONTENTS

TABLE OF CONTENTS Specifications

Page 1-1

Specifications · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-1 Tire Options · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-1 Buckets and Capacities · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-1 General Specifications · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-2

Safety

Page 2-1

General Information · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-1 Signal Words · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-1 Additional Safety Reminders · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-1 Mandatory Safety Shutdown Procedure · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-2 Liftarm Support Device · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-3 Liftarm Support Device Engagement · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-3 Liftarm Support Device Disengagement · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-4 Rollover Protective Structure (ROPS) - Raising · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-4 Rollover Protective Structure (ROPS) - Lowering · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-5 Relieving Hydraulic Pressure· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-6 Skid-Steer Loader Raising Procedure · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-6 Skid Loader Lowering Procedure · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-7

Lubrication

Page 3-1

General Information · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-1 Hydraulic Oil Reservoir · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-1 Crankcase Oil · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-2 Hydraulic Oil Tank Drain Procedure · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-2 Chaincases · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-3 Chaincase Oil Change Procedure· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-3 Grease Fitting Locations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-3 Cooling System Drain Procedure· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-4

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TABLE OF CONTENTS

SL3640/3840/4240

Mainframe

Page 4-1

Introduction · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-1 Engine Access Cover Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-2 Rollover Protective Structure (ROPS) Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-2 Seat Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-4 Seat Slide Replacement · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-4 Rollover Protective Structure (ROPS) Rear Window Removal and Installation · · · · · · · · · · · · · · · · · · 4-5 Restraint Bar Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-7 All-Tach™ Bracket Removal and Installation· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-9 Liftarm Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-10 Liftarm Bushing Replacement · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-13 Liftarm Stop Installation and Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-14 Floor Cover and Kick Plate Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-16 Fuel Level Sender Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-19 Rear Grille Removal and Installation· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-20

Wheel Drives

Page 5-1

Introduction · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-1 Drive Chain Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-2 Drive Chain Removal and Installation· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-3 Axle Removal and Installation· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-4

Controls

Page 6-1

Introduction · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-1 Control Handle Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-6 Control Handle Position and Tracking Adjustment· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-7 Dual Control Weldment Removal and Installation - T-Bar Controls · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-9 Neutral Centering Device and Pump Arm Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-10 Neutral Centering Device Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-11 Lift/Tilt Control Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-12 Lift/Tilt Control Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-13 Auxiliary Hydraulics Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-14 Auxiliary Hydraulics Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-15 Hand Throttle, Hand Throttle Cable and Throttle Rod Removal and Installation · · · · · · · · · · · · · · · · · 6-16 Foot Throttle and Foot Throttle Cable Removal and Installation - T-Bar Controls · · · · · · · · · · · · · · · · 6-18 Hand Throttle Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-19 Hand Throttle Tension Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-20 Foot Throttle Adjustment - T-Bar Controls · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-21 917170/AP0106

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TABLE OF CONTENTS

Hydrostatic System

Page 7-1

Introduction · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-1 Troubleshooting Guide· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-3 Charge Pressure Test and Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-7 Hydrostatic Pump Relief Valves · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-8 Drive Motor Hot Oil Shuttle Valve · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-8 Hydrostatic Pump Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-9 Hydrostatic Pump Flexible Drive Plate Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-11 Drive Motor Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-12

Hydraulic System

Page 8-1

Introduction · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-1 Troubleshooting Guide· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-3 System Pressure Test - Control Valve · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-7 Tilt Cylinder Test · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-9 Self-Leveling Valve Test · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-11 Self-Leveling Valve Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-12 Lift Cylinder Test · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-13 Solenoid Valve Test · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-14 Hydraulic Oil Filter Element Replacement · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-16 Tilt Cylinder Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-19 Lift Cylinder Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-21 Lift and Tilt Cylinder Disassembly and Assembly · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-23 Gear Pump Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-24 Self-Leveling Valve Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-26 Safety Lock Valves - Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-27 Lift, Tilt and Brake Safety Lock Valves - Disassembly and Assembly · · · · · · · · · · · · · · · · · · · · · · · · · 8-29 Control Valve Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-30 Hydraulic/Hydrostatic System Schematic · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-32

All-Tach is a trademark of the Gehl Company.

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SL3640/3840/4240

Electrical System

Page 9-1

Description of Operation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-1 Troubleshooting Guide· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-4 Relay Test and Operation· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-6 Electrical Circuits· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-8 Seat Switch Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-15 Restraint Bar Switch Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-16 Front and Rear Work Light Bulb Replacement · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-17 Electrical System Schematic · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-18

Engine

Page 10-1

Introduction · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-1 Troubleshooting Guide· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-2 Engine Oil Filter Element Removal and Installation· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-4 Air Cleaner Assembly Removal and Installation· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-7 Air Filter Element Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-7 Fuel Filter Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-8 Water Separator Element Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-8 Electric Fuel Pump Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-9 Priming Diesel Fuel System· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-9 Battery Removal and Installation· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-10 Starter Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-11 Exhaust Assembly Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-11 Fan Belt Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-12 Radiator/Cooler Removal and Installation· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-15 Fan Shroud Removal and Installation - 4240 Models · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-16 Fuel Tank Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-17 Engine Removal and Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-19

Index

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SPECIFICATIONS

SPECIFICATIONS SL3640/3840 Yanmar 3TNV88-XMS2 Diesel 100 CID (1,64 L) 35 hp (26 kW) @ 2600 rpm 80 ft.-lbs. (108,5 N•m) @ 1200 rpm 1050 lbs. (476 kg) 4000 lbs. (1814 kg) 3515 lbs. (1594 kg) 7.6 US qts. (7,2 L) 10.3 US gal. (39 L) 14.5 gpm (55 L/min) 6.4 mph (10,3 km/h)

Engine Make Model Fuel Displacement Horsepower - Net (SAE) Torque - Maximum Rated Operating Load (SAE)* Operating Weight Shipping Weight Engine Oil Fuel Tank Standard Flow Rate Travel Speed (max)

SL4240 Yanmar 4TNV88-XMS2 Diesel 133 CID (2,19 L) 46 hp (34 kW) @ 2600 rpm 103 ft.-lbs. (139,7 N•m) @ 1200 rpm 1350 lbs. (612 kg) 4600 lbs. (2087 kg) 4065 lbs. (1844 kg) 9.1 US qts. (8,6 L) 12.4 US gal. (47 L) 16.5 gpm (62 L/min) 6.8 mph (10,9 km/h)

Specifications below apply to all 3640, 3840 and 4240 models Capacities Chaincases (each) 8.0 US qts. (7,6 L) Hydraulic Reservoir 8.0 US gal. (30 L) Electrical Battery 12-volt DC, 675 CCA Starter 12-volt DC (2.0 kW) Alternator 40 A Hydraulic System Main Hydraulic System Pressure 2750 psi (190 bar) Tire Options 7 x 15 8.5 x 15 - 8 ply 10.50 x 15 - 8 ply 10 x 16.5 - 6 ply 10 x 16.5 - 8 ply 10 x 16.5 - 10 ply 6.5 x 16

Width 48 inches (1219 mm) 48 inches (1219 mm) 54 inches (1372 mm) 54 inches (1372 mm) 55 inches (1397 mm) 60 inches (1524 mm) 61 inches (1550 mm) 61.5 inches (1562 mm) 61.5 inches (1562 mm) 61.5 inches (1562 mm)

SS Narrow Heavy-Duty Flotation Heavy-Duty Flotation Standard Flotation Heavy-Duty Flotation/Foam-Filled Severe-Duty/Severe-Duty Foam-Filled Solid Rubber

Buckets and Capacities Description Capacity (Heaped) Dirt/Construction 9.75 cubic feet 0,27 cubic meters Utility 11.9 cubic feet 0,34 cubic meters Dirt/Construction 9.5 cubic feet 0,27 cubic meters Utility 13.5 cubic feet 0,38 cubic meters Dirt/Construction 10.5 cubic feet 0,30 cubic meters Utility 15.2 cubic feet 0,43 cubic meters Dirt/Construction 11.7 cubic feet 0,33 cubic meters Low Profile 12.6 cubic feet 0,36 cubic meters Earth & Foundry 13.0 cubic feet 0,37 cubic meters Construction 13.0 cubic feet 0,37 cubic meters

3640/3840 SAE Rated Operating Load: Operating load rated with a 54" (1372 mm) dirt/construction bucket in accordance with SAE J818.

4240 SAE Rated Operating Load: Operating load rated with a 60" (1524 mm) dirt/construction bucket in accordance with SAE J818.

PRINTED IN USA

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917170/AP0106

SPECIFICATIONS

SL3640/3840/4240

SPECIFICATIONS

SL3640/3840/4240

General Specifications A B C D E F G I M O P Q R S V W X Y Z

Overall operation height - fully raised Height to hinge pin - fully raised Overall height - top of ROPS Overall length (w/54” dirt/construction bucket down) Overall length (w/60” dirt/construction bucket down) Dump angle @ full height Dump height (w/54” dirt/construction bucket) Dump height (w/60” dirt/construction bucket) Dump reach - w/54” dirt/construction bucket (full height) Dump reach - w/60” dirt/construction bucket (full height) Rollback at ground Rollback at full height Seat-to-ground height Wheelbase Overall width - no bucket (w/27 x 8.5 x 15 tires) Overall width - no bucket (w/10 x 16.5 tires) Overall bucket width - 54” dirt/construction bucket Overall bucket width - 60” dirt/construction bucket Ground clearance to mainframe (between wheels) Overall length (no bucket) Departure angle Clearance circle - front (w/54” dirt/construction bucket) Clearance circle - front (w/60” utility bucket) Clearance circle - front (no bucket) Clearance circle - rear

SL3640/3840 (1) inches millimeters 139.6 3546 108.1 2746 70.3 1786 114.5 2908

SL4240 (2) inches millimeters 141.1 3584 110 2794 71.9 1826 116.2

2952

42°

42°

84.5

2146

22.8

578 29° 99°

32.6 34.5 48.4/58.2

828 876 1229/1428

55.3

1403

6 88.9

152 2258 26°

69.4 44.1 54.1

86.5

2197

20.6 29° 99° 33.6 36.7

523

52.5/58.4

1334/1483

60.6 8.3 91.1 29°

1539 211 2314

69.2 43.4 58.4

1758 1102 1484

853 932

1763 1120 1374

(1) Dimensions with 27 x 8.50 x 15 HD tires and 54” bucket.

(2) Dimensions with 10.00 x 16.5 HD tires and 60” bucket.

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SL3640/3840/4240

SAFETY Signal Words

“DANGER” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

General Information The above safety alert symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! It stresses an attitude of “Heads Up for Safety” and can be found throughout this service manual and on the decals on the machine.

WARNING “WARNING” indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Before operating or working on this machine, read and study the following safety information. In addition, be sure that everyone who operates or works on this equipment is familiar with these safety precautions. It is essential to have competent and careful operators, who are not physically or mentally impaired, and who are thoroughly trained in the safe operation of the machine and the handling of loads. It is recommended that the operator be capable of obtaining a valid motor vehicle operator’s license.

CAUTION “CAUTION” indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. May also alert against unsafe practices.

Additional Safety Reminders

The use of skid-steer loaders is subject to certain hazards that cannot be eliminated by mechanical means, but only by exercising intelligence, care and common sense.

Such hazards include, but are not limited to, hillside operation, overloading, instability of the load, poor maintenance and using the equipment for a purpose for which it is not intended or designed.

Read and understand the Service Manual and all decals before maintaining, adjusting or servicing this equipment.

Doors, Guards and Shields - Some photographs in this manual may show doors, guards and shields open or removed for illustrative purposes only.

BE SURE all doors, guards and shields are in their proper operating positions BEFORE starting engine to operate unit.

The Gehl Company ALWAYS considers the operator’s safety when designing its machinery and guards exposed moving parts for the operator’s protection.

However, some areas cannot be guarded or shielded in order to assure proper operation. Furthermore, the Operator’s Manual and the decals on the machine warn of additional hazards and should be read and observed closely.

Damaged or Worn-out Parts - For safe operation, replace damaged or worn-out parts with genuine Gehl service parts, BEFORE operating this equipment.

Attachments - Gehl skid-steer loaders are designed and intended to be used only with Gehl Company attachments or approved referral attachments. The Gehl Company cannot be responsible for operator safety if the loader is used with a non-approved attachment.

These topics in this chapter include procedures, which, when followed, will allow safe performance of service procedures: Mandatory Safety Shutdown Procedure, Lift Cylinder Liftarm Support Device, Roll-Over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS) Lock Mechanism, Loader Raising and Lowering Procedures, and Relieving Hydraulic Pressure.

PRINTED IN USA

Battery Safety - To avoid injury from a spark or short circuit, disconnect the negative (-) battery cable before servicing any part of the electrical system. Do not tip the battery more than 45º to avoid spilling electrolyte.

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SAFETY

DANGER

SAFETY

SL3640/3840/4240

Loader Stability - A skid-steer loader’s stability is determined by its wheelbase and tread width. The following elements can affect stability: terrain, engine speed, load being carried or dumped, and sudden control movements.

DO NOT drive too close to an excavation or ditch. BE SURE that the surrounding ground has adequate strength to support the weight of the loader and the load.

DO NOT smoke or have any spark-producing equipment in the area while filling the fuel tank or while working on the fuel or hydraulic systems.

DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE LOADER TO TIP, POSSIBLY RESULTING IN DEATH OR SERIOUS INJURY. Therefore, ALWAYS have the operator restraint bar lowered and wear the seat belt. Operate the controls only from the operator’s seat. Operate the controls smoothly and gradually at an appropriate engine speed that matches the operating conditions.

Exhaust Gases - Exhaust fumes can kill. DO NOT operate this machine in an enclosed area unless there is adequate ventilation.

Engine - NEVER use ether or starting fluid.

People - NEVER carry riders. DO NOT allow others to ride on the machine or attachment, because they could fall or cause an accident.

DO NOT exceed the rated operating load of the machine. For additional stability when operating on inclines or ramps, ALWAYS travel with the heavier end of the loader toward the top of the incline.

BE SURE all persons are away from the machine and give a warning before starting the engine.

ALWAYS look to the rear before backing up.

ALWAYS face machine and use handholds and steps when getting on or off. DO NOT jump off machine.

When parking machine, before leaving seat, check restraint bar for proper operation. The restraint bar, when raised, applies the parking brake and deactivates lift/tilt controls and auxiliary hydraulics.

Wear appropriate ear protection for prolonged exposure to excessive noise.

ALWAYS perform a daily inspection of the machine BEFORE using it. Look for damage, loose or missing parts, leaks, etc.

Keyswitch - NEVER attempt to bypass the keyswitch to start the engine. Use the jump-starting procedure detailed in the Service chapter of the Operator’s Manual.

Remove trash and debris from the machine and engine compartment each day to minimize risk of fire.

Hydraulic Fluid Leaks - NEVER use hands to search for hydraulic fluid leaks.

Instead, use paper or cardboard. Fluid under pressure can be invisible, penetrate the skin and cause a serious injury. If any fluid is injected into skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor or gangrene may result.

New operators MUST operate loader in an open area away from bystanders. Practice with controls until loader can be operated safely and efficiently.

Mandatory Safety Shutdown Procedure

Wear Safety Glasses - ALWAYS wear safety glasses with side shields when operating the machine or striking metal against metal. In addition, it is recommended that a softer (chip-resistant) material be used to cushion the blow. Failure to heed could lead to serious injury to eye(s) or other parts of the body.

BEFORE cleaning, adjusting, lubricating, or servicing the unit or leaving it unattended: 1. Move the drive control handle(s) to the NEUTRAL position.

2. Lower the liftarm and attachment completely.

3. Move the throttle to the low idle position, shut off the engine and remove the key.

ALWAYS wear safety glasses when searching for hydraulic leaks or when working near batteries.

4. However, if the liftarm MUST be left in the “raised” position, BE SURE to properly engage the liftarm support device.

Loaded Bucket/Fork - DO NOT raise or drop a loaded bucket or fork suddenly. Abrupt movements under load can cause serious loader instability.

Only after these precautions can you be sure it is safe to proceed. Failure to follow the above procedure could lead to death or serious injury.

NEVER push the lift control into the “float” position with the bucket or attachment loaded or raised, because this will cause the liftarm to lower rapidly.

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SL3640/3840/4240

SAFETY Liftarm Support Device

BEFORE leaving the operator’s compartment to work on the loader with the liftarm raised, ALWAYS engage the liftarm support device.

Turn the keyswitch to OFF, remove the key and take it with you.

Fig. 2-1

Many service procedures require a raised liftarm to allow easier access to loader components. For operator and service personnel safety, a liftarm support device is standard on Gehl skid-steer loaders. Used as a cylinder block, it helps prevent a raised liftarm from lowering unexpectedly.

The lock pin secures the liftarm support device inside the left liftarm to a welded pin.

BE SURE to engage the liftarm support device whenever the liftarm is raised. When the device is not being used, secure it to the anchor on the underside of the liftarm using the lock pin and retainer provided.

The liftarm support device is a safety device which must be kept in proper operating condition at ALL times.

The following procedures outline the correct way to engage and disengage the liftarm support device.

Liftarm Support Device Engagement 1. Lower liftarm until contact with loader frame.

Fig. 2-2

Pull down and pull out on the lock pin to release the liftarm support device.

2. Turn the keyswitch to the OFF position to stop the engine.

3. Leave the operator’s compartment. Pull down on lock pin button to release its locking mechanism.

Pull out lock pin holding support device up against liftarm. Allow support device to come down into contact with lift cylinder. Figs. 2-1, 2-2, 2-3 4. Return to the operator’s compartment and restart the engine.

5. Use lift control to raise liftarm until the lift arm support device drops over the end of the lift cylinder and around cylinder rod. Slowly lower liftarm until the free end of the support device contacts the top (rod end) of the lift cylinder. Fig. 2-4

Fig. 2-3

6. Make sure the support device is secure against the cylinder end. Then, stop the engine, remove the key and leave the operator’s compartment.

The liftarm support device rests on top of the lift cylinder base.

PRINTED IN USA

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SAFETY

WARNING

SAFETY

SL3640/3840/4240

Liftarm Support Device Disengagement

WARNING NEVER leave the operator’s compartment to disengage the liftarm support device with the engine running.

To return the liftarm support device to its storage position, proceed as follows: 1. Raise liftarm completely.

2. Turn keyswitch to OFF position to stop engine, remove key and take it with you.

Fig. 2-4

Lower liftarm until liftarm support device contacts the rod end of the lift cylinder.

Fig. 2-5

Front left ROPS mounting area where the ROPS is secured to the chassis. Right side same.

Fig. 2-6

Use wrenches to release the front of the ROPS from the chassis.

WARNING BEFORE testing the machine, ALWAYS clear people from the area.

3. Before leaving operator’s compartment, check to make sure liftarm is being held in the raised position by the solenoid valve.

NOTE: With the keyswitch OFF, and the solenoid valve working, the liftarm will stay raised when the lift control is moved forward. If the valve does NOT hold the liftarm and it begins to lower, do NOT leave the operator’s compartment. Instead, have someone store the support device for you. Then, contact your Gehl dealer to determine the reason why the liftarm lowers while the keyswitch is in the OFF position.

4. To store liftarm support device, lift it up and inside the liftarm. Insert lock pin through hole in welded lock pin below the support device. Figs. 2-1, 2-2

ROPS – Raising For service, the ROPS can be unbolted and tilted back.

Gas-charged springs help tilt it back. A self-actuating lock mechanism engages to lock the ROPS in a rolled-back position.

1. The liftarm should be lowered or locked in the raised position as per the “Liftarm Support Device Engagement” procedure in this chapter.

2. Turn the keyswitch to the OFF position to stop the engine. Remove the key and take it with you.

3. Leave the operator’s compartment.

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PRINTED IN USA

SL3640/3840/4240

SAFETY

DO NOT leave the operator’s compartment with the engine running. Before leaving the loader, shut off the engine according to the “Mandatory Safety Shutdown Procedure” described in this chapter.

4. Remove two capscrews, six flat washers and two locknuts securing the ROPS front uprights to the chassis. Figs. 2-5, 2-6 Fig. 2-7

5. Lift ROPS up and tilt it back until the self-actuating lock mechanism engages. The lock mechanism locks the ROPS in a rolled-back position. Fig. 2-7

Location of the self-actuating lock mechanism.

IMPORTANT BEFORE raising the ROPS, position the seat as far back as it will go. Avoid damaging control handles by slowly raising the ROPS. BE SURE the control handles clear the ROPS.

ROPS – Lowering Fig. 2-8

Lowering the ROPS is a two-person operation.

1. With an assistant's help, apply upward force on the ROPS while the assistant pulls the lock mechanism handle toward the front of the loader. Fig. 2-8 2. Lower ROPS until it contacts the chassis. Fig. 2-9

IMPORTANT Avoid damaging control handles by slowly lowering the ROPS. BE SURE the control handles clear the ROPS. 3. Reinstall the two capscrews, six flat washers and two locknuts that secure the ROPS front uprights to the chassis. Figs. 2-5, 2-6 Fig. 2-9

BE SURE the ROPS/FOPS clears the control handles.

PRINTED IN USA

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917170/AP0106

SAFETY

WARNING

SAFETY

SL3640/3840/4240

Relieving Hydraulic Pressure The following procedure should be used to relieve pressure in the hydraulic system prior to performing service procedures on hydraulic system components.

Lift and Tilt

1. Completely lower the bucket or attachment.

2. Turn keyswitch to OFF position to shut down engine.

Auxiliary Hydraulics

3. With the operator in the seat and the restraint bar lowered, turn the keyswitch to the ON position, but DO NOT start the engine.

4. Move the lift, tilt and auxiliary hydraulics controls through several cycles. Figs. 2-10, 2-11

Fig. 2-10 On Hand/Foot control models, the lift and tilt functions are controlled with the foot pedals on the floor of the ROPS. The auxiliary hydraulics are controlled by the right control handle.

5. Turn the keyswitch to the OFF position.

Skid-Steer Loader Raising Procedure Auxiliary Hydraulics

The following procedure is used to raise the skid-steer loader so that all four tires ARE NOT contacting the ground.

Lift and Tilt

WARNING BEFORE servicing the machine, exercise the “Mandatory Safety Shutdown Procedure” described in this chapter.

WARNING

Fig. 2-11 On T-Bar control models, lift and tilt functions are controlled with the right control handle.

The auxiliary hydraulics are controlled with the left foot on the auxiliary hydraulics pedal.

DO NOT rely on a jack or hoist to maintain the “raised” position without additional blocking and supports. Serious personal injury could result from improperly raising or blocking the skid-steer loader.

1. To raise and block the skid-steer loader, obtain four jack stands or wooden blocks of sufficient strength to support the loader.

2. Using a jack or hoist capable of raising the fully-equipped loader, lift rear of loader until tires are off the ground. Fig. 2-13 3. Place two jack stands under the flat part of the loader chassis. Place them parallel with, but not touching, the rear tires. Fig. 2-14 4. Slowly lower loader so its weight rests on the jack stands or the wooden blocks.

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SL3640/3840/4240

SAFETY 5. Repeat steps 2-4 for the front end. When the procedure is finished, all four tires will be off the ground, and they can be removed as necessary.

When service procedures are complete, the skid-steer loader can be taken down from the “raised” position. To lower the loader onto its tires: 1. Using a jack or hoist, raise front of loader until its weight no longer rests on the jack stands.

Stand Placement Location

2. Carefully remove jack stands or wooden blocks under front of loader.

Fig. 2-12 View of the jack stand placement area and tie down support locations.

3. Slowly lower loader until front tires are on ground.

4. Repeat steps 1-3 for rear of loader.

Fig. 2-13 Locations underneath the skid-steer loader to position jack stands or blocks at the front and rear. (View is from the rear of the loader.)

Fig. 2-14 View of jack stands supporting right rear of skid-steer loader.

PRINTED IN USA

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SAFETY

Skid-Steer Loader Lowering Procedure

Tie Down Support

SAFETY

SL3640/3840/4240

NOTES

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SL3640/3840/4240

LUBRICATION General Information

3

NEVER service this unit when any part of the machine is in motion. ALWAYS BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (see Safety chapter) BEFORE servicing this equipment.

2

1

Fig. 3-1

Routine lubrication is an important factor in preventing excessive part wear and early failure. Loader and engine operation depends on using correct grade, high-quality lubricating oils. This chapter and the chart below list locations, temperature ranges and type of recommended lubricants to be used when servicing this machine. In addition, refer to the engine manual for specific grades and ratings as specified by the engine manufacturer.

Hydraulic oil fill and dipstick (1), hydraulic filter (2) and engine oil dipstick (43).

NOTE: Whenever service is performed on hydraulic components (valves, cylinders, hoses, etc.), fuel tanks and lines, care must be taken to prevent discharging fluid onto the ground. Catch and dispose of fluid per local waste disposal regulations.

Hydraulic Oil Reservoir

Fig. 3-2

The oil reservoir for hydraulic and hydrostatic systems has a capacity of eight U.S. gallons (30 liters). A dipstick built into the reservoir cap provides a visual oil level indicator (Fig. 3-1) for convenient maintenance of the hydraulic oil level.

Hydraulic oil drain plug located behind the left rear tire.

Hydraulic System Reservoir

Chaincases

Grease Fittings

Crankcase Oil (Diesel Engine)

Use a Petro-Canada Use hydraulic system oil Use lithium-based grease. µ Below 32°F (0°C) use Premium HVI60, or or SAE grade 15W-40 SAE Grade* 10 or 10W-30 equivalent which contains motor oil. µ Above 32°F (0°C) use anti-rust, anti-foam, and Capacity (each side): SAE Grade* 15W-40 anti-oxidation additives & 8 Quarts (7,6 L) *Service Classification: conforms to ISO VG46.

API - CF-4/SH Capacity: Capacity: 8 Gallons (30 L) 7.6 Quarts (7,2 L) 36/3840 9.1 Quarts (8,6 L) 4240

PRINTED IN USA

3-1

Antifreeze Coolant System Add a mixture of 50% water, 50% ethylene glycol to the recovery tank if coolant level in recovery tank is low.

917170/AP0106

LUBRICATION

WARNING

LUBRICATION

SL3640/3840/4240

The hydraulic oil reservoir should be drained (Fig. 3-2) and filled after every 1000 hours of operation or annually (whichever occurs first).

Use PETRO-CANADA hydraulic oil (or ISO VG46 equivalent) which contains anti-rust, anti-foam and anti-oxidation additives. Hydraulic oil filter element should be replaced after every 500 hours of operation (See NOTE). For details, refer to “Hydraulic Oil Filter Element Replacement” procedure in Hydraulic chapter.

5 4 2

1

NOTE: An initial 50-hour hydraulic oil filter element replacement is recommended for new skid-steer loaders.

3

Hydraulic Oil Tank Drain Procedure

Fig. 3-3

Location of the engine oil filter (1), oil fill (2), oil drain - not shown (3), dipstick (4) and fuel filter (5) on left side of engine.

Fig. 3-4

Oil filter access location, underneath loader, near left rear tire.

1. Open engine access cover and rear grille.

2. Because the tank is pressurized, slowly remove hydraulic oil tank cap from filler neck at left side riser. Fig. 3-1 3. Underneath the left riser, remove drain plug on hydraulic oil tank. Place a suitable container under drain plug hole to catch hydraulic oil. Fig. 3-2 NOTE: Care must be taken to prevent discharging fluid onto the ground. Catch and dispose of fluid per local waste disposal regulations.

Crankcase Oil The Yanmar diesel engine crankcase has a capacity of 7.6 quarts (7,2 L) for 36/3840 skid-steers or 9.1 quarts (8,6 L) for 4240 skid-steers. The chart below lists recommended oil viscosity for the engine.

Engine oil should be changed and the filter element replaced every 250 hours of service. Refer to the engine operator’s manual (see NOTE) for details on changing oil and to the “Oil Filter Removal and Installation” procedure in the Engine chapter. Figs. 3-3, 3-4, 3-5

2

NOTE: Refer to engine operator’s manual for additional information on oil change intervals, including a 50-hour initial oil change interval.

Ambient Temperature

Viscosity

Below 32°F (0°C)

SAE 10 or 10W-30

Above 32°F (0°C)

SAE 15W-40

1

Fig. 3-5 Service classification: API-CF-4/SH

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3-2

Location of engine oil fill (1) and oil dipstick (2).

