Gehl V4200 V420 (EU) V420 X-Series Skid-Steer Loaders Operator’s Manual 50950233 - PDF DOWNLOAD

V4200 V420 (EU) V420 X-Series Skid-Steer Loaders

Operator’s Manual 50950233 Rev. G 02/21 Original Instructions

WARNING This product can expose you to lead which is known to the State of California to cause cancer and birth defects or other reproductive harm.

For more information go to www.P65Warnings.ca.gov

WARNING Breathing diesel engine exhaust exposes you to chemicals known to the state of California to cause cancer and birth defects or other reproductive harm.

•

Always start and operate the engine in a well-ventilated area.

• If in an enclosed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

For more information go to www.P65warnings.ca.gov/diesel.

MANITOU EQUIPMENT AMERICA, LLC WARRANTY Manitou Equipment America, LLC under the GEHL®, MUSTANG by MANITOU®, MANITOU®, brand warrants new MANITOU Group equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months or Two Thousand Hours (2000 h) from the Warranty Start Date which occur first.

MANITOU Group WARRANTY SERVICE INCLUDES: Genuine XPRT parts and labor costs required to repair or replace equipment at the selling dealer’s business location.

MANITOU Group MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT. ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL BE DEEMED DELETED FROM THIS WARRANTY; ALL OTHER TERMS WILL CONTINUE TO APPLY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW. MANITOU Group WARRANTY DOES NOT INCLUDE: 1. Transportation to selling dealer’s business location or, at the option of the Original Retail Purchaser, the cost of a service call.

2. Used equipment.

3. Components covered by their own non- MANITOU Group warranties, such as tires, batteries, trade accessories and engines.

4. Normal maintenance service and expendable, high-wear items.

5. Repairs or adjustments caused by: improper use; failure to follow recommended maintenance procedures; use of unauthorized attachments; accident or other casualty.

6. Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment.

7. Liability for consequential damages as an unfavorable environment (chemicals, dust, salt, corrosion and erosion...)

8. Repairs completed outside MANITOU Group network and/or by personnel not trained by MANITOU Group.

No agent, employee or representative of MANITOU group has any authority to bind of MANITOU group to any warranty except as specifically set forth herein.

This agreement has been prepared in multiple languages, including but not limited to, English, Spanish, and French (Canada). In the event of any inconsistency, the English version shall apply and be binding upon the parties.

50940703/A1219

Legal Notices Software IP Any extraction, decompilation, modification, duplication, or distribution of onboard software is strictly prohibited. Manitou shall have no liability for and hereby disclaims all direct and indirect liability for the consequences resulting from the use of any prohibited onboard software. Contact MANITOU for any request to correct or adapt onboard software for the purposes of interoperability.

Data Privacy Manitou connected machines are equipped with boxes that collect technical data concerning the machines (such as geolocation, operating, and component data). This data, which is organized, processed, and enriched by Manitou’s own algorithms and knowledge, constitutes a protected database in accordance with Article L.341-1 of the French Intellectual Property Code.

It is strictly forbidden to access all or part of this database or to use this data (whether or not intentional) without Manitou’s express authorization. In the event that Manitou authorizes an individual to access all or part of this database, Manitou, as producer of this database, only grants the user a personal, non-exclusive, and non-transferrable right to use the database, and only via access to a computer platform hosted on a server owned or controlled by Manitou.

In any case, the following activities are strictly prohibited: - any extraction, reproduction, representation, reuse by making available to the public, diff sion, or transfer, whether permanent or temporary, on any support, and by any means and in any form whatsoever, of all or a qualitatively or quantitatively substantial part of the contents of the database, - any extraction, reproduction, representation, reuse by making available to the public diffusion, transfer, or repeated and systematic extraction of qualitatively or quantitatively insubstantial parts of the contents of the database when these operations clearly exceed the conditions of normal use of the database by the user of the machine for his or her own needs, - any use of a means of circumventing technical measures for the protection of databases o the source code of the software embedded in the boxes, in accordance with Article L.331-5 of the Intellectual Property Code.

In the event that the above measures are absolutely essential to enable the use of the software, in accordance with its intended purpose, or to obtain the information necessary for interoperability with other independently created software, the user must first contact Manitou, which may, at its sole discretion, take necessary measures or provide access to only the information strictly necessary for interoperability.

Any violation of these prohibitions is likely to constitute an infringement for which Manitou may take legal action.

EC DECLARATION OF CONFORMITY 1. Manufacturer: 2. Address:

Manitou Equipment America, LLC One Gehl Way West Bend, WI 53095 U.S.A

3. Technical Construction File Location:

Manitou Interface and Logistics Europe

4. Authorized Representative: 5. Address:

Manitou Interface and Logistics Europe Rue DesAndains 2 Perwez, 1360 Belgium

6.

We hereby declare that the machine listed below conforms to EC Directives: 2014/30/EU (EMC), 2006/42/EC (Machinery) and 2000/14/EC (Noise Emission), as amended by 2005/88/EC.

7.

In accordance with EN/ISO Standards: EN474-1 and EN474-3

8.

Designation:

9.

10.

Model: Serial Number:

V420 SKID LOADER

11.

Net Installed Power

- KW

12.

Sound Power Levels – (measured):

- dB(A)

(guaranteed):

- dB(A)

13.

EARTH-MOVING MACHINERY/LOADERS/COMPACT

Directive / Conformity Assessment Procedure / Notified Body:

2000/14/EC

14.

Name:

15.

Position/Title:

16.

(Signature)

17.

Place:

18.

Date:

Annex VIII, fXll Quality Assurance

TÜV Industrie Service GmbH – TÜV SÜD Group Westendst. 199, D-80686 München GERMANY

The EC Declaration of Conformity document was provided with the machine if it is manufactured to comply with specific requirements of European Union. Please refer the individual Declaration of Conformity issued with the machine for exact details.

V420 Machine Operator’s Manual TABLE OF CONTENTS Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Controls and Safety Equipment . . . . . . . . . . . . . . . . . . . 25 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 127 INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Machine Model Number Machine Serial Number Engine Serial Number

Hydraloc and Hydraglide are trademarks of Manitou Group.

Gehl, Powerview, All-Tach and Power-A-Tach are registered trademarks of Manitou Group.

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50950233/G0221

CHAPTER 1 INTRODUCTION

This Operator’s Manual provides the owner/operator with information for operating, maintaining and servicing model V420 machines. More important, this manual provides an operating plan for safe and proper use of the machine. Major points of safe operation are detailed in the Safety chapter of this manual.

Users should read and understand the contents of this manual completely and become familiar with the machine before operating it. Contact your authorized dealer if you have any questions concerning information in this manual, require extra manuals, and for information concerning the availability of manuals in other languages.

Throughout this manual information is provided set in italic type and introduced by the word Note or Important. Read carefully and comply with those messages – it will improve operating and maintenance efficiency, help avoid breakdowns and damage, and extend the machine’s life.

A manual storage box in the operator’s compartment behind the seat holds the Operator’s Manual and AEM Safety Manual (also available in Spanish). Please return the manuals to this box and keep them with the unit at all times. If this machine is resold, these manuals should be given to the new owner.

The attachments and equipment available for use with this machine have a wide variety of applications. Read the manual provided with the attachment to learn how to safely maintain and operate the equipment. Be sure the machine is suitably equipped for the type of work to be performed.

Do not use this machine for any applications or purposes other than those described in this manual or those applicable for approved attachments. If the machine is to be used with special attachments or equipment other than those approved by Manitou Group, consult your authorized dealer. Any person using non-approved attachments or making unauthorized modifications is responsible for the consequences.

The Manitou dealership network stands ready to provide any assistance that may be required, including providing genuine Manitou service parts. All service parts should be obtained from your authorized dealer. Provide complete information about the part and include the model and serial numbers of the machine. Record these numbers in the space provided on the Table of Contents page as a handy reference.

Please be aware that Manitou Group strives to continuously improve its products and reserves the right to make changes and improvements in the design and construction of any part without incurring the obligation to install such changes on any previously delivered unit.

If this machine was purchased “used,” or if the owner’s address has changed, please provide your authorized dealer or Manitou Service Department with the owner’s name and current address, along with the machine model and serial number. This will allow the registered owner information to be updated, so that the owner can be notified directly in case of an important product issue, such as a safety update program.

50950233/G0221

1

Machine Identification 3

3

2

5

8

4

8

7

1

6

5. Lift Arm 6. Tires 7. Lift Arm Support Device 8. Auxiliary Couplers

1. Attachment Bracket 2. Restraint Bar 3. Front Work Lights 4. Tilt Cylinders

3 1

5

4

4 5

2

7

1. Roll-Over/Falling Object Protective System (ROPS/FOPS) 2. Lift Cylinder 3. Engine Cover

2

6

4. Rear Work Lights 5. Tail Lights (Position Lights) 6. Rear Door 7. Fuel Cover

50950233/G0221

Control/Indicator Symbols

Electrical Power

Power Off

Engine Run

Engine Start

Battery Charge

Worklight w/Tail Lights

Worklights

Safety Hazard

Hazard Flasher

Horn

Read Operator’s Manual

Volume – Full

Volume – Half Full

High – Low

Neutral

F

Forward

R

Reverse

Parking Brake

Engine Air Filter

Engine Oil

Engine Oil Filter

Engine Oil Pressure

Fuel Filter

H-L N

Engine Temperature Hydraulic System

Fasten Seatbelt

Volume – Empty

Hydraulic Oil Temperature

Hydraulic Oil Filter Grease Lubrication Point

Glow Indicator Lamp

Diesel Fuel

Hydraulic Oil

Clockwise Rotation

Counterclockwise Rotation

Fast

Slow

Ride Control

Engine Malfunction Shutdown

Self-Leveling

Bucket – Rollback

Bucket – Dump

Lift Arm – Lower

Lift Arm – Raise

Service Hours

Tie-Down

Diesel Water Separator

Power-A-Tach®

Lift Point

50950233/G0221

Service Interval

3

Control/Indicator Symbols, cont.

Low Fuel Alarm

Master Light Switch

Position Lights

Engine Speed Control

Crush Hazard

Pinch Point

Crush Hazard

Safety Lock

HVAC Fan

Auxiliary Hydraulics Flow

Diesel Exhaust Fluid (DEF)

% Engine Power Percentage

Remove Key

Hot Surface Hazard Rotating Fan - Keep Away

Lift Arm Float

Hitch Lock

Hitch Unlock

Heater

Engine Temp

Air Conditioning

Engine Error Code

Lock

Unlock

Front Window Washer

Rear Window Washer

Front Window Wiper Rear Window Wiper

Beacon

Regeneration

Regeneration Inhibit

4

Critical Error Warning

Fan Reverse

50950233/G0221

CHAPTER 2 SAFETY

This safety alert symbol means Attention! Become alert! Your safety is involved! It stresses an attitude of safety consciousness and can be found throughout this Operator’s Manual and on the decals on the machine.

Before operating this machine, read and study the following safety information.

Be sure that everyone who operates or works with this machine, whether family member or employee, 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.

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

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

Manitou Group 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. This Operator’s Manual and decals on the machine warn of additional hazards, and they should be read and observed closely.

Some photographs in this manual may show doors, guards or shields open or removed for illustrative purposes only. Be sure that all doors, guards and shields are in their proper operating positions before starting the engine to operate the unit.

Different applications may require optional safety equipment. Users must evaluate the work-site hazards and equip the machine and the operator as necessary.

The information in this manual does not replace any applicable safety rules and laws. Before operating the machine, learn the rules and laws for the local area. Be sure the machine is equipped as required in accordance with these rules/laws.

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

DANGER

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

WARNING

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

CAUTION

50950233/G0221

5

Mandatory Safety Shutdown Procedure 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 lift arm and attachment completely. If the lift arm must be left in the raised position, BE SURE to properly engage the lift arm support device (page 28).

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

4. Before exiting, move the lift/tilt control(s) to verify that the controls do not cause movement of the lift arm and hitch.

Safety Reminders Before Starting  Do not modify the ROPS/FOPS unless instructed to do so in installation instructions. Modifications such as welding, drilling or cutting can weaken the structure and reduce the protection it provides. A damaged ROPS/FOPS cannot be repaired – it must be replaced.  To ensure safe operation, replace damaged or worn-out parts with genuine XPRT service parts.  Gehl machines are designed and intended to be used only with Manitou attachments and approved attachments. To avoid possible personal injury, equipment damage and performance problems, use only attachments that are approved for use on and within the operating capacity of the machine. Contact your dealer for information on attachment approval and compatibility with specific machine models. Manitou Group cannot be responsible if the machine is used with a non-approved attachment.  Remove all trash and debris from the machine each day, especially in the engine compartment, to minimize the risk of fire.  Always face the machine and use the handholds and steps when getting on and off the machine. Do not jump off the machine.  Never use starting fluid (ether).  Walk around the machine and warn all nearby personnel before starting the machine.  Always perform a daily inspection of the machine before using it. Look for damage, loose or missing parts, leaks, etc.

6

50950233/G0221

During Operation  Machine stability is affected by: load being carried, height of the load, machine speed, abrupt control movements and driving over uneven terrain.

DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE MACHINE TO TIP, THROWING THE OPERATOR OUT OF THE SEAT OR MACHINE, RESULTING IN DEATH OR SERIOUS INJURY. Therefore: ALWAYS operate with the seatbelt fastened and the restraint bar lowered. Do not exceed the machine’s Rated Operating Capacity.

Carry the load low. Move the controls smoothly and gradually, and operate at speeds appropriate for the conditions.  When operating on inclines or ramps, always travel with the heavier end of the machine toward the top of the incline for additional stability.  Do not raise or drop a loaded bucket or fork suddenly. Abrupt movements under load can cause serious instability.  Never activate the float function with the bucket or attachment loaded or raised, because this will cause the lift arm to lower rapidly.  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 machine and the load.  Never carry riders. Do not allow others to ride on the machine or attachments, because they could fall or cause an accident.  Always look to the rear before backing up the machine.  Operate the controls only from the operator’s seat.  Always keep hands and feet inside the operator’s compartment while operating the machine.  New operators must operate the machine in an open area away from bystanders. Practice with the controls until the machine can be operated safely and efficiently.  Wear safety goggles and head protection while operating the machine. Operator must wear protective clothing when appropriate.  Exhaust fumes can kill. Do not operate this machine in an enclosed area unless there is adequate ventilation.  When parking the machine and before leaving the seat, check the restraint bar for proper operation. The restraint bar, when raised, deactivates the lift/tilt control and auxiliary hydraulics, and applies the parking brake.  Operator visibility is limited in certain areas; ROPS/FOPS posts, attachments, the lift arm, items in the cab, etc., can obstruct the operator's view and could mask hazards or people in the area around the machine. It is very important the operator is aware of these masked visibility areas before operating the machine, especially on busy worksites.

To reduce the hazards posed by masked visibility areas:  Use caution when raising or lowering attachments; masked visibility areas can change dramatically when attachments and/or the lift arm is moved.

50950233/G0221

7

 Look around the machine before operating. Objects near the machine

and close to the ground can be difficult to see from the operator’s position.  Always look in the direction of travel, including reverse. A back-up alarm is not a substitute for looking behind you when operating the machine in reverse.  Keep bystanders out of, and away from, the work area.  Keep the lift arm as low as possible while traveling.  Additional equipment may be installed on the machine to serve as visual aids (e.g., mirrors, CCTV systems) that provide visibility to areas masked by the machine structure. Keep all machine components that affect visibility in a clean, properly adjusted state and in good working order.

Maintenance  Never attempt to bypass the key switch to start the engine. Use only the jumpstarting procedure detailed in the Operation chapter of this manual.  Never use your hands to search for hydraulic fluid leaks. Instead, use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and can penetrate the skin and cause serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid must be surgically removed by a doctor or gangrene may result.  Always wear safety glasses with side shields when 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 the eyes or other parts of the body.  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.

Potential Hazards A machine operator must ALWAYS be conscious of the working environment.

Operator actions, the environmental conditions and the job being preformed require the full attention of the operator so that safety precautions can be taken.

ALWAYS maintain a safe distance from electric power lines and avoid contact with any electrically charged conductor or gas line. Accidental contact or rupture can result in electrocution or an explosion. Contact the North American One-Call Referral System at 8-1-1 in the U.S., or 1-888-258-0808 in the U.S and Canada, for the local “Digger's Hotline” number or the proper local authorities for utility line locations BEFORE starting to dig!

8

50950233/G0221

Exposure to crystalline silica (found in sand, soil and rocks) has been associated with silicosis, a debilitating and often fatal lung disease. Comply with all applicable rules and regulations for the workplace. Wear approved respiratory protection or use water spray or other means if there is no other way to control the dust.

A Silica rule “29 CFR 1929.1153" by the U.S. Occupational Safety and Health (OSHA) indicates a significant risk of chronic silicosis for workers exposed to inhaled crystalline silica over a working lifetime. Refer to the rule for more information regarding exposure limits and hazard prevention.

Safety Decals The machine has decals that provide safety information and precautions around the machine. These decals must be kept legible. If missing or illegible, they must be replaced promptly. Replacements can be obtained from your authorized dealer. If there is a decal on a part that is to be replaced, be sure that the decal is applied to the replacement part.

New Decal Application Surfaces must be free of dirt, dust, grease and foreign material before applying the decal. Remove the smaller portion of the decal backing paper and apply the exposed adhesive to the clean surface, maintaining proper position and alignment. Peel the rest of the backing paper and apply hand pressure to smooth out the decal surface. Refer to the following pages for proper decal location. Text decals begin on page 10; no-text decals begin on page 14.

Machines Equipped with Air Conditioning This product contains R134a which is a fluorinated greenhouse gas with a Global Warming Potential of 1430. The decal shown indicates the amount of R134a gas contained within the machine’s A/C system and its corresponding CO2e. “CO2e” means CO2 equivalent. The decal is located within the engine compartment and is positioned adjacent to the A/C system components that contain the R134a gas.

Do not allow the R134a gas to be discharged from the machine A/C system into the atmosphere when performing service and maintenance on this machine.

50950233/G0221

9

ANSI-Style Safety Decals inside the ROPS/FOPS

@ @ @ @ ,= >5* + = 0# 7;?@ %$7> &:8# =0 43$ @

242582 Behind operator’s ůĞŌ ƐŚŽƵůĚĞƌ

$! .- 92' @ $71)"3$/ <$)$>@

6(@

ϱϬϯϮϬϱϱϬ On right corner post.

242397 KŶ ůĞŌ ĐŽƌŶĞƌ ƉŽƐƚ͘

10

242260 KŶ ůĞŌ ĐŽƌŶĞƌ ƉŽƐƚ͘

50950233/G0221

ANSI-Style Safety Decals on the outside of the Machine

137655 – Located on front of machine and crossmember

132166 – Located on rear window emergency exit

139101 – Located on lift arm crossmember

50950233/G0221

11

ANSI-Style Safety Decals on the outside of the Machine

184214 – Located under the ROPS/FOPS

12

50950233/G0221

ANSI-Style Safety Decals in the Engine Compartment

137657 – Located on tower crossmember

Hose removal or c omponent failure can cause lift arm to drop.

Always use lift arm suppo rt device when leaving lift arm raised for ser vice.

To install lift arm support, raise lift arm and have he lper: 1. Remove retaining pin and support from storage location; 2. Install support on left lift cylinder with tab fac ing for ward; 3. Secure support with retaining pin.

Then, slowly lower lift arm until braced by support.

137756

137756 – Located on lift arm support device

IMPORTANT COOLANT FILL INSTRUCTIONS Coolant must be topped off after radiator has been drained and refilled. Operate unit until thermostat has opened, then shut off.

Allow radiator to cool before opening cap.

Top off with coolant.

50311526 – Located on coolant tank

191499 – Located on coolant tank

137658 – Located on tower crossmember

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13

ISO-Style (used Internationally) Safety Decals inside the ROPS/FOPS Safety alert: Always follow “Mandatory Safety Shutdown Procedure” in Operator’s Manual.

1 – Lower equipment to ground.

2 – Reduce throttle, stop engine.

3 – Apply parking brake; remove key.

4 – Check safety interlocks.

242568 – Located behind operator’s left shoulder Safety alert: Read Operator’s Manual and all safety signs before using machine. The owner is responsible to ensure all users are instructed on safe use and maintenance.

242246 – Located on right instrument panel Safety alert: A – Check machine before operating; Service per Operator’s Manual. Contact dealer (or manufacturer) for information and service parts.

B – Maintain 3-point contact during B A entry and exit.

C – Inspect work area. Avoid all hazards. Look in direction of C D travel. Keep children and bystanders away.

D – Start and operate machine only from seat.

F E E – Keep away from power lines; avoid contact.

F – Wear any needed Personal 242590 – Protective Equipment. Do not Located on left wear loose clothing while instrument panel operating or servicing machine.

A

A

B

242408 – Located on operator’s lower left side

C

A – Forward tip hazard: Fasten seat belt. Carry load low. Do not exceed Rated Operating Load.

B – Side tip hazard: Avoid steep slopes and high speed turns.

Travel up and down slopes with heavy end uphill.

C – Crush hazard: Keep out from under lift arm unless lift arm is supported.

D – Crush hazard: Keep hands, feet and body inside cab when operating.

B

C

D

D 242284 – Located on operator’s lower right side

14

50950233/G0221

ISO-Style (used Internationally) Safety Decals on the outside of the Machine A

B

137844 – Located on front of machine and crossmember A – Crush hazard: Keep out from under work tool unless lift arm is supported.

B – Fall hazard: No riders. Never use work tool as work platform.

132166 – Located on rear window emergency exit

A B

139101 – Located on hitch Crush hazard: Before operating with attachment, check engagement of hitch locking pin to the attachment: A – Incorrect attachment engagement B – Correct attachment engagement

50950233/G0221

15

ISO-Style (used Internationally) Safety Decals on the outside of the Machine

184711 – Located under the ROPS/FOPS Crush hazard: Be sure lock mechanism is securely engaged before working under ROPS/ FOPS. Read instructions for use in Operator’s Manual.

IMPORTANT

A

COOLANT FILL INSTRUCTIONS Coolant must be topped off after radiator has been drained and refilled. Operate unit until thermostat has opened, then shut off.

Allow radiator to cool before opening cap.

Top off with coolant.

191499 – Located on coolant tank B

C

137853 – Located on lift arm support device A – Crushing hazard; whole body.

B – Read Operator’s Manual.

C - Lock lift cylinder.

16

50950233/G0221

ISO-Style (used Internationally) Safety Decals in the Engine Compartment A

B

C

D

E

F

137845 – Located on tower crossmember A – Safety alert: Keep safety devices in place and in working order. Keep guards, screens and windows in place.

B – Fire hazard: Do not smoke while fueling or servicing machine. Clean debris from engine compartment daily to avoid fire. Keep fire extinguisher nearby.

C – Run-over hazard: Jump-start per Operator’s Manual procedure.

D – Oil injection hazard: Do not use hands to find hydraulic leaks. Escaping oil under pressure can be invisible and penetrate skin. Use a piece of cardboard to find leaks.

E – Burn hazard: Allow radiator to cool before removing cap. Loosen cap slowly to avoid burns.

F – Suffocation hazard: Operate only in a well-ventilated area.

50311526 – Located on coolant tank

A

B

137846 – Located on tower crossmember A – Rotating fan: Keep hands out or stop engine.

B – Hot surface: Do not touch hot engine or hydraulic system parts.

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17

Product and Component Plate Locations 4

6

6

1

5

3

2

Product and Component Plates 1. Operator protective system plate: with, e.g., model, certification and operator protective system serial number 2. Seat plate according to ISO 7096 3. Product plate: with Product Identification Number and, e.g., model/type designation 4. Engine plate: with, e.g., type designation, product and serial numbers 5. Component plate hydrostatic pump: with, e.g., product and serial numbers 6. Component plate drive motor: with, e.g., product and serial numbers

18

50950233/G0221

CHAPTER 3 SPECIFICATIONS Loader Specifications Specification Operating Weight (approx) Shipping Weight (approx) Rated Operating Load1 Engine Make Model Displacement Power (net) Peak Torque Hydraulic System (theoretical) Main Hydraulic System Pressure Standard-Flow Rating High-Flow System Pressure High-Flow Rating Electrical Battery (each) Starter Alternator Capacities Chaincase (each) Engine Oil DEF Tank (If So Equipped) Engine Coolant Fuel Tank Bare Hydraulic Reservoir Entire Hydraulic System Maximum Travel Speed - Low Maximum Travel Speed - High Sound Levels (with EU Sound Attenuation Package) Sound Pressure Level (Operator Ear) Sound Power Level (Environmental)

V420 5291 kg (11665 lbs.)

4837,5 kg (10665 lbs.)

1905 kg (4200 lbs.)

Deutz (Turbocharged) TCD36 3,62 L (221 cu. in.)

90 kW (120 hp) @ 2200 rpm 480 N·m (354 ft.-lb.) @ 1600 rpm 238 bar (3450 psi) 114 L/min (30.1 gpm) 238 bar (3450 psi) 155 L/min (41.0 gpm) 12 Volt DC, 750 CCA, Group 24 4.0 kW (12 Volt DC) 120-amperes 14,2 L (15 U.S. qts.)

9,5 L (10 U.S. qts.)

15,1 L (4 U.S. gal.)

18,9 L (5 U.S. gal.)

144 L (38 U.S. gal.)

59,8 L (15.8 U.S. gal.)

79 L (21 U.S. gal.)

10,5 kph (6.53 mph) 18,7 kph (11.6 mph)

83 dB(A) 103 dB(A)

1. Operating load rated with an 84 in. (2134 mm) 27.0 cu. ft. (0.76 m3) Dirt/ Construction bucket and 14 x 17.5 NHS tires in accordance with SAE J818 and ISO 14397-1.

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19

Standard Features  Multi-Function Display  Hydraulic Oil Temperature Indicator Lamp

 Battery Charge Indicator Lamp  Seatbelt Indicator Lamp and Buzzer

 One control type: Dual Joystick  Hand Throttle  Acoustical Cab Material and Headliner

 Adjustable Operator Restraint Bar

with Armrests (Hand/Foot and Dual Joystick only)  ROPS/FOPS (ISO 3471, ISO 3449 Level II)  Skid Plate for Clean Out  Interior Dome Light  Self-Leveling Lift Action  Hydraloc™ System – Brakes and Interlock for Starter, Lift Cylinders, Tilt Cylinders, Auxiliary Hydraulics, Wheel Drives  Upper-torso Restraint  Dual-Element Air Cleaner with Visual Indicator

 Anti-Vandalism Rear Door  Pre-Heat Starting Assist  Servo-Controlled Hydrostatic Drive  Lift Arm Support Device  Dual Front and Rear Halogen Work Lights and Dual Tail Lights

 Bi-directional Auxiliary Hydraulics with Flat-Faced Couplers

 Engine Auto-Shutdown System  Emergency Exit Rear Window  Air Suspension Seat  Hydraglide™ Ride Control System  Two-Speed Drive  Foot Throttle  Battery Disconnect Switch  Horn  Power-A-Tach® Attachment Mounting System

 Audible Back-Up Alarm  Engine Block Heater  Bluetooth Radio  Engine Fan Reverse  Rear Window Wiper  High-Flow Hydraulics

Optional Features  3-inch Wide Seatbelt –

where required by law  Sliding Side Windows  Rear-View Mirror  Front Door with Wiper  Operator’s Compartment Heater/ Defroster/Air Conditioner with Filters  Strobe Light

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 Bucket Bolt-On Cutting Edge Kits  Impact-Resistant Front Door Window

 Single and Four-Point Lift  LED Lights  Rear Camera  Brake Release

20

Dimensional Specifications

27.0 ft3 (0.76 m3) Bucket w/14 x 17.5 Tires inches mm A Overall Operation Height – Fully Raised 187.25 4756 B Height to Hinge Pin – Fully Raised 143.8 3653 C Overall Height – Top of ROPS 81.5 2070 D Overall Length – Bucket Down 159 4039 E Dump Angle at Full Height 31° F Dump Height 114.5 2908 G Dump Reach – Bucket Full Height 37.5 952 J Rollback at Ground 30° M Rollback Angle at Full Height 98° O Seat to Ground Height 41.2 1046 P Wheel Base – Nominal 54.5 1384 1 Q Overall Width – Less Bucket 81 2057 R Bucket Width – Overall 84 2134 S Ground Clearance – to Chassis (Between Wheels) 7.7 197 V Overall Length (Less Bucket) 123 3124 W Departure Angle 18° X Clearance Circle – Front (With Bucket) 97.8 2484 Y Clearance Circle – Front (Less Bucket) 55.5 1410 Z Clearance Circle – Rear 74 1880

V420

1. Overall width (Q) is dependent upon the amount of wheel offset.

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21

Capacities and Ratings V420 Note: Use the Common Materials and Densities table (page 23) for selecting the appropriate bucket.

Dirt/Construction Buckets Description 84 in./27.0 ft3 (2134 mm/0.76 m3) 84 in./27.0 ft3 HD (2134 mm/0.76 m3) 90 in./29.0 ft3 (2286 mm/0.82 m3) Landscaping/Grading Description 84 in./23.3 ft3 (2134 mm/0.66 m3) Light Material Description 90 in./37.0 ft3 (2286 mm/1.05 m3)

Pallet Forks - 48 in. (1229 mm) Description For 15.7 in. (400 mm) Load Center per EN 474-3 For 19.7 in. (500 mm) Load Center per EN 474-3 For 24 in. (670 mm) Load Center per SAE J1197

22

Weight 397 kg (875 lbs.)

449 kg (989 lbs.)

417 kg (919 lbs.)

Weight 373 kg (822 lbs.)

Weight 416 kg (918 lbs)

Weight 213 kg (470 lbs.)

213 kg ( 470 lbs.)

213 kg (470 lbs.)

V420 Rating 1905 kg (4200 lbs.)

1798 kg (3963 lbs.)

1905 kg (4200 lbs.)

V420 Rating 1905 kg (4200 lbs.)

V420 Rating 1905 kg (4200 lbs.)

V420 Rating 1676 kg (3695 lbs.)

1557 kg (3433 lbs.)

1447 kg (3190 lbs.)

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Common Materials and Densities Material Ashes Brick-common Cement Charcoal Clay, wet-dry Coal Concrete Cinders Coal-anthracite Coke Earth-dry loam Earth-wet loam Granite Gravel-dry Gravel-wet Gypsum-crushed Iron ore Lime Lime stone Manure-liquid Manure-solid Peat-solid Phosphate-granular Potash Quartz-granular Salt-dry Salt-rock-solid Sand-dry Sand-wet Sand-foundry Shale-crushed Slag-crushed Snow Taconite

Density lbs./cu. ft.

35-50 112 110 23 80-100 53-63 115 50 94 30 70-90 80-100 93-111 100 120 115 145 60 90 65 45 47 90 68 110 100 135 108 125 95 90 70 15-50 107

kg/m3 560-800 1792 1760 368 1280-1600 848-1008 1840 800 1504 480 1121-1442 1281-1602 1488-1776 1602 1922 1840 2320 960 1440 1040 720 752 1440 1088 1760 1602 2160 1728 2000 1520 1440 1120 240-800 1712

Note: The densities listed are average values and intended only as a guide for bucket selection. For a material that is not in the table, obtain its density value before selecting the appropriate bucket.

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23

Bucket Selection To use the table, find the material to be loaded and its maximum density. Then multiply the volumetric rating of the attachment by the material density to determine if the attachment can safely be used. See page 22 for a listing of attachments and their ratings.

Where the material density is listed as a range (snow at 15-50 lbs./ft3, for example), always use the maximum density (50 lbs./ft3 in this example) for making calculations. Also, see the following examples.

Example 1: Clay (density of 80-100 lbs./cu. ft.) is to be hauled with a V420 model skid loader using a 84 in. dirt/construction bucket (SAE J742-rated heaped capacity of 27.0 cu. ft.). With this bucket, the V420 has a rating of 4200 lbs. Multiplying the maximum density of the material by the bucket capacity (100 x 27.0) yields a load that weighs 2700 lbs. This number is less than the machine rating and thus indicates that the loader/bucket combination is safe to use in this application.

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CHAPTER 4 CONTROLS AND SAFETY EQUIPMENT Become familiar with and know how to use all safety devices and controls on the machine before operating it. Know how to stop machine operation before starting it. This machine is designed and intended to be used only with Manitou attachments or Manitou Group-approved referral attachments or accessories. Manitou Group cannot be responsible for operator safety if the machine is used with non-approved attachments.

WARNING

Guards and Shields Whenever possible and without affecting machine operation, guards and shields are provided to protect against potentially hazardous areas. In many places, safety decals are also provided to warn of potential hazards and/or to display special operating procedures.

Read and thoroughly understand all safety decals on the machine before operating it. Do not operate the machine unless all factory-installed guards and shields are properly secured in place.

WARNING

Operator Restraint Bar Lower the operator restraint bar after entering the operator’s compartment and sitting in the seat. The restraint bar is securely anchored to the ROPS/FOPS. The operator must be seated with the restraint bar in its lowered position to start or operate the machine. Refer to Safety Interlock System on page 26 for more information.

The dual joystick restraint bar provides fore-aft adjustment that allows the operator to determine the most comfortable position of the restraint bar. The right and left portions of the restraint bar system can be adjusted independent of one another by pushing the lever on the lower inside of either pad. The restraint pad can then be used to adjust to the desired position. The restraint pad locks in place when it is released.

WARNING wear the seatbelt.

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Never defeat the operator restraint bar or seat switch electrically or mechanically. Always

25

Operator’s Seat The seat is mounted on rails for rearward and forward repositioning. A springloaded lever unlocks the seat position adjustment mechanism.

Air Suspension Seat: Adjust the air suspension seat by pushing in the knob on the air seat to increase the amount of suspension. Pull knob out to release air and decrease the suspension level.

Upper-Torso Restraint WARNING

1

3

2

4

1. Restraint Bar 2. Seatbelt 3. Seat Position Adjustment Lever 4. Suspension Seat Weight Adjustment Knob

Fig. 1 Operator’s Seat

Always wear the upper-torso restraint when operating in High speed.

The seatbelt should always be fastened during operation.

Important: Inspect the seatbelt(s) for damage before use, and replace if damaged. Keep seatbelt(s) clean. Use only soap and water to wash seatbelt(s).

Cleaning solvents can cause damage to seatbelt(s).

Safety Interlock System Hydraloc™ NEVER defeat the safety interlock system by mechanically or electrically bypassing any switches, relays or solenoid valves.

WARNING

An interlock system is provided on the machine for operator safety. Together with solenoid valves, switches and relays, the interlock system:

 Prevents the engine from starting unless the operator is sitting on the seat and

the operator restraint bar is lowered.  Disables the lift arm, auxiliary hydraulics, attachment tilt and wheel drives whenever the operator leaves the seat, turns the keyswitch to OFF or raises the restraint bar.

Note: The auxiliary hydraulic circuit can be detented in the “on” position for continuous operation with the restraint bar raised and operator out of the seat.

(See Auxiliary Hydraulic Controls, page 48.)

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Testing the Safety Interlock System Before exiting the machine, check the safety interlock system for proper operation:

Restraint Bar With the engine running, raise the restraint bar. Test each of the controls. There should be no more than a slight movement of the lift arm, hitch and machine. If there is any significant movement, troubleshoot and correct the problem immediately. Contact your dealer if necessary.

Seat Switch With the engine off and the restraint bar lowered, unfasten the seatbelt, and lift your weight off the seat. Try to start the engine. If the engine starts, turn off the engine, troubleshoot and correct the problem. Contact your dealer if necessary.

ROPS/FOPS The Roll-Over/Falling Object Protective Structure (ROPS/FOPS) is designed to provide protection for the operator from falling objects and in a tip over accident, if the operator is secured inside the operator’s compartment by the seatbelt and restraint bar.

WARNING

Never operate the machine with the ROPS/ FOPS removed or locked back.

Parking Brake This machine is equipped with a springapplied, hydraulic-released parking brake.

The parking brake engages when the operator lifts or lowers the restraint bar, exits the seat or shuts off the engine. The brake can also be applied manually by using the button located on the right keypad. The brake’s default setting is ON. Check the button on the keypad before operating the machine. A red indicator in the button lights when the parking brake is applied.

Fig. 2 Parking Brake Button

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27

Horn Pressing the right button on the left control handle sounds the horn.

Rear Window Emergency Exit The ROPS/FOPS rear window has three functions: noise reduction, flying objects protection and emergency exit.

To use the emergency exit, pull on the yellow warning tag at the top of the window and remove the seal. Push or kick out the window and then exit.

See your local automotive glass specialist to reinstall the window.

Lift Arm Support Device The lift arm support device is used as a cylinder lock to prevent the raised lift arm from lowering unexpectedly. Be sure to install the support device when the lift arm is raised for service. When the support device is not being used, return it to its storage position. The support device is a safety device which must be kept in proper operating condition at all times. The following steps ensure correct usage: With the key switch OFF and the solenoid valve working properly, the lift arm will stay raised when the lift control is moved to lower the lift arm. If the valve does not hold the lift am and it begins to lower do not leave the operator’s compartment. Instead, lower the lift arm and exit the machine. Then, contact your authorized dealer immediately to determine why the lift arm lowers while the key switch is OFF.

WARNING

Installation To install the lift arm support device: 1. Raise the lift arm to full height.

2. Stop the engine.

3. Move the lift arm control to “lower” to verify that the lift arm is being held in the raised position by the safety interlock system.

4. Have an assistant remove the lift arm support device from its storage location (Fig. 4) on the left side of the machine and install the lift arm support device on the left lift cylinder (Fig. 3).

5. Secure the support device to the lift cylinder rod with the attached lock pin and chain.

6. Restart the engine.

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Fig. 3 Lift Arm Support Device Engaged

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7. Slowly lower the lift arm until it engages and locks against the lift arm support device.

8. Stop the engine and exit the machine.

Removal The safest method of installing and removing the lift arm support device requires two people – one person inside the machine and another person outside the machine to install the support device.

WARNING

To return the lift arm support device to its storage position: 1. Start the engine2. Raise the lift arm fully3. Stop the engine4. Verify that the lift arm is being held in the raised position by the safety interlock system.

With the key switch OFF and the solenoid valve for the safety interlock system functioning properly, the lift arm will stay raised when the lift control is moved to “lower”. If the lift arm moves, do NOT leave the operator’s compartment. Instead, have an assistant remove the support device for you. Then, contact your authorized dealer to determine the reason why the lift arm lowers while the key switch is in the OFF position.

WARNING

5. Have an assistant remove the lift arm support device.

6. Lower the lift arm and secure the lift arm support device with the lynch pin in the storage location (Fig. 4).

Fig. 4 Lift Arm Support Device Storage Location

Accessory Plug The 12 V accessory plug is located at the bottom of the right instrument panel.

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29

Dome Light The dome light is located on the right side of the ROPS/FOPS headliner. Push the dome light to switch it on.

Beacon/Position/Work Lights Machines have two sets of work lights. The front work lights are located at the top of the ROPS/FOPS. The rear work lights are located at the top of the rear door.

The optional beacon and front/rear work lights are all operated using the beacon/ lights button on the right keypad (Fig. 5).

• Beacon: Press the button once to activate the beacon. The LED is lit when the beacon and front work lights are on.

• Beacon and Front Work Lights: Press the button twice to activate the beacon, rear marker lights, and the front work lights. The LED is lit when the beacon, rear marker Fig. 5 Beacon/Position/Work lights, and front work lights are Lights Button on.

• Beacon and Front/Rear and Work Lights: Press the button three times to activate the beacon and the front/rear work lights. Both LEDs are lit when the beacon and the front/ rear work lights are on.

• Off: Pres the button a fourth time to turn off the beacon and the work lights. Both LEDs are off when the beacon and work lights are off.

Switch off the front work lights when traveling on public roads. Work lights can dazzle motorists and cause accidents.

WARNING

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Heater and/or Air Conditioner (option) Machines with the combination heater/air conditioner have two control buttons on the left keypad for controlling fan speed and heater/air conditioner temperature.

1

• Fan Speed Control: Controls the air flow. Press this button once for the low setting, twice for medium and three times for high. LEDs 2 above the button are lit according to the low, medium and high fan settings. Press this button a fourth time to deactivate the air circulation fan.

• Temperature Control: Press this button as desired to set the cab fan/ heat/cool settings; additional pressings of this button with Fig. 6 Heater/ Air Conditioner Controls increase the heat from low to high.

LEDs above the button are lit according to the cool, low, medium and high heat settings. There is also a fan-only setting with this control.

The sequence of the temperature control button pressings are: • When there are no LED lights lit and no icons are lit. This setting is for fan-only air recirculation in the cab.

• With one press a blue LED lights above the button and the air conditioning icon is lit. This setting is for air conditioning the cab.

• With two presses a blue and yellow LED lights above the button and the heater icon is lit. This setting is for low heat in the cab.

• With three presses a yellow LED lights above the button and the heater icon is lit. This setting is for low to medium heat in the cab.

• With four presses a yellow and red LED lights above the button and the heater icon is lit. This setting is for medium to high heat in the cab.

• With five presses a red LED lights lit above the button and the heater icon is lit. This setting is for high heat in the cab.

• With six presses the temperature control button goes off.

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31

Engine Speed Control An engine speed control (Fig. 7) sets the engine speed. Move the control clockwise to increase the engine speed, and counterclockwise to decrease the engine speed.

A foot pedal (Fig. 8) is a secondary throttle, which can be used to override the engine speed control. If the foot throttle is released, the engine will return to the speed set by the engine speed control.

Two-Speed Drive (Travel Mode Only)

Fig. 7 Engine Speed Control

Fig. 8 Foot Throttle

Dual joystick machines use the left button on the left control handle for shifting between High (H) and Low (L). Shifting to High allows the machine to exceed 6.5 mph (11,6 kph), up to a maximum speed of 11.6 mph (18,7 kph). When the machine is in High (H) an H icon on the right keypad will illuminate (Fig. 9).

Press the button once to activate, and again to deactivate.

Note: Speed varies slightly with tire size.

Fig. 9 Location of Two-Speed Indicator Light on the right keypad.