PRINTED IN USA

SL3640/3840/4240

LUBRICATION Chaincases Each chaincase requires 8.0 quarts (7,6 L) of SAE motor oil. This quantity of oil should be maintained at all times.

The oil in both chaincases should be drained and refilled every 1000 hours (See NOTE) of operation or annually, whichever occurs first.

Liftarm

Change Chaincase Oil Procedure Raise the rear of the loader off the ground following the “Loader Raising” procedure in this manual.

Fig. 3-6

1. Remove drain plugs and drain oil into a suitable container. Fig. 3-6

Location of left chaincase drain plug; right side is the same. To facilitate draining, lift rear of loader slightly with a suitable hoist or jack.

NOTE: Care must be taken to prevent discharging fluid onto the ground. Catch and dispose of fluid per local waste disposal regulations.

2. Reinstall drain plugs.

3. Remove fill/level check plug. Fig. 3-7 4. Lower the rear of the loader to return loader to a level position.

5. Add oil through fill/level check plug until oil starts to flow out of check plug. Fig. 3-7 6. Reinstall fill/level check plug.

Grease Fitting Locations Fig. 3-7

Location of chaincase oil fill/check plug.

Use lithium-based grease on all grease fittings. Figs. 3-8 through 3-11 Grease every 10 hours of operation (or daily) 1. Grease liftarm pivots.

2. Grease lift cylinder pivots.

3. Grease tilt cylinder pivots.

4. Grease All-Tach™ attachment pivots.

Fig. 3-8

Liftarm grease fitting locations.

PRINTED IN USA

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LUBRICATION

NOTE: A initial 50-hour chaincase oil change is recommended.

LUBRICATION

SL3640/3840/4240

Cooling System Drain Procedure Gehl SL36/38/4240 skid-steer loaders use a radiator/ cooler to help keep the engine from overheating. Some procedures in this Service Manual require partially or fully draining the radiator/cooler for those procedures.

Coolant / Hydraulic Oil - Drain Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine and allow to cool.

Fig. 3-10 Lower tilt cylinder grease fitting location.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Open engine access cover and rear grille.

2. Remove radiator cap.

3. A drain cock is located at bottom rear of radiator.

Open drain cock and drain coolant into a suitable container. Fig. 3-12 4. Open small access cover (belly pan) located in chassis behind radiator/cooler, placing a suitable container underneath the opening.

5. Use two wrenches on lower oil cooler hose (to prevent damage to fitting), remove lower hose and drain oil through access cover. Fig. 3-12 Fig. 3-11 Rod-end lift cylinder grease fitting location.

NOTE: Care must be taken to prevent discharging fluid onto the ground. Catch and dispose of fluid per local waste disposal regulations.

6. Close drain cock, reinstall lower oil cooler hose.

Radiator Cap

Oil Cooler Side

Radiator Side

Fig. 3-9

Fig. 3-12 Radiator/Cooler system drain locations. Left arrow indicates the radiator drain cock location, the right arrow indicates the lower oil cooler radiator hose.

Attachment bracket grease fitting locations.

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SL3640/3840/4240

MAINFRAME

Introduction Gehl SL36/38/4240 skid-steer loaders have a welded steel mainframe. Maintenance, service and repair can be performed through standard access panels. The left rear mainframe riser serves as the hydraulic reservoir. A welded steel tank bolted to the mainframe behind the ROPS/FOPS serves as the fuel tank.

Oil is used inside these cases to ensure the chains always receive proper lubrication.

The liftarm and the lift and tilt cylinders are mounted with pivot pins. Capscrews are used to secure the pivot pins. A Rollover Protective Structure/Falling Object Protective Structure (ROPS/FOPS) is standard for operator safety, and both the seat and restraint bar include safety interlock switches.

Two side cases provide mounting for the drive motors and for the front and rear axles. The side cases also serve as sealed housings for the drive chains and sprockets.

48

28

45

45

46

46

53

29

8

56

41

40 19

15

39

56 11

26

5

27 49

55

8

36

30

7

43

44

32

42

52

34

31

6 34 10

37

38

35 23

22 20

58

16

9

21 51 57

1

50

25 13

3

17

4

16

2 14

33

18

24 54

12 47

44 FOAM/SIDE RIGHT 45 GASKET/TOP WINDOW 46 GASKET/TOP WINDOW 47 SPONGE RUBBER/SEAT PLATE 48 WINDOW/TOP 49 SCREW/MACHINE 50 SCREW/CAP 51 SCREW/CAP

Fig. 4-1

52 SCREW/CAP 53 SCREW/CAP 54 SCREW/CAP 55 BOLT/CARRIAGE 56 SCREW/MACHINE 57 WASHER/FLAT 58 WASHER/FLAT

56

51

1 BOLT/SHOULDER 2 BOLT/SHOULDER 3 BOLT/SHOULDER 4 BUSHING/OILITE 5 TETHER 6 WASHER/FLAT 7 MOUNTING/ISOLATOR 8 NUT/SPEED 9 NUT/LOCK NYLON INSERT 10 NUT/HEX 11 NUT/LOCK SERRATED 12 NUT/LOCK 13 NUT/LOCK 14 NUT/LOCK 15 ISOLATOR/ROPS 16 SCREW/WHIZLOCK 17 SUPPORT/ROPS 18 LATCH/ROPS 19 BRACKET/DOME LIGHT 20 ROPS/FOPS 21 BUSHING 22 TAG/RIP CORD 23 RING 24 GAS SPRING/ROPS 25 HANDLE/GRAB 26 NUT/FLAT 27 NUT/SPECIAL 28 SCREW/MACHINE 29 PANEL/INSTRUMENT LEFT 30 SHIELD/HARNESS 31 PLATE/HEATER SEAL 32 COVER/SEAT PLATE 33 SPRING/EXTENSION 34 WASHER/FLAT 35 STRIP/LOCKING 36 HOLDER/MANUAL 37 WINDOW/REAR 38 SEAL/WINDOW 39 FOAM/HEADLINER 40 FOAM/REAR PANEL 41 FOAM/SIDE LEFT 42 FOAM/SIDE LEFT 43 FOAM/SIDE RIGHT

Assembly view of ROPS/FOPS components.

PRINTED IN USA

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Rollover & Falling Object Protective Structure (ROPS/FOPS) Components

MAINFRAME

SL3640/3840/4240

Engine Access Cover Removal and Installation

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

Spring Clip

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

Removal Procedure

Fig. 4-2

1. Open engine access cover until gas spring is completely extended.

Engine access cover gas spring attached to ball stud on engine access cover.

2. Disconnect gas spring from engine access cover by removing gas spring clip with a small screwdriver, then pull gas spring off ball stud on access cover.

Lower engine access cover. Fig. 4-2 3. Remove two locknuts securing engine access cover to ROPS bolt/mainframe and remove cover. Fig. 4-3

ROPS Bolt

Installation Procedure - Follow all warnings first, then reverse the removal steps.

ROPS Removal and Installation

WARNING

Fig. 4-3

One of two locknuts on ROPS bolt securing the engine access cover to the mainframe.

Fig. 4-4

The harness bulkhead is where the harness assembly meets the instrument panel harness.

Remove harness at front of bulkhead.

BEFORE beginning this service procedure, perform the following SAFETY procedures.

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

Removal Procedure 1. Remove the engine access cover per the procedure in this chapter.

2. Disconnect negative (-) battery cable from battery.

3. Disconnect ROPS wiring harness connector, secured to mainframe, at right of fuel tank. Also, disconnect ROPS power connector at same location. Fig. 4-4

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MAINFRAME 4. Raise ROPS per the procedure found in the Safety chapter.

5. With ROPS tilted back and locked, attach a hoist so that it is supporting the weight of the ROPS.

WARNING

Fig. 4-5

Right side gas spring on the ROPS.

6. On right side of ROPS, remove one capscrew and locknut securing gas spring to ROPS. Fig. 4-5 7. Disassemble ROPS lock mechanism by removing shoulder bolt and locknut from welded hinge on ROPS. Remove limiter assembly from ROPS. Fig. 4-6 8. Carefully remove two capscrews and locknuts securing rear of ROPS to mainframe. Figs. 4-7 and 4-8 9. Lift ROPS off loader.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

Fig. 4-6

Location of shoulder bolt to remove on the ROPS lock mechanism.

Fig. 4-7

Capscrew through riser where the ROPS connects to the mainframe.

PRINTED IN USA

Fig. 4-8

4-3

Capscrew through riser where the ROPS connects to the mainframe.

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The hoist MUST BE situated precisely above the ROPS or else performing the following steps may cause the ROPS to swing as the bolts are removed. This could cause serious bodily injury and/or damage the loader.

MAINFRAME

SL3640/3840/4240

Seat Removal and Installation

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 4-9

Location of four nuts securing seat to seat pan.

Removal Procedure 1. Remove four nuts from studs attaching seat to seat pan underneath ROPS. Fig. 4-9 2. Release lock mechanism and lower ROPS. Disconnect seat switch from wiring harness. Figs.

4-10, 4-11

Seat Switch

3. Lift seat from seat pan.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

Seat Pan Seat Slide

Seat Slide Replacement Replacement Procedure

Fig. 4-10 Front seat slide capscrews shown.

1. Remove seat per the procedure in this chapter.

2. Remove four capscrews and flat washers attaching seat slide to seat. Fig. 4-10 3. Replace with new slides using existing capscrews and flat washers.

Seat

Seat Switch

Fig. 4-11 Seat switch connected to wiring harness, behind the seat.

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MAINFRAME ROPS Rear Window Removal and Installation

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Shut off the engine.

Removal Procedure

Fig. 4-12 Location of the emergency exit tag at the bottom of the rear window.

1. Grab and pull the emergency exit tag until weatherstrip rip cord pulls free of window weatherstrip. Fig. 4-12 2. With an assistant to catch window outside ROPS, push window outward. Fig. 4-13 3. Slowly pull window weatherstrip away from metal window frame. Fig. 4-14

Installation Procedure 1. Recommended but not required: Mix a solution of 10% liquid dish soap and 90% water in a spray bottle, or, obtain some gasket lubricant.

NOTE: To install the rear window, you will need to obtain insert tools from your glass dealer. Fig. 4-15 Fig. 4-13 Assistant catches the rear window after being pushed outward from the ROPS.

2. Apply soap solution to window and weatherstrip and metal frame surfaces.

3. Start at top of metal window frame and install window weatherstrip with rip cord lip facing inside ROPS and glass lip facing out. Fig. 4-16 4. From inside operator’s compartment, spray a small amount of soap solution between glass window and inside edge of ROPS rear window.

5. Use L-hook insert tool between glass and weatherstrip and work it underneath glass. Lift glass lip up over weatherstrip. Fig. 4-17 6. Use pigtail hook insert tool to “pull down” window weatherstrip seal on outside of ROPS, which secures the window. Fig. 4-18 7. On inside of ROPS, install rip cord in rip cord lip starting at top of window weatherstrip. BE SURE to have an emergency exit tag slipped over rip cord before performing this step. Fig. 4-19

Fig. 4-14 Carefully remove/install the window weatherstrip around the metal frame.

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(For detailed instructions, refer to the Safety chapter of this manual.)

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SL3640/3840/4240

8. Using L-hook insert tool, secure rip cord in rip cord lip by “pulling down” lip over cord.

9. Test window for security and mating of all seals.

Fig. 4-17 Use gasket lube to help get the rear ROPS window in.

Rip Cord Hook

L-Hook

Pigtail Hook

Fig. 4-15 Insert tools required to install the ROPS rear window.

Fig. 4-18 The pigtail hook pulls down the window weatherstrip seal, allowing the window to slip into the weatherstrip.

Fig. 4-16 Start the weatherstrip at the bottom of the ROPS window frame.

Fig. 4-19 Start rip cord in rip cord lip at bottom center of window frame on inside of ROPS. Be sure emergency tag is slipped over rip cord before installing cord.

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MAINFRAME Restraint Bar Removal and Installation Removal Procedure 1. Pop four "Christmas tree" clips off each restraint bar hinge cover. Pull cover over shoulder bolt and down arm of restraint bar to rubber arm rests. Fig. 4-20

Christmas Tree Clip

2. Disconnect restraint bar switch wire from panel harness located below restraint bar on right side.

Fig. 4-21

NOTE: For restraint bar switch removal, refer to the Electrical chapter.

Fig. 4-20 Location of shoulder bolt on restraint bar hinge cover.

Installation Procedure - Reverse the removal steps.

Fig. 4-21 Location of restraint bar switch wire connected to the panel harness.

1 BOLT/SHOULDER 2 BUSHING/OILITE 3 NUT/SERRATED LOCK 4 NUT/LOCK 5 ACTUATOR 6 SWITCH/RESTRAINT BAR 7 GAS SPRING/SEAT BAR 8 STUD/BALL 9 SCREW/PHILLIPS PAN 10 COVER/PIVOT 11 BAR/RESTRAINT 12 STOP/RESTRAINT BAR 13 WASHER/SPECIAL 14 CLIP/CHRISTMAS TREE 15 WASHER/FLAT 16 SCREW/MACHINE ROUND HEAD 17 NUT/HEX MACHINE SCREW 18 WASHER/LOCK STAR

Restraint Bar Components

14

15

10

4

12 5

17 18

13

6

11

7 16

1 2 3 8

9

Fig. 4-22 Assembly view of the restraint bar.

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3. Remove one shoulder bolt, washer and locknut securing each side of restraint bar to ROPS. Remove restraint bar. Fig. 4-20

MAINFRAME

SL3640/3840/4240

Liftarm & All-Tach™ Attachment Bracket Components 1 BUSHING/OILITE 2 BUSHING/OILITE 3 NUT/LOCK 4 PIN/KLIK 5 LIFTARM 6 PIN/LIFTARM 7 SUPPORT/STEP 8 NUT/CENTERLOCK 9 PIN/PIVOT 10 STOP/LIFTARM 11 STOP/LIFTARM 12 ROD/WIPER 13 STOP/RUBBER 14 FITTING/GREASE 15 SCREW/CAP 16 BOLT/CARRIAGE 17 SCREW/CAP 18 SCREW/THREAD 19 NUT/JAM 20 WASHER/LOCK

17 6

1 14

5 3

1

8 13 10 18 7

11

20 4 19 16 2

12

15 1 PIN/SPRING 2 NUT/HEX 3 HANDLE/HITCH LT 4 HANDLE/HITCH RT 5 SPRING/COMPRS 6 PIN 7 ADAPTOR/ROD 8 ADAPTOR/PUSH ROD 9 ALL-TACH/TWO-PIN 10 SCREW/SOCKET 11 SCREW/CAP 12 WASHER/SPECIAL 13 WASHER 14 WASHER/FLAT 15 WASHER/SPRING 16 GRIPS 17 FITTING/GREASE 18 SCREW/CAP

3

9

2

14

SEE NOTE 1 11 7

8

5

10 SEE NOTE 1

3

2

14

9

15

4

18 16 13

12 1 SEE NOTE 2 6

17

NOTE: 1. APPLY LOCTITE™ 242 TO ITEMS 10, 11, AND 18.

2. SPRING PIN TO EXTEND EQUAL DISTANCE ON EACH SIDE OF ADAPTOR ROD, BUT NOT BEYOND FACE PLATE OF WELDMENT.

Fig. 4-23 Assembly view of liftarm and All-Tach™ attachment bracket.

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MAINFRAME All-Tach™ Bracket Removal and Installation To facilitate the removal of the attachment bracket, a slide hammer or suitable hammer and punch may be used.

Removal Procedure 1. Lower liftarm and slightly extend tilt cylinders.

Fig. 4-24 Location of lower tilt cylinder pivot pin.

3. Remove two capscrews and washers securing lower liftarm pivot pins to All-Tach™ bracket assembly.

Figs. 4-26 and 4-27 NOTE: Support the attachment bracket with suitable hoisting equipment before performing the next step.

4. Use a slide hammer to slide pins out of liftarm and attachment bracket.

Installation Procedure - Reverse the removal steps.

Fig. 4-25 Lower pivot pin slid out of its mount.

Fig. 4-26 Location of capscrew and washer securing lower liftarm pivot pins to attachment bracket assembly.

PRINTED IN USA

Fig. 4-27 Use a slide hammer to work the pin out of the lower liftarm pivot and attachment bracket.

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2. Support tilt cylinders, then remove two capscrews and locknuts securing lower tilt cylinder pivot pins to attachment bracket. Slide lower pivot pins out of their mounts. Figs. 4-24 and 4-25

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SL3640/3840/4240

Liftarm Removal and Installation Removal Procedure Liftarm Support Device

1. Lower the liftarm.

2. Remove any attachment from loader’s attachment bracket.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures:

q Relieve hydraulic system pressure. q Shut off the engine.

Fig. 4-28 Location of the left lift cylinder rod end pivot pin. The pin partly secures the liftarm support device inside the liftarm.

(For detailed instructions, refer to the Safety chapter of this manual.)

3. Attach a suitable hoist to liftarm.

4. Remove locknut and capscrew that secures lift cylinder rod end pivot pin to liftarm. Fig. 4-28 5. Support lift cylinder and remove lift cylinder pin from liftarm. Left side lift cylinder: Remove liftarm support device secured to liftarm by lift cylinder pin and lynch pin. Keep lynch pin in safe place. Fig. 4-29 6. Repeat steps 4 and 5 for other side of liftarm.

NOTE: Always clean around hydraulic fittings before disconnecting any hydraulic line. When removing hydraulic lines, cap the ends to prevent contaminating the hydraulic system.

Fig. 4-29 Location of lynch pin that partly secures the liftarm support device inside the liftarm.

NOTE: To help in the correct reassembly of the hydraulic hoses and tubes, mark them prior to disassembly with an oil-resistant chalk or marker.

7. Remove attachment bracket per the procedure in this chapter.

8. Remove both tilt cylinders from liftarm per the procedure in the Hydraulic System chapter.

9. Remove capscrews, line clips and tee fittings from tilt hoses on liftarm. Remove tilt hoses. Fig. 4-30

Line Clip

10. On left liftarm, disconnect hydraulic tubes from 90° elbows at back of auxiliary coupler bracket. Fig. 4-31 11. Unbolt three capscrews securing auxiliary coupler bracket to liftarm. Remove bracket with couplers.

Fig. 4-31 917170/AP0106

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Line Clip

Fig. 4-30 Location where the lower and upper tilt cylinder hoses connect underneath liftarm crossmember.

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MAINFRAME Aux Bracket

12. Using a suitable hoist, raise liftarm to gain access to hydraulic hoses and tube fittings.

13. Disconnect hydraulic hoses attached to hydraulic tubes found underneath the liftarm (at back of liftarm). Fig. 4-32 14. Remove capscrews, line clips, and locknuts securing hydraulic tubes to liftarm. Remove hydraulic tubes from liftarm. Figs. 4-30, 4-33

Capscrews

15. Remove two capscrews and locknuts securing two liftarm pivot pins to mainframe. Figs. 4-32, 4-34

Fig. 4-31 Location of auxiliary hydraulic tubes connected at back of auxiliary coupler bracket to 90° elbows.

17. Remove liftarm assembly from loader with a suitable hoist.

Installation Procedure 1. Use a suitable hoist to position liftarm assembly on mainframe.

NOTE: Align the liftarm in a manner that allows access to the hydraulic hose and tilt tube fittings that will be attached to the underside of the liftarm.

2. Secure liftarm to mainframe with two pivot pins.

Fig. 4-34 NOTE: Refer to liftarm bushing installation procedure in this chapter if bushings require replacement.

Fig. 4-32 Location underneath liftarm where hydraulic hoses connect to hydraulic tubes.

3. Secure liftarm pivot pin in place with two capscrews and locknuts. Figs. 4-32, 4-34 4. Before assembly, clean all hydraulic fittings to prevent contamination of hydraulic system.

NOTE: For location of the hydraulic hose and tube mounting hardware refer to the Hydraulic System chapter.

5. Attach hydraulic tubes to liftarm with capscrews, line clips and locknuts. Figs. 4-30, 4-33 6. Connect hydraulic tubes to hydraulic hose assemblies according to markings made at removal.

If no markings were made prior to removal refer to the Hydraulic System chapter for correct fit up. Fig. 4-32 7. With three capscrews, bolt in auxiliary coupler bracket on front of left liftarm. Fig. 4-31

Fig. 4-33 Some of the hardware connecting hydraulic tubes underneath the liftarm.

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8. Connect auxiliary hydraulic tubes to 90° elbows at back of auxiliary coupler bracket. Fig. 4-35

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16. Drive liftarm pivot pins out of mainframe.

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9. Attach capscrews, line clips and tee fittings to tilt hoses on liftarm crossmember. Fig. 4-30 10. Using the hoist, lower the liftarm.

11. Install tilt cylinders on liftarm per the procedure in the Hydraulic System chapter.

12. Install attachment bracket per the procedure in this chapter.

13. Connect lift cylinder to lower liftarm with one pivot pin, capscrew and locknut. Repeat this step for other side. Left side lift cylinder: Reattach liftarm support device secured to liftarm by lift cylinder pin.

Secure back end of liftarm support device with previously removed lynch pin. Figs. 4-28, 4-29

Fig. 4-34 Location of rear pivot pin for the liftarm.

NOTE: After removing/replacing any components of the lift and tilt system, ALWAYS prime hydraulic system by operating the liftarm attachment (NO LOAD) slowly up and down for several minutes. Check system for hydraulic oil leaks following guidelines in the Safety chapter. Fill the hydraulic reservoir to FULL level.

Fig. 4-35 Connect auxiliary hydraulic tubes to their respective 90° elbows.

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MAINFRAME Liftarm Bushing Replacement Replacement Procedure 1. Remove liftarm from loader per the procedure in this chapter.

2. Use a punch to drive out the four upper bushings in the liftarm. Fig. 4-36 NOTE: Applying heat to liftarm bushings will release adhesive and simplify removal.

Fig. 4-36 Two bushings inside upper liftarm pivot. Other side same.

4. Apply Loctite® 680 or equivalent to new liftarm bushings and press or drive them into liftarm.

5. If replacing lower bushings in the liftarm, use a punch to drive them out of liftarm. Fig. 4-37 6. Install new bushings by pressing them into place or using a rubber mallet to drive them into liftarm.

7. Reinstall liftarm on loader per the procedure in this chapter.

Fig. 4-37 Bushing inside the lower liftarm pivot.

Loctite is a registered trademark of the Loctite Corporation.

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3. Clean inside opening to provide a smooth surface for installation of new bushings.

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SL3640/3840/4240

Liftarm Stop Installation and Adjustment Installation/Adjustment Procedure NOTE: Liftarm stops should be shimmed as needed to assure a gap of no more than 1/8" (3 mm) between stop and the liftarm when the liftarm is completely lowered.

1. Lower liftarm and measure gap between the stop and the liftarm. Fig. 4-39 2. Add one shim for every 1/8" (3 mm) gap. Fig. 4-41 3. Raise liftarm and engage liftarm support device.

4. Remove one flat-head capscrew on liftarm stop attached to front of mainframe that needs adjustment. Fig. 4-38 5. Install shim(s) and secure with flat-head capscrew and locknut. Use removable Loctite® 242 or equivalent retaining compound.

Fig. 4-39 Location to measure gap between the stop and the liftarm. Other side same.

6. Start skid-steer loader and lower liftarm. Verify gap and repeat procedure as needed.

Lift Stop

Fig. 4-40 View of lift stop from above.

Shim

Capscrew

Fig. 4-38 Location of flat-head capscrew securing liftarm stop to the chassis.

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Fig. 4-41 Components of the liftarm stop. Add or remove shims as needed to reduce/increase gap between lift stop and liftarm.

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MAINFRAME

65

65

27

61

51 3 6

72

42

21

63

6

50

47

16

20 5 29

63

69

10

22

71

71 19

52

52 35

52

46

23

6

63 31

45

25

24 43

62

14 48 22

4

71

40

52 32

69

36 3 69

64

59

28 63

39

15 7

64 68

13

67

41

7

30 69

66

12

57

53

58 13

56

15

36

8

7

38 55 54 69 37

11

34

18 69 17

63

44

49

52

60

9 69

33 1 70

26

55 SHIM 56 WASHER/SPRING 57 WASHER/FRICTION 58 BUMPER/RUBBER 59 GRIP 60 HOSE 61 SCREW/MACHINE 62 SCREW/CAP 63 BOLT/CARRIAGE

Fig. 4-42

64 BOLT/CARRIAGE 65 BOLT/CARRIAGE 66 BOLT/CARRIAGE 67 BOLT/CARRIAGE 68 BOLT/CARRIAGE 69 SCREW/CAP 70 NUT/HEX 71 WASHER/FLAT 72 WASHER/LOCK

64

1 TIE/WIRE 2 CLAMP/HOSE 3 NUT/HEX 4 NUT/HEX 5 NUT/HEX 6 NUT/LOCK 7 NUT/LOCK 8 NUT/LOCK 9 CAP/FILLER 10 SCREW/LOCK 11 SCREW/CAP 12 HANDLE/THROTTLE 13 SEAL/BULB 14 SPRING/COMP 15 SEAL/SHROUD 16 STUD/BALL 17 PLUG SAE12 18 PLUG SAE08 19 BUSHING 20 SPRING/GAS 21 CLIP/GAS SPRING 22 NUT/SPIRALOCK™ 23 CLIP/RETAINING 24 NUT/SERRATED 25 STRIP/TRIM 26 FILTER/VENT 27 GRAB HANDLE 28 PIN/LOCK 29 TANK/FUEL 30 COVER/AXLE 31 PLATE/KICK 32 PLATE/FLOOR 33 PAN/BELLY 34 COVER/CHAINCASE 35 BRACKET/EXHAUST 36 CHASSIS 37 PLATE/COVER 38 STOP/DOWN 39 BRACKET/VALVE 40 DOOR/REAR 41 GRILLE 42 COVER/ENGINE 43 FLANGE/SIDE RAIL 44 BRACKET/LOCK 45 ROD/LATCH 46 LATCH/MOUNT 47 SUPPORT/COVER 48 LATCH/REAR DOOR 49 VENT/REMOTE 50 BRACKET/DOOR RT 51 BRACKET/DOOR LT 52 NUT/LOCK 53 NUT/LOCK 54 SCREW/CAP FLAT

Assembly view of the mainframe, mainframe control covers, and rear grille components.

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Mainframe, Floor Covers, Rear Grille and Engine Cover Components

MAINFRAME

SL3640/3840/4240

Floor Cover and Kick Plate Removal and Installation The upper floor cover, lower floor cover and the kick plate may be removed from the skid-steer loader for access to the control handle assemblies and connections to the cables, linkages and control rods.

Removal Procedure - T-Bar

WARNING Fig. 4-43 Location of four capscrews securing upper floor plate in T-Bar models.

BEFORE beginning this Service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Upper Floor Plate: a. Remove four capscrews securing upper floor plate to kick plate and control mount. Pull upper floor plate up and out around foot throttle pedal and auxiliary pedal (if so equipped). Fig. 4-43 Fig. 4-44 Disconnect auxiliary hydraulics cable prior to removal of lower floor plate.

2. Lower Floor Plate: a. Disconnect auxiliary hydraulics rod or cable from auxiliary pedal and floor bracket per the procedure in the Controls chapter. Fig. 4-44 b. Disconnect foot throttle cable and spring from foot throttle pedal and bolted bracket per the procedure in the Controls chapter. Fig. 4-45

Bracket

c. Remove six capscrews, two on auxiliary pedal assembly, securing lower plate to mainframe.

Pull lower floor plate with foot pedal and auxiliary pedal assemblies out of skid-steer loader. Fig. 4-46 3. Kick Plate: a. Loosen three truss-head screws on each boot cover (six per control handle) and remove boot covers. Fig. 4-47 917170/AP0106

Fig. 4-45 Disconnect cable, spring and bracket on foot throttle pedal.

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MAINFRAME b. Pull up boots and remove eight capscrews, two on foot throttle bracket (Fig. 4-45), securing kick plate to mainframe. Fig. 4-48 c. Pull kick plate forward and up to remove it from skid-steer loader.

2

Installation Procedure - Follow all warnings first, then reverse the removal steps.

MAINFRAME

1

Fig. 4-46 Capscrews on lower plate (1) and auxiliary pedal assembly (2) at front of loader of T-Bar models. (2) on Hand/Foot control models secures the linkage cover.

Fig. 4-47 Truss-head screws securing boot covers to the top of the kick plate.

Kick Plate

Fig. 4-48 Eight capscrews securing kick plate to mainframe.