When two-speed drive is activated, down shifting to single-speed drive while traveling at full speed is not recommended and damage may result.

WARNING

32

50950233/G0221

Hydraglide™ Ride Control System Dual joystick machines use the right button on the right control handle for shifting between normal mode and ride control mode. The ride control system provides a smoother ride over uneven surfaces. Press the button once to activate the system, and again to deactivate. The ride control system is automatically deactivated when the machine is shut off.

When the machine is in ride control an icon on the right keypad will illuminate (Fig. 10)

Fig. 10 Location of Ride Control Indicator Light on the right keypad.

When ride control is activated, the lift arm may drop slightly without a load or several inches with a heavy load.

WARNING

Float Control Dual joystick machines use the left button on the right control handle for shifting between normal mode and float mode.

This mode allows the lowered lift arm to follow the ground contour while traveling over changing ground conditions. Press and hold the button for ten seconds or longer to detent, and press again to deactivate. The float mode is automatically deactivated when the machine is shut off.

When the machine is in float control an icon on the right keypad will illuminate (Fig. 11).

Fig. 11 Location of Float Control Indicator Light on the right keypad.

Never use the float mode with the attachment raised, because this will cause the lift arm to lower very rapidly. The float mode can be used when the engine has stopped, is unable to be started, and lowering the lift arm is necessary to allow the operator to exit the machine.

WARNING

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33

Attachment Mounting The machine is equipped with the Power-A-Tach® hitch for mounting a bucket or other attachments (Fig. 12).

Power-A-Tach® System The right keypad is used to operate the Power-A-Tach System hitch. The hitch will not operate if the parking brake switch is activated or if the restraint bar is in its vertical (open) position. (Refer to page 55 for more information.)

Note: The engine fan speed may fluctuate when operating the hitch.

To retract the hitch pins:

Fig. 12 Power-A-Tach® Hitch

1. Press the Power-A-Tach unlock button on the right keypad.

To extend the hitch pins: 2. Press the Power-A-Tach lock button on the right keypad.

2

1

Fig. 13 Location of the two Power-A-Tach buttons on the right keypad.

To prevent unexpected release of the attachment from the hitch, be sure the latch pins are secure by verifying that the pin flags have moved fully to the outside of the hitch.

WARNING

34

50950233/G0221

Multi-Function Display The multi-function display (Fig. 14) is located above the ignition switch. It provides the following functionality: • Displays operational status such as engine fuel tank level, engine rpm, coolant temperature, operation time ,and system voltage • Displays error fault codes and input/output diagnostic data • Is used to initiate an emission component cleaning • Configures display settings A

esc

E

C

ok

B

G

D

F

Fig. 14 Multi-Function Display

Table 1: Multi-Function Display Ref. Item

Description

A

Navigation Rocker Button

Used for general screen navigation and other various functions, depending upon screen and context.

B

OK Button

Used for various functions, depending upon screen and context.

C

Increase Brightness/Return Button

Used for various functions, depending upon screen and context: • Used to increase display brightness. Corresponds to the symbol on the display screen.

• Used to return to previous screen. Corresponds to the symbol on the display screen.

D

Decrease Brightness Button

Used to decrease display brightness. Corresponds to the display screen.

symbol on the

Used for various functions, depending upon screen and context: • Switches to the regeneration display mode if the symbol is displayed on the screen. Also initiates regeneration if all appropriate conditions are met.

• Used to return to previous screen. Corresponds to the symbol on the display screen.

E

Standstill Regeneration/Return Button

F

Standtill Regeneration Inhibit Button

Press for 3 seconds to inhibit regeneration. Displays the

esc (escape) Button

Press to exit secondary screens and return to previously selected status screen.

G

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symbol.

35

If the LCD is broken, take care with any leaking fluid. If LCD fluid gets onto skin, wipe with a cloth and wash the area with mild soap and water. If LCD fluid gets into eyes, thoroughly rinse the eyes with clean water for several minutes and seek medical assistance. If the LCD fluid is swallowed, rinse the mouth thoroughly with clean water, then drink a substantial volume of water and induce vomiting. Then seek medical assistance.

WARNING

Multi-Function Display Symbols The following table describes symbols used on the multi-function display.

Note: Values may not display for all parameters, depending upon installed options and equipment.

Table 2: Symbol Descriptions Symbol

Description

Symbol

Description

Engine crankshaft revolutions per minute.

Parking brake.

Accumulated operation time. Time is displayed in hours, and accumulates when the engine is running.

Display brightness increase. Press button (C, Fig. 5) when this symbol is displayed to increase screen brightness.

Battery charging circuit voltage.

Display brightness decrease. Press button (D, Fig. 5) when this symbol is displayed to decrease screen brightness.

Fuel level in fuel tank.

Return to previous. Press button (B, Fig. 5) when this symbol is displayed to return to the previous screen.

n/min

Coolant temperature.

IMPORTANT: Running the engine in an overheated condition can damage the engine.

%

36

Standstill SCR regeneration. See “Selective Catalytic Reduction (SCR) Standstill Regeneration”.

Percentage of engine power based on load.

Standstill SCR regeneration inhibit. See “Selective Catalytic Reduction (SCR) Standstill Regeneration”.

Critical error warning. Causes error screen(s) to display. See “Error/Status/ History Screens”.

Standstill SCR regeneration regeneration inprogress (elevated temperature). See “Selective Catalytic Reduction (SCR) Standstill Regeneration”.

Engine oil pressure warning.

Amber error condition warning. Causes error screen(s) to display. See “Error/Status/ History Screens”.

Engine temperature

Diesel Exhaust Fluid (DEF)

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Multi-Function Display Screens Note: Values may not display for all parameters, depending upon installed options and equipment.

Note: Press the left/right sides of the navigation rocker button (A, Fig. 14) to switch between display mode screens.

Table 3: Status and Maintenance Screens Display Mode

Description

Status/Maintenance Screens Primary Display H

A

F

G

DEF

A.

Fuel level.

B.

Fuel level amber warning region. Indicates low fuel level.

C.

Fuel level red stop region. Indicates almost empty fuel tank.

D.

Accumulated operation time.

NOTE:Operation time is displayed in hours, and accumulates when the engine is running.

123.4 C

B

D

E.

Engine coolant temperature.

F.

Engine coolant temperature amber warning region. Indicates elevated coolant temperature (above 212°F/100°C).

G. Engine coolant temperature red stop warning region. Indicates serious coolant overheating condition (above 220°F/104°C).

E

IMPORTANT: Running the engine in an overheated condition can damage the engine.

H.

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Diesel Exhaust Fluid (DEF) level.

37

Table 3: Status and Maintenance Screens Display Mode

Description Dual Gauge Display

D

B

A

H

G

F

A.

Fuel level.

B.

Fuel level amber warning region. Indicates low fuel level.

C.

Fuel level red stop region. Indicates almost empty fuel tank.

D.

Diesel Exhaust Fluid (DEF) level.

E.

Accumulated operation time.

NOTE:Operation time is displayed in hours, and accumulates when the engine is running.

DEF

F.

Engine coolant temperature.

G. Engine coolant temperature amber warning region. Indicates elevated coolant temperature (above 212°F/100°C).

50% %

H.

Engine coolant temperature red stop warning region. Indicates serious coolant overheating condition (above 220°F/104°C).

IMPORTANT: Running the engine in an overheated condition can damage the engine.

123.4

I.

E

C

I

Allows a selection between several parameters. Press the top/bottom of navigation rocker button (A, Fig. 5) to switch between parameters: • Coolant temperature.

• Battery voltage.

• Engine power.

• Accumulated operation time.

• Engine crankshaft revolutions per minute.

• Engine oil pressure.

DEF Quad Gauge Display

n/min

0 RPM

123.4 Hrs T

12.3 V

38

90 °F

Displays four different status parameters simultaneously. To change the displayed parameters, press and hold the ok button (E, Fig. 5) until orange bar (T) displays. Press the left/right side of navigation rocker button (A, Fig. 5) to select the parameter and press the top/bottom of navigation rocker button to change the selected parameter. Press the ok button again to dismiss orange bar (T).

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Table 3: Status and Maintenance Screens Display Mode

Description

Regeneration Screens

n/min

These screens are associated with the Selective Catalytic Reduction (SCR) standstill regeneration procedure. See “Selective Catalytic Reduction (SCR) Standstill Regeneration”.

Secondary Screens

All Secondary Screens

Secondary screens are accessed by holding down the ok button (E, Fig. 5) for 10 seconds while either the primary or dual gauge display screen is displayed. Press the left/right side of navigation rocker button (A, Fig. 5) to switch between secondary screens.

NOTE: Press “esc” button (G, Fig. 5) to exit secondary screens and return to the previously selected status screen.

REVISIONS DISPLAY 04 14 2017 MCU ************ MAIN KEYPAD ************ ROAD LIGHTS KEYPAD ************ HEATER/WIPER KEYPAD ************

Revision Screen Displays information IRU FRQWURO PRGXOHV software information.

UNITS SAE

Units Screen Press the top/bottom of navigation rocker button (A, Fig. 5) to switch between SAE or metric units for values displayed in the screens.

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39

Table 3: Status and Maintenance Screens Display Mode

Description

T

Error/Status/History Screens

DM1 1-8

SPN: 522619 FMI: 9 OCI: 1

Displays engine, drive system and control system error status and history code message information. The number of available messages is displayed at the top left of the screen (T). Press the left/right side of navigation rocker button (A, Fig. 5) to switch between screens and press the top/bottom of navigation rocker button to scroll through the codes.

See “Error Codes” for specific error code details.

DIAGNOSTIC INPUTS Float HydraGlide High Gear Aux Detent Alternator Hyd Filter Clog High Hyd Temp Wiper Interlock

Ignition Run Ignition Start Seat Switch Restraint Bar LH Backup RH Backup High Flow FWD High Flow REV

DIAGNOSTIC INPUTS Park Brake Beacon/Work Lt Self Level Pow Tach Lock Pow Tach Unlock

Diagnostic Inputs/Outputs Status Screens

DIAGNOSTIC OUTPUTS High Gear Self Level Hydraglide Rear Work Lts Front Work Lts Starter All Tach Lock All Tack Unlock

Float Backup Alarm High Flow Rev High Flow Fwd Beacon Lts Disable Park Brake

Displays input/output electronic/CAN status. Press the left/right side of navigation rocker button (A, Fig. 5) to switch between input/output screens. Status colors indicate the following: • Green – Active • Blank – Inactive • Yellow – Short or open circuit

DIAGNOSTIC OUTPUTS Front Wiper Front Washer Rear Wiper Rear Washer Blower Low Blower Med Blower High Condenser Fan

40

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Control Buttons/Switches A

B

C

D

E

F

G

H

I

J

K

L

M

Fig. 15 Buttons/Switches

Table 4: Buttons/Switches No

Item

Description Engages / disengages parking brake.

Indicator in switch is lit when parking brake is applied.

A

Parking Brake Button

B

Heat/Air Conditioning Fan (HVAC) Button

C

HVAC Button

D

Self-Leveling Cancel (option) Button

IMPORTANT: Parking brake is applied whenever the safety bar/arm rests are in the raised position, the operator is not in the seat, and/or if the swingout door (if equipped) is opened.

When the parking brake is applied, both travel drive and attachment lift and tilt are disabled.

Turns cab HVAC blower fan on/off. Low, medium, and high settings are available.

See “HVAC (Option)”.

Turns cab heat/cool on/off. Low, medium, and high settings are available. See “HVAC (Option)”.

Press top of switch to deactivate self-leveling; press bottom of switch to restore the self-leveling function.

Indicator in switch is lit when self-leveling is deactivated.

E

Beacon/Work Lights (option) Button

Activates optional beacon and/or work lights. See “Beacon/Position/Work Lights”.

F

Front Windshield Washer (option) Button

Activates windshield washer. See “Windshield Wipers/Washer”.

G

Rear Window Washer (option) Button

H

Front Windshield Wiper (option) Button

Indicator in switch is lit when the beacon and/or the work lights are on.

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Activates rear window washer. See “Windshield Wipers/Washer” Turns windshield wiper on/off. Slow, medium, and fast settings are available. See “Windshield Wipers/Washer”.

41

Table 4: Buttons/Switches No

Item

Description

I

Rear Window Wiper (option) Button

Turns rear window wiper on/off. Slow, medium, and fast settings are available. See “Windshield Wipers/Washer”.

J

Power-A-Tach® System Hitch Lock Button

Press and hold to lock attachments onto optional Power-A-Tach® System Hitch. See “Connecting/Disconnecting Attachments”

K

Power-A-Tach® System Hitch Unlock Button

Press and hold to unlock attachments onto the optional Power-A-Tach® System Hitch. See “Connecting/Disconnecting Attachments”

L

High-Flow Auxiliary Hydraulics Forward Flow Button

Press to activate auxiliary hydraulics forward flow. See “High-Flow Auxiliary Hydraulics Control (Option)”.

M

High-Flow Auxiliary Hydraulics Reverse Flow Button

Press to activate auxiliary hydraulics reverse flow. See “High-Flow Auxiliary Hydraulics Control (Option)”.

Indicator Panel Note: Control Panel indicators are visible only when the indicator lamps are activated.

B

A

C

F

E D H

I

G

K L J

Fig. 16 Indicator Panel (Refer to Table 5)

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Table 5: Control Keypad Indicators Item

Indicator

Description

Details

A

High-Speed Travel Range Indicator

Indicates high-speed travel range is activated.

B

Lift Arm Float Indicator

Indicates lift arm float is activated.

C

Hydraglide™ Indicator

Indicates HydraglideTM lift arm cushion is activated.

D

Engine Pre-heat Indicator

Is lit when ignition keyswitch is in the ON/RUN position and engine pre-heat is required; goes out when engine pre-heat is complete.

E

Seat Belt Reminder Indicator

Is lit when ignition is turned on as a reminder to lower the safety bars and fasten the seat belt.

F

Battery Voltage Warning Indicator

Indicates battery charging system malfunction. During normal operation this indicator should be OFF.

G

Indicates engine air filter requires service. See “Engine Air Engine Air Filter Restriction Indicator Cleaner”. During normal operation this indicator should be OFF.

H

Indicates hydraulic oil filter requires service. See“Changing Hydraulic Oil Filter Warning Indicator Hydraulic Oil Filter”. During normal operation this indicator should be OFF.

I

Hydraulic Oil Temperature Warning Indicator

Indicates hydraulic temperature is too high. During normal operation this indicator should be OFF.

J

Engine Malfunction Indicator

Is lit when the engine electronic control unit (ECU) has detected an error condition. Refer to “Engine Diagnostic Trouble Codes (DTC)”.

K

Coolant Temperature Warning Indicator

Indicates coolant temperature is too high.

During normal operation this indicator should be OFF. Indicates engine oil pressure is too low.

L

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Engine Oil Pressure Warning Indicator

During normal operation this indicator should be OFF. IMPORTANT! Immediately shut down the engine if this indicator is lit. Correct the problem before restarting the engine.

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Instrument Panels Left Panel

A B A. A/C Indicator (option) – Illuminates when the air conditioning is D operational.

B. Heat Indicator (option) – IlluC minates when the heater is operaF tional.

C. HVAC Button – Turns the fan/ heat/cool on/off. Low, medium and E high settings are available.

D. Fan Button – Turns the fan on/ G off. Low, medium and high settings are available.

H E. Front Windshield Wiper Button (option) – Turns the windshield wiper button on/off. Low, medium Fig. 17 Left Panel and high settings are available.

F. Front Windshield Washer (option) – Activates the windshield washer.

G. Rear Windshield Wiper Button – Turns the windshield wiper button on/ off. Low, medium and high settings are available.

H. Rear Windshield Washer (option) – Activates the windshield washer.

Right Panel A. Multi-Function Display – See page 35.

B. Keyswitch – In a clockwise rotation, the positions are: • OFF Position – With the key vertical, power from the battery is disconnected from the controls and instrument panel electrical circuits. This is the only position from which the key can be inserted or removed.

• ON (or RUN) Position – With the key turned one position clockwise from vertical,

44

A

Fig. 18 Multi-Function Display 50950233/G0221

power from the battery is supplied to all control and instrument panel circuits.

• START Position – With the key turned fully clockwise, the electric starter engages, to start the engine. Release the key to RUN position after the engine starts.

Note: The engine cannot be started unless the operator is sitting in the seat and the restraint bar is lowered.

C. Engine Speed Control – Controls the engine speed. Move the control clockwise to increase and counter-clockwise to decrease the engine speed.

D. Indicator Panel - See page 42.

E. Parking Brake Switch – Used to manually apply, on release, the parking brake. Lights when the parking brake is applied.

F. Beacon/Work Light Button – Activates optional beacon and/or work lights. Illuminates when the beacon or work lights are on.

B

C Fig. 19 Keyswitch and Hand Throttle

G. Self-Leveling Cancel Button Press the top of the switch to deactivate self-leveling. Press the bottom of the switch to restore the self-leveling D function. Illuminates when self-leveling is deactivated.

E H. Power-A-Tach System Hitch Lock Button - Press and hold to lock attachments onto the hitch.

F I. Power-A-Tach System Hitch G Unlock Button - Press and hold to H unlock attachments from the hitch.

I J. High-Flow Auxiliary HydrauJ K lics Reverse Flow Button - Press to L activate reverse auxiliary hydraulics flow.

K. High-Flow Auxiliary HydrauFig. 20 Lower Right Panel lics Forward Flow Button - Press to activate forward auxiliary hydraulics flow.

L. 12V Accessory Plug - For multiple uses.

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Be sure the joystick controls are in neutral before starting the engine. Operate the controls gradually and smoothly. Excessive speed and quick control movements without regard for conditions and circumstances are hazardous and could cause an accident.

WARNING

Joystick Controls The machine is equipped with dual joystick controls, (Fig. 21). The left joystick controls the drive, and the right joystick controls the lift/tilt.

1

2

Drive Controls Forward, reverse, speed and turning maneuvers are accomplished by movement of the left joystick. To go forward, push the drive control forward; for reverse, pull the control rearward. To turn right, push the Fig. 21 Dual Joystick Controls control right; to turn left, push 1. Lift/Tilt Control 2. Drive Control the control left. To go forward and left, move the control forward and left. To go forward and right, move the control forward and right. To move back and left, move the control back and to the right. To move back and right, move the control back and to the left.

Moving the joystick further from neutral increases the speed steadily to the maximum travel speed. Tractive effort decreases as speed increases. For maximum tractive effort, move the joystick only slightly away from the neutral position.

The engine may stall if the control is moved too far forward when loading the bucket.

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Lift/Tilt Control Moving the lift arm and tilting the attachment are accomplished by movement of the right joystick. To raise the lift arm, pull the control straight rearward; to lower the lift arm, push the control straight forward. To tilt the attachment forward and downward, move the control to the right; to tilt the attachment up and back, move the control to the left.

Note: The speed of the lift/tilt motion is directly proportional to the amount of joystick movement and engine speed.

To place the lift arm into the “float” position, push and hold the top left button on the right joystick. This mode allows the lowered lift arm to follow the ground contour while traveling over changing ground conditions. An indicator lamp in the left instrument panel will blink when float is activated.

Never push the float control button with the attachment raised, because this will cause the lift arm to lower very rapidly.

WARNING

Releasing the float button will cancel the float mode if the button was pressed less than five seconds. If the float mode button is pressed longer than five seconds, the float feature will stay on and the float indicator lamp will stay lighted until the button is pressed again or the machine is turned off.

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Auxiliary Hydraulic System Auxiliary hydraulics are used with attachments that have a mechanism requiring hydraulic power.

Always be sure the auxiliary hydraulic control is in neutral before starting the machine or disconnecting the auxiliary hydraulic couplers.

WARNING

Standard-Flow Auxiliary Hydraulic Control Machines are equipped with a standard-flow auxiliary hydraulic system with flatface couplers. The couplers are located on top of the lift arm on the left side.

The black rocker switch located on the right-hand control controls the direction and amount of flow. The farther the switch is moved from center, the higher the flow to the auxiliary circuit. The direction of flow is reversed when the rocker switch is moved in the opposite direction from the center. Pushing the switch to the right will pressurize the standard auxiliary male coupler. For continuous operation, move the switch in either direction and push the trigger button, located on the front of the grip for five seconds, and release. To cancel continuous operation, push the button or move the black switch in either direction.

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Fig. 22 Joystick Electric Auxiliary Control

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High-Flow Auxiliary Hydraulic Control In addition to a standard-flow auxiliary hydraulic system, machines are equipped with a reversible high-flow auxiliary hydraulic system. The couplers are located on top of the right lift arm. The high-flow auxiliary hydraulic system is used for operating certain hydraulic attachments (e.g., cold planer, snowblower) that require higher flows.

The high-flow auxiliary switch controls the direction of hydraulic oil flow. Push the right button for forward flow or the left button for reverse flow. Pushing the Fig. 23 High-Flow Auxiliary right button will pressurize the high-flow Switch male coupler. To disengage, push and release the button. Turning off the machine, raising the restraint bar, or restarting the engine will also reset the high-flow to neutral. A LED light above the buttons will illuminate when the high-flow auxiliary hydraulic system is engaged.

WARNING

Only connect high-flow attachment couplers to the high-flow auxiliary couplers.

Battery Disconnect Switch A battery disconnect switch is located at the front of the machine, beneath the left control handle, behind a panel with two turn screws. Turn the switch to the OFF position to disconnect the batteries from the electrical system.

Fig. 24 Battery Disconnect Switch

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Notes

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CHAPTER 5 OPERATION Before starting the engine and operating the machine, review and comply with all safety recommendations in the Safety chapter of this manual. Know how to stop the machine before starting it. Also, be sure to fasten and properly adjust the seatbelt(s) and lower the operator restraint bar.

WARNING

Before Starting the Engine Before starting the engine and running the machine, refer to the Controls and Safety Equipment chapter and become familiar with the various operating controls, indicators and safety devices on the machine.

Fuel Deutz will allow up to a 5% (B5) mixture of BioDiesel.

Starting the Engine The following procedure is recommended for starting the engine: 1. Open the door. Carefully step up onto the back of the bucket or attachment and grasp the handholds to enter the operator’s compartment.

2. Close the door, fasten the seatbelt(s), and lower the restraint bar.

3. Verify the following:  the lift/tilt, drive and auxiliary hydraulic controls are in their neutral positions  the parking brake switch is ON Note: When the key is turned to the RUN position, an indicator lamp will light on the instrument panel and a buzzer will sound momentarily to remind users to fasten the seatbelt.

4. Turn the key to the START position.

Note: If the temperature is below 32°F (0°C), see the Cold-Starting Procedure on page 52.

Important: Do not engage the starter for longer than 15 seconds at a time.

Longer use can overheat and damage the starter. If the engine fails to start within 15 seconds, return the key to the OFF position or check for engine error codes.

Allow the starter to cool for 20 seconds and repeat step 4. If the engine stalls during operation, wait three seconds before restarting the engine.

After the engine starts, allow a five-minute, low idle warm-up period before operating the controls.

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Important: If the indicator warning lamps do not turn off, stop the engine and investigate the cause.

Cold-Starting If the temperature is below 32°F (0°C), the following is recommended to make starting the engine easier:

 Replace the engine oil with API-CK-4 and SAE 5W-30 synthetic oil;.  Make sure the battery is fully charged.

Let the engine run for a minimum of five minutes to warm the engine and hydraulic fluid before operating the machine.

The standard block heater is recommended for starting in temperatures of 20°F (-7°C) or lower.

Cold-Starting Procedure Do not use starting fluid (ether) with pre-heat systems. An explosion can result, which can cause injury, death or engine damage.

WARNING

1. Turn the key to the RUN position. A wait-to-start symbol will appear on the multi-function display. Wait for this symbol to turn off.

2. Turn the key to the START position.

3. If the engine does not start, return the key to OFF position and repeat steps 1 and 2.

Stopping the Machine Use the following procedure to stop the machine: 1. Be sure that the drive control handle(s) is (are) in neutral position.

2. Lower the lift arm and rest the attachment on the ground.

3. Turn throttle knob back to the low idle position (and release the throttle pedal for joystick and t-bar control machines). Allow the engine to idle for five minutes if the engine was operated under full load.

4. Turn the keyswitch to the OFF position and remove the key.

5. Move the lift/tilt control to verify that the safety interlock system is preventing movement.

6. Raise the restraint bar, unfasten the seatbelt(s) and grasp the handholds while climbing out of the operator’s compartment.

Note: The machine is equipped with a spring-applied automatic parking brake.

The parking brake is applied when the operator lifts the restraint bar, leaves the operator’s seat or shuts off the engine, or actuates the parking brake switch.

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Parking the Machine Park the machine away from traffic on level ground. If this is not possible, park the machine across the incline and block the tires to prevent movement.

Brake Release Operation (option) The machine may have, as an option, a brake release system installed. Utilizing the brake release system disables the parking brake, allowing the machine’s wheels to freely move in either a forward or rearward direction.

Before utilizing the brake release, be sure to secure the vehicle with wheel chocks or tow lines. Verify the machine’s travel paths are clear of personnel before utilizing the brake release system.

WARNING

1. Locate the brake release jack and handle, located on the right side of the chassis.

2. Remove any existing access cover.

3. Position the receiver and insert the jack handle.

4. Push the plunger on the receiver and hold.

5. Begin actuating the pump. Hydraulic pressure developed will retain the plunger so it no longer requires to be pushed. Continue to actuate the pump until the resistance of the jack handle does not increase. There is an internal relief valve in the jack assembly that prevents damage to the motor.

6. You may now tow the machine a short distance or pull it onto a trailer.

Depending on the drive motor’s internal leakage rate, the machine may roll easily once the brake is released, or the tires may skid until the oil is forced from the motor.

7. The brake can be reset by pulling up on the plunger or starting the machine.

Jump-starting If the batteries become discharged or do not have enough power to start the engine, use jumper cables and the following procedure to jump-start the engine.

The ONLY safe method for jump-starting a discharged battery is for TWO PEOPLE to perform the following procedure. The second person removes the jumper cables so that the operator does not have to leave the operator’s compartment with the engine running. NEVER make jumper cable connections directly to the starter solenoid of either engine. DO NOT start the engine from any position other than on the operator’s seat and then ONLY after being sure ALL controls are in “neutral.”

WARNING

Closely follow the procedure, in order, to avoid personal injury. In addition, to protect your eyes wear safety glasses and avoid leaning over the batteries while jump-starting.

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53

DO NOT jump-start the batteries if they are frozen because they may rupture or explode.

Note: BE SURE the jumper battery is a 12-volt D.C. battery.

1. Turn the keyswitches of both vehicles to OFF be sure both vehicles are in “neutral” and NOT touching each other.

2. Connect the positive (+) jumper cable to the positive (+) remote battery terminal (Fig. 1) on the disabled machine first. DO NOT allow the positive clamps to touch any metal other than the positive (+) remote battery terminal.

3. Connect the other end of the positive jumper cable to the jumper vehicle’s battery positive (+) terminal.

4. Connect the negative (-) jumper cable to the jumper vehicle’s battery negative (-) terminal.

Fig. 1 Positive (+) Remote Battery Terminal

5. Make the final negative (-) jumper cable connection to the negative (-) remote battery terminal (Fig. 2) on the disabled machine. DO NOT allow the negative clamps to touch any metal other than the negative (-) remote battery terminal 6. Start the machine. If it does not start at once, start the jumper vehicle’s engine to avoid excessive drain on the booster battery.

7. After the disabled machine is started Fig. 2 Negative (-) Remote and running smoothly, have the second Battery Terminal person remove the jumper cables [negative (-) jumper cable first] from the jumper vehicle’s battery and then from the disabled machine, while being careful NOT to short the two cables together.

Allow sufficient time for the machine batteries to build up a charge before operating the machine or shut off the engine.

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Changing Attachments To prevent unexpected release of the attachment from the hitch, be sure to properly secure the hitch latch pins by verifying that the pin flags moved fully to the outside of the hitch. (Power-A-Tach® hitch.) Locking pins must be fully engaged through the holes in the attachment frame before using the attachment. The attachment could fall off if it is not locked on the hitch and cause serious injury or death.

WARNING

Connecting Attachments 1. Activate the switch to unlock the hitch and fully retract the latch pins. (See 1 1 page 34 for a detailed description of this procedure.).

2. Start the machine engine and be sure the lift arm is lowered and in contact with the machine frame.

3. Align the machine squarely with the back of the attachment.

4. Tilt the hitch forward until the top edge of the hitch is below the flange on the back side of the attachment and 1. Latch Pins (shown unlocked) centered between the vertical plates.

Fig. 3 Power-A-Tach Hitch 5. Slowly drive the machine forward and, at the same time, tilt the hitch back to engage the flange on the back side of the attachment.

6. Stop forward travel when the flange is engaged, but continue to tilt the hitch back to lift the attachment off the ground.

7. Press the locking Power-A-Tach button on the right instrument panel to extend the hitch pins and to lock the hitch and fully engage the latch pins.

Important: To check that the attachment is properly installed tilt the attachment forward slightly, apply downward pressure to the attachment prior to operating.

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Connecting Auxiliary Hydraulic Couplings Note: The machine is equipped with quick couplers designed to release trapped pressure. The pressure is automatically released by pushing the coupler inward, returning the oil through the case drain line back to the machine.

Standard-Flow Auxiliary Hydraulics

Couplers are located on the left lift arm. When the auxiliary control switch is activated in either direction, the inside and outside couplers can be “pressure,” or “return” depending on which direction the switch is activated. The smaller center coupler is for the case drain.

High-Flow Auxiliary Hydraulics Couplers are located on the right lift arm. When the auxiliary control button is activated in either direction, the inside and outside couplers can be “pressure,” or “return” depending on which directional button is activated. The smaller center coupler is for the case drain.

WARNING

Only connect high-flow attachment couplers to the high-flow auxiliary couplers.

Removing Attachments

1. Tilt the hitch back until the attachment is off the ground.

2. Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 6).

3. With the engine off, leave the operator’s compartment and disconnect the auxiliary hydraulic hoses.

4. Start the engine, press the unlock Power-A-Tach button on the right keypad to retract the hitch pins to unlock the hitch and fully retract the latch pins.

5. Start the engine (if it is not already on) and be sure that the lift arm is fully lowered and in contact with the machine frame.

6. Tilt the hitch forward and slowly back the machine away until the attachment is free from the machine.

Self-Leveling The selectable feature is intended to automatically keep the attachment level while the lift arm is being raised. The LED button above the self-leveling keypad button illuminates when self-leveling is off.

Self-Leveling Cancel The self-leveling cancel option allows for deactivation of the self-leveling feature. To deactivate self-leveling, press the self-level cancel button on the keypad.

To restore self-leveling, press the button a second time.

Note: Self-leveling defaults to the activated condition is the engine is shutoff.

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Using a Bucket Always maintain a safe distance from electric power lines and avoid contact with any electrically charged conductor or gas line. Accidental contact or rupture can result in electrocution or an explosion. Contact the “Call Before You Dig” referral system at 8-1-1 in the U.S., or 888-2580808 in the U.S. and Canada or proper local authorities for utility line locations before starting to dig.

WARNING

Driving over Rough Terrain

When traveling over rough terrain, activate the ride control system and drive slowly with the bucket lowered.

Driving on an Incline

When traveling on an incline, travel with the heavy end pointing uphill.

Digging with a Bucket

Approach the digging site with the lift arm slightly raised and the bucket tilted forward until the edge contacts the ground. Dig into the ground by driving forward and gradually lowering the lift arm (Fig. 4).

When the bucket is filled, tilt the bucket back and back the machine away from the material. Rest the lift arm against the machine frame before proceeding to the dumping area.

Fig. 4 Digging

Always carry the loaded bucket with the lift arm resting on the machine frame. For additional stability when operating on inclines, always travel with the heavier end of the machine toward the top of the incline.

WARNING

Loading a Bucket Approach the pile with the lift arm fully lowered and the bucket tilted slightly forward until the edge contacts the ground.

Drive forward into the pile, lifting the lift arm and tilting back the bucket to fill it.

Back away from the pile (Fig. 5).

Fig. 5 Loading

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Dumping the Load onto a Pile Carry a loaded bucket as low as possible until the pile is reached. Gradually stop forward motion and raise the lift arm high enough so that the bucket clears the top of the pile. Then, slowly move the machine ahead to position the bucket to dump the material on top of the pile. Dump the material and then back the machine away while tilting the bucket back and lowering the lift arm.

Never push the “float” button with the bucket or attachment raised, because this will cause the lift arm to lower rapidly.

WARNING

Dumping the Load into a Truck (or Hopper) Carry the loaded bucket low and approach the vehicle (or hopper.) Stop as close to the side of the truck (or hopper) as possible while allowing for clearance to raise the lift arm and loaded bucket. Next, raise the lift arm until the bucket clears the top of the truck (or hopper) and move the machine ahead to position the bucket over the inside of the truck (or hopper.) Dump the material and then back away while tilting the bucket back and lowering the lift arm (Fig. 6).

Fig. 6 Dumping into a Truck (or Hopper)

Dumping the Load over an Embankment Do not drive too close to an excavation or ditch. Be sure the surrounding ground has adequate strength to support the weight of the machine and the load.

WARNING

Carry the loaded bucket as low as possible while traveling to the dumping area.

Stop the machine where the bucket extends half-way over the edge of the embankment. Tilt the bucket forward and raise the lift arm to dump the material.

Dump the material, and then back away from the embankment while tilting the bucket back and lowering the lift arm.

Scraping with a Bucket For scraping, the machine should be operated in the forward direction. Position the lift arm down against the machine frame.

Tilt the bucket cutting edge forward at a slight angle to the surface being scraped.

While traveling slowly forward with the bucket in this position, material can flow over the cutting edge and collect inside the bucket (Fig. 7).

58

Fig. 7 Scraping

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Leveling the Ground Drive the machine to the far edge of the area to be leveled. Tilt the bucket forward to position the bucket cutting edge at a 30 to 45 degree angle to the surface being leveled. Then place the lift arm into “float” position and drive the machine rearward, dragging the dirt and, at the same time, leveling it (Fig. 8).

Fig. 8 Leveling the Ground

Note: The “float” detent is activated by pressing the top middle button on the right control handle.

WARNING travel.

Check that the work area is clear of people and obstacles. Always look in the direction of

Vibration Information Compact construction equipment is generally used in harsh environments. This type of usage can expose an operator to uncomfortable levels of vibration. It is useful to understand exposure to vibration levels when operating compact equipment and what can be done to reduce vibration exposure. As a result, equipment operation can be more efficient, productive and safe.

An operator’s exposure to vibration occurs in two ways:

 Whole-Body Vibration (WBV)  Hand-Arm Vibration (HAV)

This section will cover primarily WBV issues, because evaluations have shown that operation of mobile compact construction equipment on jobsites typically results in HAV levels less than the allowed exposure limit of 2.5 m/s2.

Employers in Member States of the European Union must comply with the Physical Agents (vibration) Directive, 2002/44/EC. Effective control of vibration exposure for an operator involves more than just vibration levels on the machine. The job site, how the machine is used, and proper training all play important roles in reducing vibration exposure.

Vibration exposure results from:

 worksite conditions  how the machine is operated  the machine characteristics Common causes of high WBV vibration levels:

 Using a machine that is improper for the task  Work site with potholes, ruts and debris 50950233/G0221

59

 Improper operating techniques, such as driving too fast  Incorrect adjustment of the seat and controls  Other physical activities while using the machine

Vibration Measurement and Actions The vibration directive places the responsibility for compliance on employers.

Actions that should be followed by employers include:

 Assess the levels of vibration exposure.  Determine from this assessment if operators will be exposed to vibration levels above the limits stated in the directive.

 Take appropriate actions to reduce operator’s exposure to vibration.  Provide operators with information and training to reduce their exposure to vibration.

 Keep good records and update operations and training on a regular basis.

If the assessment concludes that vibration level exposure is too high, one or more of the following actions may be necessary: 1. Train operators  Perform operations (accelerating, steering, braking, etc.) in a smooth manner.  Adjust machine speed appropriately.  Adjust the controls, mirrors and seat suspension for comfortable operation.  Travel across the smoothest parts of the work site and avoid ruts and potholes.

2. Choose proper equipment for the job  Use machines with the proper power and capacity.  Select machines with good suspension seats.  Look for controls that are easy to use.  Ensure good visibility from the operator’s position.

3. Maintain the work site  Smooth ruts and fill potholes in traffic areas whenever possible.  Clean up debris frequently.  Vary traffic patterns to avoid exposure to rough terrain.

4. Maintain the equipment  Ensure correct tire pressures.  Check that seat suspension and all controls work smoothly and properly.

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Vibration Levels The following table shows typical Whole-Body and Hand-Arm Vibration levels for Gehl V420 machines.

Whole-Body and Hand-Arm Vibration Levels* Control Dual Joystick

Whole-Body Vibration m/s2 1.09

Uncertainty m/s2 0.55

Hand-Arm Vibration m/s2 1.16

Uncertainty m/s2 0.58

*Whole-Body Vibration levels in accordance with ISO 2631-1. Hand-Arm Vibration levels in accordance with ISO 5349-1.

Highway Travel If it becomes necessary to move the machine a long distance, use a properly rated trailer. (See Transporting/Towing the Machine on page 62.) For short distance highway travel, attach an SMV (Slow-Moving Vehicle) emblem (purchased locally) to the back of the machine. For highway operation, install the optional amber strobe light. Check state and local laws and regulations.

Storing the Machine If the machine is to be stored for a period in excess of two months, the following procedures are suggested: 1. Fully inflate the tires.

2. Lubricate all grease zerks.

3. Check all fluid levels and replenish as necessary. (Review and follow the engine manufacturers recommendations from the Engine Operator’s Manual.)

4. Add stabilizer to the fuel per the fuel supplier’s recommendations. If the fuel has a mixture of BioDiesel, empty the fuel tank before storing.

5. Turn the electrical disconnect switch to its OFF position and remove the batteries, charge them fully and store in a cool, dry location.

6. Protect against extreme weather conditions such as moisture, sunlight and temperature.

7. Diesel Exhaust Fluid (DEF) quality may be affected after long-term storage.

Monitor the fluid and verify the time it has been in storage.

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Removing Machine from Storage 1. Check the tire air pressure and inflate the tires if they are low.

2. Connect the batteries and check that the electrical disconnect switch is turned to its ON position.

3. Check all fluid levels (engine oil, transmission/hydraulic oil, engine coolant and any attached implements). (Review and follow the engine manufacturers recommendations from the Engine Operator’s Manual.)

4. Start the engine. Observe all gauges. If all gauges are functioning properly and reading normal, move the machine outside.

5. Once outside, park the machine and let the engine idle for at least five minutes.

6. Shut the engine off and walk around machine. Make a visual inspection looking for evidence of leaks.

Transporting/Towing the Machine Park the truck or trailer on a level surface. Be sure the vehicle and its ramps have the weight capacity to support the machine. Make sure the vehicle surface and its ramps are clear of debris and slippery material that may reduce traction. Move the machine on and off the vehicle ramp slowly and carefully. Failure to follow these instructions could result in an overturn accident. Towing the machine is not recommended as a means of transportation.

WARNING

Observe all local regulations governing the loading and transporting of equipment (Reference: U.S. Federal Motor Carrier Safety Regulations, Section 392).

Ensure that the hauling vehicle meets all safety requirements before loading the machine. Use the tie down/retrieval points in situations where lifting the machine is not possible and the overall distance by which the machine is to be moved is less than 100 feet (30.5 m) at 6 mph (10 km/hr) or less. The optional brake release package (page 53) facilitates machine retrieval in such situations. When transporting a machine:

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1. Block the front and rear of the hauling vehicle’s tires.

2. If the machine has an attachment, lift it slightly off the ground.

3. Back the machine slowly and carefully up the ramp onto the vehicle.

4. Lower the machine attachment to the vehicle deck, turn off the engine and remove the key.

Fig. 9 Left Front Tie-Down / Front Retrieval - Right Side Same

5. Fasten the machine to the hauling vehicle at the points indicated by the tie-down decals (Fig. 9 and Fig. 10).

6. Measure the clearance height of the machine and hauling vehicle. Post the clearance height in the cab of the vehicle.

When towing a machine: 1. Connect the towline to both tie down/ retrieval points at the front or the rear Fig. 10 Rear Tie-Down/Rear of the machine. Use of only a single Retrieval retrieval point or connecting the towline to any point on the machine other than the designated retrieval locations could result in machine damage.

2. The towline strength is at least 1.5 times the gross weight of the machine. The towline length is such that the maximum towing angle does not exceed 20°.

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63

Lifting the Machine The machine can be lifted using a single-point or four-point lift kit, which are available from your authorized dealer.

WARNING • •

Before lifting, check the lift kit for proper installation.

Never allow riders in the operator’s compartment while the machine is lifted.

• Keep everyone a safe distance away from the machine while it is lifted.

• Machine may only be lifted with an empty bucket or empty pallet forks, or with no attachment. Never lift the machine with attachments other than those stated.

Lift equipment used and its installation is the responsibility of the party conducting the lift. All rigging MUST comply with applicable regulations and guidelines.

1. Using suitable lift equipment, hook into the lift eyes. Adjust the length of the slings or chains to lift the machine level.

Note: The machine may be slightly off level (10 degrees max.) when lifted.

2. Center the hoist over the ROPS/FOPS. To prevent shock loading of the equipment and excessive swinging, slowly lift the machine off the ground. Perform all movements slowly and gradually. As needed, use a tag line to help position the machine and keep it from swinging.

Camera Observation System A camera observation system is optionally available on all models. The camera observation system utilizes a rear-facing camera mounted within the rear door of the machine to provide full visibility to the region behind the machine of which portions of that region may otherwise be masked by the machine’s structure.

The camera system is configured to turn on automatically when the machine’s ignition switch is moved to the “ON” position. The camera image is displayed on the monitor which is centered above the front door opening of the operator’s compartment.

The vertical viewing angle of the monitor is adjustable by loosening the knobs positioned on either side of the monitor. Prior to operating the machine the operator should check the monitor to verify that the monitor is positioned at the optimum viewing angle for them.