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Removal Procedure - Hand/Foot

WARNING BEFORE beginning this Service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 4-49 Two of four capscrews on linkage cover. The other two capscrews are at the front of the loader between dirt clean-out openings.

1. Linkage Cover: a. Remove four capscrews securing linkage cover to kick plate. Two of four capscrews are found at front of loader between and above dirt clean-out openings. Figs. 4-46, 4-49 2. Floor Plate: a. Remove two locknuts on female rod ends attached to foot pedal pivots underneath foot pedals. Fig. 4-50 b. Remove four capscrews securing foot pedal mount to center of floor plate. Pull entire foot pedal assembly from skid-steer loader. Fig. 4-51 c. Remove four capscrews securing floor plate to mainframe and pull floor plate up at front and out of loader.

Fig. 4-50 Location of two locknuts to remove on foot pedal pivots.

3. Kick Plate: a. Loosen three truss-head screws on each boot cover (six per control handle) and remove boot covers. Fig. 4-47 b. Pull up boots and remove eight capscrews securing kick plate to mainframe. Fig. 4-48 c. Pull kick plate forward and up to remove it from skid-steer loader.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

Fig. 4-51 Location of four capscrews securing foot pedal mount to floor plate.

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MAINFRAME Fuel Level Sender Removal and Installation #0

Removal Procedure

WARNING

#25

BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support q Shut off the engine.

Fig. 4-52 Location of fuel level sender.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Open engine access cover and rear grille.

2. Locate fuel level sender right of the fuel tank cap.

3. Disconnect two wires (#0 and #25) from fuel level sender. Fig. 4-52 4. Remove remaining five capscrews securing sender, then remove sender and gasket from fuel tank.

Installation Procedure 1. Clean old gasket adhesive off fuel tank.

2. Match holes in new gasket to holes on fuel tank.

Fig. 4-53 Spread Form-A-Gasket around fuel level sender opening on fuel tank.

3. Install a new gasket using Form-A-Gasket #765-1211 (or equivalent) to seal around sender opening on fuel tank. Fig. 4-53 4. Match the fuel level sender holes to the gasket holes and install sender in fuel tank. Fig. 4-54 5. Install four capscrews through fuel level sender into fuel tank. DO NOT OVERTIGHTEN.

Fuel Float

6. Connect fuel level sender by attaching #25 (brown) wire to center stud with a nut and #0 (black) wire to sender using fifth capscrew. Fig. 4-52

Fig. 4-54 Note orientation of float when installing fuel level sender into fuel tank.

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device.

MAINFRAME

SL3640/3840/4240

Rear Grille Removal and Installation Removal Procedure 1. Open engine access cover and rear grille.

2. Disconnect rear grille harness. Fig. 4-55 3. Remove one capscrew, washer and hex nut securing top rear grille pin to top hinge on mainframe. Fig. 4-56 4. Remove lock pin securing bottom of rear grille to the mainframe. Fig. 4-57 5. Pull rear grille off the mainframe.

Installation Procedure - Reverse the removal steps.

Fig. 4-55 Location of rear grille harness connector.

Hex Nut

Washer

Capscrew

Fig. 4-56 Location of hardware to remove from the rear grille.

Lock Pin

Fig. 4-57 Location of hardware to remove from the rear grille.

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WHEEL DRIVES

Introduction This chapter covers removal, installation, assembly, and adjustment procedures for wheel drive system components on GEHL SL36/38/4240 skid-steer loaders. Wheel drive components covered in this chapter are shown below.

fixed-displacement hydrostatic drive motors. The drive motors are directly connected to chaincases. Each motor drives one set of wheels on each side of the loader through a chain and sprocket system.

Service procedures related to the hydrostatic pump and drive motors can be found in the Hydrostatic System chapter.

SL36/38/4240 skid-steer loaders are equipped with a hydrostatic pump assembly coupled to the diesel engine which provides hydrostatic power to the two

WHEEL DRIVES

Wheel Drives Components

19

7

4 12

13

18 11

2 1 8

16

10

9 17 15 5 14 3 6

1 BOLT/HUB 2 CONE/BEARING 3 CUP/BEARING 4 ASSY/ROLLER CHAIN 5 ASSY/ROLLER CHAIN 6 SEAL/OIL 7 PLATE/MOTOR MOUNT

Fig. 5-1

8 ASSEMBLY/AXLE 9 NUT/LUG 10 NUT/LOCK 11 O-RING 12 RING/SNAP INTERNAL 13 SPROCKET/MOTOR 14 SPROCKET/AXLE

15 WASHER/SPECIAL 16 WASHER/BACKING 17 PIN/COTTER 18 SCREW/CAP 19 NUT/HEX SLOTTED

Assembly view of the wheel drive components.

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Drive Chain Adjustment Skid-steer loader drive chain tension should be checked every 1000 hours of operation or annually (whichever occurs first).

Capscrew

Adjustment Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 5-2

Chaincase access cover located between the wheel axles of the skid-steer loader is secured with ten capscrews.

Fig. 5-3

Location of six locknuts shown on drive motor mounting plate.

Fig. 5-4

Install new gasket material prior to reinstalling the chaincase access cover.

1. Drain chaincase oil per the procedure in the Lubrication chapter.

2. Remove wheels and tires on side of loader being service.

3. Remove ten capscrews on chaincase access cover to gain access to drive chain and motor. Fig. 5-2 4. Loosen six locknuts on drive motor. Slide drive motor in slots on motor mounting plate to adjust chain tension. Fig. 5-3 NOTE: Correct chain deflection is 1/8"- 3/8" @ 20 lbs. force (3.2 mm- 9.5mm @ 89 N) on the forward chain.

Correct chain deflection should not exceed 1.00" @ 20 lbs. force (25.4 mm @ 89 N) on the rear chain.

5. After the proper chain tension is obtained, retighten locknuts on drive motor.

IMPORTANT Overtightening of drive chain causes premature drive chain and axle sprocket wear.

6. Reinstall chaincase access covers using oil-resistant RTV sealant between the cover and chaincase. Fig. 5-4 7. Replenish chaincase oil per the procedure in the Lubrication chapter.

8. Repeat adjustment procedure for other side.

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SL3640/3840/4240

WHEEL DRIVES Drive Chain Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Drain chaincase oil per the procedure in the Lubrication chapter.

Rotate drive chain until connector pin, sidebar and connector link are accessible.

2. Remove wheels and tires on side of loader being serviced. Wheel nut torque is 120 ft.-lbs. (163 N•m).

3. Remove ten capscrews on chaincase access cover (between tires) to gain access to drive chain. Fig. 5-2 4. Split drive chain by removing the connector pin and connector link. On connector link, remove the sidebar, then pull link out from back of chain. It may be necessary to rotate the drive chain for access to the connector link. Figs. 5-5, 5-6, 5-7 5. Remove drive chain from axle sprocket.

Sidebar

Fig. 5-6

Installation Procedure

Remove sidebar on connector link.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

Connector Link

NOTE: When connecting left and right side drive chains of the loader, connect the inside chain first.

1. Drain chaincase oil per the procedure in the Lubrication chapter.

2. Wrap drive chain around sprocket of axle.

Fig. 5-7

Disconnect connector link and remove drive chain.

3. Wrap drive chain around drive motor shaft sprocket.

4. Connect drive chain with connector link, sidebar and cotter pin.

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Fig. 5-5

WHEEL DRIVES

SL3640/3840/4240

5. Adjust drive chain to the proper tension. See the procedure in this chapter.

6. Install chaincase access covers using oil-resistant RTV sealant between the cover and chaincase.

7. Remove fill/level check plug in chaincase cover and refill chaincase oil up to fill/level check plug opening (reference procedure in Lubrication chapter). Replace fill/level check plug.

Lug Nut

8. Install wheels and tires. Wheel nut torque is 120 ft.-lbs. (163 N•m).

Axle Removal and Installation

Fig. 5-8

Lug nuts securing tires and wheels to the axles.

Fig. 5-9

Location of right front axle access cover. Other side same.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Roll back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Drain chaincase oil per the procedure in the Lubrication chapter.

2. Remove lug nuts (120 ft.-lbs.)(163 N•m), wheels and tires on side of loader being serviced. Fig. 5-8 3. Remove floor cover(s) per the procedure in the Mainframe chapter for access to front axle access covers. Rear axle access covers are behind the drive motors on the chaincase housing. Fig. 5-10 4. Remove ten capscrews securing chaincase access cover to mainframe. Fig. 5-2 5. Remove drive chain per the procedure in this chapter.

Chaincase Housing

6. Inside loader, remove four capscrews on the axle access cover on each axle. Figs. 5-9, 5-10 7. Remove large cotter pin, slotted locknut and washer securing axle to axle sprocket at back of axle sprocket. Fig. 5-11

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Fig. 5-10 Location of right rear axle access cover, behind the drive motors in the chaincase. Other side same.

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WHEEL DRIVES 8. Use a slide hammer mounted to axle hub. A slight impact is needed to remove axle from inner bearing.

9. Support axle with a suitable hoist and pull axle away from axle sprocket and mainframe.

10. Remove outer axle bearing and, if needed, the seal.

NOTE: Note orientation of bearing and seal at removal for correct reassembly.

Installation Procedure 1. Install a new seal (if old was replaced) and outer bearing on axle. Fig. 5-12 NOTE: Pack tapered bearings with grease before assembling.

Fig. 5-11 Behind the axle access cover, remove the large cotter pin, slotted locknut and washer securing the axle to the sprocket.

3. Support axle with a suitable hoist and insert into axle sprocket in axle housing weldment.

4. Slip washer onto axle hub. Tighten slotted locknut on axle hub to 100 ft.-lbs. (136 N•m) to press bearings into place.

5. Rotate axle for ten revolutions to help seat bearings.

6. Strike outside end of axle with lead shot or soft hammer to ensure bearings are seated.

7. Recheck that slotted locknut on axle hub is tightened to 100 ft.-lbs. (136 N•m).

8. Back off slotted locknut until nut is free from pressure.

Fig. 5-12 Location of the outer axle bearing.

9. Retighten slotted locknut to 30 ft.-lbs. (41 N•m), then increase to alignment slot with cotter pin hole.

If nut slot lines up with cotter pin hole at 30 ft.-lbs.

(41 N•m), then use that slot.

10. Install cotter pin.

11. Install and adjust the drive chains per the procedures in this chapter.

12. Fill the chaincase with motor oil until it is up to the oil fill/level check plug.

13. Install chaincase access covers using oil-resistant RTV sealant between the cover and chaincase.

Fig. 5-13 Install inner bearing on axle.

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2. Reinstall inner bearing on axle. Fig. 5-13

WHEEL DRIVES

SL3640/3840/4240

NOTES

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CONTROLS

Introduction This chapter covers removal, installation, assembly, and adjustment procedures for standard and optional controls equipment on GEHL SL36/38/4240 skid-steer loaders.

T-Bar Controls On loaders with “T-Bar controls,” the left T-Bar controls the forward and reverse directions of the hydrostatic drive motors and pumps for both sides of the loader. The right T-Bar controls the lift and tilt functions of the liftarm and bucket. For control of engine speed, both foot and hand throttles are provided. A pivoting foot pedal control on the floor is provided for control of the auxiliary hydraulics.

Equipment Identification Because there are a variety of options available for the SL36/38/4240, it is IMPORTANT to properly identify the equipment BEFORE beginning service procedures.

Illustrations and photographs are provided with each procedure to aid in servicing this equipment.

Hand/Foot Controls

CONTROLS

On loaders with “Hand/Foot controls,” left and right drive control handles operate independently of each other. Pushed forward together moves the loader forward, but push either one farther forward than the other and the loader turns. Separate foot pedals control the lift and tilt functions of the liftarm and bucket.

Engine speed is controlled with the hand throttle lever located to the right of the operator’s seat. The auxiliary hydraulics are actuated by the right control handle.

Hand/Foot controls

T-Bar controls

5 6

2

4

3

4 1&6

2&3 1 1

1 - Drive Control 2 - Lift Control 3 - Tilt Control

Fig. 6-1

4 - Hand Throttle 5 - Foot Throttle 6 - Auxiliary Hydraulics Control

Control locations on T-Bar and Hand/Foot controls.

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T-Bar Control Models - Drive, Auxiliary Hydraulics, Lift and Tilt Controls

47

46

A

66 51

48

66

47

9 37 69

1

25

12

64

59 8

13 12

57

64

5

4

63

76

24

70

41

62

A

16 32 10

B

42

C

23 55

15 10

38

44 65

13

2

21

7

12 22

62 62

9

56 6 7

62

54 45

52

67

66

61

2

30

18

47

3

12

68

10

19

62

2

69

14

58

2 34

53

5

39 63

13

17

72

26

71

58

20

74

65

1

4

73

11

1 11

27

31

55

64

29

C

40

66

43

49

6

33

72

B

51

66

28

15 46 48

2

75

9 50

39

66

36

13

60 73

Fig. 6-2

35

Assembly view of T-Bar drive, auxiliary hydraulics, lift and tilt controls.

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CONTROLS

Parts Listing - T-Bar Control Models - Drive, Auxiliary Hydraulics, Lift and Tilt 55 SPACER 56 SPRING 57 WASHER 58 BOOT/T-BAR 59 BUSHING 60 SCREW/CAP 61 SCREW/CAP 62 SCREW/CAP 63 SCREW/CAP 64 SCREW/CAP 65 SCREW/CAP 66 NUT/HEX 67 PIN/COTTER 68 SCREW/CAP 69 BOLT/CARRIAGE 70 BOLT/CARRIAGE 71 BOLT/CARRIAGE 72 SCREW/MACHINE TRUSS HEAD SLOTTED 73 SCREW/HEX WASHER HEAD THREAD-FORMING 74 WASHER/FLAT 75 SCREW/CAP 76 NUT/HEX

Fig. 6-3

CONTROLS

1 BEARING/FLANGE MOUNT 2 BEARING/FLANGE MOUNT 3 SCREW/SHOULDER 4 COVER/BOOT RIGHT 5 COVER/BOOT LEFT 6 BUSHING/SUPER OILITE 7 BUSHING/OILITE 8 BUSHING/OILITE FLANGED 9 END/ROD FEMALE STUD 10 NUT/SERRATED LOCK 11 NUT/LOCK 12 NUT/LOCK 13 NUT/LOCK 14 NUT/LOCK 15 SCREW/FLANGE WHIZLOCK 16 NUT/HEX WHIZLOCK 17 SCREW/CAP WHIZLOCK 18 CABLE/THROTTLE 19 CABLE/AUXILIARY 20 PEDAL/THROTTLE 21 PIVOT/DRIVE CONTROL 22 CONTROL/DRIVE 23 MOUNT/BRACKET CABLE 24 PIVOT/AUXILIARY 25 STOP/T-BAR 26 DAMPER 27 HANDLE/CONTROL LEFT 28 HANDLE/CONTROL RIGHT 29 SOLENOID 30 BRACKET/CONTROL 31 BRACKET/LOCK BASE 32 MOUNT/CONTROL 33 BRACKET/CONTROL MOUNT 34 SUPPORT/HYDRAULIC CONTROL 35 MOUNT/CONTROL 36 PEDAL/AUXILIARY 37 ROD END/FEMALE 38 YOKE 39 JOINT/BALL 40 LINKAGE/SPOOL LOCK AUXILIARY 41 NUT/LOCK FLANGE CENTERLOCK 42 NUT/LOCK FLANGE CENTERLOCK 43 NUT/HEX JAM 44 NUT/HEX CENTERLOCK 45 PIN/CLEVIS 46 PIN/CLEVIS 47 PIN/CLIP RUE 48 YOKE 49 ROD 50 ROD/CONTROL 51 ROD/CONTROL 52 SCREW/FLANGE WHIZLOCK 53 PLATE/FLOOR 54 PLATE/SOUND

Parts listing for Fig. 6-2.

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Hand/Foot Control Models - Drive, Auxiliary Hydraulics, Lift and Tilt Controls

44 32 53

26

33

29 48

5

F

8

28

3 4

35

43

47 12 34

9

9

D

C

10

2

49

40

33 E

22 9 50

23

48

34

32 6

11 6

15

48 1

19

38

5 31

51

17

52

39

D 11

A

25

E

42

F

D

8

2 16 3

B 6

10

A

50 41

D 42

C

13

9

49

20

11 9

44

16

45

55

56

46

8

30

14

48

36

48

40

48

B

5

53

7

4

6

50

37

27 54

18

43

37

5 24

13 24 50

54

Fig. 6-4

5 41

21

54

Assembly view of hand/foot drive, auxiliary hydraulics, lift and tilt controls.

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CONTROLS

Parts Listing - Hand/Foot Control Models - Drive, Auxiliary Hydraulics, Lift and Tilt

Fig. 6-5

CONTROLS

1 BOLT/SHOULDER 2 BOLT/SHOULDER 3 COVER/BOOT RIGHT 4 COVER/BOOT LEFT 5 BUSHING/OILITE 6 END/ROD FEMALE STUD 7 NUT/SERRATED LOCK 8 NUT/LOCK 9 NUT/LOCK 10 NUT/LOCK 11 SCREW/FLANGE WHIZLOCK 12 SCREW/CAP WHIZLOCK 13 PEDAL/FOOT 14 CRANK/AUXILIARY BELL 15 END/ROD MALE 16 ABSORBER/SHOCK 17 SOLENOID 18 COVER/LINKAGE 19 PIVOT/AUXILIARY HANDLE 20 BRACKET/LOCK BASE 21 MOUNT/PEDAL CENTER FOOT 22 LINKAGE/CONTROL UPPER 23 LINKAGE/CONTROL LOWER 24 PIVOT/FOOT PEDAL 25 MOUNT/CONTROL 26 HANDLE/CONTROL RIGHT 27 HANDLE/CONTROL LEFT 28 END/ROD FEMALE 29 LINKAGE/SPOOL LOCK AUXILIARY 30 NUT/HEX FLANGED CENTERLOCK 31 NUT/HEX JAM 32 PIN/CLEVIS 33 PIN/CLIP RUE 34 YOKE 35 ROD 36 ROD/CONTROL 37 ROD/LINKAGE 38 SCREW/CAP SELF-TAPPING 39 WASHER/PINION 40 WASHER/SPECIAL 41 WASHER/FLAT 42 WASHER/SPECIAL 43 BOOT/T-BAR 44 GRIP 45 SCREW/CAP 46 SCREW/CAP 47 SCREW/CAP 48 NUT/HEX 49 SCREW/CAP 50 SCREW/CAP 51 BOLT/CARRIAGE 52 BOLT/CARRIAGE

Parts listing for Fig. 6-4.

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SL3640/3840/4240

Control Handle Removal and Installation

Studded Rod End T-Bar Stop

WARNING

Tilt Rod

Capscrew

BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support

Lift Rod

device.

Locknut

q Shut off the engine. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 6-6

Right T-Bar control handle.

Removal Procedure - T-Bar Models 1. Remove kick plate per the procedure in the Mainframe chapter for the left T-Bar control handle.

2. Right T-Bar (Fig. 6-6): Remove locknut and T-Bar stop on studded rod end attached to tilt control rod at control handle. Pull rod end out of control handle and remove control handle. Left T-Bar (Fig. 6-7): Remove locknut and capscrew securing control handle to drive control weldment and remove control handle.

Locknut Jam Nut Capscrew

Center Control Rod

Installation Procedure - T-Bar Models - Follow all warnings first, then reverse the removal steps.

NOTE: When control handle is installed, control handle shaft has a 10° forward tilt. If changes are needed, refer to “Control Handle Position Adjustment” procedure in this chapter.

Fig. 6-7

Left T-Bar control handle.

Locknut

Removal Procedure - Hand/Foot Models 1. Remove floor cover and kick plate per the procedure in the Mainframe chapter.

Locknut

2. Right Handle (Figs. 6-8, 6-10): Remove locknut and studded rod end attached at far left end of control handle. Remove large capscrew and locknut securing control handle to pivot weldment and remove control handle. Left Handle (Figs. 6-9, 6-11): Remove one sholder bolt, capscrew on pivot weldment and rod end from the left handle weldment.

Capscrew

Rod End

Fig. 6-8

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Right Hand/Foot control handle.

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SL3640/3840/4240

CONTROLS Installation Procedure - Hand/Foot Models - Follow all warnings first, then reverse the removal steps.

Rod End

NOTE: When control handle is installed, control handle shaft has a 10° forward tilt. If changes are needed, refer to “Control Handle Position Adjustment” procedure in this chapter.

Control Handle Position and Tracking Adjustment

Capscrew Shoulder Bolt

Fig. 6-9

Control handles are adjusted three ways for proper operation: vertically straight appearance, tracking and handle orientation.

Left Hand/Foot control handle.

Adjustment Procedure

WARNING q Raise liftarm; engage liftarm support

Alignment Rod Hole

device.

q Shut off the engine. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

Alignment Rod Holes

1. Remove floor cover and kick plate per the procedure in the Mainframe chapter.

Fig. 6-10 View of T-Bar dual control weldment.

2. T-Bar Models: a. Left T-Bar: Install two 3/8” (9.5 mm) alignment rods, one through pivot weldment and control weldment, and the other through control weldment and T-Bar pivot. Loosen jam nuts on center control rod and adjust rod between rod ends. Retighten jam nuts. Next, loosen jam nuts and adjust two turnbuckles on hydrostatic pump arm rods to obtain a 10° forward tilt to control handle. Retighten turnbuckle jam nuts. Remove alignment rods.

BE SURE adjustment allows for full activation of hydrostatic pump arms in both directions of handle operation. Figs. 6-7, 6-10, 6-12, 6-13 NOTE: If control handles do not return to NEUTRAL position after adjustment, refer to “Neutral Centering Device” adjustment procedure in this chapter.

PRINTED IN USA

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CONTROLS

BEFORE beginning this service procedure, perform the following SAFETY procedures:

CONTROLS

SL3640/3840/4240

b. Right T-Bar: Remove locknut and T-Bar stop on studded rod end attached to tilt control rod at control handle. Pull rod end out of control handle. Remove locknut on studded rod end attached to lift control rod and bottom of T-Bar pivot. Loosen jam nuts on lift and tilt control rods and adjust rod ends to obtain a 10° forward tilt to the control handle. After adjustment, retighten jam nuts against rod ends and reconnect control rods to control handle and pivot with their hardware. BE SURE adjustment allows for full activation of control valve in both directions of handle operation. Figs. 6-6, 6-12 3. Hand/Foot Models:

Fig. 6-11 Location of turnbuckles on hydrostatic pump arms of Hand/Foot control skid-steer loader.

a. Left and Right Control Handles: Loosen jam nuts and adjust two turnbuckles on hydrostatic pump arm rods to obtain a 10° forward tilt to the control handles. Retighten turnbuckle jam nuts.

BE SURE adjustment allows for full activation of hydrostatic pump arms in both directions of handle operation. Figs. 6-10, 6-11, 6-12 NOTE: If control handles do not return to NEUTRAL position after adjustment, perform the “Neutral Centering Device” adjustment procedure in this chapter.

Fig. 6-12 A metal plate, bent to 10°, may be used to measure the 10° forward tilt of control handles.

Adjust the turnbuckle until the control handle is flush against the plate.

Fig. 6-13 Location of turnbuckles on hydrostatic pump arms of T-Bar control skid-steer loader.

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CONTROLS Dual Control Weldment Removal and Installation - T-Bar The dual control weldment in T-Bar control skid-steer loaders houses the pivots for the left control handle and provides a location for control of skid-steer loader drive functions.

Center Control Rod

Removal Procedure Pivot

Capscrew

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

Fig. 6-14 Location of locknuts on studded rod ends connecting hydrostatic pump arms to pivot.

q Raise liftarm; engage liftarm support device.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove floor cover and kick plate per the procedure in the Mainframe chapter.

Centering Device

2. Remove control handles per the procedure in this chapter.

3. Remove locknuts on rod ends attaching hydrostatic pump arms to pivot weldment. Fig. 6-14 4. At front of dual control weldment, remove two locknuts on studded rod ends on center control rod, attached between two pivots. Figs. 6-7, 6-14

Fig. 6-15 Locations to disconnect centering device on dual control weldment.

5. Remove locknut and washer securing centering device to welded tab on dual control weldment. Fig. 6-15

Dual Control Weldment

6. Remove capscrew, spacer and locknut on lower right flange bearing of dual control weldment. Fig. 6-16 7. Remove capscrew securing lower left portion of dual control weldment to mainframe. Fig. 6-14 Installation Procedure - Follow all warnings first, then reverse the removal steps.

Fig. 6-16 Location of capscrew, spacer and locknut securing dual control weldment on lower right side.

PRINTED IN USA

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q Shut off the engine. q Tilt back ROPS until lock engages.

CONTROLS

SL3640/3840/4240

Neutral Centering Device and Pump Arm Removal and Installation The neutral centering device and pump arm weldment are designed to be interchangeable on the front and rear hydrostatic pumps.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support

Fig. 6-17 Two locations to disconnect hand throttle cable and move out of the way.

device.

q Shut off the engine. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove a cotter pin and clevis pin on yoke of hand throttle cable attached at throttle pivot. Disconnect throttle cable from cable bracket and move throttle cable out of the way. Fig. 6-17 2. Disconnect two hydrostatic pump arm control rods by removing a locknut and two washers securing control rods to pump arms. Fig. 6-18 3. Remove two outer horizontal locknuts and capscrews securing upper bracket to lower bracket.

Loosen center locknut until upper bracket lifts free.

Fig. 6-21

Fig. 6-18 Two locations to disconnect hydrostatic pump arms from neutral centering devices.

4. Remove two capscrews securing lower neutral centering device bracket to hydrostatic pump. Fig. 6-19 5. Remove two capscrews securing pump arm retainer and pump arm weldment to hydrostatic pump shaft.

Fig. 6-20 6. Repeat steps 1-5 for other neutral centering device.

Installation Procedure* - Follow all warnings first, then reverse the removal steps. * After installation, perform the “Neutral Centering Device Adjustment” procedure in this chapter, BUT, if the control rods’ lengths were not altered and the rod end slips right in, then no adjustment should be necessary.

917170/AP0106

Lower Bracket Capscrew

Fig. 6-19 Location of center locknut on neutral adjust plate.

6-10

PRINTED IN USA

SL3640/3840/4240

CONTROLS Neutral Centering Device Adjustment Gehl SL36/38/4240 skid-steer loaders come equipped with two neutral centering devices on the hydrostatic pump assembly. These devices allow control handles and control arms to automatically return to NEUTRAL when the operator releases the control handles.

Pump Arm Retainer

Adjustment Procedure

WARNING

Pump Arm

BEFORE beginning this service procedure, perform the following SAFETY procedures:

Fig. 6-20 Location of one of two capscrews securing pump arm retainer to pump arm weldment.

q Raise and block loader so the tires are off the ground.

q Raise liftarm; engage liftarm support device.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Rotate neutral centering device, checking centering torsion spring backlash.

2. Adjust backlash by loosening three locknuts on horizontal bolts securing upper neutral centering device bracket to lower neutral centering device bracket. Fig. 6-27 Fig. 6-21 Location of three locknuts used to disassemble the upper bracket from lower bracket, and adjust backlash on neutral centering device.

Neutral Adjust Plate

3. Rock upper bracket side-to-side to remove clearance between torsion spring “legs,” neutral adjusting plate and pump arm pin. Fig. 6-28 4. Retighten three locknuts on horizontal bolts.

5. Start loader with restraint bar down and seat switch depressed to release parking brakes.

Torsion Spring "Legs" on Pump Arm Pin

Fig. 6-22 Location of two locknuts on neutral centering device used for removing any noticeable tire creep. Same for other neutral centering device.

PRINTED IN USA

6. Run loader at HALF throttle and check for NEUTRAL setting of the hydrostatic pump arms.

When pump arms are in NEUTRAL, tires MUST remain stationary.

7. To remove any noticeable tire creep, loosen two locknuts on bolts at top of centering device - NOT the center bolt. Twist upper bracket until creep is eliminated. Retighten the locknuts. Fig. 6-28 8. To test operation of control handle(s), move control handle(s) forward and backward, and allow neutral centering devices to return control handle(s) to NEUTRAL position.

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q Tilt back ROPS until lock engages.

CONTROLS

SL3640/3840/4240

Lift and Tilt Control Removal and Installation

WARNING

Tilt Rod

BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support device.

Lift Rod

q Shut off the engine. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 6-23 Location of locknut on lift control rod. Tilt control rod similar.