As an integral safety feature of the machine it is important for the operator to verify that the camera system is operating properly prior to moving the machine.

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50950233/G0221

A camera system that is operating properly will display a sharp image that is free of any obstructions when the key is switched on. The displayed image should be centered on the area directly behind the machine. If the displayed image does not meet this criteria the following system checks can be made:

 While the system is configured to power up automatically upon key on,

depress the system power button at the display to see if the system powers up.  Verify that the electrical connections to the monitor and camera are intact. This includes checking the A/V cable connection into the rear of the monitor and the camera connection to the camera extension cable located in the engine compartment in close proximity to the rear door hinges.  Roll back the ROPS\FOPS and check the camera system harness connections forward of the engine flywheel housing. The connection of the camera system power harness to the accessory power connections in the chassis harness are located in this region. Verify that these connections are intact.  Locate the fuse holder in the camera system power harness near the cable’s interface with the chassis harness. Verify that the two Amp fuse within is intact and fully inserted into the fuse holder terminals. Also, verify that the 20A chassis accessory fuse in the uppermost power distribution module is functional.  If the monitor displays a picture but that picture is not bright and clear, verify that the camera lens is clean and that the camera is properly aligned with the aperture in the rear door. The mounting brackets allow for left/right, up/down, and fore/aft adjustment. When making adjustments, ensure that the resulting pictures displayed on the monitor squarely shows the area behind the machine.

Additional troubleshooting measures are detailed in the camera observation system manual for instructions on how to correct any issues.

If the camera system is not able to be made functional after these initial checks, contact your dealer for service. A camera system that is unable to provide a clear image of the rear of the machine should be considered disabled and the machine should not be operated until the camera is made to function properly again.

Back-Up Alarm A back-up alarm system is standard which serves to warn people working in the area around the machine of the machine’s rearward movement. The back-up alarm is installed within the engine compartment on the inside surface of the rear door. The alarm emits a tone whenever the machine begins to move in the rearward direction.

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65

14-Pin Auxiliary Connector A 14-pin auxiliary connector is optionally available on all models. It is located at the knee joint of the lift arm (Fig. 11) and is intended for attachments equipped with 14-pin compliant connections using direct 12 volt actuation control.

Note: Contact your dealer for information about approved 14-pin-equipped attachments.

Switch / Pin Assignments

Fig. 11 Location of the 14pin auxiliary connector

Refer to Fig. 12 and Fig. 13 and the following table (Table 1) for details about the 14-pin control switches and the associated pins in the 14-pin connector.

1

2

3 4

6

5 Fig. 12 View of the 14-pin auxiliary control handle switches

Fig. 13 Switch-to-Pin Assignments

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50950233/G0221

Table 1: 14-Pin Switch and Pin Assignments Switch Switch Position 1 2 3 4 5 6

Switch Type

Wire Color

Forward Gray Momentary Reverse Orange Forward White Momentary Reverse Purple Forward Blue Momentary Reverse Tan On Latching On/Off Pink N/A Momentary N/A N/A Momentary N/A

Pin Description Ground Not Used 12V Power Not Used Not Used Not Used Not Used

Connector Max. Current Pin (Amps) D C F E H G A N/A N/A

Connector Pin B J K L M N P

Notes

15

Open

15

Open

15

Open

10 N/A N/A

Open Vehicle Horn Vehicle 2‐Spd On/Off (Option)

Max. Current (Amps) 20 N/A 15 N/A N/A N/A N/A

Switches 1, 2, and 3 have a combined total capacity of 15A. Switches 1, 2, 3 and 4 have a combined total capacity of 20A. Note: Depending upon the attachment, an adapter harness may be necessary.

Refer to the documentation supplied with the attachment, or contact your dealer.

Fan Reverse To reverse the direction of the engine’s hydraulically driven engine fan, press the lights/beacon button and the self-leveling button (Fig. 14) together for 10 seconds.

An icon will appear on the multi-function display to indicate reverse mode.

The fan will slow and enter the reverse direction for 30 seconds. It will then slow and return to normal operation.

Engine speed should be at 1800 rpm or higher. Fan speed is limited to 1500 rpm Fig. 14 Press these two buttons to in its reverse mode. begin the fan reverse function.

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67

Selective Catalytic Reduction (SCR) Standstill Regeneration (If So Equipped) Diesel Exhaust Fluid (DEF) crystallization in the Selective Catalytic Reduction (SCR) system must be periodically reduced using standstill regeneration.

When SCR system crystallization is detected, the standstill regeneration request screen (Fig. 15) appears on the multi-function display.

Standstill regeneration requires operator action to initiate and takes approximately 35-50 minutes to complete.

Important: The machine cannot be operated and must be parked in a well-ventilated area away from flammable materials when standstill regeneration is in progress.

n/min

Fig. 15 Standstill Regeneration Request Screen

Important: Because standstill regeneration slightly dilutes the engine oil with diesel fuel, engine oil replacement is required after standstill regeneration is complete.

There is a possibility of carbon monoxide poisoning if standstill regeneration occurs in an enclosed space. Always perform standstill regeneration in a wellventilated area.

WARNING

During regeneration, there will be high exhaust gas temperatures, even at low load.

Stay clear of the engine compartment during regeneration.

WARNING

The machine cannot be used during standstill regeneration and cannot be moved without interrupting the standstill regeneration process.

The standstill regeneration request screen can be temporarily dismissed by pressing the regeneration inhibit button (U, Fig. 16) for three seconds until the previous screen displays. The standstill regeneration request screen will continue to return after being dismissed, for as long as the request remains active.

Important: Perform standstill regeneration as soon as possible when the standstill regeneration request screen displays. Postponing standstill regenera68

U

ok

Fig. 16 Regeneration Inhibit Button

50950233/G0221

tion will result in CAN errors, engine derating, and declining engine power and performance.

To proceed with standstill regeneration: 1. Park the machine in a safe, will-ventilated location away from flammable materials.

2. Lift the restraint bar/armrests to apply the parking brake. A check A mark is displayed next to the parking B brake symbol (A, Fig. 17).

3. When the engine coolant has reached C n/min operating temperature (above 149° F (65° C), a check mark is displayed next to the coolant temperature symZ bol (B).

4. Place the throttle controls to the lowest speed setting. A check mark is displayed next to the RPM symbol (C) when the engine is running at low idle. ok

Fig. 17 Standstill Regeneration

5. When all three check marks (A, B, C) are displayed on the standstill regeneration screen, press and hold the button (Z, Fig. 17) until the standstill regeneration in-progress screen displays (Fig. 18).

Remaining Regeneration Time 42 Minutes

Note: Standstill regeneration can be interrupted at any time by releasing the parking brake, advancing the throttle, or stopping the engine. Standstill regeneration must start again from the beginning Fig. 18 Standstill Regeneration Inif it is interrupted.

Standstill regeneration time remaining is displayed during the standstill regeneration process.

Progress Screen

Note: Standstill regeneration takes approximately 35-50 minutes.

CAUTION 50950233/G0221

It is not necessary to stay in the machine during standstill regeneration. Keep the 69

machine under observation while regeneration is in progress in case of malfunction. Keep bystanders away from the machine while regeneration is in progress.

6. After the standstill regeneration process is complete, change the engine oil.

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CHAPTER 6 SERVICE Before servicing the machine, unless expressly instructed to the contrary, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 6).

WARNING

After service has been performed, be sure to restore all guards, shields and covers to their original positions before resuming operation.

This Service chapter details procedures for performing routine maintenance checks, adjustments and replacements. Most procedures are referred to in the Troubleshooting and Maintenance chapters of this manual. Refer to the Maintenance Interval Chart (page 115) for service intervals. Refer to the separate engine manual for engine-related adjustments, lubrication and service procedures.

Note: All service procedures, except those described under the Dealer Services topic are owner-operator responsibilities.

Important: Always dispose of waste lubricating oils and hydraulic fluids according to local regulations or take to a recycling center for disposal. Do not pour onto the ground or down the drain.

Dealer Services The following areas of component service, replacement and adjustments require special tools and knowledge for proper servicing and should be performed only by your authorized machine dealer: hydrostatic drive components, hydraulic system pumps, valves, hydraulic cylinders, electrical components (other than battery, fuses or relays).

Sliding Side Window Removal Procedure The sliding side windows inside the ROPS/FOPS can be removed for cleaning. To begin, open the cab door and slide one of the side windows to the rear.

Using a non-marring tool, separate the front plastic rail underneath the sliding window from the window frame. Pull the plastic rail forward until it releases from the window frame. Then slide the side window to the front and separate the rear plastic rail from the window frame in the Fig. 1 Rail removed from same manner, pulling the rail rearward to window frame. release it from the window frame. The sliding side window may now be removed from the ROPS/FOPS. To reinstall the window, reverse the removal steps.

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71

Machine Raising Procedure To raise the skid-steer machine so all four tires are off the ground, use the procedure below: 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 machine.

WARNING

1. To block the machine, obtain enough suitable blocks (solid wood, hard plastic or metal) so all of the tires are raised off the ground.

Fig. 2 Machine Properly Blocked

2. Using a jack or hoist capable of lifting the fully-equipped weight of the machine (with all attached options), lift the rear of the machine until the rear tires are off the ground.

3. Stack wooden, hard plastic or metal blocks under the flat part of the machine chassis. They should run parallel with, but not touch, the rear tires.

4. Slowly lower the machine until its weight rests on the blocks. If the tires still touch the ground, raise the machine again, add more blocks and lower again.

5. Repeat steps 2 through 4 for the front end. When the procedure is finished, all four tires are off the ground, so they could be removed.

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Machine Lowering Procedure When service or adjustment procedures are complete, the machine can be lowered from the raised position. To lower the machine onto its tires: 1. Using a jack or hoist, raise the front of the machine until its weight no longer rests on the front blocks.

2. Carefully remove the blocking under the front of the machine.

3. Slowly lower the machine until the front tires are resting on the ground.

4. Repeat steps 1 through 3 for the rear of the machine. When the procedure is finished, all four tires will be on the ground and the blocks removed from under the machine.

Engine Compartment Access To open the engine compartment, lift the engine cover. Then push the rear door latch down (Fig. 3) and carefully swing open the rear door. There is another rear door latch near the top hinge pin of the door to secure the door open.

Additionally, the radiator swings out for service (Fig. 4). Pull up the spring-loaded latch that secures the radiator to the chassis bumper and place the latch grip in its welded tab placeholder, then pull the radiator outward.

Fig. 3 Rear Door Latch Location

A pin located at the lower left area of the radiator can be used to secure the cooler open.

Fig. 4 Radiator shown open in the engine compartment 50950233/G0221

73

Tilting Back the ROPS/FOPS A manual lock mechanism is used as a gas spring lock to prevent the raised ROPS/ FOPS from lowering unexpectedly. The manual lock mechanism engages to lock the ROPS/FOPS in a tilted-back position.

To tilt back the ROPS/FOPS, remove two hex nuts on two anchor bolts at the front of the ROPS/FOPS. Tilt it back slowly, moving the control handles out of the way.

Two gas-charged springs help tilt it back.

A self-actuating lock mechanism will engage to lock when the ROPS/FOPS is in a rolled-back position. To lower the ROPS/ FOPS, return the lock mechanism to the unlocked position (flipper up). Lower the ROPS/FOPS slowly onto the chassis.

Reinstall the anchor bolts, washers and locknuts. Refer to the Torque Specifications chart (page 127) for torque information.

Fig. 5 ROPS/FOPS Lock Mechanism – Engaged

Fig. 6 ROPS/FOPS Lock Mechanism – Disengaged

Never operate the machine with the ROPS/ FOPS removed or tilted back. Be sure the lock mechanism is securely engaged when the ROPS/FOPS is tilted back. Be sure to reinstall the anchor bolts, washers and locknuts before resuming operation. Additionally, DO NOT raise or lower the lift arm with the ROPS/FOPS rolled back.

WARNING

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50950233/G0221

Adjustments Control Handles The control handles do not require routine adjustment. Refer to the Service Manual for the initial setup procedure.

Removing Foreign Material The machine should be cleared daily of dirt and other foreign materials in the following areas: • • • • • •

around the lift cylinders at the front of the machine on the hitch, especially around tilt cylinder around the hydraulic oil reservoir breather in the engine compartment in the operator’s compartment

Important: Build-up of foreign materials in these areas can interfere with the operation of the machine, cause component damage or become a fire hazard.

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75

Lubrication Listed below are the temperature ranges and types of lubricants for this machine.

Refer to the separate engine manual for more information regarding engine lubricants, quantities and grades required.

Note: Refer to the specific service sections for detailed information on periodic checking and replenishing of lubricants.

Refer to Fig. 7 for grease fitting locations. Wipe dirt from the fittings before greasing them to prevent contamination. Replace any missing or damaged fittings. To minimize dirt build-up, avoid excessive greasing.

Important: Always dispose of waste lubricating oils and hydraulic fluids according to local regulations or take to a recycling center for disposal. Do not pour onto the ground or down the drain.

76

System

Lubricant

Hydraulic System Oil

Use Petro Canada HVI60, Mobil DTE 15M or equivalent, which contain anti-rust, anti-foam and anti-oxidation additives, and conforms to ISO VG46.

Entire System Capacity: 92,7 L (24.50 U.S. gallons) Bare Reservoir Capacity: 59,8 L (15.8 U.S. gallons)

Chaincase Oil

Use SAE grade 15W-40 or 10W-30 motor oil.

Capacity (each side): 14,2 L (15 U.S. quarts)

Grease Fittings

Use lithium-based grease.

Engine Oil

For 250 Hour Change Interval: Use SAE Grade* 5W-30 synthetic, *Service Classification: API certified CK-4 For 500 Hour Change Interval: Must meet one of these Deutz Certifications: DQC III-18 LA, or DQC IV-18 LA Capacity: 9,5 L (10.0 U.S. quarts)

50950233/G0221

500 500

250

10

10

1000

250

1000

Fig. 7 Service Locations Lubrication Procedure Check Engine Oil Level (page 83) Check Hydraulic Oil Level (page 103)

10 Hours (or Daily)

250 Hours

500 Hours (or Yearly)

 

Grease Hitch, Hitch-related Cylinder Pivots and Latch Pins (page 77)



Grease Lift Arm Pins (page 77)



Check Oil Level in Chaincases (page 78)

 

•

Change Engine Oil and Filter (page 83)

1

Change Hydraulic Oil Filter (page 104)

•

2



Change Hydraulic Oil (page 104)

 

Change Chaincase Oil (page 78) Check & Drain Water Separator (page 84) Reservoir Breather

1000 Hours (or Yearly)

 

Change DEF Filter



1 - 250 hour engine oil change interval when using API certified CK-4 oil.

2 - 500 hour engine oil change interval when using oil meeting of these Deutz certifications: DQC III-18 LA, or DQC IV-18 LA. 50950233/G0221

77

Chaincases There is a chaincase on each side of the machine. Refer to the Maintenance Interval Chart (page 115) for change intervals. Refer to the Lubrication chart (page 77) for the type of lubricant.

Checking and Adding Oil 1. Park the machine on a level surface and raise the lift arm, refer to the Lift Arm Support Device Engagement Procedure (page 28). Shut off the engine and remove the key.

2. At the front of each chaincase and on top of the chaincase there is a fill location underneath a bolt-in cover.

Unbolt the cover to access the fill location (Fig. 8).

3. Prior to checking, the chaincase must be made level from front to back. At the front of the machine are two plugs in the chassis (Fig. 10). The top Fig. 8 Bolt-in Cover over chainplug is the oil level check plug, while case fill spot the lower plug is the chaincase drain plug.

4. Remove the oil level check plug on the front side of the chaincase to be serviced. The oil level should be no more than 3/4 in. (19 mm) below it.

5. If the oil level is low, add oil through the fill plug until the oil level is no more than 3/4 in. (19 mm) below the check plug hole. Reinstall the plugs.

Draining Oil 1. Park the machine on a level surface, or on a sloping surface with the machine facing downhill and the tires blocked.

2. Remove the chaincase drain plug on each chaincase and drain the oil into a suitable container.

3. Reinstall and tighten the drain plugs.

4. Refill the chaincases at the fill plugs per the procedure above.

78

Fig. 9 Fill Plug Location

Fig. 10 Check Plug (upper) and Drain Plug (lower)

50950233/G0221

Drive Chains Drive chains are located in the chaincase on each side of the machine. Refer to the Maintenance Interval Chart (page 115) for tension check interval.

Checking Chain Tension 1. Raise the machine following the Machine Raising Procedure (page 72).

2. Rotate each tire by hand. The proper amount of chain defection should be 1/8 inch to 1 inch (3 to 25 mm) forward and rearward tire movement. If the chain defection is more than 1 inch (25 mm) or less than 1/8 inch (3 mm) in either direction, the chains should be adjusted.

Adjusting Chain Tension 1. Raise the machine following the Machine Raising Procedure (page 72).

2. Remove the tire from the axle to be adjusted.

3. Loosen (but DO NOT remove) the bolts holding the axle to the chaincase.

4. Front Chain Tension – To tighten the front chain, move the front axle assembly toward the front of the machine. To loosen the chain, move the front axle assembly toward the rear of the machine.

Rear Chain Tension – To tighten the rear chain, move the rear axle assembly rearward. To loosen the chain, move the rear axle assembly toward the front of the machine.

5. Proper tension is set when both axles can move by a distance of one rubber tire lug width only.

6. After proper tension is achieved, retighten the bolts.

Important: Be careful not to over-tighten the drive chains. Over-tightening will cause premature drive chain and axle sprocket wear.

7. Reinstall the tire.

8. Repeat steps 2 through 6 for any other axle requiring adjustment.

9. Lower the machine following the Machine Lowering Procedure (page 73).

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79

Engine Air Cleaner Important: Failure to follow proper filter servicing instructions could result in catastrophic engine damage.

The air cleaner assembly consists of an outer (primary) filter element and an inner (secondary) filter element. There is an electrical air filter restriction indicator for monitoring the condition of the elements. If the air filter becomes restricted, this indicator will trigger a lamp light in the right indicator panel to warn the operator that the air cleaner requires service.

The outer element should be replaced only when the restriction indicator lamp lights. The inner element should be replaced every third time the outer element is replaced, unless the outer element is damaged or the inner element is visibly dirty.

Along with a daily check of the restriction indicator, check that the air cleaner intake hose and clamps, and the mounting bracket hardware are properly secured.

5

2 3 4

8

7

7

6 1

1. Restriction Indicator 2. Element Housing 3. Mounting Bracket 4. Inner Filter Element

Fig. 11 Dual-Element Air Cleaner

5. Outer Filter Element 6. Dust Ejector 7. Hose Clamp 8. Air Intake Tube

Access 1. Open the engine cover.

2. Unlatch the four clamps on the air cleaner cover and remove the cover.

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50950233/G0221

Outer Element 1. Carefully pull the outer element out of the housing. Never remove the inner element unless it is to be replaced.

2. Clean out any dirt built up in the housing. Leave the inner element installed during this step to prevent debris from entering the engine intake manifold.

3. Use a trouble light inside the outer element to inspect for bad spots, pinholes or ruptures. Replace the outer element if any damage is noted. The outer element must be replaced if it is oil- or soot-laden.

Note: Cleaning the outer element is not recommended.

Inner Element Note: Replace the inner element only if it is visibly dirty or if the outer element has been replaced three times.

1. Before removing the inner element from the housing, clean out any dirt built up in the housing. Leave the inner element installed during this step to prevent debris from entering the engine intake manifold.

2. Remove the inner element.

Reinstallation 1. Check the inside of the housing for any damage that may interfere with the elements.

2. Be sure that the element sealing surfaces are clean.

3. Insert the element(s), making sure that they are seated properly.

4. Secure the cover to the housing with the four clamps.

5. Check the hose connections and make sure they are all fitted and tightened properly.

Note: Periodically inspect intake system tubes, rubber elbows and connections.

Inspect for cracks, loose fits and loose clamps. Tighten or replace as needed.

Intake system must be air tight.

Note: Refer to the Maintenance Interval chart (page 115) for change intervals.

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81

Engine Service Fig. 12 Engine Service Components

1. Diesel Oxidation Catalyst 2. Air Cleaner 3. Coolant Tank 4. Heat Exchanger 5. Cooler 6. Alternator Belt 7. Engine Oil Filter

8. Water Separator 9. Fuel Filter 10. Engine Oil Drain 11. Engine Oil Fill Cap 12. Engine Oil Dipstick 13. Selective Catalytic Reduction/Muffler 14. Engine Oil Drain Valve

11

6

DEF/SCR engines on the left. Non-DEF/SCR engines on the right.

12 8

10 9

14

5

3

4

13 2 7

82

50950233/G0221

Refer to the Maintenance Interval chart (page 115) for change intervals.

Refer to the Engine Operator’s Manual for detailed engine information.

Checking Engine Mounting Hardware All bolts that secure the engine mounting brackets to the engine and the machine frame should be checked and re-torqued as necessary. Refer to the Torque Specifications Chart (page 127) for torque information.

WARNING

Allow hot engine and hydraulic system components to cool before servicing.

Checking Engine Oil Level Open engine cover (page 73), pull out the dipstick and check the oil level. Markings on the dipstick represent FULL and LOW (add oil) levels.