Removal Procedure - Right T-Bar Control Handle 1. Remove locknut securing studded rod end of lift and tilt control rods to control handle and pivot. Release rod ends from handle assembly. Fig. 6-23 2. Disconnect lift and tilt control rods from control valve spools by removing two clip pins and clevis pins. Fig. 6-24 Installation Procedure - T-Bar Controls - Follow all warnings first, then reverse the removal steps.

Removal Procedure - Hand/Foot Controls 1. Remove floor cover and kick plate per the procedure in the Mainframe chapter.

Fig. 6-24 Disconnect locations at main control valve for lift and tilt control rods.

2. Behind kick plate and in front of gear pump, remove two locknuts on studded rod ends connecting pedal control rods to upper and lower control linkages.

Fig. 6-25 3. At other end of upper and lower control linkages, remove two locknuts securing lift and tilt control rods. Fig. 6-26 4. At control valve spools, remove two clip pins and clevis pins on tilt and lift control rods. Fig. 6-27 Foot Pedal Adjustment Rods

Installation Procedure - Hand/Foot Controls Follow all warnings first, then reverse the removal steps.

Fig. 6-25 Location of two locknuts connecting pedal control rods to upper and lower control linkages (bellcranks).

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CONTROLS Lift/Tilt Control Adjustment

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Tilt back ROPS until lock engages.

Fig. 6-26 Location of two locknuts securing lift and tilt control rods to upper and lower control linkages (bellcranks).

(For detailed instructions, refer to the Safety chapter of this manual.)

Adjustment Procedure - T-Bar Controls

The “Self-Leveling Valve Adjustment” procedure in the Hydraulic System chapter is also related to correct operation of the lift and tilt controls. Refer to this procedure as needed.

Adjustment Procedure - Hand/Foot Controls 1. Remove floor cover and kick plate per the procedure in the Mainframe chapter.

Fig. 6-27 Location of three clevis pins and clip pins securing lift, tilt and auxiliary control rods to main control valve spools.

2. With lift and tilt spools in NEUTRAL position, adjust lift and tilt control rods at control valve so that both bellcranks are even and parallel to kick plate.

Tighten hardware. Fig. 6-28 3. Reinstall kick plate.

4. Check for full-range spool travel and that bellcranks are not contacting the kick plate.

5. Move lift spool into detent (FLOAT) position.

6. On lift pedal: Twist rod ends in or out as necessary to adjust lift pedal height until pedal is level, parallel to floor plate. Fig. 6-25

Bellcranks

7. Reinstall control rod ends and tighten jam nuts.

8. Return lift pedal to NEUTRAL position.

Fig. 6-28 Location of two rods to adjust until both bellcranks (upper and lower control linkages) are even and parallel to kick plate.

PRINTED IN USA

9. On tilt pedal: Twist rod ends in or out as necessary to adjust tilt pedal height until tilt pedal matches lift pedal. Fig. 6-25 10. Reinstall control rod ends and tighten jam nuts.

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The lengths of the lift and tilt control rods can be adjusted to obtain the proper position of the T-Bar. Refer to the “Control Handle Position and Tracking Adjustment” procedure in this chapter.

CONTROLS

SL3640/3840/4240

Auxiliary Hydraulics Removal and Installation T-Bar control models use a control cable between the auxiliary pedal and control valve to actuate the auxiliary hydraulics. The actuation of auxiliary hydraulics in Hand/Foot control models is in the right control handle.

Auxiliary Hydraulics Cable Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

Fig. 6-29 Location of ball joint connection to auxiliary hydraulics foot pedal and cable connection to the auxiliary control mount plate.

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove floor cover and kick plate per the procedure in the Mainframe chapter.

2. Remove clevis and clip pin securing the spool lock linkage to main control valve spool. Fig. 6-31 3. Remove ball joint off ball stud on auxiliary cable at auxiliary foot pedal assembly. Loosen jam nut on auxiliary cable at welded tab on floor of auxiliary control mount weldment. Pull cable out of welded tab. Fig. 6-29

Fig. 6-30 Location of jam nut on welded tab and ball joint connection (partially obscured) on auxiliary bellcrank.

4. At other end of cable, remove ball joint off ball stud on auxiliary cable rod end at auxiliary bellcrank.

Loosen jam nut on auxiliary cable at auxiliary handle pivot. Pull cable out of pivot. Fig. 6-30

Auxiliary Bellcrank

5. Remove the cable. If replacing cable, remove rod ends, washers and jam nuts from old cable.

6. Hand/Foot Control Models Only: Remove shoulder screw and washer attaching right control handle to the auxiliary bellcrank. Fig. 6-31 Installation Procedure* -Follow all warnings first, then reverse the removal steps. * For cable adjustment, refer to “Auxiliary Hydraulics Adjustment” procedure in this chapter.

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Main Control Valve

Fig. 6-31 View of auxiliary hydraulics connections on a Hand/Foot model skid-steer loader.

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CONTROLS Auxiliary Hydraulics Adjustment The auxiliary hydraulics cable (or control rod) should be adjusted so that the hydraulic control valve is engaged when the foot pedal is locked open with the bar stop.

Bellcrank

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

Jam Nut Ball Joint

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Tilt back ROPS until lock engages.

Fig. 6-32 Location of auxiliary hydraulics control rod.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove floor cover and kick plate per the procedure in the Mainframe chapter.

Spool Lock Linkage

Fig. 6-33 Location of where to insert alignment capscrew.

2. With auxiliary hydraulics spool in NEUTRAL position, loosen jam nuts on control rod and position female rod end in a line with the bellcrank (pivot).

Retighten jam nuts and loosely secure rod end to bellcrank with capscrew, washer and locknut. Fig. 6-32 3. With auxiliary hydraulics spool still in NEUTRAL, loosen jam nut and adjust ball joint on cable at bellcrank to position cable in mid-travel position.

4. Tighten hardware on cable and control rod.

Spool Lock Solenoid

5. At auxiliary hydraulics foot pedal, loosen jam nut on ball joint and adjust so that foot pedal is horizontal (level) with auxiliary hydraulics valve spool in NEUTRAL position. Fig. 6-29 6. Check for full-range spool travel. Retighten locknut on studded rod end of auxiliary hydraulics control cable.

Adjustment Procedure - Hand/Foot Controls 1. Remove floor cover and kick plate per the procedure in the Mainframe chapter.

Fig. 6-34 Location of two adjusting bolts of the auxiliary hydraulics spool lock solenoid bracket.

2. Loosen two locknuts on adjusting bolts of auxiliary hydraulics spool lock solenoid bracket. Fig. 6-34 3. On control valve, place auxiliary hydraulics spool in NEUTRAL position.

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Auxiliary Hydraulics Cable Adjustment Procedure T-Bar Controls

CONTROLS

SL3640/3840/4240

4. Remove clip pin and clevis pin from auxiliary hydraulics spool lock linkage. Fig. 6-27 5. Install alignment capscrew in right control handle.

Fig. 6-33 6. Adjust spool lock linkage so clevis pin hole aligns with auxiliary hydraulics spool hole.

Jam Nut

7. Tighten hardware and remove alignment capscrew from control handle.

8. Check for full-range spool travel in spool lock solenoid and auxiliary hydraulics spool on control valve.

9. Adjust auxiliary hydraulics spool lock solenoid to lock spool lock linkage when spool on control valve is in NEUTRAL position.

Fig. 6-35 Location of clevis pin and cotter pin securing the throttle cable yoke to the hand throttle grip.

Hand Throttle, Hand Throttle Cable and Throttle Rod Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

Hand Throttle Cable

q Raise liftarm; engage liftarm support

Foot Throttle Cable

device.

q Shut off the engine. q Tilt back ROPS until lock engages.

Fig. 6-36 Locations to remove hand throttle cable and foot throttle cable from pivots.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove floor cover and kick plate per the procedure in the Mainframe chapter.

2. Remove clevis pin and cotter pin securing hand throttle cable yoke to throttle handle grip. Fig. 6-35 Weld Tab

3. Remove carriage bolt, locknut, friction washer and spring washers securing hand throttle lever to chassis. Note orientation of two spring washers for reassembly later. Remove hand throttle grip.

4. Loosen jam nut on throttle cable below control handle, and lift cable out of slot in mainframe. Fig. 6-35

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Fig. 6-37 Location of throttle rod ball joint on ball stud.

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CONTROLS

Fuel Injector Arm

5. At engine mount weldment, remove clevis pin and cotter pin on yoke attaching other end of throttle cable to hand throttle pivot. Fig. 6-36 NOTE: T-Bar control skid-steer loaders will have the foot pedal throttle cable attached to its own throttle pivot at the same place. Perform “Foot Throttle Removal and Installation” procedure in this chapter to remove that cable. Fig. 6-36

Throttle Support Bracket

6. Loosen jam nut securing hand throttle cable to tab welded to the engine mount weldment. Fig. 6-37 7. Remove the cable. If replacing cable, remove yokes, washers and jam nuts from old cable.

Fig. 6-38 Location of throttle rod connection to the engine.

8. Next, disconnect ball joint on ball stud securing throttle control rod to throttle pivot. Fig. 6-37

10. Remove shoulder bolt and locknut securing throttle rod support bracket to fuel injector arm on engine.

Fig. 6-38 11. Pull throttle rod out the back of skid-steer loader.

Installation Procedure* - follow all warnings first, then reverse the removal steps. * Perform “Hand Throttle Adjustment” procedure found in this chapter after the installation is complete.

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CONTROLS

9. Raise engine cover and open rear grille. Locate throttle rod connection to support bracket on rear lower left side of engine. Fig. 6-38

CONTROLS

SL3640/3840/4240

Foot Throttle and Foot Throttle Cable Removal and Installation - T-Bar Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Tilt back ROPS until lock engages.

Fig. 6-39 Location to disconnect foot throttle cable from foot pedal.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove floor cover and kick plate per the procedure in the Mainframe chapter.

Throttle Tab

2. Remove clevis pin and clip pin on throttle cable yoke connected to foot pedal throttle assembly. Fig. 6-39 3. Remove socket head shoulder screw securing extension spring to throttle pedal. Fig. 6-40 4. Remove capscrew and locknut securing the foot pedal throttle to auxiliary control mount weldment and remove pedal. Fig. 6-41 5. Loosen jam nut on foot throttle cable securing cable to throttle tab. Slide cable out of tab. Fig. 6-40

Fig. 6-40 Remove socket head shoulder screw on spring from foot pedal.

6. At the engine cable mount weldment, disconnect clevis pin and clip pin securing yoke of foot throttle cable to foot throttle pivot. Fig. 6-42 NOTE: To remove the hand throttle cable and throttle rod on engine, see the “Hand Throttle, Hand Throttle Cable and Throttle Rod Removal and Installation” procedure in this chapter.

Foot Throttle Pedal

7. Loosen jam nut securing foot throttle cable to cable mount bracket. Pull cable out of bracket. Fig. 6-42 8. Remove the cable. If replacing cable, remove yokes, washers and jam nuts from old cable.

Installation Procedure* - Follow all warnings first, then reverse the removal steps. * Perform “Foot Throttle Adjustment” procedure found in this chapter after the installation is complete.

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Fig. 6-41 Location of capscrew and locknut securing foot throttle pedal to the auxiliary mount weldment.

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CONTROLS Hand Throttle Adjustment Foot Throttle Cable

The hand throttle is adjusted at the factory to provide a full range of engine speed adjustment, from IDLE to FULL throttle. If the hand throttle cable is replaced, it may be necessary to make the following adjustment.

Adjustment Procedure The hand throttle can be adjusted at four different locations: (1) at the yoke attached to the throttle grip, (2) at the yoke on the throttle pivot, (3) at the ball joint end of throttle rod, and (4) the clevis attached to the engine.

Figs. 6-43, 6-44, 6-45, 6-46

Fig. 6-42 Location of cable mount bracket.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support q Shut off the engine. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

IMPORTANT DO NOT attempt to adjust hand throttle lever at the two fuel injection pump adjustment screws.

Fig. 6-43 One of the locations to adjust the hand throttle.

1. Test the movement of the hand throttle to determine if the cable needs to be shortened or lengthened.

When the hand throttle and the fuel injection pump are at the low idle position simultaneously, proper adjustment is achieved. BE SURE that the hand throttle lever does not interfere with the yoke attached to it.

2. If cable needs adjustment, choose a location: a. Loosen the jam nut on the yoke, clevis or ball joint. b. Remove the clevis pin and cotter pin on the yoke or the ball joint on the ball stud. c. Twist the yoke or ball joint to shorten or lengthen the throttle cable as needed.

Fig. 6-44 One of the locations to adjust the hand throttle.

d. Reattach the yoke or ball joint. Next, push and pull the hand throttle to check for correct PRINTED IN USA

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device.

CONTROLS

SL3640/3840/4240

operation. Repeat the adjustment steps as needed.

3. Tighten the jam nut against the yoke or ball joint to secure the adjustment.

Hand Throttle Tension Adjustment Hand throttle tension should be tight enough to maintain the desired engine RPM, but loose enough to allow easy operation. The hand throttle tension can be INCREASED or DECREASED. Adjustment Procedure (Fig. 6-47) Fig. 6-45 One of the locations to adjust the hand throttle.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

NOTE: The spring washers and the friction washer must be installed properly to provide tension against the hand throttle.

1. To INCREASE TENSION, tighten the capscrew and locknut that attaches the hand throttle to the mainframe.

2. To DECREASE TENSION, loosen the capscrew and locknut that attaches the hand throttle to the mainframe.

Fig. 6-46 One of the locations to adjust the hand throttle.

Fig. 6-47 Orientation of two spring washers on throttle lever.

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CONTROLS Foot Throttle Adjustment - T-Bar

Control Mount

Loaders with T-Bar controls include a foot throttle to control the engine RPM, to match increased power requirements. The foot throttle is coupled to the hand throttle through a throttle rod pivot assembly. The foot throttle is at proper adjustment when pushing the hand throttle FULLY FORWARD causes the foot pedal to be pressed flush against the floor plate.

Adjustment Procedure

Foot Pedal

WARNING

Fig. 6-48 Location to disconnect throttle cable from foot pedal.

BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support device.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove floor cover per the procedure in the Mainframe chapter.

2. With the hand throttle pulled back to IDLE position, disconnect clevis pin attaching yoke on foot pedal assembly. Fig. 6-48 3. Push down on foot pedal until it is flush with the top of the auxiliary control mount weldment. Fig. 6-48 4. Loosen jam nut on yoke of foot pedal assembly.

Adjust foot throttle cable after moving hand throttle lever to HIGH IDLE position. Retighten jam nut on yoke.

5. Start engine and test foot pedal throttle for full range of engine speed. Repeat adjustment steps as needed.

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CONTROLS

q Shut off the engine. q Tilt back ROPS until lock engages.

CONTROLS

SL3640/3840/4240

NOTES

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HYDROSTATIC SYSTEM

Introduction This chapter covers troubleshooting, testing, removal, installation and adjustment procedures for the hydrostatic system components on GEHL SL36/38/4240 skid-steer loaders. The primary components are shown below.

pumps and drive motors are controlled individually, allowing complete flexibility in forward and reverse and in gradual, pivot and spin turns.

For detailed information on hydrostatic pump or drive motor internal repair, consult the GEHL Service Department and/or the hydrostatic component manufacturer’s service manual. Other related hydraulic components are covered in the Hydraulic System chapter of this manual.

In this system, a hydrostatic pump assembly coupled to the engine provides hydrostatic power to the two fixed-displacement hydrostatic drive motors. The drive motors drive the wheels on each side of the loader through a chain and sprocket system. The hydrostatic

Hydrostatics Pump Assembly and Drive Motors 24 4 13

9

20

18

12

8

16

22 17

A

11

6 14

10

5

7

A 21

19 23 13

B

1

B

12

2

2 15

19

5

10

11

1 FITTING/STRAIGHT 2 FITTING/TEE 3 FITTING/90° 4 FITTING/STRAIGHT 5 FITTING/STRAIGHT 6 FITTING/STRAIGHT

Fig. 7-1

7 FITTING/TEE 8 VALVE/RELIEF 9 PUMP/TANDEM 10 HOSE 11 HOSE 12 HOSE

13 HOSE 14 TUBE/MOTOR 15 TUBE/MOTOR 16 TUBE/MOTOR 17 FITTING/STRAIGHT 18 FITTING/RED/EXP

19 MOTOR/HYDRAULIC 20 SCREW/CAP 21 SCREW/CAP 22 WASHER/SEAL 23 O-RING 24 WASHER/FLAT

Assembly view of the hydrostatics pump assembly and drive motors.

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3

HYDROSTATIC SYSTEM

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Hydrostatic Controls 5 12

3

22

1

6

22

9

17

13

10

4

21

14

18

21

4 7 16 8

11

20 23

12

19 2

21 15 13 10 21

1 MOUNT/NEUTRAL 2 BRACKET/NEUTRAL 3 PLATE/NEUTRAL 4 HUB/NEUTRAL 5 NUT/LOCK 6 NUT/LOCK

Fig. 7-2

7 SPACER 8 ARM/PUMP 9 ROD END/FEMALE 10 TURNBUCKLE 11 RETAINER/PUMP ARM 12 NUT/LOCK

13 NUT/HEX 14 ROD/CONTROL RIGHT 15 ROD/CONTROL LEFT 16 SCREW/CAP 17 SPRING/TORSION 18 WASHER

19 SCREW/CAP 20 SCREW/CAP 21 NUT/HEX 22 BOLT/CARRIAGE 23 SCREW/CAP

Assembly view of the hydrostatic controls.

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HYDROSTATIC SYSTEM

Troubleshooting Guide The following troubleshooting guide lists potential hydrostatic system problems, as well as possible causes and remedies, for GEHL SL36/38/4240 skid-steer loaders.

IMPORTANT

When a problem occurs, be sure not to overlook possible simple causes. A malfunction can be caused by something as simple as low oil level. After a mechanical failure has been corrected, be sure to locate and correct the cause of the problem.

Problem

Possible Cause

Remedy

No response from the hydrostatic drive or the lift/tilt systems.

Hydraulic oil viscosity is too high.

Allow longer warm-up or replace oil with the proper viscosity oil.

Hydraulic oil supply is too low.

Check for low oil level in reservoir. Add oil as needed.

Hydrostatic pump drive is disconnected.

Flexible drive plate failure.

Check for broken or worn pump flexible drive plate and replace, as needed.

Parking brake is engaged.

Disengage parking brake.

Hydraulic oil supply too low.

Check for low oil level in reservoir. Add oil if necessary.

Control rod linkage disconnected.

Check linkage connection at control levers and neutral centering mechanisms. Reconnect linkage.

Low or no charge pressure.

See hydrostatic pump manual.

Hydrostatic pump relief valves are malfunctioning.

Inspect and clean the relief valves.

Replace them as needed.

High pressure hydraulic hoses between the hydrostatic pump and the drive motors are connected wrong.

Reconnect hoses to proper ports on the drive motors. Refer to the schematic in the Hydraulic System chapter.

Traction drive will not operate in either direction.

Drive wheels do not turn in proper direction for T-Bar movement.

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DO NOT attempt to service or repair major hydrostatic system components, such as the hydrostatic pumps or drive motors, unless authorized to do so by your GEHL dealer/distributor. Any unauthorized repair will void the warranty.

HYDROSTATIC SYSTEM

SL3640/3840/4240

Problem

Possible Cause

Remedy

Neutral is difficult to maintain.

Ball joints loose on centering mechanism or servo rod.

Check and tighten or replace components.

Neutral centering mechanism(s) out of adjustment.

Adjust neutral centering mechanism(s).

See Controls chapter for procedure.

Key is missing in one or both control arm assemblies.

Install key.

Clamping bolt is loose.

Torque capscrew on the pump arm to 30 ft.-lbs. (40 N•m).

Hydrostatic pump out of adjustment.

See hydrostatic pump manual.

Air in the hydraulic system.

Cycle the lift and tilt cylinders to maximum stroke and maintain pressure for a short time to clear air from system. Check hydraulic oil reservoir, fill as needed.

Hydraulic oil supply is too low.

Check hydraulic oil reservoir. Add oil, if necessary.

Low hydrostatic system charge pressure.

See hydrostatic pump manual.

Drive motor(s) or hydrostatic pump(s) have internal damage or leakage.

Refer to component manufacturer’s service manual.

Engine is not responding under load.

Troubleshoot engine.

Automatic parking brake is partially engaged.

Contact your dealer.

Drive system overloaded continuously.

Improve efficiency of operation.

Lift, tilt or auxiliary system overloaded continuously.

Improve efficiency of operation.

Drive motor(s) or hydrostatic pump(s) have internal damage or leakage.

Refer to component manufacturer’s service manual.

Oil cooler fins are plugged with debris.

Clean oil cooler fins.

Loader being operated in a high temperature area with no air circulation.

Reduce duty cycle and improve air circulation.

Sluggish response to acceleration.

Hydrostatic drive is overheating.

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HYDROSTATIC SYSTEM

Problem

Possible Cause

Remedy

Hydrostatic (drive) system is noisy.

Hydraulic oil viscosity is too high.

Allow longer warm-up or replace existing oil with the proper viscosity oil.

Drive motor(s) or hydrostatic pump(s) have internal damage or leakage.

Refer to component manufacturer’s service manual.

Air in hydraulic system.

Cycle lift and tilt cylinders to maximum stroke and maintain pressure for a short time to clear air from system. Also, check for low oil level in reservoir, fill as needed.

Excessive internal leakage in right drive motor.

Repair or replace as needed. Refer to motor manufacturer’s service manual.

Excessive leakage in rear hydrostatic pump.

Refer to the pump manufacturer’s manual for service procedures. Repair or replace rear pump as needed.

Key missing on rear pump arm control shaft.

Replace the key. Torque capscrew on the arm to 30 ft.-lbs. (40 N•m).

Relief valves on rear hydrostatic pump malfunctioning.

Switch valves with those on front hydrostatic pump. See “Hydrostatic Pump Relief Valves” information in this chapter; problem should switch to the left side.

Replace defective relief valve.

Control rod linkage to rear hydrostatic Servo is disconnected.

Reattach control rod linkage.

Relief valve on rear hydrostatic pump is malfunctioning.

Switch one relief valve with the other relief valve on rear pump; problem should switch to reverse direction. Clean or replace the faulty valve as needed.

Rear hydrostatic pump malfunctioning.

Refer to pump manufacturer’s manual for service procedures. Repair or replace rear pump as needed.

Hydraulic oil viscosity is too heavy.

Allow longer warm-up or replace with proper viscosity oil.

Hydraulic oil level is low.

Check oil level in reservoir. If oil is low, check for an external leak. Repair and add oil.

Solenoid valve(s) malfunctioning.

Check electrical connections to lift solenoid and repair.

Restraint bar or seat switch malfunction.

Check switches.

Right side does not drive in either direction. Left side operates normally.

Right side does not drive in one direction.

Lift/tilt controls fail to respond.

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HYDROSTATIC SYSTEM Problem

SL3640/3840/4240

Possible Cause

Remedy

Left side does not drive in Excessive internal leakage in left drive either direction. Right motor. side operates normally.

Excessive leakage in front hydrostatic pump.

Key missing on front pump arm control shaft.

Relief valves on front hydrostatic pump malfunctioning.

Repair or replace as needed. Refer to motor manufacturer’s service manual.

Refer to pump manufacturer’s manual for service procedures. Repair or replace the front pump as needed.

Replace the key. Torque capscrew on the pump arm to 30 ft.-lbs. (40 N•m).

Switch valves with those on rear hydrostatic pump. See “Hydrostatic Pump Relief Valves” information in this chapter; problem should switch to the right side.

Replace defective relief valve as needed.

Reattach control rod linkage.

Control rod linkage to front hydrostatic servo is disconnected.

Left side does not drive in Relief valve on front hydrostatic pump is one direction. malfunctioning.

Switch relief valve with other relief valve on front pump; problem should switch to the reverse direction. Clean or replace the faulty valve as needed.

Front hydrostatic pump malfunctioning.

Refer to pump manufacturer’s manual for service procedures. Repair or replace front pump as needed.

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HYDROSTATIC SYSTEM Charge Pressure Test and Adjustment Before performing the following test, run loader until hydraulic oil is at normal operating temperature.

NOTE: This test requires a minimum 500 PSI (35 bar) pressure gauge.

Test Procedure

WARNING Fig. 7-3

BEFORE beginning this Service procedure, perform the following SAFETY procedures:

Location of the charge pressure port on the brake valve.

q Shut off the engine. q Raise and block the loader so all four tires are off the ground.

q Tilt back ROPS until lock engages.

1. Using an Allen wrench, remove plug and install pressure gauge on brake valve charge pressure port.

Figs. 7-3, 7-4 2. Depress brake switch on instrument panel to leave parking brakes locked.

3. Start engine and run at full throttle.

Fig. 7-4

4. Check pressure reading on gauge under three different conditions: (1) with steering controls in NEUTRAL, (2) both pumps stroked forward and backward, and (3) when stroking each pump individually. The gauge should read as follows: 130-150 PSI (9-10 bar). Minimum pressure: 100 PSI (7 bar).

Pressure gauge attached to charge pressure port on brake valve.

5. A slight drop in pressure is normal when a load is put on the hydrostatic pump. If the pressure reading on the gauge is either lower or higher than specified, see the manufacturer’s service manual for the hydrostatic pump.

Main Control Valve

Fig. 7-5

Adjustment Procedure 1. Add or remove shims on charge pressure relief valve to adjust pressure. Add shims to increase charge pressure; remove shims to decrease charge pressure.

Location of brake check valve (charge relief poppet) on hydrostatic pump.

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(For detailed instructions, refer to the Safety chapter of this manual.)

HYDROSTATIC SYSTEM

SL3640/3840/4240

Hydrostatic Pump Relief Valves

Relief Valve Assembly

Each hydrostatic pump is equipped with two high-pressure relief valves, for a total of four hydrostatic pump relief valves in the hydrostatic drive system (Figs.

7-6 and 7-7). The two front relief valves on the hydrostatic pump assembly control the front hydrostatic pump, which drives the left side of the skid-steer loader.

The two rear relief valves on the hydrostatic pump assembly control the rear hydrostatic pump, which drives the right side of the loader. Refer to the manufacturer’s manual for service procedures.

1

2 2

Drive Motor Hot-Oil Shuttle Valve

1

The hot-oil shuttle valve is a spring-loaded spool valve located in the end cover of each drive motor. The purpose of the shuttle is to allow a small portion of the closed-loop circuit oil back to the hydraulic reservoir for cooling and filtering. (This is referred to as "case drain" oil.)

2 2

Cooling oil must be taken from the low-pressure side of the closed-loop circuit. This is necessary to prevent loss of drive power. Because the drive motors are reversible, neither of the ports are continuously high or low pressure, depending on direction of travel.

Fig. 7-6

Pump relief valve assembly view.

1. Relief valve 2. O-Ring

The spool valve senses pressure differentials and moves to block the high-pressure port and open the low-pressure side to the hydraulic reservoir. When the loader is in NEUTRAL, the spool is in the center position.

There is another shuttle relief valve in the case drain line to control the amount of oil flow and to maintain pressure in the drive motor circuit. It is necessary to remove the drive motors to service the shuttle. Refer to the manufacturer’s manual for service procedures.

Fig. 7-7

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7-8

Location of two of four hydrostatic pump relief valves. Two more are located on the top side of the pump.

PRINTED IN USA

SL3640/3840/4240

HYDROSTATIC SYSTEM Hydrostatic Pump Removal and Installation The hydrostatic piston pumps are installed in tandem and mounted directly to the engine flywheel housing cover, and are supported by a cradle under the pumps. It is not necessary to remove the engine to remove the hydrostatic pump assembly (but it is recommended).

Removal Procedure

WARNING Fig. 7-8

BEFORE beginning this Service procedure, perform the following SAFETY procedures:

Location of pressure cap on hydraulic oil reservoir.

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Tilt back ROPS until lock engages.

1. Remove pressure cap from hydraulic oil reservoir to relieve any pressure. Fig. 7-8 2. Drain oil from hydraulic reservoir. Refer to the Hydraulic System chapter for the procedure.

Fig. 7-9

IMPORTANT

Locations to disconnect pump arm control rods from hydrostatic pump.

Hydraulic hoses and fittings should be capped/plugged after they are disconnected to prevent contaminants from entering the hydraulic system.