Changing Engine Oil and Filter

Engine oil and filter service every 250 hours or every 500 hours depending on type of oil used.

NOTE: Follow specifications in the Lubrication Chart on (page 77) for type and viscosity of new oil to use for the change interval.

Important: Always dispose of waste lubricating oil according to local regulations or take to a recycling center for disposal; do not pour onto the ground or down the drain.

Raise the lift arm and engage the lift arm support device as described in the “Lift Arm Support Device” on page 28.

The engine oil filter is located on the left side of the engine. Access the filter by removing the left rear access panel (two rubber latches) and the lower access plate (Fig. 13).

Fig. 13 Rubber latches on left side access cover and additional access plate.

Access for draining the engine oil is located on the lower rear left side of the chassis (Fig. 14).

Drain oil by first removing the plug. Follow the drain line to the engine; lift and turn the interior drain valve 1/4 turn counterclockwise to allow oil to drain out.

After draining the oil, turn the drain valve at the engine 1/4 turn clockwise and reinstall the plug.

50950233/G0221

83

To add new oil, open the engine access cover. Remove the oil fill cap and add the recommended type and quantity of oil. Refer to the Lubrication chart, page 76. Visually inspect the remote oil drain hose for damage or leaks.

Changing Fuel Filter The fuel filter is located on the left Fig. 14 Remote Engine side of the engine, near the oil filter.

Oil Drain Plug Unlatch the left engine access panel to access the filter and clean dirt from around the filter head. Remove the filter from the engine. Replace with a new filter element. Lubricate the seal on the new filter element with fuel before installing. Turn the keyswitch to the ON position for three minutes to fill the filter via the electric fuel pump. Start the engine and check for leaks. See page 82 for location on the engine.

Checking the Water Separator The water separator is located above the fuel fill cap. Check on a daily basis and drain if necessary. If excess water collects in the separator an alarm will be shown on the multi-function display. Water can be drained from the separator by opening the valve located at the bottom of the separator bowl.

Note: A water-in-fuel sensor leading from the bottom of the separator may need to be unplugged to open the valve.

After draining the separator, turn the keyswitch to the ON position for three minutes to fill the filter via the electric fuel pump.

84

Fig. 15 Location of Water Separator

50950233/G0221

Engine/Machine Diagnostic Charts When detecting faults, the multi-function display (page 35) uses a diagnostic trouble code (DTC) screen to alert the operator to the occurrence of the fault conditions.

The data port for the engine is located inside the cab behind the seat and on the right side of the operator’s seat.

The data port for the machine is located inside the cab behind the seat and on the left side of the operator’s seat.

Fig. 16 Data Ports for the Engine and Machine.

Left and right are determined by sitting in the operator’s seat and facing forward.

The following pages list descriptions, diagnostic trouble codes and fault codes for the engine and machine.

As an additional reference, Deutz engine trouble diagnostic codes can be found at this website: http://serdia.deutz.com/Service/Technik/Servicedoku/sis_publ.nsf/ gestaltungsdokumente/serdia2010/. Click on the Deutz trouble code list EMR4_DE_EN.pdf file.

50950233/G0221

85

Engine Diagnostic Chart DTC SPN

FMI

Trouble Code Type

Error Description

29

2

Plausibility Error

Plausibility error between sensor and idle switch; Acceleration pedal detection.

29

3

Short-Circuit Error

Hand throttle idle validation switch; short circuit to battery

29

4

Out-Of-Range/Short Circuit Error

Hand throttle; short circuit to ground

51

0

Out-Of-Range Error

Warning threshold for an internal actuator error exceeded, < 4L EGR.actuator und >4L air intake flap

51

1

Out-Of-Range Error

Shut off threshold for an internal actuator error exceeded, < 4L EGR.actuator und >4L air intake flap

51

3

EGR Valve Actuator Error

Actuator of the external EGR valve: the ECU detects a short circuit to battery; short cut to battery on ECU pin A19 or pin A20;

51

4

EGR Valve Actuator Error

Actuator of the external EGR valve: The ECU detects a short circuit to ground; Short cut to ground on ECU pin A19 is detected; measured voltage by ECU is under limit

51

5

EGR Valve Actuator Error

Actuator error EGR Valve: signal range check low, measured current is blow target; open load on ECU output is detected

51

6

EGR Valve Actuator Error

Actuator error EGR Valve: signal range check high, measured current by ECU is over target; too high current is going into the actuator, output is switched off; overload by short-circuit

51

7

EGR Valve Actuator Error

Actuator position for EGR Valve is not plausible, internal error, angular misalignment of the flap

51

11

EGR Valve Actuator Error

Actuator EGR valve: temperature limit in powerstage of the actuator is reached due to high current

DTC SPN 107 520601 520603 520604 520607 520612 520622 520642 520643 520646 520649 520650 520651

86

FMI 0 5.6 5.6 5.6 5.6 5.6 5.6 5 5 5.6 5 5.6 5.6

Trouble Code Type Air Filter Restriction Self-Level Hydraglide Starter Float Parking Brake High Gear Front Work Lights Rear Work Lights Tilt/Lift Lockout Rear Marker Lights All-Tach Lock All-Tach Unlock

50950233/G0221

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description

91

3

Accelerator Pedal Sensor Error

Analog accelerator pedal sensor 1: the voltage measured by ECU is out of the target

91

4

Accelerator Pedal Sensor Error

Analog accelerator pedal sensor 1: the voltage measured by ECU is out of the target

91

11

Accelerator Pedal Sensor Error

Plausibility error between APP1 and idle switch

94

1

Low Fuel Pressure Sensor Error

Low fuel pressure: the low fuel pressure calculated by ECU is underneath the target range; the ECU activates a system reaction

94

3

Low Fuel Pressure Sensor Error

Low fuel pressure: the voltage of sensor measured by ECU is out of the target range, high

94

4

Low Fuel Pressure Sensor Error

Low fuel pressure: the voltage of sensor measured by the ECU is out of the target range, low

97

3

Water in Fuel Sensor Error

Fuel filter water level sensor: the voltage of sensor measured by ECU is out of the target range, high

97

4

Water in Fuel Sensor Error

Fuel filter water level sensor: the voltage of sensor measured by ECU is out of the target range, low

97

12

Water in Fuel Sensor Error

Fuel filter water level sensor: the maximum level is exceeded

100

1

Oil Pressure Sensor Error

Oil pressure is below the target range: warning, power reduction or shutdown threshold

100

3

Oil Pressure Sensor Error

Oil pressure sensor: the voltage of sensor measured by ECU is out of target range, high

100

4

Oil Pressure Sensor Error

Oil pressure sensor: the voltage of sensor measured by ECU is out of target range, low

102

1

Charge Air Pressure Out-Of-Range

Pressure downstream charge air cooler, pressure below lower physical threshold

102

2

Charge Air Pressure Sensor Error

Charge air pressure measured by sensor is above the warning threshold or shutdown threshold

102

3

Charge Air Pressure Sensor Error

Charge air pressure sensor: the measured voltage of sensor by ECU is out of the target range, high

102

4

Charge Air Pressure Sensor Error

Charge air pressure sensor: the measured voltage of sensor by ECU is out of the target range, low

105

0

Charge Air Temperature Sensor Error

Charge air temperature downstream calculated

by ECU is above the target range: the ECU activates a warning threshold or shutdown threshold

50950233/G0221

87

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description

105

3

Charge Air Temperature Sensor Error

Charge air temperature Sensor: the voltage of sensor measured by ECU is out of target range, high

105

4

Charge Air Temperature Sensor Error

Charge air temperature Sensor: the voltage of sensor measured by ECU is out of target range, low

107

0

Air Filter Differential Pressure Sensor Error

Air filter differential pressure: the pressure difference of the intake air between the filter inlet and outlet calculated by ECU is above the target range and the ECU activates a warning threshold

110

0

Coolant Temperature Sensor Error

Coolant temperature: the coolant temperature calculated by ECU is above the target range; the ECU activates a warning power reduction or a shutdown threshold

110

1

Coolant Temperature Out-Of-Range

Physical range check low for coolant temperature

110

3

Coolant Temperature Sensor Error

Coolant Temperature sensor: the voltage of the sensor measured by ECU is out of the target range, high

110

4

Coolant Temperature Sensor Error

Coolant Temperature sensor: the voltage of the sensor measured by ECU is out of the target range, low

111

1

Coolant Level

Coolant Level: the coolant level calculated by the ECU is underneath the allowed minimum

157

3

Rail Pressure Sensor Error

Rail Pressure Sensor: the voltage of sensor measured by ECU is out of target range, high

157

4

Rail Pressure Sensor Error

Rail Pressure Sensor: the voltage of sensor measured by ECU is out of target range, low

164

2

Rail pressure safety function is not executed correctly

Threshold for error detection is an internal ECU threshold. Reset the fault and at reappearance check ECU and injection system

168

0

Battery Voltage Sensor Error

Battery Voltage: the voltage measured by ECU is out of the target range, high

168

1

Battery Voltage Sensor Error

Battery Voltage: the voltage measured by ECU is out of the target range, low

168

2

Battery Voltage Sensor Error

Battery Voltage: the voltage measured by ECU is out of the target range, battery voltage above warning threshold

168

3

Battery Voltage Sensor Error

Battery Voltage: the voltage measured by ECU is out of the target range, battery voltage above warning threshold, short cut to battery

88

50950233/G0221

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description

168

4

Battery Voltage Sensor Error

Battery Voltage: the voltage measured by ECU is out of the target range, battery voltage above warning threshold, short cut to ground

171

3

SCR Sensor Error

Sensor error SCR-System environment temperature; DPF-System air inlet temperature; signal range check high

171

4

SCR Sensor Error

Sensor error SCR-System environment temperature; DPF-System air inlet temperature; signal range check low

190

0

Engine Speed

Maximum engine speed exceeded

190

2

Engine Speed

ECU measures a offset angle between crankshaft and camshaft sensor is too large

190

8

Engine Speed

Camshaft Speed Sensor: ECU receives no signal, uses crankshaft sensor to calculate engine speed. Crankshaft Speed Sensor: disturbed signal

190

11

Engine Speed

Engine Speed: the engine speed calculated by ECU is above the target range, the ECU activates a warning threshold

190

12

Engine Speed

Crankshaft Speed Sensor Unavailable: ECU uses camshaft speed sensor. Speed detection; out of range, signal disrupted, erratic signal

190

14

Engine Speed

Engine Speed: the engine speed calculated by ECU is above the target range, the ECU activates an engine speed warning threshold

411

3

EGR Sensor Error

Sensor error differential pressure venturi unit (EGR), signal range check low

411

4

EGR Sensor Error

412

3

EGR Electrical Error

Electrical error EGR cooler downstream temperature. Signal range check high

412

4

EGR Electrical Error

Electrical error EGR cooler downstream temperature. Signal range check low

520

9

CAN Timeout Error

Timeout Error of CAN-Receive-Frame TSC1TR; control signal

630

12

EEPROM Error

The ECU finds an error during the access to its EEPROM memory or works with an alternative value

639

14

CAN-Bus error

CAN-Bus “BusOff-Status”

50950233/G0221

Physical range check low for EGR differential pressure Sensor error differential pressure venturi unit (EGR), signal range check high

89

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description

651

3

Electrical Error

Injector Cyl. 1: the current drop measure by ECU is above the target range, short circuit to injector 1

651

5

Electrical Error

Injector Cyl. 1: interruption of electrical connection

652

3

Electrical Error

Injector Cyl. 3: the current drop measure by ECU is above the target range, short circuit to injector 1

652

5

Electrical Error

Injector Cyl. 3: interruption of electrical connection

653

3

Electrical Error

Injector Cyl. 4: the current drop measure by ECU is above the target range, short circuit to injector 1

653

5

Electrical Error

Injector Cyl. 4: interruption of electrical connection

654

3

Electrical Error

Injector Cyl. 2: the current drop measure by ECU is above the target range, short circuit to injector 1

654

5

Electrical Error

Injector Cyl. 2: interruption of electrical connection

655

3

Short-Circuit Error

Injector 5 (in firing order); short circuit

655

5

Electrical Error

Injector 5 (in firing order); interruption of electric connection

656

3

Short-Circuit Error

Injector 6 (in firing order); short circuit

656

5

Electrical Error

Injector 6 (in firing order); interruption of electric connection

676

11

Cold Start Device Error

Cold start device relay error; cold start aid relay open load Starter Relay (high side power stage): The current drop measured by ECU is above the target range; starter relay high side short circuit to battery.

677

3

Starter Relay Error Starter Relay (high side power stage): The current drain measured by ECU is above the target range; starter relay low side, short circuit to battery

90

50950233/G0221

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description Starter Relay (high side power stage): The current drop measured by ECU is above the target range; starter relay low side short circuit to ground.

677

4

Starter Relay Error Starter Relay (high side power stage): The current drain measured by ECU is above the target range; starter relay high side, short circuit to ground

677

5

Starter Relay Error

Starter Relay (low side power stage): the current drop measured by ECU is above the target range; open circuit/disconnection LowSideOutput

677

12

Starter Relay Error

Starter Relay (low side power stage): the current drop measured by ECU is above the target range; starter relay powerstage over temperature

729

3

Short-Circuit Error

Intake Air Heater Device; short-circuit to battery

729

4

Short-Circuit Error

Air intake heater; Short circuit to ground error for powerstage on CJ945

729

5

Cold Start Error

Cold start aid relay open load

898

9

Timeout Error

Timeout error: limp mode activated

1079

13

(ECU) Error

Internal Hardware Monitoring: the ECU detects a deviation of the target range of the power supply voltage of sensor output 1

1080

13

(ECU) Error

Internal Hardware Monitoring: the ECU detects a deviation of the target range of the power supply voltage of sensor output 2

1109

2

Engine Shut-off Error

Operator ignores the engine shut off request within an allowed period.

1136

0

ECU Temperature Range Check Error

Physical range check high for ECU temperature

1176

0

Turbine Pressure Sensor Out-Of-Range Error

Pressure sensor upstream turbine, physical range check high

1176

3

Turbine Pressure Sensor Out-Of-Range Error

Pressure sensor upstream turbine, signal range check (SRC) high

1176

4

Turbine Pressure Sensor Out-Of-Range Error

Pressure sensor upstream turbine, signal range check (SRC) low

1231

14

CAN BusOff Error

CAN Bus 1: the ECU is not allowed to send messages, because the status “BusOff” is detected

1235

14

CAN Bus Error

CAN-Bus 2 = engine bus BusOff-Status

1237

2

Override Switch Error

Override Switch: the ECU receives a permanent signal, plausibility error

50950233/G0221

91

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description

1761

2

DEF Tank Error

DEF tank level plausibility error

1761

14

DEF Tank Error

DEF level below first warning threshold

2791

0

EGR Temperature Error

EGR actuator, temperature critically high

2791

2

EGR CAN error

EGR actuator, CAN error

2791

3

EGR Electrical Error

EGR actuator supply voltage above the maximum threshold

2791

4

EGR Electrical Error

EGR actuator supply voltage below minimum threshold

2791

6

EGR Electrical Error

EGR actuator current above maximum threshold

2791

7

EGR Error

EGR actuator blocked; EGR actuator, broken spring detected

2791

12

EGR Electrical Error

EGR actuator, internal electrical fault EGR actuator, EOL calibration error; EGR actuator, learning process aborted; EGR actuator, learning process out-of-range

2791

13

EGR Error

2791

16

EGR Error

EGR actuator, temperature high

2797

4

Timeout Error

Timeout of short-circuit ground diagnosis cyl. bank 0;_IVDiaShCirGndToutBnk_0

2798

4

Short-Circuit Error

Injector diagnostic; Short circuit to ground cylinder bank 0 Injector diagnostic; Short circuit to ground cylinder bank 1

3031

0

DEF Tank Error

DEF temperature in DEF tank too high

3031

1

DEF Tank Error

DEF temperature below lower physical threshold

3224

9

CAN timeout Error

Timeout Error of CAN-Receive-Frame AT1IG1Vol; NOX sensor

3234

2

CAN Error

DLC Error of CAN-Receive-Frame AT1O1Vol NOX

3234

9

CAN Error

Timeout Error of CAN-Receive-Frame AT1OG1Vo

3251

0

DPF Error

Differential pressure DPF maximum value is exceeded Differential pressure sensor across DPF exceeds warning high limit

3251

1

DPF Error

Differential pressure DPF, pressure below lower shutoff threshold Differential pressure DPF, pressure below lower warning threshold.

3253

2

DPF Error

Differential pressure DPF, plausibility error

92

50950233/G0221

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description

3253

3

Electrical Error

Electrical error differential pressure B58 (DPF); (signal range check high)

3253

4

Electrical Error

Electrical error differential pressure (DPF); signal range check low

3361

3

Short-Circuit Error (DEF)

DEF dosing valve; short circuit to battery on low side DEF dosing valve; short circuit to battery or open load on high side

3361

4

Short-Circuit Error (DEF)

Urea dosing valve; short circuit to ground or open load on low side DEF dosing valve; short circuit on high side

3361

6

DEF Error

DEF dosing valve; power at the end of injection too high

3519

3

DEF Error

DEF quality sensor, internal temperature sensor short circuit to battery or open load

3519

4

DEF Error

DEF quality sensor, internal temperature sensor short circuit to ground

3519

12

DEF Error

DEF tank temperature, temperature too high

3519

13

Invalid UQS Temperature

Temperature at UQS out of range the specified thresholds; invalid temperature quality

3520

1

DEF Error

Bad DEF quality

3520

2

DEF Error

DEF quality seonsor, bad DEF quality detected or no DEF measuring possible

3520

3

DEF Error

DEF quality sensor, short circuit to battery or open load

3520

4

Short-Circuit Error (DEF)

DEF quality sensor, short circuit to ground

3520

8

DEF Error

DEF quality seonsor, measurement conditions not fulfilled

3520

13

Invalid UQS Urea Quality

Urea quality at UQS out of range the specified thresholds; invalid quality of the urea qualiy

3532

3

DEF Error

Sensor error DEF tank level; signal range check high The DEF Level at UQS out of max. physical range

3532

4

DEF Error

Sensor error DEF tank level; signal range check low Quality at UQS out of min. physical range

3532

13

DEF Error

DEF qualitysensor, tank level; DEF level out of physial range

3711

12

Standstill Error

Temperature during standstill main phase too low or too high

50950233/G0221

93

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description

3936

14

Standstill Error

Standstill request ignored too long Standstill time based escalation requests Inducement step 2

4171

2

SCR Error

Dynamic check of temperature before SCR

4334

0

DEF Error

Supply module DEF, DEF pressure above upper physical threshold

4334

2

DEF Error

DEF supply module pressure, plausibility error

4341

3

Short-Circuit Error (DEF)

SCR-heater DEF supplyline; short circuit to battery

4341

4

Short-Circuit Error (DEF)

SCR-heater DEF supply line; short circuit to ground

4341

5

DEF Error

SCR heater relay DEF supply line primary side; open load

4343

3

DEF Error

SCR heater DEF pressureline; short circuit to battery

4343

4

DEF Error

SCR heater DEF pressureline; short circuit to ground

4343

5

DEF Error

SCR heater relay DEF pressureline primary side; open load

4345

3

DEF Error

SCR heater DEF returnline; short circuit to battery

4345

4

DEF Error

SCR heater DEF returnline; short circuit to ground

4345

5

DEF Error

SCR heater relay DEF returnline primary side; open load

SCR-Cat Over-Temperature

Exhaust temperature upstream SCR-Cat, temperature above upper physical threshold; The filtered DEF cat upstream temperature is greater than an applicable maximum temperature threshold

4360

94

0

50950233/G0221

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description Error at static plausibility check: absolute temperature difference of sensed temperature upstream SCR catalyst and ambient temperature > as static plausibility limit at engine cold start (engine was off for at least 8 h), temperature upstream of SCR catalyst is expected to be identical to ambient temperature =>

4360

2

SCR-Cat Temperature Plausibility Error

Error at dynamic plausibility check: temperature difference of sensed temperature upstream SCR catalyst and ambient temperature < as dynamic plausibility limit dynamic check is blocked if static plausibility check is already faulty => Temperature upstream SCR catalyst must be by 40°C higher than ambient temperature if engine runs and a certain delay time has expired

4361

3

DEF Error

DEF catalyst upstream temperature sensor: the voltage of sensor measured by ECU is out of the target range

4361

4

DEF Error

DEF catalyst upstream temperature sensor: the voltage of sensor measured by ECU is out of the target range

4365

3

Urea Tank/DEF Error

Urea tank temperature sensor: the current drain measured by ECU is above the target range; DEF qualitysensor, tank temperatur; short circuit to battery or open load

4365

4

Urea Tank/DEF Error

Sensor error urea tank temperature; short circuit to ground; DEF qualitysensor, tank temperature; short circuit to ground

4365

12

Urea Tank Error

Urea tank temperature above the warning threshold

4365

13

Urea Tank/DEF Error

DEF qualitysensor, tank temperature; temperature out of physial range SCR Tank heating valve; short circuit to ground

4366

4

Short-Circuit Error (SCR)

4366

5

SCR Error

SCR tank heating valve primary side; open load

4375

3

Short-Circuit Error (SCR)

Urea pump motor; short circuit to battery

4375

4

Short-Circuit Error (SCR)

Urea pump motor; short circuit to ground

4375

5

SCR Error

Urea pump motor; open load

4376

3

Short-Circuit Error (SCR)

SCR reversal valve; short circuit to battery

4376

4

Short-Circuit Error (SCR)

SCR reversing valve; short circuit to ground

4376

5

SCR Error

SCR reversal valve; open load

50950233/G0221

95

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description

4765

0

Exhaust Temperature Error

Temperature upstream DOC, temperature above upper shutoff threshold; temperature above upper warning threshold

4766

0

Exhaust Temperature Error

Temperature downstream DOC, temperature above upper shutoff threshold; temperature above upper warning threshold

4768

2

Exhaust Temperature Error

Temperature upstream DOC, plausibility error; Exhaust gas temperature sensors up- and downstream DOC are physically swapped

4768

3

Exhaust Temperature Error

Electrical error exhaust gas temperature upstream (DOC); signal range check high

4768

4

Exhaust Temperature Error

Electrical error exhaust gas temperature upstream (DOC); signal range check lo

4769

2

Exhaust Temperature Error

Temperature downstream DOC, plausibility error

4769

3

Exhaust Temperature Error

Sensor error exhaust gas temperature downstream (DOC); signal range check high

4769

4

Exhaust Temperature Error

Sensor error exhaust gas temperature downstream (DOC); signal range check low

520521

5

Actuator Error (EGR)

Actuator error EGR-Valve (2.9;3.6) or ThrottleValve (4.1;6.1;7.8); signal range check low

523009

9

Pressure Relief Valve Error

Rail Pressure Relief Valve: reached maximum allowed opening count

523009

10

Pressure Relief Valve Error

Rail Pressure Relief Valve: reached maximum allowed opening time

523211

9

Timeout Error (CAN)

Timeout Error of CAN-Receive-Frame EBC1

523212

9

Timeout Error (CAN)

Timeout Error of CAN-Receive-Frame ComEngPrt; Engine Protection

523240

9

Timeout Error (CAN)

Timeout CAN-message FunModCtl; Function Mode Control

523350

4

Injector Short Circuit Error

Injector Cylinder - Bank 1: short circuit

523352

4

Injector Short Circuit Error

Injector Cylinder - Bank 2: short circuit

523354

12

Injector Error

ECU detects an error of its injector high current output; injector powerstage output defect PRV will be forced to open; performed by pressure increase.

523470

2

Pressure Relief Valve (PRV) Error PRV: is open, will be forced to open, the forced open failed; performed by pressure shock

523470

96

7

Pressure Relief Valve (PRV) Error

Rail pressure is out of the expected range; Maximum rail pressure in limp home mode exceeded, monitoring for maximum rail pressure in limp home mode with PRV

50950233/G0221

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description

523470

11

Pressure Relief Valve (PRV) Error

Rail pressure relief valve can’t be opened due to rail pressure; PRV error; rail pressure out of tolerance range; average rail pressure is outside the expected tolerance range

523470

12

Pressure Relief Valve (PRV) Error

Rail pressure relief valve open; PRV forced to open; system reaction initiated, fault path indicating shutoff condition in case of open PRV; power reduction may result

523470

14

Pressure Relief Valve (PRV) Error

Rail pressure relief valve open;PRV is open; PRV in rail is open; power reduction may result

523550

12

T50 Start Switch Error

Terminal 50: ECU receives a permanent signal; T50 start switch active for too long; Start information to starter T50 Switch erratic/defect

523601

13

Sensor Supply Voltage Monitor 3 Error

Internal Hardware Monitoring: the ECU detects a deviation of the target range of the power supply voltage of sensor output 3

523605

9

Timeout Error (CAN)

Timeout Error of CAN-Receive-Frame TSC1AE; Traction Control

523606

9

Timeout Error (CAN)

Timeout Error of CAN-Receive-Frame TSC1AR; Retarder

523612

3

Electrical Error

Reported supply over-voltage

523612

4

Electrical Error

523612

12

Software Error

Reported supply under-voltage ECU Internal software error; power reduction may result.

Internal ECU monitoring detection reported error

523612

523613

523613

14

0

1

50950233/G0221

Software Error

Internal Hardware Monitoring: ECU CPU reset and cause is logged internally; no item created in error memory; software reset CPU, software visibility resets in DSM

Rail Pressure Error

Rail Pressure: fuel pressure in rail below target range dependant on engine speed; rail pressure disrupted, Positive governor deviation; maximum positive rail pressure deviation exceeded concerning set fuel flow; power reduction may result

Rail Pressure Error

Rail Pressure: fuel pressure in rail exceeds target range dependant on engine speed; rail pressure disrupted, maximum negative rail pressure deviation with metering unit on lower limit is exceeded

97

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description

523613

2

Metering Unit Error

Rail Pressure: fuel pressure in rail exceeds target rage dependant on engine speed; rail pressure disrupted, leakage detected based on fuel quantity balance; power reduction may result

523615

3

Metering Unit Error

Rail Pressure: fuel pressure in rail exceeds target range dependant on engine speed; rail pressure disrupted, maximum rail pressure exceeded

523615

4

Metering Unit Error

Rail Pressure: fuel pressure in rail calculated by ECU is below the target range which is dependant on engine speed; minimum rail pressure exceeded

523615

5

Fuel System Error

Fuel metering unit: the ECU detects no load or temperature excess of the ECU component for power supply of the valve; Metering unit (FuelSystem); open load; power reduction may result

523632

3

Sensor Error

Sensor error urea pump pressure; signal range check high

523632

4

Sensor Error

Sensor error urea pump pressure; signal range check low

523632

11

Electrical Error

Pump motor not available for actuation

523698

11

SCR Error

Rail Pressure: fuel pressure in rail calculated by ECU is below the target range which is dependant on engine speed; setpoint of metering unit in over-run mode not plausible

523718

3

Short-Circuit Error (SCR)

SCR main relay (primary side); short circuit to battery

523718

4

Short-Circuit Error (SCR)

SCR main relay (primary side); short circuit to ground

523718

5

Electrical Error

Tank heating valve; open load

523719

3

Short-Circuit Error (SCR)

SCR heater DEF supplymodule; short circuit to battery

523719

4

Short-Circuit Error (SCR)

SCR heater DEF supplymodule; short circuit to ground

523719

5

Electrical Error (SCR)

SCR heater relay DEF supplymodule primary side; open load

523720

8

Temperature Error (DEF)

DEF supply module heater temperature; duty cycle in failure range; duty cycle in invalid range

523721

8

Temperature Error

DEF supply module temperature; duty cycle in failure range; Urea supply module temperature; duty cycle in invalid range.

523721

11

Temperature Error

Urea supply module temperature measurement not available

98

50950233/G0221

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description

523722

8

PWM Signal Error (DEF)

DEF supply module PWM signal; period outside valid range; Detect faulty PWM signal from supply module

523741

14

CAN Error

Engine shutoff request through CAN

523766

9

Timeout Error (CAN)

Timeout Error of CAN-Receive-Frame Active TSC1AE

523767

9

Timeout Error (CAN)

Timeout Error of CAN-Receive-Frame Passive TSC1AE

523768

9

Timeout Error (CAN)

Timeout Error of CAN-Receive-Frame Active TSC1AR

523769

9

Timeout Error (CAN)

Timeout Error of CAN-Receive-Frame Passive TSC1AR

523776

9

Timeout Error

Fuel Metering Unit: current drain measured by ECU is above the target range; short circuit to battery high side; short circuit to battery low side

523777

9

Passive Timeout Error

Fuel Metering Unit: current drain measured by ECU is above the target range; short circuit to ground high side; short circuit to ground low side

523778

9

Timeout Error (CAN)

Timeout Error of CAN-Receive-Frame TSC1TR

523779

9

Timeout Error (CAN)

Passive Timeout Error of CAN-Receive-Frame TSC1TR

523895

13

Injector Adjustment Error

Engine Shut Off request from supervisory monitoring function

523896

13

Injector Adjustment Error

Timeout Error; limp mode activated

523897

13

Injector Adjustment Error

Passive Timeout Error; limp mode activated

523898

13

Injector Adjustment Error

Missing or wrong injector adjustment value programming (IMA) injector 1

523900

13

Fuel Injector Error

Check of missing injector adjustment value programming (IMA) injector 6 (in firing order)

523906

3

Fuel Pump Error

ECU detects short cut to battery in fuel feed pump circuit; electric fuel pre-supply pump short circuit to battery

523906

4

Fuel Pump Error

ECU detects short cut to ground in fuel feed pump circuit; electric fuel pre-supply pump short circuit to ground

523906

5

Fuel Pump Error

ECU detect open load on the electric fuel feed pump output: electric fuel pre-supply pump open load, cable break

523906

12

Fuel Pump Error

ECU detects to high temperature in powerstage of fuel pump circuit; electric fuel pre-supply pump powerstage over temperature

50950233/G0221

99

Engine Diagnostic Chart (cont.)

DTC SPN

523912

FMI

4

Trouble Code Type

Error Description

Electrical/CAN Error

@ engines < 4l: Throttle valve error, open load or short cut to battery, blocked valve or wrong control signal for valve. @ engines with burner T4i: Pressure sensor error after valve (DV2), lower limit reached

523924

4

Short-Circuit Error

UB2; short-circuit to ground of actuator relay 2

523925

3

Short-Circuit Error

UB3: short-circuit to battery of actuator relay 3

523925

4

Short-Circuit Error

UB3; Short circuit to ground of actuator relay 3

523926

4

Short-Circuit Error

UB4; short-circuit to ground of actuator relay 4

523927

3

Short-Circuit Error

UB5; short-circuit to battery of actuator relay 5

523935

12

Timeout Error (CAN)

Timeout Error of CAN-Transmit-Frame EEC3VOL1; engine send messages

523936

12

Timeout Error (CAN)

Timeout Error of CAN-Transmit-Frame EEC3VOL2; Engine send messages

523942

9

Calibration Error

Calibration message 1 of the after-catalyst NOx sensor has failed

523960

0

Temperature Error (EGR)

Physical range check high for EGR cooler downstream temperature

523982

0

Powerstage Diagnosis Disabled

Powerstage Diagnosis Disabled; high battery voltage

523982

1

Powerstage Diagnosis Disabled

Powerstage Diagnosis Disabled; low battery voltage

523984

3

Short-Circuit Error

UB7; short-circuit to battery error of actuator relay 7 UB6; short-circuit to ground actuator relay 6

523986

4

Short-Circuit Error

523987

4

Short-Circuit Error

UB7; short-circuit to ground actuator relay 7

Timeout Error

Maximum launch time for standstill exceeded (60min)

524025

8

524057

2

Fuel Pressure Error

Electric Fuel Pump; fuel pressure build up error

524063

3

Short-Circuit Error (SCR)

SCR heater main relay; short-circuit to battery

524063

4

Short-Circuit Error (SCR)

SCR heater main relay load side (K31) on heating valve (Y31), short-circuit to ground

100

50950233/G0221

Engine Diagnostic Chart (cont.)

DTC SPN

FMI

Trouble Code Type

Error Description Urea backflow line heater: broken wiring detected Threshold 1 < SCRHtr_rUHtrMeasRatio_mp < Threshold 2

524063

5

Electrial Error

SCR main relay not connected; SCR heater pressureline; open load; Relay Urea suction line: broken wiring detected (open load) -- SCR suction line (K28) SCR heater supply module; open load SCR heater tank; open load

524063

12

Timeout Error

DEF tank, time for defrosting too long

524065

0

Over-Pressure Error

Pressure sensor upstream SCR-CAT, pressure above upper physical threshold

524065

1

Under-Pressure Error

Pressure sensor upstream SCR-CAT, pressure below lower physical threshold

524065

2

Plausibility Error

Pressure sensor upstream SCR-CAT, plausibility error

524065

3

Electrial Error

Pressure sensor upstream SCR-CAT; short circuit battery or open load

524065

4

Short-Circuit Error

Pressure sensor upstream SCR-CAT; short circuit ground

524067

0

Over-Temperature Error

DEF supply module, heater temperature above upper physical threshold

524067

1

Under-Temperature Error

DEF supply module, heater temperature below lower physical threshold

524067

2

Plausibility Error

Supply module heater temperature, plausibility error

524074

9

Electrial Error

NOx sensor downstream SCR-CAT, sensor internally open load

524075

11

Short-Circuit Error

NOx sensor downstream SCR-CAT, sensor internally short circuit

524076

9

Electrial Error

NOx sensor upstream SCR-CAT, sensor internal open line

524077

11

Short-Circuit Error

NOx sensor upstream SCR-CAT, sensor internal short-circuit

524078

9

Plausibility Error

NOx sensor downstream SCR-CAT, lambda value above upper physical threshold

524079

9

Plausibility Error

NOx sensor downstream SCR-CAT, lambda value below lower physical threshold

524080

9

Plausibility Error

NOx sensor upstream SCR-CAT, lambda value above upper physical threshold

50950233/G0221

101

Engine Diagnostic Chart (end) DTC SPN

FMI

Trouble Code Type

Error Description

524081

9

Plausibility Error

NOx sensor upstream SCR-CAT, lambda value below lower physical threshold

524108

9

Timeout Error

Missing CAN message of EGR throttle valve; Timeout Error of CAN-Transmit-Frame ComEGRTVActr, Missing CAN Bus message

524109

9

Timeout Error

Missing message of EGR throttle valve; Timeout error of CAN-Receive-Frame ComRxEGRTVActr, Missing CAN Bus message

524133

2

Electrial Error

State of digital input standstill release switch

524134

0

Threshold Error

DPF ash load exceeds the shutoff threshold

524135

0

Threshold Error

DPF ash load exceeds the warning threshold; DPF soot load exceeds the shutoff threshold

524135

14

Threshold Error

DPF soot load exceeds the service request threshold

524147

7

SCR System Error

SCR system reverting valve blocked SCR system pressure build-up not possible Set together with DFC_SCRCoBldUpLoPres.

DFC_SCRCoBldUpLoPresRst is only used for inducement purposes. It ensures that legal inducement is working correctly

524147

13

Plausibility Error

524152

2

Timeout Error (CAN)

Urea quality sensor; Timeout CAN message

524153

2

Timeout Error (CAN)

Urea tank level and urea tank temperature via CAN bus, timeout of CAN message

524175

0

Threshold Error

SCR-CAT Nox emissions above maximum threshold

524178

7

Out-of-Range Error (CAN)

SCR system DEF pressure out-of-range

524190

14

DEF Error

Inducement level 1 active; Not enough urea in tank, low urea quality, hardware tampering failure is detected, or hardware failure is detected

524191

14

DEF Error

Inducement level 2 active; Low DEF tank level, a low DEF quality is detected, hardware tampering(system components are pinched off) or hardware failures as shortcut to battery, shortcut to ground etc. are detected

524193

8

Timeout Error

Standstill regeneration mode time exceeds longlimit threshold; machine too long or too often in standstill mode

524194

8

Timeout Error

Standstill regeneration mode time exceeds short-limit; Machine too long or too often within a short time in standstill mode

524195

14

Timeout Error

Standstill request due to crystalisation ignored too long

DTC SPN

FMI

Trouble Code Type

Error Description

524267

14

2nd Level Inducement Error

General inducement error. Refer to official Deutz engine error code documentation for more information

102

50950233/G0221

Hydraulic System Refer to the Maintenance Interval Chart (page 115) for service intervals.

Checking Hydraulic Oil Level Inside the engine compartment, the machine has a hydraulic tank dipstick left of the coolant tank. To check the level, run the machine to allow the hydraulic system to reach its operating temperature, then let the engine IDLE and remove the dipstick. Clean the dipstick and replace in its holder. Remove the dipstick again and check the fluid level, (Fig. 17).

Fig. 17 Hydraulic Oil Dipstick

Add hydraulic oil as required in the hydraulic oil fill tube. The fill tube is located under a cover at the left side of the engine compartment. Refer to the Lubrication chart (page 76). Replace the fill cap.

Fig. 18 Hydraulic Oil Fill Tube Cover Plate

50950233/G0221

103

Changing Hydraulic Oil Filter The hydraulic oil filter element is located underneath a flat cover plate on top of the reservoir tank. To change the hydraulic filter element: 1. Park the machine on a level surface and raise the lift arm, refer to the Lift Arm Support Device Engagement Procedure (page 28). Shut off the engine and remove the key.

2. Tilt back the ROPS/FOPS, refer to the ROPS/FOPS Procedure (page 74).

3. Remove the left side access cover.

4. Clean any dirt/debris off the surface of Fig. 19 Hydraulic Oil Filter Cap and Spring the filter housing.

5. Remove four bolts on the cover plate and remove the plate and spring.

6. Pull up on the filter element and remove it from the reservoir (Fig. 20).

7. Apply a small amount of hydraulic oil to the o-ring at the bottom of the new filter and install the new filter element in the reservoir.

8. After properly positioning the spring, reinstall the cover plate and its hardware.

9. Refill the hydraulic oil reservoir with oil (if needed). Refer to the Lubrication chart (page 76).

Fig. 20 Hydraulic Oil Filter Element

Changing Hydraulic Oil The hydraulic oil must be replaced if it becomes contaminated, after major repairs and after 1000 hours or one year of use.

1. Under the machine near the left rear tire, unbolt a small left rear floor plate cover to access the drain plug.

2. Install a catch pan of sufficient capacity under the oil reservoir. See page 76.

104

50950233/G0221

3. Remove the drain plug on the reservoir tank and allow the oil to drain (Fig. 21).

4. Reinstall the drain plug and floor plate cover.

5. Change the oil filter.

6. Refill the reservoir. Refer to the Lubrication chart (page 76).

7. Start the engine and operate the hydraulic controls.

8. Stop the engine and check for leaks at the filter and reservoir drain plug.

9. Check the fluid level and add fluid, if needed.

Fig. 21 Hydraulic Oil Reservoir Drain Plug

Bucket Cutting Edge The bucket cutting edge should be replaced when it is worn to within 1 in.

(25 mm) of the bucket body.

Alternator Belt Refer to the separate engine manual for setting proper belt tension. If the belt is worn, cracked or otherwise deteriorated, replace the belt following the procedure in the engine manual.

Wheel Nuts Wheel nut torque must be checked before initial operation and every two hours thereafter until the wheel mounting hardware torque remains at 240 ft.-lbs.

(325 N·m). When wheels are removed and reinstalled this procedure must be repeated.

Lift Arm Pivots The Power-A-Tach® pivot should be torqued every 250 hours to 380 ft.-lbs. (515 N·m). Refer to the Maintenance Interval Chart (page 115).

50950233/G0221

105

Cooling System Important: Check the cooling system daily to prevent overheating, loss of performance and engine damage.

Checking Coolant Level 1. With the engine at operating temperature, open the engine cover. Looking at its visual sight gauge, check that the coolant tank fluid is half way up on the sight glass of the coolant tank (Fig. 22).

2. Allow the coolant to cool. Do not remove the cap when the coolant is hot. Serious burns may occur.

3. Add premixed coolant meeting Deutz CB-14 approval to the tank if the coolant level is low.

Fig. 22 Coolant Tank Visual Sight Gauge

Cleaning the Cooling System Allow sufficient time for the oil radiator to cool before working on or near it. Parts get extremely hot during operation and can burn you.

WARNING

The radiator assembly is mounted between the engine and the hinged rear door.

When operating correctly, air is blown through the openings between the fins by the engine fan. During operation dust and debris can build up on the engine side of the radiator and restrict air flow through the fins. To remove this restriction, use compressed air and direct the flow through the fins from the rear of the radiator toward the engine.

1. Lower the lift arm and stop the engine.

Allow the machine to cool.

2. Raise the engine cover and open the rear door (page 73).

3. Pull up on the radiator lock pin and put it in its placeholder (Fig. 23), then swing the radiator out (Fig. 4).

4. As necessary, clean the radiator and air cooler by blowing compressed air through the fins from the rear, toward the engine.

Fig. 23 Radiator Latch Pin Placeholder 106

50950233/G0221

Draining/Flushing the Cooling System 1. Lower the lift arm and stop the engine. Allow the machine to cool.

2. Raise the engine cover and open the rear door (page 73).

3. Remove the radiator cap on the coolant tank (Fig. 22).

4. Open the drain cock on the radiator (Fig. 24) and drain the coolant into a suitable container.

Note: Coolant must be drained from the radiator and the engine.

5. Close the drain cock.

Note: Protect the cooling system by adding premixed coolant meeting Deutz CB-14 approval to the tank if the coolant level is low.

Fig. 24 Radiator Drain Cock 6. Fill the radiator fully and the coolant tank to half full.

7. Reinstall the radiator cap and run the engine until it is at operating temperature.

8. Stop the engine and let it cool. Check the coolant level. Add more fluid, if necessary.

Tires Inflating or servicing tires can be dangerous.

When possible, trained personnel should service and mount tires. To avoid possible death or serious injury, follow the safety precautions below.

WARNING

To keep tire wear even, rotate the tires from front to rear and rear to front.

It is important to keep the same size tire on each side of the machine to prevent excessive wear on tires, chains, or other damage. If different sizes are used, tires will be turning at different speeds, causing excessive wear.