3. Disconnect hydrostatic pump arm control rods from neutral centering devices. Fig. 7-9 4. Disconnect three hoses at gear pump.

5. Support pump. Remove two capscrews and washers securing gear pump to hydrostatic pump. Pull gear pump forward and up, out of mainframe. Fig. 7-10 6. Disconnect and label hydraulic hoses connected to hydrostatic pump. Plug or cap hoses, fittings and tubes to prevent hydraulic fluid loss or contaminants from entering hydraulic system. Figs. 7-11, 7-12

Gear Pump

Fig. 7-10 Location of hardware securing the gear pump to the hydrostatic pump.

PRINTED IN USA

7. Position a hoist above the hydrostatic pump. Attach lifting strap around pump and raise hoist just enough to remove slack from hoist strap. The hoist should 7-9

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(For detailed instructions, refer to the Safety chapter of this manual.)

HYDROSTATIC SYSTEM

SL3640/3840/4240

now be prepared to support weight of hydrostatic pump.

8. Remove two capscrews (35 ft.-lbs.) (48 N•m) connecting pump support to pump flange. Fig. 7-13 9. Remove two capscrews (80 ft.-lbs.) (112 N•m) and washers securing hydrostatic pump to flywheel housing cover. Lift pump slightly to remove capscrews. Fig. 7-11 10. Pull hydrostatic pump forward to disengage splined pump shaft from drive plate and pull pump out of flywheel.

11. Lift and maneuver hydrostatic pump out of loader.

Installation Procedure* - Follow all warnings first, then reverse the removal steps. * Coat pump shaft splines (male and female) with molybdenumdisulfide (“moly”) grease.

Fig. 7-11 Hoses to remove on left side of hydrostatic pump. Arrow points to location of one of two capscrews securing hydrostatic pump to the flywheel housing cover.

IMPORTANT After removing and/or replacing any component in the hydrostatic drive system, ALWAYS prime hydrostatic pump by running engine at idle for a short time. Drive loader slowly forward and backward (with no load) until noise, caused by air in the system, stops.

Then, stop the loader and recheck the hydraulic fluid level in the reservoir. Add fluid if necessary.

Fig. 7-12 Hoses to remove on right side of hydrostatic pump.

WARNING NEVER use your hands to search for hydraulic fluid leaks. Use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

ALWAYS wear safety glasses when checking for hydraulic fluid leaks.

Escaping fluid under pressure can be invisible and cause permanent eyesight damage if safety glasses are not worn.

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Fig. 7-13 Location of capscrews at bottom of hydrostatic pump securing pump to the pump support bracket.

7-10

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HYDROSTATIC SYSTEM Hydrostatic Pump Flexible Drive Plate Removal and Installation

Flywheel Housing

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Tilt back ROPS until lock engages.

Fig. 7-14 Two capscrews securing lower pump support to flywheel housing cover.

(For detailed instructions, refer to the Safety chapter of this manual.)

Flywheel Cover

1. Disconnect any hand or foot throttle cables and engine throttle rod from pivots and weld tabs on engine mount weldment per the procedures in the Controls chapter.

Capscrews

Fig. 7-15 Location of three carriage bolts securing top of engine mount weldment to engine cross-angle brace (behind it).

Flexible Drive Plate

3. Remove two capscrews (50 ft.-lbs.) (70 N•m) and washers securing pump support to flywheel housing cover. Fig. 7-14 4. Remove three carriage bolts (80 ft.-lbs.) (112 N•m) and locknuts securing top of engine mount weldment to engine cross-angle brace. Fig. 7-15 5. Remove remaining four capscrews and lock washers securing flywheel housing cover and engine mount weldment to engine. Remove cover and weldment from loader. Fig. 7-15 6. Remove eight capscrews (18 ft.-lbs.) (24 N•m) attaching flexible drive plate to engine. Fig. 7-16 Installation Procedure - Follow all warnings first, then reverse the removal steps.

Fig. 7-16 Remove eight capscrews securing flexible drive plate to engine.

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2. Remove hydrostatic pump per the procedure in this chapter.

HYDROSTATIC SYSTEM

SL3640/3840/4240

Drive Motor Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Drain chaincase oil per the procedure in the Lubrication chapter.

Fig. 7-17 Disconnect all hydraulic hoses and tubes from drive motor to be removed.

2. Raise and block skid-steer loader so that all tires are off the ground per the procedure in the Safety chapter.

3. Perform the drive chain removal procedure in the Wheel Drives chapter.

4. Remove six capscrews on belly pan underneath loader and remove belly pan.

5. If necessary, drain oil from the hydraulic reservoir per the procedure in the Hydraulic System chapter.

NOTE: If the hydraulic hoses and tubes are plugged after removal to prevent oil leakage, it should not be necessary to drain the hydraulic reservoir. Hydraulic hoses and tubes should be plugged to prevent contaminants from entering the hydraulic system.

6. BEFORE disconnecting hydraulic hoses and tubes from drive motor, mark each hose/tube and port where it attaches to drive motor (hoses/tubes can then be correctly reattached during installation).

Disconnect all hydraulic hoses/tubes on drive motor. Fig. 7-17

Fig. 7-18 Location of four capscrews and seal washers securing drive motor to chaincase.

7. Remove four capscrews (120 ft.-lbs.) (168 N•m) (Loctite 242) and seal washers attaching drive motor to chaincase. Lower drive motor and o-ring seal through belly pan with a suitable hoist. Fig. 7-18 Installation Procedure* - Follow all warnings first, then reverse the removal steps. * Install o-ring seal on the drive motor. Fig. 7-19 Perform drive chain adjustment procedure in the Wheel Drives chapter after reinstallation of drive chains.

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Fig. 7-19 Be sure o-ring seal is on drive motor prior to reinstallation into skid-steer loader.

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HYDRAULIC SYSTEM

Introduction This chapter covers troubleshooting, testing, removal, installation, and adjustment procedures for hydraulic system components on GEHL SL36/38/4240 skid-steer loaders. The primary hydraulic system components covered in this chapter are shown below and on following pages.

auxiliary hydraulics system with connections on the left liftarm for attachment hookup.

Information on recommended hydraulic fluids, capacities and filter change intervals is in the Lubrication chapter. For detailed information on gear pump or control valve internal repair, consult the GEHL Service Department and/or the hydraulic component manufacturer’s service manual. Hydraulic components related to the drive system are covered in the Hydrostatic System chapter.

Power for the liftarm functions and auxiliary hydraulics is provided by a gear pump attached to the front of the hydrostatic pumps. Models include a standard flow

Hydraulics - Liftarm

41

27

3

26

20 18

38 19

26

7

13 10

15

13

16

21

43

7 38

2

8

3 33 4 42 17

33

34 12

9

32

28 7

17 30

34 5

24

38 4

36 37

38

40

11

5

29

7

3

36 14

10

22

1

6

30

27

23

4

28

41

3

33

2

40

19

HYDRAULICS

21

20

25

42

6

24 14

39 40

35

9

39

31 28

7 31 40

1 BRACKET/COUPLER 2 ADAPTOR/STRAIGHT 3 FITTING/ELBOW 90° 4 SCREW/CAP LOCKING 5 FITTING/TEE TUBE 6 ELBOW/SWIVEL 90° 7 NUT/LOCK 8 FITTING/90° 9 FITTING/45° 10 CLAMP/HOSE 11 COUPLER/MALE

Fig. 8-1

28

7

35

23 HYDRAULIC LINE 12 COUPLER/FEMALE 24 HOSE 13 CYLINDER/LIFT 25 HOSE 14 CYLINDER/TILT 15 HYDRAULIC LINE/OUTER 26 HOSE 16 HYDRAULIC LINE/INNER 27 PIN/PIVOT LIFT 28 PIN/PIVOT 17 HOSE/HYDRAULIC 29 PIN/PIVOT TILT 18 HOSE AND TUBE CYLINDER 19 HOSE AND TUBE 30 SCREW/CAP 20 HOSE 31 SEAL 21 LINE/LIFT CYLINDER 32 RING/SNAP 22 HYDRAULIC LINE

33 CLIP/HYDRAULIC LINE 34 CLIP/HYDRAULIC LINE 35 WASHER/SPECIAL 36 WASHER/SPECIAL 37 WASHER/SPECIAL 38 ZERK/GREASE 39 ZERK/GREASE 90° 40 SCREWCAP 41 SCREW/CAP 42 SCREW/TAPPING 43 SCREW/CAP

Assembly view of the liftarm hydraulics.

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Hydraulics - Chassis

11 46

8

33

35 35

18

15

1 8

41 45 36

10

9

14

23

16

18

31

20 35 2

2

39

3

27

35

43

28

35

43 2 35

27

3 39

22

7 28 32

34 TO LIFT TUBE

38

20 37 7

10

36

44

13

23

6

30

9

42

26

19

35

29

32

2

28

2

40

4

TO TILT TUBES

27

TO TANK

21

5

24

17

12

7 25

42

1 BRACKET/BULKHEAD 2 ADAPTER/STRAIGHT 3 FITTING/90° 4 FITTING/90° 5 FITTING/90° 6 NUT/LOCK 7 FITTING/STRAIGHT 8 FITTING/STRAIGHT 9 CLAMP/TUBE 10 FITTING/STRAIGHT 11 SWITCH/OIL TEMP 12 ADAPTER/90°

Fig. 8-2

13 FITTING/STRAIGHT 14 FITTING/TEE 15 ASSEMBLY/FILTER 16 TEE/BULKHEAD 17 VALVE/BRAKE 18 VALVE/LOCK-LIFT 19 VALVE/CONTROL 20 TUBE/LIFT LEFT 21 TUBE/LIFT TO BRAKE 22 TUBE/TANK - BRAKE 23 HOSE 24 HOSE

25 TUBE/MOTOR BRAKE 26 TUBE/BRAKE VALVE 27 TUBE/AUX UPPER 28 TUBE/AUX LOWER 29 FITTING/TEE 30 TUBE/LIFT 31 TUBE/LIFT 32 TUBE/LIFT 33TUBE/OIL FILTER 34 FITTING/TEE 35 NUT/LOCK 36 NUT/LOCK

37 TUBE/UNION 38 FITTING/TEE MALE 39 CLIP/HYDRAULIC LINE 40 PLUG/PIPE 41 BOLT/CARRIAGE 42 BOLT/CARRIAGE 43 BOLT/CARRIAGE 44 BOLT/CARRIAGE 45 BOLT/CARRIAGE 46 PLUG/PIPE

Assembly view of the chassis hydraulics.

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HYDRAULIC SYSTEM

Troubleshooting Guide The following troubleshooting guide lists potential hydraulic system problems, as well as possible causes and remedies, for GEHL SL36/38/4240 skid-steer loaders.

IMPORTANT

When a problem occurs, be sure to avoid overlooking simple causes. A malfunction could be caused by something as simple as low fluid level in the hydraulic reservoir. After a mechanical failure has been corrected, be sure to locate and correct the cause of the problem.

Problem

Possible Cause

Remedy

Lift/tilt controls fail to respond.

Hydraulic oil viscosity is too heavy.

Allow longer warm-up or replace with proper viscosity oil.

Solenoid valve(s) malfunctioning.

Check electrical connections to lift solenoid and repair connections as needed. Perform “Solenoid Valve Test." Replace solenoid as needed.

Hydraulic oil level is low.

Check oil level in reservoir. If oil is low, check for an external leak. Repair and add oil.

Hydraulic oil flow to the gear pump is blocked.

Inspect suction hose. Clean or replace as needed.

System relief valve is malfunctioning.

Perform “Control Valve Relief Pressure Test." Adjust or replace relief valve as needed.

Drive is disconnected.

Check for broken or worn pump drive coupling and replace as needed.

Sheared spline or broken shaft in hydrostatic pump assembly.

Check splined shaft of pump closest to engine. Replace shaft if broken or if splines are sheared.

Sheared spline or broken shaft in gear pump.

Remove gear pump from hydrostatic pump, inspect the splined shaft and coupler. Replace components as needed.

Restraint bar switch or seat switch not closing.

Check switches and wiring. Replace as needed.

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DO NOT attempt to service or repair major hydraulic system components, such as the gear pump, unless authorized to do so by your GEHL dealer/distributor. Any unauthorized repair will void the warranty.

If you cannot locate a particular hydraulic system problem in this chart, also consult the Hydrostatic System chapter troubleshooting chart.

HYDRAULIC SYSTEM

SL3640/3840/4240

Problem

Possible Cause

Remedy

Hydraulic cylinder action is slow for lift/tilt functions.

Low engine speed.

Operate engine at higher speed.

Hydraulic oil viscosity is too heavy.

Allow longer warm-up or replace existing oil with proper viscosity oil.

Hydraulic oil leaking past cylinder piston seals.

Perform “Tilt Cylinder Test” and /or “Lift Cylinder Test." Replace cylinder seals and o-rings as needed.

Control linkage is not fully activated.

Perform “Lift/Tilt Control Adjustment” procedure in controls chapter.

Worn gear pump.

Check oil flow at high idle.

Lift solenoid valve malfunctioning.

Check electrical connections to lift solenoid and repair connections as needed. Perform “Solenoid Valve Test."

Replace solenoid as needed.

Relief valve in control valve not Perform “Control Valve Relief Pressure functioning properly. Squealing noise Test." Adjust or replace relief valve as should be evident. needed.

Liftarm does not raise, bucket tilt works properly.

Lift solenoid valve malfunctioning.

Check electrical connections to lift solenoid and repair connections as needed. Perform “Solenoid Valve Test."

Replace solenoid as needed.

Lift spool in control valve not actuated or leaking.

Check hose or tube connection to valve.

Check pressure and flow.

Jerky liftarm and bucket action. Restraint bar switch or seat switch malfunction.

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Check electrical connections to the switch. (See mainframe chapter) Replace switch as needed.

Air in the hydraulic system.

Cycle lift and tilt cylinders to maximum stroke and maintain pressure for short time to clear air from system.

Oil in hydraulic reservoir low.

Check and add oil to reservoir as needed.

Liftarm cushions faulty.

Check seals in liftarm cylinders.

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Problem

HYDRAULIC SYSTEM

Possible Cause

Remedy

Liftarm doesn’t maintain Oil leaking past lift cylinder seals raised position with lift control (internal or external). in NEUTRAL.

Perform “Lift Cylinder Test." Also check condition of cylinder tube bore.

Replace seals or cylinder tube as needed.

Liftarm will not lower or raise.

Bucket drifts downward with tilt control in NEUTRAL.

Liftarm will not raise a heavy load or any load at all.

PRINTED IN USA

Self-leveling valve is malfunctioning.

Repair or replace as needed.

Leaking hydraulic hoses, tubes, or fittings between control valve and cylinders.

Inspect hoses and tubes, tighten fittings as needed. Replace hoses or tubes as needed.

Lift cylinder liftarm support device engaged.

Raise liftarm and disengage the liftarm support device.

Lift solenoid valve is malfunctioning.

Perform “Solenoid Valve Test." Check electrical connections to solenoid.

Repair or replace as needed.

Restraint bar not lowered.

Lower restraint bar.

Restraint bar switch or seat switch malfunction.

Check electrical connections to the switch. Replace switches as needed.

Oil leaking past tilt cylinder seals (external or internal).

Perform “Tilt Cylinder Test." Also check condition of cylinder tube bore.

Replace seals, o-rings, and/or cylinder as needed.

Self-leveling valve is malfunctioning.

Repair or replace as needed.

Leaking hydraulic hoses, tubes, or fittings between control valve and cylinders.

Inspect hoses and tubes, tighten fittings as needed. Replace hoses or tubes as needed.

Relief valve in the control valve is malfunctioning. Squealing noise should be evident.

Perform “Control Valve Relief Pressure Test." Adjust or replace relief valve as needed.

Lift port relief in the control valve is malfunctioning. Squealing noise should be evident.

Replace lift port relief or contact the Gehl Service Department.

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Oil leaking past lift spool in control valve. Check valve body for scores or cracks.

Replace control valve as needed.

HYDRAULIC SYSTEM

Problem

SL3640/3840/4240

Possible Cause

Remedy

No downward pressure on the Control valve in “float” position. bucket.

Tilt cylinders are malfunctioning.

Take control out of “float” position.

Perform “Tilt Cylinder Test." Also check condition of cylinder tube bore. Replace seals, O-rings, and/or cylinder tube as needed.

Relief valve in control valve not functioning properly. Squealing noise should be evident.

Perform “Control Valve Relief Pressure Test." Adjust or replace relief valve as needed.

Bucket does not level on the lift cycle.

Self-leveling valve misadjusted or malfunctioning.

Perform “Self-Leveling Valve Adjustment." If adjustment fails to correct problem, repair or replace self-leveling valve as needed.

Bucket will not tilt, liftarms work properly.

Tilt solenoid valve is malfunctioning.

Check electrical connections to tilt solenoid and repair connections as needed. Perform “Solenoid Valve Test." Replace solenoid as needed.

Tilt spool in control valve not actuated or leaking.

Check hose or tube connection to Valve. Check pressure and flow.

Restraint bar is raised.

Lower the restraint bar.

Lock solenoid is malfunctioning.

Check electrical connections to lock solenoid valve and repair connections as needed. If lock solenoid still does not operate properly, contact your dealer.

Restraint bar switch is malfunctioning.

Check electrical connections to restraint bar switch and repair connections as needed. If switch still does not operate properly, contact your dealer.

Auxiliary hydraulics do not function.

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HYDRAULIC SYSTEM System Pressure Test - Control Valve The control valve on the skid-steer loader controls lift and tilt functions of the liftarm and auxiliary hydraulics.

It is located on the right side of the mainframe. The relief valve (Figs. 8-3, 8-4) inside the control valve can be tested by taking a pressure reading at the auxiliary hydraulics coupler on the liftarm.

Test Procedure

WARNING Fig. 8-3

BEFORE beginning this service procedure, perform the following SAFETY procedures:

Location of the relief valve on the main control valve. View from rear of loader.

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Relieve hydraulic system pressure.

(For detailed instructions, refer to the Safety chapter of this manual.)

To prevent contamination, ALWAYS clean the area around the hydraulic fittings before disconnecting any hydraulic plug, hose or tube.

Fig. 8-4

Location of the relief valve on the main control valve. View from top of control valve.

1. What you’ll need: an assistant and a minimum 5000 PSI (345 bar) pressure gauge.

2. Install pressure gauge in male coupler end and activate auxiliary hydraulic to pressurize the line.

Fig. 8-5 3. Climb into operator’s seat, lower restraint bar.

4. Depress brake switch to leave parking brakes locked and start loader engine. For the test, engine should be running at HIGH idle. Have an assistant read pressure gauge.

5. Using the tilt control handle, roll bucket all the way back. Hold tilt control handle in this position.

Fig. 8-5

6. Have assistant observe pressure reading on gauge.

The pressure reading should be at least 2450 PSI (169 bar), but NOT more than 2550 PSI (176 bar).

Install a pressure gauge on liftarm to measure system pressure.

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IMPORTANT

HYDRAULIC SYSTEM

SL3640/3840/4240

7. If pressure reading is NOT between 2450 PSI (169 bar) and 2550 PSI (176 bar), adjust pressure as follows:

WARNING

Locknut

BEFORE continuing this service procedure, perform the following SAFETY procedures:

q Shut off the engine. q Tilt back ROPS until lock engages.

Adjuster Screw

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 8-6

Close-up view of relief valve on the main control valve.

Fig. 8-7

View of both wrenches (9/16" and 1/2") on the main control valve relief valve.

Fig. 8-8

Test system pressure at the relief valve of the main control valve.

a. With a 9/16" box wrench, through an opening under the right front engine mount, loosen locknut on control valve adjuster screw. Figs.

8-6, 8-7, 8-8 b. With a 1/2" socket wrench, turn adjuster screw IN to increase pressure or OUT to decrease pressure. Figs. 8-6, 8-7, 8-8 c. Repeat steps 3 through 6. d. Once pressure is within the 2550-2450 PSI (176-169 bar) range, with 2500 PSI (172 bar) optimum setting, tighten locknut on control valve adjuster screw to secure adjustment.

8. If after the adjustment there is NO CHANGE in the pressure reading, this indicates a defective hydraulic gear pump or relief valve cartridge (on the control valve). To determine which is the cause, first replace the relief valve cartridge. If the pressure reading still does not change, the hydraulic gear pump should be repaired or replaced.

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SL3640/3840/4240

HYDRAULIC SYSTEM Tilt Cylinder Test If the bucket (or attachment) settles down with the tilt control in the NEUTRAL position, first check the tilt cylinders for external leakage. If external leakage is evident, a new seal kit should be installed in the leaking cylinder(s). If NO external leakage is evident, check the tilt cylinders for internal leakage according to the following procedure.

Fig. 8-9

NOTE: When checking the bucket for settling, the ignition key MUST BE ON, with an operator in the seat, and the restraint bar lowered. The maximum allowable tilt cylinder circuit settling with a loaded bucket is 0.88" (22 mm) of cylinder extension in ten minutes.

For the tilt cylinder test, load a bucket with dirt, gravel or sand to begin the test.

Test Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Shut off the engine. q Relieve hydraulic system pressure.

IMPORTANT To prevent contamination, ALWAYS clean the area around the hydraulic fittings before disconnecting any hydraulic plug, hose or tube.

Fig. 8-10 Location of the lower hydraulic hose on the left tilt cylinder.

1. What you’ll need: an assistant, tee fitting and a minimum 5000 PSI (345 bar) pressure gauge.

2. Checking one tilt cylinder at a time, install tee fitting with pressure gauge between hydraulic hose and rod end of tilt cylinder circuit.

3. With liftarm lowered, start engine and roll bucket all the way back.

4. Lower bucket four to six inches at cutting edge and shut off engine. Turn ignition key to ON position (with engine OFF) and operate tilt control in both directions.

Fig. 8-11 Location of the lower hydraulic hose on the right tilt cylinder.

PRINTED IN USA

5. Add weight to bucket until pressure gauge reads 1000 PSI (69 bar). Measure distance between rod end of cylinder barrel and All-Tach™ pin.

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(For detailed instructions, refer to the Safety chapter of this manual.)

HYDRAULIC SYSTEM

SL3640/3840/4240

6. Wait ten minutes and measure that distance again.

The maximum allowable tilt cylinder circuit settling with a loaded bucket is 0.88" (22 mm) of cylinder extension in ten minutes.

9. To determine if either the control valve or the self-leveling valve is faulty and causing the bucket to settle, perform the “Self-Leveling Valve Test” procedure in this chapter.

7. If bucket settles, the blocked tilt cylinder has leaking seals. If it DOES NOT settle, reconnect hydraulic hose to tilt cylinder, and then test the other tilt cylinder in the same way, repeating steps 2-6.

8. Once both tilt cylinders have been tested, BE SURE hydraulic hoses are reconnected.

NOTE: If both tilt cylinders have good seals, and the bucket still settles, the fault could be in either the control valve or the self-leveling valve. Continue the procedure with step 9 below. Also, refer to the Troubleshooting Guide in this chapter.

Hydraulics - Self-Leveling 9

1 FITTING/STRAIGHT 2 NUT/LOCK 3 FITTING/90° 4 FITTING/TEE 5 UNION/HYDRAULIC FITTING 6 VALVE/SELF-LEVEL 7 TUBE/CONTROL VALVE/LIFT 8 TUBE/SELF-LEVEL TOP 9 TUBE/SELF-LEVEL BOTTOM 10 ADAPTER/SWIVEL 11 BOLT/CARRIAGE

5 8

6 11

1

4

2

7

10

3

Fig. 8-12 Assembly view of the self-leveling hydraulics.

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HYDRAULIC SYSTEM Self-Leveling Valve Test Test Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

Battery

Fig. 8-13 Loosen the jam nut on the self-leveling valve adjuster screw.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Open engine access cover and rear grille.

2. Loosen jam nut on self-leveling valve adjuster screw. Fig. 8-13 NOTE: For step 3, BE SURE to count and write down the number of turns so the adjuster screw can be returned to its original setting after the test.

4. Perform steps 2-6 in the “Tilt Cylinder Test” procedure. If bucket no longer settles, the self-leveling valve is defective. If bucket continues to settle, the control valve is defective and in need of repair or replacement.

Fig. 8-14 Self-leveling valve adjusted with an Allen wrench.

PRINTED IN USA

5. Refer to the “Self-leveling Valve Adjustment” procedure in this chapter for correct adjustment of the self-leveling valve.

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3. With an Allen wrench, turn adjuster screw in (clockwise) until it bottoms out. The self-leveling valve is now disabled and won’t have an effect on tilt operations. Fig. 8-14

HYDRAULIC SYSTEM

SL3640/3840/4240

Self-Leveling Valve Adjustment Adjustment Procedure 1. Raise and lower liftarm several times to ensure there is no air in hydraulic system.

2. Lower liftarm completely then fully retract tilt cylinders (roll back).

3. Raise liftarm to its maximum height, then lower it to the ground. Fig. 8-15 4. Measure how far tilt cylinder rod extends from tilt cylinder. The distance should be between 8-1/4 and 8-1/2” (209.5-216 mm). If measurement is outside this range, the self-leveling valve needs to be adjusted according to steps 5-9 of this procedure.

Fig. 8-16

Fig. 8-15 Liftarm raised to its maximum height.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures:

q Shut off the engine. q Surfaces inside engine compartment may be extremely hot, particularly engine muffler and exhaust pipes. Serious injury may occur from touching components which have become hot while the engine was running.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 8-16 The tilt cylinder rod measurement should be between 8-1/4” and 8-1/2” (209.5 - 216 mm).

5. Open rear grille to access self-leveling valve on right riser.

6. Hold adjuster screw with Allen wrench while loosening adjuster screw locknut.

7. Insert an Allen wrench into adjuster screw and adjust valve. Turn adjuster screw IN (clockwise) to shorten cylinder extension. Turn adjuster screw OUT (counterclockwise) to lengthen cylinder extension.Fig. 8-14

10. Once adjustment is complete, tighten adjuster screw locknut while holding adjuster screw with Allen wrench.

8. To check for proper operation, climb into operator’s seat, lower restraint bar and start engine.

9. Repeat steps 2 through 4 above to check for proper operation of self-leveling valve. If further adjustment is needed, perform safety procedures again and repeat steps 5 through 7.

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HYDRAULIC SYSTEM Lift Cylinder Test If the liftarm settles with the lift control in NEUTRAL position, and the ignition key OFF, first check the lift cylinders for external leakage. If external leakage is evident, a new seal kit should be installed in the leaking cylinder(s). If NO external leakage is evident, check the lift cylinders for internal leakage according to the following procedure.

NOTE: When checking liftarm for settling, the ignition key MUST BE OFF. The maximum allowable lift cylinder settling is 0.75" (19 mm) of cylinder extension in ten minutes.

Fig. 8-17 Location of hose to remove on base end of lift cylinder.

Test Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Shut off the engine. q Relieve hydraulic system pressure.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 8-18 Raise liftarm approximately 5” (127 mm).

2. Checking one lift cylinder at a time, install tee fitting with pressure gauge between hydraulic hose and base end of lift cylinder circuit. Fig. 8-17 3. With liftarm lowered, start engine and roll bucket all the way back.

4. Raise liftarm 5.00” (127 mm) and shut off engine.

Turn ignition key to ON position (with engine OFF) and operate lift control in both directions. Fig. 8-18 5. Add weight to bucket until pressure gauge reads 1000 PSI (69 bar). Measure distance between cylinder barrel and center of cylinder liftarm pin.

Fig. 8-19 6. Wait ten minutes and measure that distance again.

The maximum allowable lift cylinder circuit settling with a loaded bucket is 0.75" (19 mm) of cylinder extension in ten minutes.

Fig. 8-19 Measure the distance between the cylinder barrel and center of liftarm pin.

PRINTED IN USA

NOTE: If neither lift cylinder shows signs of external or internal leakage, and the liftarm still settles, the problem could be due to leaking hydraulic hose fittings between the control valve and the lift cylinders. Check 8-13

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1. What you’ll need: an assistant, tee fitting and a minimum 5000 PSI (345 bar) pressure gauge.

HYDRAULIC SYSTEM

SL3640/3840/4240

all hydraulic hose fittings thoroughly. The fault could also be in either the control valve or the self-leveling valve. Continue the procedure with step 9. Also refer to the Troubleshooting Guide in this chapter.

7. The other lift cylinder may be checked in the same manner by repeating steps 2-6.

8. Once both tilt cylinders have been tested, BE SURE hydraulic hoses are reconnected.

9. To determine if either the control valve or the self-leveling valve is faulty, perform the “Self-Leveling Valve Test” procedure in this chapter.

Fig. 8-20 Location of the lift solenoid.

Solenoid Valve Test During normal operations, solenoid valves should prevent operation of liftarm and drive functions if any one of the safety interlocks are open. For example: Ü Operator not sitting on seat. Ü Restraint bar not lowered in front of operator.

Test Procedure 1. Climb into operator’s seat, lower restraint bar and start engine.

Self-Level Valve

2. Using lift control, raise liftarm high enough that bucket can be tilted.

3. Raise restraint bar, then use lift, tilt and drive controls (one at a time) to see if any operate.

Fig. 8-21 Location of the tilt solenoid.

a. If the liftarm can be raised or lowered, the lift solenoid is malfunctioning. Fig. 8-20 b. If the bucket can be tilted, the tilt solenoid is malfunctioning. Fig. 8-21 c. If the loader can be moved, the brake solenoid is malfunctioning. Fig. 8-22

Fig. 8-22 Location of the brake solenoid.

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HYDRAULIC SYSTEM 4. If any solenoid appears to be malfunctioning, test the solenoid coil as follows:

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedure:

q Raise liftarm; engage liftarm support device.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 8-23 Lift solenoid test with metal ruler.

a. Have an assistant sit on operator’s seat, lower restraint bar and turn keyswitch to ON position.

DO NOT start engine. b. Using a thin strip of steel (such as a pocket ruler), check suspected solenoid by moving steel strip close by. Fig. 8-23, 8-24, 8-25 c. If steel strip is magnetically attracted to solenoid coil, coil works and solenoid cartridge may be causing malfunction.

HYDRAULICS

5. For service procedures, refer to “Solenoid Valve Removal and Installation/Disassembly and Reassembly” procedure in this chapter.

Fig. 8-24 Tilt solenoid test with metal ruler.

Fig. 8-25 Brake solenoid test with metal ruler.

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Hydraulic Oil Filter Element Replacement Replacement Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Lift engine access cover and open rear grille. Fig. 8-26

Fig. 8-26 Location of hydraulic oil filter element.

2. Use a filter wrench, turn element counterclockwise to remove it from filter head. Fig. 8-27 3. Install correct capacity filter element (refer to GEHL Service Parts Manual). BEFORE installation, apply a light coat of oil to new element gasket, then install it on filter head. Fig. 8-28 4. Hand tighten element until gasket contacts filter head, then turn element another 3/4 turn to seat gasket.

5. If needed, refill the hydraulic reservoir. Refer to the Lubrication chapter in this manual for hydraulic fluid requirements and specifications.

Fig. 8-27 Filter wrench on hydraulic oil filter element.

WARNING NEVER use your hands to search for hydraulic fluid leaks. Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

Oil Seal

ALWAYS wear safety glasses when checking for hydraulic fluid leaks.

Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

Fig. 8-28 Apply a light coat of oil on the filter oil seal.

6. ALWAYS check for hydraulic fluid leaks after assembling components of the hydraulic system.

917170/AP0106

8-16

PRINTED IN USA

SL3640/3840/4240

HYDRAULIC SYSTEM

Hydraulics - Auxiliary

8 4 2 5 1

7 10

1

3

TO TANK

9 6

12

SEE NOTE 12

3

HYDRAULICS

NOTE: APPLY LOCTITE 242 TORQUE TO 30 FT/LBS

11

1 CLAMP/HOSE 2 FITTING/90° 3 FITTING/STRAIGHT 4 HYDRAULIC HOSE AND TUBE 5 FITTING/90° 6 PUMP/DOUBLE GEAR 7 HOSE/SUCTION 8 HYDRAULIC HOSE/TUBE 9 ADAPTOR 45° 10 O-RING 11 SCREW/CAP 12 WASHER/LOCK

Fig. 8-29 Assembly view of auxiliary hydraulics.

PRINTED IN USA

8-17

917170/AP0106

HYDRAULIC SYSTEM

SL3640/3840/4240

Hydraulics - Chassis

1

1 2

2

T-BAR

1

1 PLUG 2 TUBE/CONTROL VALVE/LIFT 2

HAND/FOOT

1 TUBE/TILT UPPER 2 TUBE/TILT TLOWER

Fig. 8-30 Assembly view of chassis hydraulic components.

917170/AP0106

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PRINTED IN USA

SL3640/3840/4240

HYDRAULIC SYSTEM Tilt Cylinder Removal and Installation Removal Procedure NOTE: Refer to “Liftarm Removal and Installation” procedure in the Mainframe chapter for help on removing the complete liftarm group, including the tilt cylinders.

1. Remove bucket or attachment.

2. With engine running, lower liftarm until it is in contact (or near contact) with liftarm stops (on front of mainframe).

Fig. 8-31 Remove upper tilt cylinder hoses.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures:

q Shut off the engine. q Relieve hydraulic system pressure.

(For detailed instructions on the above, refer to the Safety chapter in this manual.)

4. Disconnect upper and lower tilt cylinder hoses from tee fittings on crossmember. BE SURE to install plugs in hoses and cap fittings to prevent fluid loss and contamination of hydraulic system. Figs. 8-31, 8-32 Fig. 8-32 Remove lower tilt cylinder hoses.

NOTE: To aid in correct reassembly of hydraulic hoses, mark the hoses to be removed BEFORE disconnection in step 4.

5. Support the weight of the tilt cylinder and remove capscrew and locknut securing lower tilt cylinder pivot pin. Then drive pivot pin out to release rod end of tilt cylinder. Figs. 8-33, 8-34 6. Loosen capscrew on upper tilt cylinder pin by two to three counterclockwise turns. Strike bolt head to drive pin into liftarm to break pin free of the taper.

Remove capscrew and washer. Remove upper tilt cylinder pin while supporting tilt cylinder and remove tilt cylinder. Fig. 8-35 7. Remove tilt cylinder from upper tilt cylinder pin.

Fig. 8-33 Remove capscrew and locknut securing lower tilt cylinder pin to the attachment bracket.

PRINTED IN USA

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917170/AP0106

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3. Support attachment bracket with suitable hoist.

HYDRAULIC SYSTEM

SL3640/3840/4240

Installation Procedure 1. Install base end of tilt cylinder on liftarm pivot pin.

Use Loctite® 242 or equivalent on capscrew before reinstalling with washer and torque to 80 ft.-lbs.

(107 N•m). Fig. 8-36 2. Position rod end of tilt cylinder (with grease fitting facing inward) and insert pivot pin through cylinder and attachment mount. Secure pivot pin with a capscrew and locknut. Figs. 8-33, 8-34 3. Remove plugs/caps and attach upper and lower tilt cylinder hoses to cylinders according to markings made at removal. Figs. 8-31, 8-32 NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter in this manual for hydraulic fluid requirements and specifications.

Fig. 8-34 Drive lower tilt cylinder pin out of cylinder attachment bracket.

WARNING NEVER use your hands to search for hydraulic fluid leaks. Use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once.

Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

Fig. 8-35 Remove upper tilt cylinder pin and tilt cylinder together.

ALWAYS wear safety glasses when checking for hydraulic fluid leaks.

Escaping fluid under pressure can be invisible and cause permanent eyesight damage or loss if safety glasses are not worn.

4. ALWAYS check for hydraulic fluid leaks after assembling components of the hydraulic system.

5. Remove the hoist.

Fig. 8-36 Use a plastic hammer and seat the base end of the tilt cylinder over the upper tilt cylinder pin in the knee of the liftarm.

917170/AP0106

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PRINTED IN USA

SL3640/3840/4240

HYDRAULIC SYSTEM Lift Cylinder Removal and Installation Removal Procedure 1. Remove any bucket or attachment.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures:

Hose Clamp

q Shut off the engine. q Relieve hydraulic system pressure.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 8-37 Location of hydraulic hose and tube to remove on base end of lift cylinder prior to removal.

2. Attach a suitable hoist to attachment bracket and raise liftarm to a position where access to tubes and hoses on lift cylinder is maximized.

3. Remove clamp securing hydraulic tube to lift cylinder. Fig. 8-37

4. Disconnect one hydraulic tube and hose on lift cylinder. BE SURE to install plugs/caps in hoses/tubes to prevent fluid loss and contamination of hydraulic system. Figs. 8-37, 8-38 Fig. 8-38 Location of hydraulic tube to remove on rod end of lift cylinder prior to removal.

5. Remove capscrew and locknut securing rod end lift cylinder pivot pin. Drive pivot pin out to release rod end of lift cylinder. Fig. 8-39 6. Open engine access cover and rear grille.

Self-Level

Fig. 8-39 Location of capscrew and locknut securing rod end lift cylinder pivot pin in liftarm.

PRINTED IN USA

Fig. 8-40 Location of capscrew and locknut securing base end lift cylinder pivot pin in riser.

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NOTE: To aid in correct reassembly of hydraulic hoses/tubes, mark the hoses/tubes to be removed BEFORE removal in step 4.

HYDRAULIC SYSTEM

SL3640/3840/4240

7. Support weight of lift cylinder and remove capscrew and locknut securing base end lift cylinder pivot pin in riser (mainframe). Drive pivot pin outward of mainframe. Remove lift cylinder from mainframe. Fig. 8-40

NOTES

8. Remove fittings and any o-rings from cylinder.

Installation Procedure 1. Attach a suitable hoist to attachment bracket and raise liftarm to a position where access to tubes and hoses on lift cylinder is maximized.

2. Install lift cylinder on liftarm/mainframe so rod end is forward (grease fitting face down) and hydraulic tube ports on lift cylinder face up.

3. Insert rear and front pivot pins through lift cylinder pivots and secure with capscrews and locknuts.

4. Remove plugs/caps and connect hydraulic hose and tube to port fittings on lift cylinder according to markings made at removal.

5. Secure tube to lift cylinder with hose clamp.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter in this manual for hydraulic fluid requirements and specifications.

WARNING NEVER use your hands to search for hydraulic fluid leaks. Use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once.

Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

ALWAYS wear safety glasses when checking for hydraulic fluid leaks.

Escaping fluid under pressure can be invisible and cause permanent eyesight damage if safety glasses are not worn.

6. ALWAYS check for hydraulic fluid leaks after assembling components of the hydraulic system.

917170/AP0106

8-22

PRINTED IN USA

SL3640/3840/4240

HYDRAULIC SYSTEM Lift and Tilt Cylinder - Disassembly and Assembly The lift cylinders have a built-in cushion, which slows the travel of the cylinder as it nears the end of its stroke.

Nicks or burrs on a cylinder shaft can cause seal damage in the gland, which can cause external leaks. Shaft inspection can detect damage early before it becomes large enough to damage seals.

Disassembly Procedure 1. Remove lift or tilt cylinder from loader. See the corresponding procedure in this chapter.

Fig. 8-41 Location of set screw on collar of cylinder.

2. Purge oil from cylinder by facing ports downward, and pumping cylinder rod back and forth several times.

3. Use an Allen wrench to loosen set screw on cylinder collar. Fig. 8-41 4. Clamp rod end in a vise and slide cylinder onto shaft to prevent cylinder tube from turning.

5. Use a clamp or pipe wrench to remove collar from cylinder tube. Fig. 8-42 6. Remove rod assembly and inspect cylinder rod and tube for dents or nicks that may cause damage to o-rings and seals. Fig. 8-43

8. Remove piston assembly. Fig. 8-43 Fig. 8-42 Use pipe wrench to loosen collar from cylinder barrel.

9. Slide head gland, seals, and o-rings off cylinder rod and inspect for wear.

10. Change seals as needed. Refer to lift or tilt cylinder assembly views for reassembly order.

Piston

Head Gland

NOTE: Soaking seals in warm water prior to installation will make them pliable and easier to install.

However, BE SURE to dry them and coat with hydraulic oil for proper installation.

Assembly Procedure 1. Slide collar onto cylinder rod (threaded end of collar should face threaded end of cylinder rod).

Cylinder Rod

2. Slide head gland, larger diameter first, onto cylinder rod.

3. Install piston on cylinder rod.

Fig. 8-43 View of piston assembly.

PRINTED IN USA

4. Secure head gland and piston on cylinder rod with a washer and locknut. The locknut should be torqued to 225 ft.-lbs. (305 N•m).

8-23

917170/AP0106

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7. Loosen and remove locknut that secures head gland, seal kit, and piston on cylinder rod.

HYDRAULIC SYSTEM

SL3640/3840/4240

5. Install cylinder rod into tube.

Gear Pump

6. Slide collar down to cylinder tube, thread it onto tube and tighten with a chain clamp wrench. Tighten set screw on collar and torque to 79 ft.-lbs. (107 N•m).

7. Install cylinder on loader. See “Lift Cylinder Installation” or “Tilt Cylinder Installation” procedures in this chapter.

Gear Pump Removal and Installation Removal Procedure Fig. 8-44 Location of three hoses to remove from gear pump.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Relieve hydraulic system pressure. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Drain hydraulic oil per the procedure in the Lubrication chapter.

2. Loosen hose clamp on suction line. Pull hose off beaded insert. Plug hose and cap insert. Fig. 8-44

Fig. 8-45 Location of two capscrews securing gear pump to hydrostatic pump.

3. Disconnect two hydraulic hoses from fittings on left gear pump. Fig. 8-44 NOTE: Cap or plug hydraulic hoses and fittings to prevent fluid loss/contamination of hydraulic system.

4. Remove two capscrews and lock washers attaching gear pump to hydrostatic pump. Fig. 8-45 5. Pull gear pump forward and out of hydrostatic pump. BE CAREFUL not to lose o-ring. Fig. 8-46

Installation Procedure 1. Install o-ring on mating surface of gear pump. Fig. 8-46 2. Attach gear pump to hydrostatic pump (BE SURE gear pump shaft engages splined coupler). Install 917170/AP0106

Fig. 8-46 Location of o-ring on gear pump mating surface.

8-24

PRINTED IN USA

SL3640/3840/4240

HYDRAULIC SYSTEM

two lock washers and capscrews with Loctite® 242 applied to secure gear pump to hydrostatic pump.

NOTES

3. Remove caps or plugs and connect hydraulic hoses to gear pump.

4. Install new hydraulic oil filter per the procedure in this chapter.

5. Replace hydraulic oil drained out of reservoir in step 1 of removal procedure.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for hydraulic fluid requirements and specifications.

WARNING NEVER use your hands to search for hydraulic fluid leaks. Use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once.

Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

HYDRAULICS

ALWAYS wear safety glasses when checking for hydraulic fluid leaks.

Escaping fluid under pressure can be invisible and cause permanent eyesight damage if safety glasses are not worn.

6. ALWAYS check for hydraulic fluid leaks after assembling components of the hydraulic system.

PRINTED IN USA

8-25

917170/AP0106

HYDRAULIC SYSTEM

SL3640/3840/4240

Self-Leveling Valve Removal and Installation

Self-Leveling Valve

Removal Procedure Locknut

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Shut off the engine. q Relieve hydraulic system pressure.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 8-47 Disconnect electrical harness prior to self-leveling valve removal.

IMPORTANT Cap or plug hydraulic hoses and fittings after disconnecting to prevent fluid loss and contamination of the hydraulic system.

1. Open engine access cover and rear grille.

2. Disconnect rear grille electrical harness and move harness out of the way. Fig. 8-47 3. Disconnect five hydraulic tubes from hydraulic fittings on self-leveling valve. Two of them connect at tee fitting. Figs. 8-48, 8-49 NOTE: To aid in correct reassembly of hydraulic hoses/tubes, mark the hoses/tubes to be removed BEFORE removal in step 3.

4. Loosen bulkhead nut at retainer bracket directly beneath the self-leveling valve. Fig. 8-49

Fig. 8-48 Location of three of five hydraulic tubes to remove from self-leveling valve. The other two tubes (see Fig. 8-49) are connected at a tee fitting directly beneath the self-leveling valve.

5. Remove two locknuts securing self-leveling valve to mainframe. Fig. 8-47 6. Pull self-leveling valve off carriage bolts.

7. If replacing, remove fittings from valve ports.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for fluid requirements and specifications.

Installation Procedure* - Follow all warnings first, then reverse the removal steps. *ALWAYS check for hydraulic fluid leaks after assembling any components of the hydraulic system.

917170/AP0106

Hydraulic Tubes

Fig. 8-49 Location of bulkhead nut securing tee fitting to bulkhead retainer.

8-26

PRINTED IN USA

SL3640/3840/4240

HYDRAULIC SYSTEM Safety Lock Valves - Removal and Installation GEHL SL36/38/4240 skid-steer loaders are equipped with separate electric safety lock valves for the lift, tilt and drive functions of the hydraulic system. The lift solenoid is located behind the ROPS. The tilt solenoid is located on the right side of the mainframe near the self-leveling valve. The brake solenoid is located on the inside left mainframe fender.

Removal Procedure

WARNING

Fig. 8-50 Lift safety lock valve.

BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support device.

q Shut off the engine. q Relieve hydraulic system pressure. q Tilt back ROPS until lock engages.

IMPORTANT Cap or plug ALL hydraulic hoses, tubes, fittings, and control valve ports immediately after they are disconnected to prevent fluid loss and contamination of the hydraulic system.

Fig. 8-51 Tilt safety lock valve.

Oil Temp. Switch

1. Lift Safety Lock Valve Removal: Disconnect electrical connector from solenoid coil. Disconnect four hydraulic tubes attached to solenoid. Remove two locknuts securing solenoid to mainframe. Pull solenoid off carriage bolts. Fig. 8-50 2. Tilt Safety Lock Valve Removal: Disconnect electrical connector from solenoid coil. Disconnect two hydraulic tubes and two hydraulic hoses attached to solenoid. Remove two locknuts securing solenoid to mainframe. Pull solenoid off carriage bolts. Fig. 8-51 Fig. 8-52 Brake safety lock valve.

PRINTED IN USA

3. Brake Solenoid Valve Removal: Disconnect electrical connector on solenoid coil and oil temperature switch. Remove four hydraulic tubes 8-27

917170/AP0106

HYDRAULICS

(For detailed instructions, refer to the Safety chapter of this manual.)

HYDRAULIC SYSTEM

SL3640/3840/4240

and one hydraulic hose attached to solenoid.

Remove two locknuts securing solenoid to mainframe. Pull solenoid off carriage bolts. Fig. 8-52

NOTES

Installation Procedure - Follow all warnings first, then reverse the removal steps.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for hydraulic fluid requirements and specifications.

WARNING NEVER use your hands to search for hydraulic fluid leaks. Use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once.

Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

ALWAYS wear safety glasses when checking for hydraulic fluid leaks.

Escaping fluid under pressure can be invisible and cause permanent eyesight damage if safety glasses are not worn.

4. ALWAYS check for hydraulic fluid leaks after assembling any component of the hydraulic system.

917170/AP0106

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PRINTED IN USA

SL3640/3840/4240

HYDRAULIC SYSTEM

Solenoid Coil

Lift, Tilt and Brake Safety Lock Valves Disassembly and Assembly Lift, tilt and brake safety lock valves can be removed from the loader for parts replacement, but may not be necessary. If it is necessary, refer to the procedure in this chapter.

Disassembly Procedure 1. Remove the nut that secures the coil to the cartridge.

The coil can then be removed from the cartridge.

Fig. 8-53

Coil Retaining Nut

Cartridge

Fig. 8-53 Solenoid valve components.

2. Unscrew cartridge from the valve body. Fig. 8-54 3. Install seal kit (or other new parts). Assemble solenoid valve in reverse order of disassembly. Fig. 8-55

IMPORTANT DO NOT torque coil retaining nut more than 45 in.-lbs. (5,1 N•m).

4. If removed from the loader, install the lift or tilt solenoid on the hydraulic system. Refer to the procedure in this chapter.

HYDRAULICS

Valve Body

Fig. 8-54 Solenoid cartridge removed from the valve body.

O-Ring

Backup Rings

Fig. 8-55 Detail drawing of backup rings and o-ring on solenoid valve cartridge.

PRINTED IN USA

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917170/AP0106

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SL3640/3840/4240

Control Valve Removal and Installation The main hydraulic control valve is located on the right side of the mainframe, in front of the engine. The control valve ports have been numbered for reference.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support

Fig. 8-56 Disconnect control rods from main control valve spools (Hand/Foot models).

device.

q Shut off the engine. q Relieve hydraulic system pressure. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

Locknut

1. If necessary, drain oil from hydraulic reservoir per the procedure in the Lubrication chapter.

NOTE: If hydraulic hoses and tubes are plugged to prevent oil leakage, it should not be necessary to drain hydraulic reservoir. BE SURE to plug/cap ALL hydraulic hose and tube fittings to prevent contamination of the hydraulic system.

2. Disconnect three control rods (lift, tilt and auxiliary hydraulics) attached to control valve spools. Figs.

8-56, 8-57

Fig. 8-57 Disconnect control rods from main control valve spools (T-Bar models).

NOTE: To aid in reassembly of hydraulic hoses and tubes, mark hoses and tubes to be removed BEFORE disconnection.

2

3

1

3. Port 8: Disconnect return hose on straight fitting.

Fig. 8-59 4

4. Ports 6 and 7: Disconnect two auxiliary tubes from 90° elbows on control valve.

5. Ports 4 and 5: Disconnect two tilt tubes from straight fittings on control valve.

6 5

6. Ports 2 and 3: Disconnect lift tubes from straight fittings on control valve.

8

7

7. Port 1: Disconnect return tube on straight fitting.

8. Remove two carriage bolts and locknuts securing control valve to its mounting bracket. Fig. 8-57

917170/AP0106

Fig. 8-58 Control valve port reference numbers.

8-30

PRINTED IN USA

SL3640/3840/4240

HYDRAULIC SYSTEM Installation Procedure 1. Mount control valve on bracket and secure with two carriage bolts and locknuts. If fittings are not in valve, install at this time.

2. Port 1: Connect return tube on straight fitting.

3. Ports 2 and 3: Connect lift tubes on straight fittings on control valve.

Port 8

4. Ports 4 and 5: Connect two tilt tubes on straight fittings on control valve.

5. Ports 6 and 7: Connect two auxiliary tubes on 90° elbows on control valve.

6. Port 8: Connect return hose on straight fitting.

Fig. 8-59 Hose can be removed on port 8 at the straight fitting.

7. Connect three control rods (lift, tilt and auxiliary hydraulics) to control valve spools.

8. Install hydraulic drain plug and refill with hydraulic oil. Refer to Lubrication chapter for hydraulic oil requirements and specifications.

Port 7 Port 5

NEVER use your hands to search for hydraulic fluid leaks. Use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once.

Injected fluid MUST BE surgically removed by a doctor familiar with this type of injury or gangrene may result.

Port 1

Port 6

Port 2 Port 4

Fig. 8-60 Numbered ports identified.

ALWAYS wear safety glasses when checking for hydraulic fluid leaks.

Escaping fluid under pressure can be invisible and cause permanent eyesight damage if safety glasses are not worn.

9. Lift control valve out. Removal may require loosening opposite ends of disconnected tubes.

9. ALWAYS check for hydraulic fluid leaks after assembling any component of the hydraulic system.

IMPORTANT Cap or plug ALL hydraulic hoses, tubes, fittings and control valve ports immediately after being disconnected to prevent fluid loss and contamination of the hydraulic system.

PRINTED IN USA

8-31

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HYDRAULICS

WARNING

Port 3

917170/AP0106 14.5 (36/3840) 16.5 (4240)

12.2 1.20 1.37

36/3840: 35 HP @ 2600 4240: 46 HP @ 2600 LOW IDLE (36/3840): 1500 RPM LOW IDLE (4240): 1200 RPM HIGH IDLE (36/38/4240): 2800 RPM

EATON

HYDRAULIC SYSTEM SL3640/3840/4240

Hydraulic/Hydrostatic System Schematic

8-32

PRINTED IN USA

SL3640/3840/4240

ELECTRICAL SYSTEM

Introduction Description of Operation The following items describe the normal operation of electrical system components on the SL36/38/4240 skid-steer loaders. Fig. 9-1

Hourmeter

1. When the operator is in the seat, the restraint bar is down, and the key switch is turned to the “ON” position the following indicator lamps will light:

Fuel Level Gauge

q Fasten Seat Belt (momentary) q Engine Oil Pressure

Engine Coolant Temp.

Gauge

q Battery q Fasten Seat Belt buzzer will sound for five seconds. (momentary) NOTE: Timed buzzer is separate from engine glow cycle.

Fasten Seat Belt

NOTE: The glow plugs cycle ON and OFF when the glow switch is pressed and the keyswitch is ON. However, glow plugs WILL NOT cycle if ambient temperature is above 32° F (0° C). Refer to glow control module operation in this chapter.

Engine Oil Pressure Battery

Hydraulic Oil Temperature

Glow Indicator

2. The key switch can then be turned to the START position.

On Off Keyswitch

Parking Brake Switch

q The engine oil pressure and battery indicator

Start

lamps will go out after the engine starts.

3. The lift and tilt solenoids should be energized when the operator is on the seat, the restraint bar is down, and the key switch is turned to the ON position.

Glow Switch

NOTE: To verify that the seat and restraint bar switches are working, after the key switch is turned to ON, raise the restraint bar or lift body off the seat. Either action should prevent the engine from cranking with the key switch turned to START.

Light Switch

Circuit Breakers

12-V Accessory Outlet

Fig. 9-1

Right instrument panel (not to scale).

PRINTED IN USA

9-1

917170/AP0106

ELECTRICAL

Engine Temp.

ELECTRICAL SYSTEM

SL3640/3840/4240

Electrical - Instrument Panel 33 31 26 27

32

30 23 4

3

14

1

4 11

4

13

31 24 10

19

22

32

29

2

21

30 30

9 7

6

12

5

20

8

18 15 33 30 16 17 3

25

32

31 28

33

1 TIE/WIRE 2 SCREW/CAP LOCK 3 NUT/LOCK SERRATED 4 GAUGE/HOURMETER 5 SWITCH/LIGHT 6 HOUSING/DISPLAY 7 SWITCH/IGNITION 8 SWITCH/GLOW PLUG 9 SWITCH/BRAKE 10 BUZZER 11 BULB/LAMP

Fig. 9-2

12 GASKET/DISPLAY HOUSING 13 GAUGE/WATER TEMP 14 GAUGE/FUEL LEVEL 15 CONNECTOR/12 V 16 DECAL/INSTRUMENT PANEL 17 PANEL/INSTRUMENT 18 BREAKER/CIRCUIT 15 A 19 WIRE/HARNESS ROPS 20 BREAKER/CIRCUIT 25 A 21 NUT/HEX WHIZLOCK 22 NUT/HEX ACORN

23 SCREW/MACHINE 24 SCREW/PHILLIPS 25 CLAMP 26 TIMER/DELAY 27 TIMER/SEAT BELT 28 BREAKER/CIRCUIT 8 A 29 MOUNT/WIRE 30 SCREW/MACHINE 31 WASHER/LOCK 32 NUT/HEX MACHINE SCREW 33 SCREW/MACHINE

Assembly view of the electrical instrument panel.

917170/AP0106

9-2

PRINTED IN USA

SL3640/3840/4240

ELECTRICAL SYSTEM

Electrical - Chassis

23

19

TO FLASHER OPTION TO REAR TAIL/ WORK LIGHTS 13

23

15

24

22 17

1

20 23

15 20

6 SEE NOTE 3

2

10 TO FUEL SENDER TILT SOLENOID 5

5 16 TO ENGINE WATER TEMP. SENDER

ROPS MAIN POWER

TO AIR PREHEAT

TO ALTERNATOR SEE NOTE 2

TO LOCKOUT LIFT SOL.

TO STARTER

3

TO ENGINE GROUND 9

3

11 3

8 26

TO AUX. SOL. LOCK

7

GROUND TO CHASSIS

21

TO ENGINE OIL 3 TO HYD. TEMP SWITCH

AUXILIARY POWER

SEE NOTE 1

TO BACKUP ALARM (OPTION)

TO PRESSURE PUMP

25

12 4

SEE NOTE 1

TO FUEL SHUTOFF

18

TO BRAKE SOLENOID

NOTES: 1. COIL AND TIE BACKUP ALARM WIRES IN SAFE LOCATION WHEN NOT IN USE. 2. WIRE TIE ALTERNATOR WIRES TO THE STARTER. WIRES CANNOT CONTACT EXHAUST MANIFOLD OR MUFFLER.

ELECTRICAL

TO ROPS MAIN CONNECTOR 14

TO ENGINE WATER TEMP.

3. USE GASKET SEALER.

1 BOLT/CARRIAGE 2 STOP/BATTERY 3 TIE/WIRE 4 NUT/SERRATED LOCK 5 NUT/LOCK 6 GASKET/FUEL SENDER 7 CABLE/BATTERY NEGATIVE 8 SCREW/CAP LOCKING 9 COVER/TERMINAL

Fig. 9-3

10 SENDER/FUEL 11 BATTERY 12 CLAMP/TUBE 13 BRACKET/CIRCUIT BREAK 14 HARNESS/CHASSIS 15 NUT/WHIZLOCK 16 NUT/LOCK 17 CLAMP/BATTERY 18 CABLE/BATTERY POSITIVE

19 BREAKER/CIRCUIT 35 A 20 RELAY 21 CABLE/SOLENOID 22 BOLT/CARRIAGE 23 BOLT/CARRIAGE 24 SCREW/CAP 25 WASHER/LOCK STAR 26 SCREW/CAP

Assembly view of the engine wiring harness.

PRINTED IN USA

9-3

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SL3640/3840/4240

Troubleshooting Guide Problem

Possible Cause

Remedy

Entire electrical system does not function.

Battery disconnect switch (optional) is “OFF."

Turn battery disconnect switch to “ON."

15 ampere breaker(s) are tripped.

Consult wiring diagram, check circuit and locate trouble; pinched wires, faulty connections, etc. before resetting breaker.

Main wiring harness connectors at rear of ROPS not properly plugged-in.

Check main connectors.

Battery terminals or cables are loose or Clean battery terminals and cables and corroded. tighten them.

Battery is faulty.

Test battery and replace as needed.

No instrument panel lamps 25 ampere breakers are tripped. light with key switch turned to “ON." Battery terminals or cables are loose or corroded.

Consult wiring diagram, check circuit and locate trouble before resetting breaker.

Seat belt buzzer indicator not sounding when key turned to “ON,” indicator lamps work properly.

Buzzer is disconnected

Reconnect wires to buzzer.

Faulty buzzer.

Replace buzzer.

Fuel gauge does not work.

Faulty fuel gauge sender.

Replace fuel gauge sender.

Loose wiring/terminal connections.

Verify wiring connections.

Faulty fuel gauge.

Replace fuel gauge.

Faulty sender.

Replace temperature sender.

Loose wiring/terminal connections.

Verify wiring connections.

Faulty temperature gauge.

Replace temperature gauge.

Loose wiring/terminal connections.

Verify wiring connections.

Faulty alternator.

Repair or replace alternator.

Faulty hour meter.

Replace hourmeter.

Engine temperature gauge does not work.

Hourmeter does not work.

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Clean battery terminals and cables and tighten them.

PRINTED IN USA

SL3640/3840/4240

ELECTRICAL SYSTEM

Troubleshooting Guide Problem

Possible Cause

Remedy

Starter will not engage when key is turned to “START."

Seat or restraint bar switch malfunctioning or not activated.

Operator is in the seat with the restraint bar down. Replace switches as needed.

Poor connections to starter relay in instrument panel.

Verify relay connections.

Faulty starter relay in the panel.

Test starter relay. Replace as needed.

Battery terminals or cables are loose or corroded.

Clean battery terminals and cables and tighten them.

Battery discharged or defective.

Recharge or replace battery.

Starter solenoid is malfunctioning.

Troubleshoot circuit per wiring diagram, locate trouble. Replace starter solenoid.

Ignition wiring, seat switch, restraint bar switch, Check wiring for poor connections, broken etc. loose or disconnected. leads; repair wiring or connection.

Battery will not recharge.

Starter or pinion faulty.

Remove starter; repair/replace as needed.

Battery terminals or cables are loose or corroded.

Clean battery terminals and cables and tighten them. Replace cables as needed.

Battery or alternator is defective.

Test battery and alternator. Replace.

Work lights not Single light doesn’t work: Light bulb functioning properly. See burned out, faulty wiring. See Note. note.

Check and replace light bulb as needed.

NOTE: When changing the halogen bulb, DO NOT directly touch the light bulb. Use a clean rag to handle the bulb. Check wiring connection to light.

Lift/Tilt and/or drive lock solenoids do not work.

PRINTED IN USA

Faulty light switch or poor ground.

Replace light switch. Check ground wire connections.

Wiring to solenoids disconnected; faulty.

Refer to wiring diagram, locate trouble and repair as needed.

Faulty seat or restraint bar switch.

Replace seat and/or restraint bar switches as needed.

Faulty solenoid valve coil.

Perform “Solenoid Valve Test” in Hydraulic System chapter. Replace solenoid valve coil(s) as needed.

Faulty hydraulic solenoid relay in instrument panel.

Test relay, replace as needed.

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No lights at all: 25 ampere breaker tripped. Consult wiring diagram, check circuit, and find trouble before resetting breaker.

ELECTRICAL SYSTEM

SL3640/3840/4240

Relay Test and Operation

35 A Circuit Breaker

Seat Relay

Glow Plug Relay Operation The glow plug relay, mounted right of the fuel tank, is a control module that cycles the glow plugs ON and OFF in the sequence described below.

Starter Relay

1. Turn key switch to ON position. Push glow plug switch on instrument panel to ON position.

Restraint Bar Relay

2. If ambient temperature is below 32° F (0° C), glow indicator lamp will come on while glow plug element is activated. After indicator lamp goes out, start engine. Push glow plug switch to OFF position.

Glow Plug Relay

3. If engine fails to start, recycle glow control module by returning ignition switch to OFF position and starting this procedure over.

Fig. 9-4

Identification of relays.

Fig. 9-5

Unbolt four relays from mainframe.

Fig. 9-6

View of relays ready for testing.

Glow Plug Test Procedure u

With key switch OFF, there should be power (12 VDC) at #30 terminal (11 A wire).

u

With glow switch depressed, there should be in-put voltage (12 VDC) at #85 terminal (23 lt blu) and out-put voltage (12 VDC) at #87 terminal (24 lt blu).

Starter, Seat, and Restraint Bar Relay Test Functional relays require that the restraint bar and seat switches be connected. Also required, the battery is producing 12.6 V and there is continuity between terminals at the starter on the engine. The following procedure can be used to test three relays, mounted right of the fuel tank. Figs. 9-4, 9-7

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PRINTED IN USA

SL3640/3840/4240

ELECTRICAL SYSTEM Test Procedure

35 A Circuit Breaker

Seat Relay

WARNING

Starter Relay

BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Raise liftarm; engage liftarm support

Restraint Bar Relay

device.

q Shut off the engine. q Tilt back ROPS until lock engages.

Glow Plug Relay

Fig. 9-7

For detailed instructions on the above, refer to the Safety chapter in this manual.

Identification of relays.

1. Unbolt four relays from mainframe. Fig. 9-5 2. Hang all four relays out of loader as far as possible.

If more clearance is needed, unbolt 35 A circuit breaker too. Fig. 9-6 3. CAREFULLY AND SLOWLY lower ROPS so that the wiring harness is not pinched between ROPS and mainframe.

Fig. 9-8

Fig. 9-9

u

With key switch OFF, there should be continuity between terminals #85 and #86. There should not be continuity between terminals #87 and #30.

u

Turn key switch ON. There should be power (12 VDC) to the #30 terminal of the seat bar switch only.

u

Lowering restraint bar should provide power (12 VDC) at the #85 terminal (52 wh from the seat bar switch), the #87 terminal and the #30 terminal of the seat relay.

u

Depressing seat switch will provide power (12 VDC) at #85 terminal (#51 wh from seat switch), #87 terminal and #30 terminal of starter relay.

u

Turning key switch to START will provide power (12 VDC) at the #85 terminal (#21 wh from start switch) to starter solenoid.

Continuity test on the interlock relays with a multimeter.

Illustration of the interlock relay terminals.

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4. Using a volt/ohm multi-meter, confirm following conditions with wiring plug connected to relay. An assistant should be in operator’s seat with restraint bar down: Figs. 9-8, 9-9

ELECTRICAL SYSTEM

SL3640/3840/4240 f. Restraint bar relay output;

Electrical Circuits The electrical system of Gehl SL36/38/4240 skid-steer loaders can be separated into their own circuits.

Following are descriptions and schematics of operations for those circuits.

u

Seat relay input

u

Auxiliary linkage lock solenoid

g. Seat switch h. Seat relay output;

Starter Circuit - Fig. 9-10 The starter circuit is a 12 V negative ground circuit. The starter motor is controlled by an electrical solenoid which, in turn, is controlled by a switch and relay.

1. The starter circuit is controlled by the following components:

u

Starter relay input

u

1.5 second delay brake timer

u

Lift and tilt hydraulic lock solenoids

u

Brake delay timer signal

i. Starter relay output;

a. Main circuit breaker - 35 A

u

Starter solenoid

b. Ignition switch

u

Fuel cutoff solenoid

c. Manual reset circuit breaker - 15 A

j. Starter solenoid

d. Recycling circuit breaker - 8 A

k. Starter motor

e. Restraint bar switch

Starter Circuit

Fig. 9-10 Schematic of the starter circuit.

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ELECTRICAL SYSTEM

Alternator Circuit - Fig. 9-11 The alternator is a 12 V negative ground alternator with an integral regulator circuit. An output signal at the “L” terminal will send a voltage signal to the indicator light if the charging circuit is not charging. An input to the “R” terminal is required to “excite” the alternator. A diode is required between the ignition circuit and the warning cluster to prevent the engine from running after the key is turned OFF. 1. The alternator circuit is controlled by the following components: a. Ignition switch b. Rear accessory circuit breaker - 15 A c. Diode (isolating alternator system and warning light voltage) d. Excite terminal “R” e. Indicator light terminal “L”

ELECTRICAL

Alternator Circuit

Fig. 9-11 Schematic of the alternator circuit.

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SL3640/3840/4240 h. Seat relay output;

Fuel Circuit - Fig. 9-12 The fuel solenoid is comprised of two windings, a pull-in winding and a hold-in winding. Both windings are powered while the engine is being cranked. When the engine has started and the starter circuit is no longer functioning, the hold-in winding is maintained to allow continued fuel flow to the injectors.

a. Main circuit breaker - 35 A

Lift and tilt hydraulic lock solenoids

u

Brake delay timer signal

u

Starter solenoid

u

Fuel cutoff solenoid

a. Main circuit breaker - 35 A

f. Restraint bar relay output; Auxiliary linkage lock solenoid

u

2. The fuel circuit (hold-in winding) is controlled by the following components:

e. Restraint bar switch

u

1.5 second delay brake timer

k. Ground connections

c. Manual reset circuit breaker - 15 A

Seat relay input

u

j. Fuel solenoid winding

b. Ignition switch

u

Starter relay input

i. Starter relay output;

1. The fuel circuit (pull-in winding) is controlled by the following components:

d. Recycling circuit breaker - 8 A

u

b. Ignition switch c. Manual reset circuit breaker - 15 A d. Fuel solenoid winding

g. Seat switch

e. Ground connections

Fuel Circuit

Fig. 9-12 Schematic of the fuel circuit.

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SL3640/3840/4240

ELECTRICAL SYSTEM f. Restraint bar relay output;

Hydraulic Lock Valves Circuit - Fig. 9-13 A hydraulic lock is located in the lift-down hydraulic circuit and the tilt-dump hydraulic circuit to prevent these circuits from functioning unless the operator is in the seat and the restraint bar is down. The auxiliary controls are lock with an electrical solenoid. This solenoid can be released by turning the ignition switch ON and pulling the restraint bar down. This allows the operator to operate attachments like backhoes without being in the seat.

1. The hydraulic lock valve circuit is controlled by the following components: a. Main circuit breaker - 35 A

u

Seat relay input

u

Auxiliary linkage lock solenoid

g. Seat switch h. Seat relay output; u

Starter relay input

u

1.5 second delay brake timer

u

Lift and tilt hydraulic lock solenoids

u

Brake delay timer signal

i. Lift and tilt circuit hydraulic lock valves j. Auxiliary circuit lock solenoid

b. Ignition switch c. Manual reset circuit breaker - 15 A d. Recycling circuit breaker - 8 A e. Restraint bar switch

ELECTRICAL

Hydraulic Lock Valves Circuit

Fig. 9-13 Schematic of the hydraulic lock valves circuit.

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SL3640/3840/4240

Brake Circuit - Fig. 9-14

h. Restraint bar switch

The brake circuit consists of a dash-mounted switch and a frame-mounted brake control valve. This control valve will supply hydraulic pressure to the brake circuits in the drive motors. To effectively release the brakes, the operator MUST BE in the operator’s seat, have the restraint bar down and the dash-mounted switch depressed to the UP position (green).

i. Restraint bar relay output; u

Seat relay input

u

Auxiliary linkage lock solenoid

j. Seat switch k. Seat relay output; u

Starter relay input

u

1.5 second delay brake timer

a. Main circuit breaker - 35 A

u

Lift and tilt hydraulic lock solenoids

b. Ignition switch

u

Brake delay timer signal

1. The brake circuit is controlled by the following components:

c. Manual reset circuit breaker - 15 A

l. Brake switch

d. 1.5 second delay brake timer

m. Brake solenoid

e. Input from 15 A circuit breaker f. Signal from seat relay output g. Output to brake switch

Brake Circuit

Fig. 9-14 Schematic of the brake circuit.

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ELECTRICAL SYSTEM

Seats - Standard and Suspension

Standard

2

3

4

5

1 5

1

1 NUT/HEX WHIZLOCK 2 SEAT 3 BRACKET/SEAT BELT 4 SCREW/CAP 5 WASHER/FLAT

1

4

1

2

ELECTRICAL

Suspension

1 1

1 1

Fig. 9-15 Assembly view of standard and suspension seat options.

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SL3640/3840/4240

Electrical - Lights

9 12

11

9

10

7

6

4 5

5 2 8

1 TIE/WIRE 2 CLAMP/HOSE 3 NUT/LOCK 4 CLIP/SINGLE 5 CLIP/DOUBLE 6 LAMP/WORK

1

3

2 3

3

2

6

7

2 4

3

7 LAMP/TAIL 8 HARNESS/REAR LIGHT 9 GROMMET 10 LOCK/SECONDARY 11 HOUSING/CONNECTOR 12 HEADLIGHT

Fig. 9-16 Assembly view of the ROPS/FOPS lights and the rear grille lights.

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SL3640/3840/4240

ELECTRICAL SYSTEM Seat Switch Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 9-17 Disconnect this wire from seat switch.

1. Remove the seat from the loader per the procedure in the Mainframe chapter. Turn seat over.

2. Disconnect wire on seat switch. Fig. 9-17 3. Remove two Phillips screws and nuts securing seat switch to seat. Press three tabs to separate dome from base. Press two tabs to remove switch from base. Fig. 9-18

WARNING Phillips Screw

DO NOT attempt to operate the loader without the seat switch installed.

Phillips Screw

Installation Procedure* - Follow all warnings first, then reverse the removal steps. * Install seat on loader as per procedure in Mainframe chapter.

ELECTRICAL

Fig. 9-18 Location of three tabs securing seat switch dome to its base.

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SL3640/3840/4240

Restraint Bar Switch Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the restraint bar per the procedure in the Mainframe chapter.

Fig. 9-19 Location of restraint bar switch on welded tab inside the hinge cover.

2. Remove lock washers, flat washers, hex nuts on two machine screws securing switch to restraint bar.

Remove same hardware for switch on welded tab inside the hinge cover. Figs. 9-19, 9-20, 9-21 3. Remove switches.

WARNING DO NOT attempt to operate loader without the restraint bar switch installed.

Installation Procedure* - follow ALL Warnings first, then reverse the removal steps. * Install the restraint bar per the procedure in the Mainframe chapter.

Fig. 9-20 Remove hex nut, lock washer and flat washer on each machine screw.

Fig. 9-21 Pull switch and machine screws off mount.

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ELECTRICAL SYSTEM Front/Rear Work Light Bulb Replacement Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

Mount Screw

Fig. 9-22 Location electrical connector on front work light.

1. Front Work Light Only: Loosen work light mount screw and turn light down. Fig. 9-22 2. Detach electrical connector. On rear work lights, detach the bulb retaining clip. Figs. 9-22, 9-23 3. Twist lamp base counterclockwise (on front work lights) and remove bulb. Figs. 9-24, 9-25

IMPORTANT Halogen bulbs SHOULD NOT be touched with bare fingers; they can fail prematurely. Wear clean gloves or use a clean rag if you must handle the halogen bulbs.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

Fig. 9-24 GE862 bulb in the front work lights.

Fig. 9-25 H3 halogen bulb in the rear work lights.

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Fig. 9-23 Location of bulb retaining clip on rear work light.

4. Replace used GE862 bulb with new bulb, on rear work lights, replace with a same wattage rated H3 bulb.

ELECTRICAL SYSTEM

SL3640/3840/4240

Electrical System Schematic (schematic overlaps onto following page)

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ELECTRICAL SYSTEM

ELECTRICAL

Electrical System Schematic (schematic overlaps from previous page)

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SL3640/3840/4240

NOTES

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SL3640/3840/4240

ENGINE

Introduction This chapter covers troubleshooting, removal, installation, and adjustment procedures for engine components on GEHL SL36/38/4240 skid-steer loaders. The primary engine system components are shown below and on following pages.

four-cylinder, 133-cubic-inch displacement (2,19 L) engines with a compression ratio of 18.5:1. It is a four-stroke engine that uses direct fuel injection. The firing order is 1, 3, 4, 2.

A “full-flow” oil filter is used in the lubrication system.

As in any engine, clean oil, fuel, and air are critical to satisfactory performance and long engine life. If properly maintained, this engine will provide thousands of hours of trouble-free operation.

SL36/3840 skid-steer loaders are equipped with a Yanmar 3TNV88-XMS2 naturally-aspirated diesel engine. It is a three-cylinder, 100-cubic-inch displacement (1,64 L) engine witha compression ratio of 18.5:1. It is a four-stroke engine that uses direct fuel injection. The firing order is 1, 3, 2.

When ordering engine parts, always check the GEHL Service Parts Manual to see if any special parts have been fitted to the engine. If GEHL parts are required, they can be ordered from GEHL Company.

SL4240 skid-steer loaders are equipped with a Yanmar 4TNV88-XMS2 turbo-diesel engine. It is a

Engine and Engine Controls Assembly NOTES: 27

1. APPLY LOCTITE 242.

FUEL RETURN 2. ACTUAL NUT PLACEMENT TO REAR OF WATER SEPARATOR. 29

42

31

35 10

29

12 3

FUEL SUPPLY

3

3. TORQUE TO 35 FT/LBS. 4. SET (EU) RPM TO 2600.

SET NON-(EU) RPM TO 2800.

24

18

31

17

51 25 39

1

4 53

54 SEE NOTE 4

DETAIL A

A

19 5 SEE NOTE 2

SEE NOTE 1 20

17

26

52

6

43 50

44

50 49

21

23 32

7 48

SEE NOTE 1 34

33 SEE NOTE 1

36

50 13

41

11

45

AS REQUIRED OPT (1)

36

50

41 28

8

47

9 SEE NOTE 1

38

22

50

35

14 50 SEE NOTE 1 52

37 40

15 34 46 SEE NOTES 1&3

16

ENGINE

1 BUSHING/OILITE 2 JOINT/BALL 3 CLAMP/HOSE 51 4 NUT/LOCK 5 NUT/LOCK 6 NUT/LOCK 7 NUT/LOCK 8 NUT/LOCK 9 SCREW/LOCK 10 CABLE/THROTTLE 11 NUT/LOCK 12 FITTING/BARB 13 ISOLATOR 14 SCREW/SHOULDER 15 PLATE/MOUNT 16 BRACKET 17 HOSE/FUEL 18 HOSE/FUEL 19 HOSE/FUEL 20 BRACE/ENGINE 21 MOUNT/ENGINE 22 SUPPORT/PUMP 23 MOUNT/ENGINE 24 PIVOT/THROTTLE 25 ENGINE/YANMAR 26 PIVOT/THROTTLE 27 VALVE/SHUT OFF 28 ROD/THROTTLE 29 YOKE 30 NUT/HEX LOCK 31 PIN/CLEVIS 32 PLATE/DRIVE 33 SCREW/CAP 34 SCREW/CAP 35 WASHER

2

41

30

36 WASHER 37 WASHER/FLAT 38 MOUNT/ENGINE 39 BUSHING 40 SCREW/CAP 41 NUT/HEX 42 SCREW/CAP

43 SCREW/CAP 44 BOLT/CARRIAGE 45 SCREW/CAP 46 SCREW/CAP 47 WASHER/FLAT 48 WASHER/FLAT 49 WASHER/FLAT

50 WASHER/LOCK 51 PIN/COTTER 52 SCREW/CAP 53 NUT/HEX 54 SCREW/CAP

Fig. 10-1 Assembly view of the major engine components.

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SL3640/3840/4240

Troubleshooting Guide The following troubleshooting guide lists potential engine problems, as well as possible causes and remedies, for GEHL SL36/38/4240 skid-steer loaders.

When a problem occurs, don’t overlook possible simple causes. A malfunction could be caused by something as simple as an empty fuel tank. After a mechanical failure has been corrected, be sure to locate and correct the cause of the problem.

NOTE: For further troubleshooting information, refer to the engine manufacturer’s manual.

IMPORTANT DO NOT attempt to service or repair major components, such as the fuel injector pump, unless authorized to do so by your GEHL dealer/distributor. Any unauthorized repair will void the warranty.

Problem

Possible Cause

Remedy

Starter will not crank engine

Battery terminals or cables corroded or loose.

Clean battery terminals and cables and secure them tightly.

Battery discharged or defective.

Recharge or replace battery.

Starter solenoid not functioning.

Troubleshoot circuit per wiring diagrams to locate trouble and repair or replace starter solenoid.

Seat switch or restraint bar switch malfunctioning.

Sit on seat and lower restraint bar; if engine still doesn’t start, troubleshoot circuit and replace faulty switch as needed.

Wiring to and from ignition, seat switch, restraint bar switch, etc. is loose or disconnected.

Check wiring for poor connections or broken leads and repair wiring or connection.

Starter or pinion faulty.

Remove starter and repair or replace as needed.

Engine cranking speed too slow.

Battery requires recharging or replacing, or, in cold temperatures, pre-warm the engine.

Fuel tank empty or faulty fuel gauge sender

Refill fuel tank. Replace fuel gauge sender.

Glow plug module malfunctioning.

Check connection and voltage, replace as needed.

Engine turns over but will not start.

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ENGINE

Problem

Possible Cause

Remedy

Engine turns over but will not start.

Fuel shutoff solenoid not energizing.

Check electrical connections and voltage to shutoff solenoid.

Engine oil not warm enough.

Cycle glow plug; check glow plug wiring connections.

Ambient temperature is too low.

Install a block heater.

Fuel pump not working.

Refer to engine manual or contact Gehl Service.

Moisture in the fuel line.

Bleed water out of fuel filter and fuel tank.

Auxiliary valve engaged.

Return the control valve to NEUTRAL.

Crankcase oil level too low or too high.

Add or remove oil as required.

Engine overloaded.

Reduce operating load.

Fan air circulation blocked or restricted.

Turn engine OFF, wait for fan to stop, remove blockage or restriction.

Fan shroud improperly positioned.

Perform “Fan Shroud Adjustment” procedure in this chapter.

Grade of oil improper or excessively dirty.

Drain and replace with clean oil of proper grade.

Exhaust restricted.

Allow exhaust to cool and remove the restriction.

Air filter is restricted.

Replace the filter(s).

Oil or radiator flow restricted.

Flush cooler inside and out.

ENGINE

Engine overheats.

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SL3640/3840/4240

Engine Oil Filter Element Removal and Installation The engine oil filter is attached low on the left side of the engine. The filter can be replaced without an oil change, but it is not recommended.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 10-2 Engine oil filter access point underneath the skid-steer loader.

Removal Procedure - Figs. 10-2, 10-3, 10-4 1. Under loader, behind left rear tire and in front of left riser, find a small access cover to the engine oil filter element.

2. Remove one capscrew securing access cover to floor of mainframe and remove cover.

3. Clean area around oil filter element and place a drip pan to catch any lost oil.

4. Turning counterclockwise, loosen oil filter element with a filter wrench.

Oil Drain Plug

5. Turn the filter element by hand until it is free of the oil filter head.

Fig. 10-3 View of oil filter through access panel.

Installation Procedure 1. Clean the oil filter mating surface of any debris before installing new element.

2. Apply a thin film of oil to the seal on the filter element before installing.

3. Hand tighten the filter element, turning it clockwise, until the gasket contacts the filter mating surface, then turn the element another 3/4 turn to seat the gasket.

4. If old oil has been removed also, fill crankcase with five quarts (4,8 L) of oil (see Lubrication chapter).

5. Start engine and check for leaks near the oil filter.

Shut off engine, recheck oil level, and fill as needed.

Fig. 10-4 View of oil filter from above.

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ENGINE

Air Cleaner and Muffler Components - 3640/3840 Models

5

8

9

11

13

14

2

7 10 15

3

17

6

12

16 2 4

1 SCREW/WHIZLOCK 2 CLAMP/HOSE 3 TUBE/HOSE CONNECTOR 4 MOUNT/MUFFLER 5 END CAP/AIR FILTER 6 ELBOW 7 CLAMP/FILTER

8 ELEMENT/PRIMARY 9 ELEMENT/SECONDARY 10 HOSE/AIR FILTER 11 CLEANER/AIR 12 NUT/HEX WHIZLOCK 13 GAUGE/RESTRICTION 14 MUFFLER

ENGINE

1

REMOVE BOLT FROM ENG/ALT ASSEMBLY AND REPLACE AFTER MUFFLER MOUNT HAS BEEN PLACED

15 BOLT/CARRIAGE 16 WASHER/LOCK 17 NUT/HEX

Fig. 10-5 Assembly view of the 3640/3840 air cleaner and muffler components.

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SL3640/3840/4240

Air Cleaner and Muffler Components - 4240 Models

9

20 12

13

1 8 6

3 15 19

2

14

16

11

2

7

23

17

5

21

10

18

1 4

22

1 NUT/SERRATED LOCK 2 U-CLAMP 3 SCREW/WHIZLOCK 4 CLAMP/HOSE 5 GASKET/EXHAUST 6 ISOLATOR 7 TUBE/HOSE CONNECTOR 8 PLATE/MUFFLER MOUNT

9 END CAP/AIR FILTER 10 ELBOW 11 CLAMP/FILTER 12 ELEMENT/PRIMARY 13 ELEMENT/SECONDARY 14 HOSE/AIR FILTER 15 CLEANER/AIR 16 TUBE/EXHAUST FLEXIBLE

17 PIPE/EXHAUST 18 NUT/SERRATED LOCK 19 GAUGE/RESTRICTION 20 MUFFLER 21 BOLT/CARRIAGE 22 WASHER/LOCK 23 NUT/HEX

Fig. 10-6 Assembly view of the 4240 air cleaner and muffler components.

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ENGINE Air Cleaner Assembly Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 10-7 Location of hose clamp securing air cleaner hose on engine to air cleaner assembly.

1. Open the engine access cover and rear grille.

2. Clean area around the hose connections.

3. Loosen hose clamp between on air cleaner hose and air cleaner assembly. Pull hose off assembly. Cover air cleaner hose opening to prevent contamination.

Fig. 10-7 4. Remove two locknuts on carriage bolts securing filter clamp to mainframe. Fig. 10-8 5. Pull air cleaner assembly off carriage bolts.

Fig. 10-8 Remove two locknuts on carriage bolts (1 of 2 shown) to remove the air filter and its mounting band.

Installation Procedure - Follow all warnings first, then reverse the removal steps

Air Filter Element Removal and Installation Service air filter elements when restriction gauge shows in the red zone. The red zone indicates a clogged air filter. If gauge shows red with engine stopped, replace both air filter elements. After fitting clean elements, push gauge reset button located on gauge’s end.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fig. 10-9 Remove the two clip latches (1 of 2 shown) on cover assembly.

Removal Procedure 1. Open engine access cover and rear grille.

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Mounting Band

ENGINE

SL3640/3840/4240

2. Release two clips securing air cleaner cover and remove cover. Clean any dirt in cover. Fig. 10-9 3. Pull primary air filter from housing. Fig. 10-10 4. Pull secondary air filter from housing. Fig. 10-11 5. Replace both air filter elements.

6. Check condition of dust vacuator.

Installation Procedure* - Follow all warnings first, then reverse the removal steps * Clean mating plastic body for radial seal surfaces.

Fuel Filter Removal and Installation Fig. 10-10 Primary air filter shown.

The fuel filter is a maintenance item in the fuel system.

Removal Procedure 1. Shut off fuel supply by turning valve on the water separator. Fig. 10-14 2. Shut off the return line by turning valve on the fuel tank. Fig. 10-13 3. Remove the fuel filter.

Installation Procedure 1. Lubricate new fuel filter gasket with diesel fuel.

2. Install and turn filter one-half turn past point where gasket contacts filter head.

3. Reverse steps 1 and 2 of the removal procedure.

NOTE: When the fuel filter is changed the system MUST BE primed (see procedure on following page).

Fig. 10-11 Secondary air filter shown.

Water Separator Element - Removal and Installation The water separator and its element are maintenance items in the fuel system. Check for water in the separator by checking the level of the float in the separator bowl.

Removal Procedure 1. Shut off the fuel supply by turning the fuel shutoff valve on top of the water separator. Fig. 10-14 2. Turn nut at bottom of separator bowl to release bowl from the valve head. Dispose of remaining fuel and water.

3. Remove and clean element with warm water.

4. Clean separator bowl and reinstall element and o-ring. If element is damaged, replace it with a new one.

917170/AP0106

Fig. 10-12 Location of the fuel filter on the engine.

10-8

PRINTED IN USA

SL3640/3840/4240

ENGINE Installation Procedure 1. Lubricate o-ring with diesel fuel, return separator bowl to valve head and turn nut to tighten.

2. Turn on fuel supply valve at top of water separator.

NOTE: When the fuel filter is changed the system MUST BE primed (see procedure below).

Electric Fuel Pump Removal and Installation The electric fuel pump is located between the water separator and the fuel filter on the left inside riser.

Fig. 10-13 Location of the shutoff valve on the fuel return line at the fuel tank.

Removal Procedure - Fig. 10-15 1. Unplug electrical connector on fuel pump.

2. Shut off the fuel supply by turning the fuel shutoff valve on top of the water separator. Fig. 10-14 3. Shut off the return line by turning valve on the fuel tank. Fig. 10-13 4. Loosen two small hose clamps at the top and bottom of the electric fuel pump.

5. Remove two locknuts securing the electric fuel pump to the chassis.

6. Slip fuel hoses off of the pump and plug the hoses.

Installation Procedure - Fig. 10-15

Separator Bowl

Fig. 10-14 Location of shutoff valve on water separator.

1. Slip new electric fuel pump (with electrical connector positioned lower) over bolts in the chassis, tighten with locknuts.

2. Unplug fuel hoses (if plugged to prevent fuel leakage) and connect at top and bottom of pump and secure with hose clamps.

NOTE: When the fuel filter is changed the system MUST BE primed (see following procedure).

Electrical Connector

Priming Diesel Fuel System Hose Clamp

When the fuel filter is changed or if the diesel engine runs out of fuel, the system MUST BE primed.

Priming Procedure 1. Turn the keyswitch to the ON position to charge the electric fuel pump.

Fig. 10-15 Location of the electric fuel pump bolted to left inside riser. View of front looking rearward.

2. Air is vented through excess fuel return line to fuel tank. There is no vent plug to open.

3. Leave keyswitch in the ON position until air is no longer heard being released in fuel tank.

PRINTED IN USA

10-9

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ENGINE

3. Reverse steps 1-3 of the removal procedure.

ENGINE

SL3640/3840/4240

Battery Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

Positive Battery Cable

(For detailed instructions, refer to the Safety chapter of this manual.)

Negative Battery Cable

Fig. 10-16 The negative battery cable is closest to the rear of the loader.

WARNING Review the following safety considerations before working on or around the battery.

q Keep sparks and flames away from battery. Gas given off by the battery’s electrolyte solution is extremely explosive.

q Avoid contact with battery electrolyte; wash off any electrolyte immediately.

q Wear safety glasses when working near battery.

q Do not tip battery more than 45° to avoid spilling electrolyte solution.

r To avoid injury from spark or short

Fig. 10-17 Location of long carriage bolt securing battery in the skid-steer loader.

circuit, disconnect negative (-) battery cable before servicing electrical system.

1. Open engine access cover and rear grille.

2. Disconnect and remove negative (-) battery cable from battery. Fig. 10-16 3. Disconnect and remove positive (+) battery cable from battery. Fig. 10-16 4. Remove locknut from long carriage bolt securing battery clamp to mainframe. Slip battery clamp out of loader. Fig. 10-17 5. Slide battery rearward and out of mainframe.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

917170/AP0106

Fig. 10-18 Location of positive battery cable attached at starter solenoid.

10-10

PRINTED IN USA

SL3640/3840/4240

ENGINE Starter Removal and Installation For wiring connections to the starter and solenoid, refer to the Electrical System chapter of this manual.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support device.

Fig. 10-19 Location of cable and wires to remove from starter solenoid prior to removing the starter.

q Shut off the engine. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Disconnect and remove negative (-) battery cable from battery. Fig. 10-16 2. Disconnect and remove positive (+) battery cable and wire from starter solenoid. Remove small screw securing wire above cable. Figs. 10-18, 10-19 3. Clip plastic tie securing wires to starter solenoid.

4. Remove two capscrews securing starter to engine.

Fig. 10-20 5. Remove starter from engine.

Muffler Plate

Installation Procedure - Follow all warnings first, then reverse the removal steps

Exhaust Assembly Removal and Installation Removal Procedure

WARNING

Muffler Mount

Shut off engine. Engine compartment may be extremely hot, particularly the engine muffler and exhaust pipes.

Serious injury can occur touching hot components.

Fig. 10-21 Location of capscrew securing rear of muffler to the muffler plate.

PRINTED IN USA

1. Open engine access cover and rear grille.

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ENGINE

Fig. 10-20 Location of one of two capscrews securing starter to engine.

ENGINE

SL3640/3840/4240

2. Remove one capscrew securing rear of muffler to muffler mount bracket. Fig. 10-21 3. 3640/3840 Models Only: Remove four hex nuts and lock washers on studs at front of muffler.

Remove muffler. Fig. 10-22

Muffler

4. 4240 Models Only: Loosen top U-clamp on the flexible exhaust tube and remove the muffler. Fig. 10-23 Installation Procedure* - Follow all warnings first, then reverse the removal steps. * Check alignment of exhaust assembly so extension pipe is centered in opening on engine access cover when cover is closed, tighten the mounting hardware. * If skid-steer loader isequipped with spark-arresting muffler, first remove spark-arresting plug and clean out muffler out. Reinstall spark-arresting plug prior to reinstalling muffler onto skid-steer loader.

Fig. 10-22 Location of two of four hex nuts and lock washers securing muffler to engine on 3640 and 3840 models.

Fan Belt Adjustment Adjustment Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine.

Fig. 10-23 Location of top U-clamp on the flexible exhaust tube on 4240 models.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Open engine access cover and rear grille.

2. Test fan belt tension by pushing on belt midway between alternator and engine crankshaft pulley.

The belt should deflect about 1/2" (13 mm) under a force of 20 lbf. (90 N). If adjustment is needed, follow steps 3-5 below.

3. Loosen two bolts on alternator. Fig. 10-24 4. Rotate alternator in a clockwise direction until correct belt tension is achieved.

5. Retighten bolts on alternator.

Fig. 10-24 Location of two bolts to adjust fan belt tension.

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10-12

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SL3640/3840/4240

ENGINE

Radiator/Cooler System Components - 36/3840 Models

3

6

1 3 8 10

1 4

5

11

12

12 7

2

1 CLAMP/HOSE 2 CLAMP/HOSE 3 ELBOW/SWIVEL 90° 4 NUT/LOCK

5 HYDRAULIC HOSE/TUBE 6 ASSEMBLY/COOLER 7 FAN/COOLING 8 HOSE/UPPER RADIATOR

9

9 HOSE/RADIATOR 10 HOSE 11 BOTTLE/WATER 12 SCREW/THREAD FORMING

Fig. 10-25 Assembly view of the 3640/3840 radiator/cooler system.

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ENGINE

1

ENGINE

SL3640/3840/4240

Radiator/Cooler System Components - 4240 Models

3 9

5

7

3

13

4

8 5

1 18

11

6

15 10 4

1 16

1

17

12

20

2 14 19

1 CLAMP/HOSE 2 CLAMP/HOSE 3 FITTING/90° 4 SEAL/SHROUD 5 SCREW/CAP WHIZLOCK 6 HYDRAULIC HOSE/TUBE 7 COOLER/RADIATOR

8 HOSE/FUEL 9 BRACE/COOLER 10 SHROUD/FAN 11 SUPPORT/SHROUD RIGHT 12 SUPPORT/SHROUD LEFT 13 HOSE/UPPER RADIATOR 14 HOSE/RADIATOR

TO TANK

15 FAN/COOLING 16 HOSE 17 NUT/LOCK 18 BOTTLE/WATER 19 BOLT/CARRIAGE 20 SCREW/THREAD FORMING

Fig. 10-26 Assembly view of the 4240 radiator/cooler system.

917170/AP0106

10-14

PRINTED IN USA

SL3640/3840/4240

ENGINE Radiator/Cooler Removal and Installation

Upper Oil Cooler Hose

The radiator/cooler is located at the rear of the engine compartment, in front of the rear grille.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Shut off the engine and allow to cool. DO

Overflow Hose

NOT attempt to service any part of the radiator/cooler system until engine has been allowed to cool down. Serious injury may result from high temperature oil or the high pressure.

Fig. 10-27 Location of top radiator hose.

q Relieve hydraulic pressure in system.

(For detailed instructions, refer to the Safety chapter of this manual.)

Capscrew

1. Open engine access cover and rear grille.

2. Drain antifreeze mixture per the procedure in the Lubrication chapter.

Capscrew Capscrew Drain Cock

Fig. 10-28 Location of bottom radiator hose. Note the antifreeze drain cock.

3. If necessary, drain hydraulic oil reservoir per the procedure in the Lubrication chapter.

NOTE: If hydraulic hoses/tubes are plugged or capped after removal to prevent oil leakage, it should not be necessary to drain hydraulic reservoir. Plug/cap hydraulic hoses/tubes to prevent contaminants from entering hydraulic system.

5. Loosen two hose clamps at top and bottom ports on left side of radiator and pull off hoses. Figs. 10-27, 10-28

Capscrew

NOTE: Radiator hoses should be plugged or capped to prevent contaminants from entering cooling system.

Capscrew Capscrew

Fig. 10-29 Location of upper and lower oil cooler hoses.

PRINTED IN USA

6. Place a suitable container underneath lower hydraulic hose port (right side) on oil cooler, disconnect hose and drain cooler. Disconnect upper hydraulic hose on oil cooler. Fig. 10-29 NOTE: BE SURE to use two wrenches for step 6, one on hose fitting and one on oil cooler, to prevent damage to oil cooler.

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4. Disconnect recovery tank hose leading to overflow bottle at radiator cap. Fig. 10-27

ENGINE

SL3640/3840/4240

7. 4240 Models Only: Support radiator/cooler with a suitable hoist and remove six capscrews securing radiator/cooler sides to shroud. Figs. 10-28, 10-29 8. 3640/3840 Models Only: Remove four screws securing the radiator/cooler/shroud to the floor of the chassis. Fig. 10-30 9. Remove radiator/cooler.

Installation Procedure* - Follow all warnings first, then reverse the removal steps. * Safely check for hydraulic fluid leaks following the correct procedure (refer to Hydraulic System chapter). * ALWAYS check for hydraulic fluid leaks after assembling any components of the hydraulic system. * BE SURE and uncap/unplug the hydraulic hoses prior to reconnecting them to the oil cooler.

Fig. 10-30 Location of two screws securing radiator/cooler on right side (left side same) on 36/3840 models.

* After removing and/or replacing any component in the cooling system, ALWAYS check the fluid level in the radiator, cooler and recovery tank. Add fluid if necessary.

Fan Shroud Removal and Installation 4240 Models The fan shroud, mated to the radiator/cooler and chassis floor, is mounted behind the engine’s blower fan.

Removal Procedure Fig. 10-31 Location of screws securing left side of the fan shroud to the chassis on 4240 models. Other side is the same.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

q Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

Fan Shroud

1. Open engine access cover and rear grille.

2. Remove the radiator/cooler per the procedure found in this chapter.

Fan Blade

3. Remove four screws securing left and right shroud support brackets to floor of the chassis. Fig. 10-31 4. Carefully remove fan shroud from engine compartment without contacting engine fan blades.

Fig. 10-32

PRINTED IN USA

Fig. 10-32 Remove fan shroud from engine compartment without contacting engine fan blades.

10-16

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SL3640/3840/4240

ENGINE Fuel Tank Removal and Installation

Water Separator

The welded-steel fuel tank on Gehl SL36/38/4240 skid-steer loaders is nestled in a chassis crossmember behind the ROPS. Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

q Raise liftarm; engage liftarm support

Fig. 10-33 Location of water separator shut off valve.

device.

q Shut off the engine and allow to cool. q Tilt back ROPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

Electric Fuel Pump

1. Open engine access cover and rear grille.

2. Remove the air cleaner assembly per the procedure found in this chapter.

3. Remove the muffler assembly per the procedure found in this chapter.

4. Turn water separator fuel shut off valve to OFF position. Fig. 10-33 Fig. 10-34 Location of the fuel supply hose connected at the electric fuel pump.

5. Loosen clamp on fuel supply hose at bottom of electric fuel pump. Place hose end in an approved container with enough capacity [10.3 gal. (39 L) for 36/3840 models; or 12.4 gal. (47 L) for 4240 model,] to hold a full tank of fuel. Fig. 10-34

7. Reinstall fuel supply hose at electric fuel pump.

8. Loosen clamps on two hose lines at fuel tank and pull hoses off barbed fitting and shut off valve. Fig. 10-35 9. Remove fuel sender wiring and fuel sender per the procedure in the Mainframe chapter. Fig. 10-36 10. Remove one hydraulic hose and tube attached to either side of oil filter assembly. Fig. 10-37 Fig. 10-35 Location of hose clamps on fuel hoses at the fuel tank.

PRINTED IN USA

NOTE: Cap or plug all hydraulic hoses and tubes immediately after they are disconnected to prevent fluid loss and contamination of the hydraulic system.

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ENGINE

6. Turn water separator valve to ON position, loosen fuel cap on tank and drain diesel fuel into approved container. Return shut off valve to OFF position.

ENGINE

SL3640/3840/4240 11. Remove four capscrews securing hydraulic filter assembly to fuel tank welded tab. Fig. 10-37 12. Remove two locknuts on carriage bolts securing fuel tank bracket to left side chassis riser. Fig. 10-38 13. Remove three locking capscrews at front of fuel tank securing tank to chassis crossmember. Fig. 10-39 14. Maneuver tank out of mainframe. Fig. 10-40 Installation Procedure* - follow all warnings first, then reverse the removal steps. * Perform the “Priming Diesel Fuel System” procedure in this chapter after re-connection of fuel tank.

Fig. 10-36 Location of fuel sender and wiring.

Hyd. Tube

Hyd. Hose

Fig. 10-37 Location of four bolts securing hydraulic oil filter assembly to welded tab on the fuel tank.

Fig. 10-39 Location of three locking capscrews securing fuel tank to chassis crossmember.

Fig. 10-38 Location of fuel tank locknuts on carriage bolts securing fuel tank to left side chassis riser.

Fig. 10-40 Remove fuel tank from skid-steer loader.

917170/AP0106

10-18

PRINTED IN USA

SL3640/3840/4240

ENGINE Engine Removal and Installation This procedure allows removal of the diesel engine with hydrostatic pump assembly (recommended). Some hydraulic hoses will need to be disconnected in this procedure, and if they cannot be capped/plugged to prevent fluid loss, the hydraulic reservoir should be drained before disconnecting the hydraulic hoses.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

Fig. 10-41 Remove both battery cables, negative (-) first.

q Raise liftarm; engage liftarm support device.

q Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove ROPS per the procedure in the Mainframe chapter.

2. Drain antifreeze coolant per the procedure in the Lubrication chapter.

3. Drain hydraulic oil reservoir per the procedure in the Lubrication chapter (as required).

Fig. 10-42 Location of several components needing removal prior to removing engine.

4. Perform the fuel tank removal per the procedure found in this chapter.

5. Disconnect both battery cables, negative (-) first.

Fig. 10-41

7. Remove rear grille per the procedure in the Mainframe chapter. Fig. 10-42 8. Remove air cleaner assembly per the procedure in this chapter. Fig. 10-42

WARNING Fig. 10-43 Location of two capscrews securing rear engine mount rubber to mainframe.

PRINTED IN USA

DO NOT PROCEED with the following steps unless the engine has completely cooled and is safe to touch.

9. Remove radiator/cooler per the procedure in this chapter. Fig. 10-42 10-19

917170/AP0106

ENGINE

6. Remove engine access cover per the procedure in the Mainframe chapter. Fig. 10-42

ENGINE

SL3640/3840/4240

10. Remove oil cooler and shroud per the procedure in this chapter. Fig. 10-42 11. Remove exhaust assembly per the procedure in this chapter. Fig. 10-42 12. Remove two capscrews securing rear engine rubber mount to the mainframe. Fig. 10-43 NOTE: The following steps include disconnection of hydraulic hoses. Mark all hoses to ease reinstallation. If the hoses cannot be capped/plugged to prevent fluid loss, the hydraulic reservoir should be drained before disconnecting the hoses. Refer to the Hydraulic System chapter for the procedure.

NOTE: ALWAYS clean area around hydraulic fittings BEFORE disconnecting any hydraulic hose or tube.

Fig. 10-44 Four locations to disconnect throttle cable.

13. Remove all hoses on hydrostatic pump and gear pump.

14. Disconnect throttle cable from cable bracket(s) and throttle pivot(s) at engine mount weldment. Fig. 10-44

Reset Button

15. Disconnect hydrostatic pump arms per the procedure in the Controls chapter.

16. Disconnect the following wiring connections: a. Hydraulic Lock Solenoids Fig. 10-46 b. Fuel Tank Sender c. Firewall Relays and Reset (per the procedure in the Electrical chapter) Fig. 10-45 d. Fuel Shut Off Solenoid

Fig. 10-45 Remove relays from right side chassis riser.

Disconnect 35 A reset button and one hydraulic lock solenoid connection in same area.

e. Engine Temperature Sensors/Switch f. Starter g. Alternator h. Hydraulic Temperature/Oil Pressure Switch i. Hydraulic Oil Filter j. Parking Brake Solenoid k. Ground Cable from Engine to Mainframe Fig. 10-47 l. Instrument Panel Wiring Harness Fig. 10-48 17. Attach a lifting fixture engine. Fig. 10-49 18. Remove locknut, capscrew and two washers securing each front engine rubber mount to mainframe. Fig. 10-50 19. With hoist attached to engine, lift slightly and pull engine and hydrostatic pump rearward. Continue 917170/AP0106

Fig. 10-46 One of three hydraulic lock solenoids to electrically disconnect.

10-20

PRINTED IN USA

SL3640/3840/4240

ENGINE

pulling engine rearward until pump is free from skid-steer loader. Fig. 10-51 20. Remove hydrostatic pump from engine per the procedure in the Hydraulic System chapter.

Installation Procedure* - follow all warnings first, then reverse the removal steps.* * If the diesel fuel was drained, add fuel, then prime the fuel system according to “Priming Diesel Fuel System” procedure in this chapter. Also check engine oil and hydraulic oil levels prior to starting the skid-steer loader. * Safely check for hydraulic fluid leaks following the correct procedure (refer to Hydraulic System chapter).

Perform neutral centering adjustment procedure found in the Controls chapter.

Fig. 10-49 Lifting fixtures attached to top of engine.

Fig. 10-50 Remove locknut, capscrew and two washers off two front rubber engine mounts.

Fig. 10-48 Remove instrument panel electrical harness from engine.

Fig. 10-51 Pull engine rearward, out of the skid-steer loader.

ENGINE

Fig. 10-47 Location of ground cables connected at engine.

PRINTED IN USA

10-21

917170/AP0106

ENGINE

SL3640/3840/4240

NOTES

917170/AP0106

10-22

PRINTED IN USA

INDEX

Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Adjustment Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Control Handle Position and Tracking . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Foot Throttle - T-Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Hand Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Hand Throttle Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Lift and Tilt Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Liftarm Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Neutral Centering Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Self-Leveling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Air Cleaner Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . 10-7 Air Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 All-Tach Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Assembly View Air Cleaner and Muffler Components - 3640/3840 Models. . . . . . . . . . . . . 10-5 Air Cleaner and Muffler Components - 4240 Models . . . . . . . . . . . . . . . . 10-6 Electrical - Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Electrical - Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Electrical - Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Engine and Engine Controls Assembly . . . . . . . . . . . . . . . . . . . . . . . 10-1 Hand/Foot Control Models - Drive, Auxiliary Hydraulics, Lift and Tilt Controls . . 6-4 Hydraulics - Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Hydraulics - Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2, 8-18 Hydraulics - Liftarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Hydraulics - Self-Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Hydrostatic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Hydrostatics Pump Assembly and Drive Motors . . . . . . . . . . . . . . . . . . . 7-1 Liftarm and All-Tach Attachment Bracket Components . . . . . . . . . . . . . . . 4-8 Mainframe, Floor Covers, Rear Grille and Engine Cover Components. . . . . . . 4-15 Radiator/Cooler System Components - 36/3840 Models . . . . . . . . . . . . . 10-13 Radiator/Cooler System Components - 4240 Models . . . . . . . . . . . . . . . 10-14 Restraint Bar Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 ROPS/FOPS Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Seats - Standard and Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13 T-Bar Control (Early) Models - Auxiliary Hydraulics . . . . . . . . . . . . . . . . 6-4 T-Bar Control Models - Drive, Auxiliary Hydraulics, Lift and Tilt Controls . . . . 6-2 Wheel Drives Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Auxiliary Hydraulics Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Auxiliary Hydraulics Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 6-14 Axle Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

PRINTED IN USA

Index-1

917170/AP0106

INDEX

A

INDEX

B Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

C Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Change Chaincase Oil Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Charge Pressure Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Circuit Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Hydraulic Lock Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Control Handle Position and Tracking Adjustment . . . . . . . . . . . . . . . . . . . . . . 6-7 Control Handle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30 Controls Chapter Auxiliary Hydraulics Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Auxiliary Hydraulics Removal and Installation . . . . . . . . . . . . . . . . . . . 6-14 Control Handle Position and Tracking Adjustment. . . . . . . . . . . . . . . . . . 6-7 Control Handle Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . 6-6 Dual Control Weldment Removal and Installation - T-Bar. . . . . . . . . . . . . . 6-9 Foot Throttle Adjustment - T-Bar . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Foot Throttle and Cable Removal and Installation - T-Bar . . . . . . . . . . . . . 6-18 Hand Throttle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Hand Throttle Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Hand Throttle, Hand Throttle Cable and Throttle Rod - Removal and Installation . 6-16 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Lift and Tilt Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Lift and Tilt Control Removal and Installation . . . . . . . . . . . . . . . . . . . 6-12 Neutral Centering Device Adjustment. . . . . . . . . . . . . . . . . . . . . . . . 6-11 Neutral Centering Device and Pump Arm Removal and Installation . . . . . . . . 6-10 Cooling System Drain Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

D Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Drive Chain Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Drive Motor Hot-Oil Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Drive Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Dual Control Weldment Removal and Installation - T-Bar . . . . . . . . . . . . . . . . . . 6-9

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E Electric Fuel Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Electrical System Chapter Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Front and Rear Work Light Bulb Replacement . . . . . . . . . . . . . . . . . . . 9-17 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Relay Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Restraint Bar Switch Removal and Installation . . . . . . . . . . . . . . . . . . . 9-16 Seat Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 9-15 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Engine Access Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Engine Chapter Air Cleaner Assembly Removal and Installation . . . . . . . . . . . . . . . . . . 10-7 Air Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . 10-7 Battery Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Electric Fuel Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . 10-9 Engine Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . 10-4 Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Exhaust Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . 10-11 Fan Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Fan Shroud Removal and Installation - 4240 Models . . . . . . . . . . . . . . . 10-16 Fuel Filter Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Fuel Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Priming Diesel Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Radiator/Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . 10-15 Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Water Separator Element Removal and Installation. . . . . . . . . . . . . . . . . 10-8 Engine Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . 10-4 Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Exhaust Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-11

Fan Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Fan Shroud Removal and Installation - 4240 Models . . . . . . . . . . . . . . . . . . . 10-16 Floor Cover and Kick Plate Removal and Installation . . . . . . . . . . . . . . . . . . . . 4-16 Foot Throttle Adjustment - T-Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Foot Throttle and Cable Removal and Installation - T-Bar . . . . . . . . . . . . . . . . . 6-18 Front and Rear Work Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . 9-17 Fuel Filter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Fuel Level Sender Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Fuel Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

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F

INDEX

G Gear Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 Grease Fitting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

H Hand Throttle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Hand Throttle Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Hand Throttle, Hand Throttle Cable and Throttle Rod Removal and Installation . . . . . . 6-16 Hydraulic Oil Filter Element Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Hydraulic Oil Tank Drain Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hydraulic System Chapter Control Valve Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . 8-30 Gear Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 8-24 Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . 8-16 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Lift and Tilt Cylinder - Disassembly and Assembly . . . . . . . . . . . . . . . . 8-23 Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 8-21 Lift Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Lift, Tilt and Brake Safety Lock Valves - Disassembly and Assembly . . . . . . . 8-29 Safety Lock Valves - Removal and Installation . . . . . . . . . . . . . . . . . . . 8-27 Self-Leveling Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Self-Leveling Valve Removal and Installation . . . . . . . . . . . . . . . . . . . 8-26 Self-Leveling Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Solenoid Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 System Pressure Test - Control Valve . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Tilt Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 8-19 Tilt Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Hydrostatic Pump Flexible Drive Plate Removal and Installation . . . . . . . . . . . . . . 7-11 Hydrostatic Pump Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Hydrostatic Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Hydrostatic System Chapter Charge Pressure Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Drive Motor Hot-Oil Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Drive Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 7-12 Hydrostatic Pump Flexible Drive Plate Removal and Installation . . . . . . . . . 7-11 Hydrostatic Pump Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Hydrostatic Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . 7-9 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

I INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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L Lift and Tilt Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Lift and Tilt Control Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 6-12 Lift and Tilt Cylinder - Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . 8-23 Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Lift Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Lift, Tilt and Brake Safety Lock Valves - Disassembly and Assembly . . . . . . . . . . . 8-29 Liftarm Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Liftarm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Liftarm Stop Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Liftarm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Liftarm Support Device Disengagement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Liftarm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Lubrication Chapter Chaincase Oil Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Cooling System Drain Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Grease Fitting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Hydraulic Oil Tank Drain Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

M

INDEX

Mainframe Chapter All-Tach Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . 4-9 Engine Access Cover Removal and Installation . . . . . . . . . . . . . . . . . . . 4-2 Floor Cover and Kick Plate Removal and Installation . . . . . . . . . . . . . . . 4-16 Fuel Level Sender Removal and Installation . . . . . . . . . . . . . . . . . . . . 4-19 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Liftarm Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Liftarm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Liftarm Stop Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . 4-14 Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Restraint Bar Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-7 ROPS Rear Window Removal and Installation . . . . . . . . . . . . . . . . . . . . 4-5 ROPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Seat Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Seat Slide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

N Neutral Centering Device Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Neutral Centering Device and Pump Arm Removal and Installation . . . . . . . . . . . . 6-10

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P Priming Diesel Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

R Radiator/Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Rear Grille Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Relay Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Restraint Bar Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Restraint Bar Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 9-16 ROPS Rear Window Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ROPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ROPS, Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ROPS, Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

S Safety Chapter Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Liftarm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Liftarm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . 2-4 Liftarm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . 2-2 Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 ROPS, Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ROPS, Raising. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Skid-Steer Loader Lowering Procedure. . . . . . . . . . . . . . . . . . . . . . . . 2-7 Skid-Steer Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Safety Lock Valves - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 8-27 Schematic Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18, 9-19 Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32 Seat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Seat Slide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Seat Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 Self-Leveling Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Self-Leveling Valve Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 8-26 Self-Leveling Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Skid-Steer Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Skid-Steer Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Solenoid Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 System Pressure Test - Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 917170/AP0106

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T TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-i Test Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Self-Leveling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 System Pressure - Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Tilt Cylinder Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19 Tilt Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Troubleshooting Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

W

INDEX

Water Separator Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . 10-8 Wheel Drives Chapter Axle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Drive Chain Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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917170/AP0106

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917170/AP0106

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