Note: The tread bars of all tires should point the same direction.

 BE SURE the rim is clean and free of rust.  Lubricate the tire beads and rim flanges with a soap solution. Do NOT use oil or grease.

 Use a clip-on tire chuck with remote hose and gauge, allowing you to stand clear while inflating the tire.  NEVER inflate beyond 35 psi (240 kPa) to seat the beads. If the beads have not seated by the time the pressure reaches 35 psi (240 kPa), deflate the assembly, reposition the tire on the rim, lubricate both parts and re-inflate.

50950233/G0221

107

Inflation pressure beyond 35 psi (240 kPa) with unseated beads may break the bead or rim with explosive force sufficient to cause death or serious injury.  After seating the beads, adjust the inflation pressure to the recommended operating pressure.  Do NOT weld, braze or otherwise attempt to repair and use a damaged rim.

Checking Tire Pressure Correct tire pressure should be maintained to enhance operating stability and extend tire life. Refer to the chart below for proper inflation pressures.

Tire Size

Inflation Pressure Max psi

Max kPa

14 x 17.5 12-ply Heavy-Duty Flotation

80

552

14 x 17.5 14-ply Heavy-Duty Flotation

80

552

14 x 17.5 14-ply Severe-Duty

80

552

Heater/Air Conditioner Filters The optional heater and heater/air conditioner include two filters: fresh air intake and recirculation air.

Filters should be replaced as needed.

Fresh Air Intake Filter: Located directly behind the cover on the HVAC (heating, ventilating and air conditioning) housing mounted on the upper rear corner of the cab. Remove the threaded knobs on both sides of the cover to access the filter.

Recirculation Air Filters: Located behind the covers in the headliner directly above the rear window. The access, remove the screws on either side of the covers.

Important: Keeping the cab clean will reduce need for service and help ensure proper air conditioner and heater operation. Failure to do so can cause evaporator and heater core plugging, fan noise, vibration and failure.

108

50950233/G0221

Electrical System Fuse Panels The main fuse panels (Fig. 25) are located behind two covers in the operator’s compartment directly behind the operator’s foot area, as well as the electrical engine disconnect switch.

Shown below are the decals for the fuse covers in this area.

Fig. 25 Main Fuse Panels, center foam cover and the Engine Disconnect Switch

&

The left side fuse decal is for Diesel Exhaust Fluid ((DEF) / Selective Catalytic Reduction (SCR) enabled machines.

The right side fuse decal is for machines that do not have DEF/SCR functions.

50950233/G0221

9

109

Battery Before servicing the batteries or electrical system, be sure the electrical engine disconnect switch is in the OFF position or disconnect the negative (ground) battery cable.

WARNING

The batteries on the machine are 12-volt, group 24, wet-cell batteries. To access the batteries, remove the floor mat and pull up on the center foam cover (Fig. 25) between the control handles to release it from its fasteners, then remove the metal cover beneath the crossmember.

The battery top must be kept clean. Clean it with an alkaline solution (ammonia or baking soda and water). After foaming has stopped, flush the battery top with clean water. If the terminals and cable connection clamps are corroded or have a build-up, disconnect the cables and clean the terminals and clamps with the same alkaline solution. Apply protective spray to prevent corrosion.

Explosive gas is produced when a battery is in use or being charged. Keep flames and sparks away from the battery area. ALWAYS charge the battery in a well-ventilated area.

WARNING

Never lay a metal object on top of a battery, because a short circuit can result.

Battery acid is harmful on contact with skin or fabrics. If acid spills, follow these first-aid tips: 1. Immediately remove any clothing on which acid spills.

2. If acid contacts the skin, rinse the affected area with running water for 10 to 15 minutes.

3. If acid contacts the eyes, flood the eyes with running water for 10 to 15 minutes. See a doctor at once. Never use any medication or eye drops unless prescribed by the doctor.

4. To neutralize acid spilled on the floor, use one of the following mixtures: a. 1 pound (0.5 kg) of baking soda in 1 gallon (4 L) of water, or b. 1 pint (0.5 L) of household ammonia in 1 gallon (4 L) of water Whenever a battery is removed, be sure to disconnect the negative (-) battery terminal connection first.

110

50950233/G0221

Diesel Exhaust Fluid (DEF) Service (If So Equipped) Diesel Exhaust Fluid (DEF) Level The DEF level (F, Fig. 26) is shown on the multi-function display.

DEF

The DEF symbol will appear on the multi-function display when the DEF tank F level reaches 15%. The symbol will begin flashing when the DEF level falls below 10%. If the level falls below 5%, a Fig. 26 DEF Level Indicator warning tone will be activated and an additional warning light will activate. If the DEF tank is still not filled, the warnings and an alarm tone will continue.

Additionally, the engine will begin to de-rate to IDLE and reduce engine power.

DEF fluid quality is also monitored. DEF fluid meeting ISO 22241 must be used for this machine. If the DEF quality is not correct, an error symbol will appear on the multi-function display and the engine will de-rate if the DEF fluid quality is not remedied within a certain period of time.

The DEF fluid reservoir filler is located behind a latched cover at the rear right side of the chassis.

DEF Dosing Unit Filter Replacement The DEF dosing unit is located above the DEF reservoir tank. Inspect the area around the seal and vent of the aftertreatment DEF dosing unit filter cap for signs of leakage.

Note: DEF leaks are indicated by white deposits.

50950233/G0221

Fig. 27 DEF Reservoir

111

The DEF dosing unit (Fig. 28) is located above the reservoir tank, behind the right rear engine cover panel. Inspect the area around the seal and vent of the aftertreatment DEF dosing unit filter cap for signs of leakage.

Note: DEF leaks are indicated by white deposits.

Fig. 28 DEF Dosing Unit filter cap

Diesel exhaust fluid (DEF) contains urea.

Avoid eye contact. In case of eye contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow DEF. In the event that DEF is ingested, contact a physician immediately. Reference the Materials Safety Data Sheet (MSDS) for additional information.

WARNING

Do not disconnect the DEF line between the aftertreatment DEF dosing unit and the dosing valve while the machine is running or for some time after engine shutdown. Pressure in the line could cause ejection of DEF fluid. Shut off the machine and allow at least five minutes for the system to complete the purge cycle before disconnecting the DEF line.

WARNING

Note: Do not disconnect the batteries until the DEF dosing system has completed the purge cycle. Before performing any maintenance on the DEF system, wait at least five minutes after shutting off the machine for the aftertreatment DEF dosing system to purge DEF from the system. The purge cycle occurs automatically; a pumping noise can be heard during the purging process.

1. Remove the right rear engine cover panel to access the DEF dosing system.

2. Place a collection container below the filter cap to collect any residual DEF in the filter housing.

3. Unscrew the DEF filter cap.

Note: A 27 mm wrench can be used on the cap to aid in its removal.

4. Check the condition of the DEF dosing unit cap. Replace the cap if the cap has cracks or holes that could create a DEF leak path and/or if the cap threads are damaged.

5. Inspect the threads on the aftertreatment DEF dosing unit casing. This is especially important if the aftertreatment DEF dosing unit cap was damaged.

If the aftertreatment DEF dosing unit casing threads are damaged, replace the entire aftertreatment DEF dosing unit.

112

50950233/G0221

6. Remove the aftertreatment DEF filter equalizing element (O, Fig. 29) and discard.

7. Remove the old aftertreatment DEF dosing unit filter element (P, Fig. 29).

O M

P

Note: A disposable service tool is included with the filter to aid in filter removal. Refer to the instructions included with the replacement filter. Use Fig. 29 DEF Dosing Unit Filter the appropriate end of the tool, depending Removal on the color of the plastic on the filter.

When inserting the tool, a “click” sound can be heard which indicates a proper engagement with the filter.

Important: If the filter element and equalizing element are removed from the aftertreatment DEF dosing unit, they must be discarded and replaced, regardless of condition.

8. Slide a new DEF filter equalizing element (O) into the DEF filter cartridge (P). Insert the assembly into the aftertreatment DEF dosing unit.

9. Clean the aftertreatment DEF dosing unit cap and threads on the dosing unit with warm water and a clean cloth.

10. Install and tighten the cap (M). A 27 mm wrench can be used to install and tighten the filter cap. Torque the cap to 20 NM (177 in-lb).

Important: Never operate the machine with the DEF cap removed.

50950233/G0221

113

Notes

114

50950233/G0221

CHAPTER 7 MAINTENANCE

This Maintenance Interval chart was developed to match the Service chapter of this manual. Detailed information on each service procedure is in the Service chapter. A Maintenance Log follows this chart for recording maintenance performed. Recording 10-hour (or daily) service intervals is impractical and is not recommended.

Important: Under severe operating conditions, more frequent service than the recommended intervals may be required. You must decide, based on your use, if your operation requires more frequent service.

Service Procedure Remove Foreign Material (page 75) Check Engine Air Cleaner Restriction Indicator (page 80) Check Engine Oil Level (page 83) Check Hydraulic Oil Level (page 103) Check Tire Pressures (page 108) Grease Hitch, Hitch-related Cylinder Pivots and Latch Pins (page 77) Check Bucket Cutting Edge (page 105) Test Safety Interlock System (page 26) Check Coolant Level (page 106) Clean Cooling System (page 106) Grease Lift Arm Pins (page 77)

Maximum Interval

10 Hours (or Daily)

          

Check Power-A-Tach® Pivot Torque (page 105) Check Oil Level in Chaincases (page 78) Check Alternator/Fan Belt Tensions (page 105)

    

•

Change Engine Oil and Filter* (page 83)

1

Change Hydraulic Oil Filter (page 104) Check Battery (page 110)

• 2

   

Check Engine Mounting Hardware (page 83) Change Fuel Filter (page 84) Change Hydraulic Oil (page 104) Check and Drain Water Separator (page 84)

500 Hours (or Annually)



Check Drive Chain Tension (page 79) Check Wheel Nuts Torque (page 105)

250 Hours



Change Chaincase Oil (page 78)



 Perform the initial procedure at 2 hours then at “” intervals.  Perform the procedure at 1000 hours. * Every 500 hours or six months.

1- 250 Hour Change Interval when using API certified CK-4 2 -500 Hour Change Interval when using Deutz Certifications: DQC III-18 LA, or DQC IV-18 LA 50950233/G0221 115

Maintenance Log Date

116

Hours

Service Procedure

50950233/G0221

Maintenance Log Date

50950233/G0221

Hours

Service Procedure

117

Maintenance Log Date

118

Hours

Service Procedure

50950233/G0221

CHAPTER 8 TROUBLESHOOTING Table 1: Electrical System

Problem

Loss of electrical power.

Multi-function display does not activate when ignition is on.

Possible Cause

Corrective Action

Battery terminals or cables loose or corroded.

Clean battery terminals/cable connections and tighten.

Battery malfunction. 'LVFRQQHFW 6ZLWFK

Test battery. Recharge/replace as necessary. &\FOH VZLWFK

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Battery terminals or cables loose or corroded.

Clean battery terminals/cable connections and tighten.

Ignition switch malfunction.

Replace switch.

In very cold weather, display screen slow Wait a few minutes for display to activate. to display.

Starter does not engage when key switch turned to start position.

Loose/corroded starter electrical connections

Check/tighten/clean connections.

Battery terminals or cables loose or corroded.

Clean battery terminals/cable connections and tighten.

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Starter relay malfunction.

Contact dealer.

Battery malfunction.

Test battery. Recharge/replace as necessary.

Starter solenoid malfunction.

Contact dealer.

Starter or pinion malfunctioning.

Repair/replace as needed.

Lower arm rests/safety bars to operating Arm rest/safety bar in raised position; position. Engine will not start with either swing-out cab door not closed (if arm rest/safety bar raised, or the swingequipped)’ operator’s seat not occupied. out cab door open (if equipped). Occupy operator’s seat. &KHFN 0&8 /(' V Single light not working; light bulb burned Check and replace light bulb as needed, out, faulty wiring. check wiring connections.

Work/road lights malfunction.

50950233/G0221

No lights; NH\SDG PDOIXQFWLRQ.

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Poor electrical ground.

Check ground wire connections.

119

Table 2: Engine Troubleshooting Problem

Engine does not start.

Possible Cause

Dead batteries.

Charge or replace batter\(ies).

Operator not in operator’s seat.

Operator’s seat must be occupied for the engine to start.

Malfunctioning seat switch or safety bar arm/rest switch.

Replace seat switch or safety bar arm/rest switch. &KHFN 0&8 /(' V

Swing-out cab door open (if equipped).

Close swing-out cab door.

Starter malfunction.

Contact dealer.

Engine electronics logic error.

Contact dealer.

Fuel pump malfunction.

Check electrical connections / voltage to fuel pump. Contact dealer.

Engine cranking speed too slow.

Engine turns over but does not start

120

Corrective Action

Check batteries and charge/replace as necessary.

Tighten cables at battery terminals.

Paraffin separation in winter.

Use winter grade diesel fuel.

Pre-heating module malfunction.

Check connection and voltage and charge/replace as necessary.

Fuel pump malfunction.

Contact dealer.

50950233/G0221

Table 2: Engine Troubleshooting Problem

Possible Cause

Corrective Action

Engine oil level incorrect.

Adjust oil level.

Cooling air circulation restricted.

Turn engine off and allow it to cool.

Remove restriction.

Fan shroud improperly positioned.

Contact dealer.

Improper oil grade or oil excessively dirty. Change engine oil and filter.

Engine overheating.

Exhaust restricted.

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Air filter restricted.

Replace filter(s).

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Low coolant level.

Check for leaks in coolant system and repair/replace. &KHFN HUURU FRGHV

Loose/worn belt.

Tighten/replace belt.

Dirty/restricted radiator.

Clean radiator.

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Parking brake applied.

Disengage parking brake.

Parking brake switch malfunction.

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Blown fuse.

Engine runs, but travel drive does not operate.

50950233/G0221

Check circuit and replace fuse.

Operator not in operator’s seat.

Operator’s seat must be occupied for travel drive to operate.

Swing-out cab door open (if equipped).

Close swing-out cab door. Swing-out cab door (if equipped) must be closed for travel drive to operate.

Drive system component malfunction.

Contact dealer.

121

Table 3: Hydrostatic Drive System Problem

Possible Cause

Corrective Action Allow longer warm-up.

Hydrostatic drive not responsive.

Drive does not operate in either direction.

Hydraulic oil viscosity too heavy.

Replace hydraulic oil with proper type/ grade.

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Contact dealer.

Parking brake applied.

Disengage parking brake.

Low hydraulic oil level.

Top-off hydraulic oil.

Low or no charge pressure.

Contact dealer.

Hydrostatic pump(s) relief valves malfunction.

Contact dealer.

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Contact dealer.

Allow longer warm-up.

Drive system noisy.

Sluggish acceleration.

Hydraulic oil viscosity too heavy.

Replace hydraulic oil with proper type/ grade.

Low hydraulic oil level.

Top-off hydraulic oil.

Air in hydraulic system.

Cycle lift and tilt cylinders to maximum stroke and maintain for a few seconds to clear air from the hydraulic system.

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

Contact dealer.

Low hydraulic oil level.

Top-off hydraulic oil.

Low hydraulic system charge pressure.

Contact dealer.

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

Contact dealer.

Engine running rough.

Poor fuel quality or incorrect fuel type/ grade. Replace fuel with proper type/ grade.

Restricted fuel filter/fuel system.

Replace fuel filter; remove restriction.

Contact dealer.

122

50950233/G0221

Table 4: Hydraulic System Problem

Possible Cause Low hydraulic oil level.

Hydraulics do not work or have poor performance.

Hydraulic oil is not at operating temperature.

Allow longer warm-up.

Engine to pump coupling or hydraulic pump damaged.

Contact dealer.

Pressure limiting valves set too low or damaged.

Contact dealer.

Hydraulic cylinder(s) damaged.

Contact dealer.

Control valve(s) damaged.

Contact dealer.

Engine speed too low.

Incorrect fuel type/grade.

Hydraulic oil leaking past cylinder seals (internal and/or external).

Attachment tilts forward with control in neutral.

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Replace fuel with proper type/grade.

Contact dealer.

Contact dealer.

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Lift spool in control valve not actuated or Contact dealer. leaking.

Joystick/electrical malfunction.

50950233/G0221

Adjust engine speed.

Leaking hydraulic system components, such as hoses, tubes, fittings, valves, etc. Repair as necessary.

Leak past spool in control valve.

Joystick/electrical malfunction.

Lift arm does not raise/lower.

Corrective Action Top-off hydraulic oil.

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123

Table 4: Hydraulic System Problem

Possible Cause

Corrective Action

Tilt spool in control valve not actuated or Contact dealer.

Attachment tilt not working, but lift arm work leaking. properly. &RQWDFW GHDOHU Joystick/electrical malfunction.

Lift arm does not raise but attachment tilt works properly.

Lift spool in control valve not actuated or Contact dealer. leaking.

Joystick/electrical malfunction.

Dirty hydraulic oil cooler.

Hydraulic system overheating.

Lift and/or tilt functions inconsistent/jerky.

Low hydraulic oil level.

Clean hydraulic oil cooler.

Top-off hydraulic oil.

Load too high.

Reduce load.

Air in hydraulic system.

Cycle lift and tilt cylinders to maximum stroke and maintain for a few seconds to clear air from the hydraulic system.

Low hydraulic oil level.

Cylinder(s) malfunction.

Joystick/electrical malfunction.

Lift arm does not maintain position with control joysticks in neutral.

&RQWDFW GHDOHU

Top-off hydraulic oil.

Contact dealer. &RQWDFW GHDOHU

Hydraulic oil leaking past cylinder seals (external leak).

Contact dealer.

Hydraulic oil leaking past lift spool in control valve.

Contact dealer.

Leaking hydraulic hoses, tubes of fittings Contact dealer. between control valve and cylinders.

Auxiliary hydraulics not functioning.

124

Spool in control valve not actuated or leaking.

Contact dealer.

Hydraulic oil leaking past seals.

Contact dealer.

Auxiliary hydraulics connected improperly.

Correct hydraulic connections.

50950233/G0221

Table 4: Indicator Troubleshooting Indicator Icon

Indicator Description

Possible Cause Engine oil pressure too low.

Engine oil pressure.

Engine oil level incorrect.

Oil pump malfunction.

Corrective Action Stop engine immediately. Check oil level and add oil of necessary.

Adjust oil level.

Contact dealer.

Check cooling system.

Hydraulic oil temperature too hot.

Check hydraulic oil level.

Hydraulic oil temperature.

Drive system continuously overloaded.

Improve operation procedure.

Lift/tilt or auxiliary system continuously overloaded.

Improve operation procedure.

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

Contact dealer.

Oil cooler fins restricted.

Hydraulic oil filter restricted.

Clean oil cooler fins.

Replace filter.

Replace hydraulic oil and filter.

Hydraulic oil filter.

Coolant temperature.

Hydraulic oil filter maintenance required.

NOTE: During cold start in cold temperatures, this indicator may be activated until hydraulic oil warms to operating temperature.

Coolant level too low.

Add coolant.

Air filter plugged.

Replace air filter.

Coolant leak.

Repair cooling system and top-off coolant.

Adjust belt tension.

Battery voltage.

Engine air filter restriction.

50950233/G0221

Alternator not charging properly.

Repair/replace alternator.

Air filter dirty/restricted.

Replace air filter(s).

Blockage in air filter housing.

Remove blockage.

125

Notes

126

50950233/G0221

CHAPTER 9 TORQUE SPECIFICATIONS

Use these torque values when tightening hardware (excluding locknuts, and selftapping, thread-forming, and sheet metal screws) unless otherwise specified.

UNIFIED NATIONAL THREAD 8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-12

METRIC COARSE THREAD M6-1 M8-1.25 M10-1.5 M12-1.75 M14-2 M16-2

GRADE 2

GRADE 5

GRADE 8

DRY

LUBED

DRY

LUBED

DRY

LUBED

19* 20* 27* 31* 66* 76* 11 12 20 23 32 36 50 55 70 80 100 110 175 200 170 180 250 270

14* 15* 21* 23* 50* 56* 9 9 15 17 24 27 35 40 55 60 75 85 130 150 125 140 190 210

30* 31* 43* 49* 9 10 17 19 30 35 50 55 75 90 110 120 150 180 260 300 430 470 640 710

22* 23* 32* 36* 75* 86* 13 14 23 25 35 40 55 65 80 90 110 130 200 220 320 360 480 530

41* 43* 60* 68* 12 14 25 25 45 50 70 80 110 120 150 170 220 240 380 420 600 660 900 1000

31* 32* 45* 51* 9 10 18 20 35 35 55 60 80 90 110 130 170 180 280 320 460 500 680 740

GRADE 8.8

GRADE 10.9

GRADE 12.9

DRY

LUBED

DRY

LUBED

DRY

LUBED

8 19 37.5 65 103.5 158.5

6 14 28 48 76.5 117.5

11 27 53 91.5 145.5 223.5

8 20 39 67.5 108 165.5

13.5 32.5 64 111.5 176.5 271

10 24 47 82 131 200

*All torque values are in ft.-lbs., except those marked with an *, which are in in.-lbs.

For metric torque value (N·m), multiply ft.-lbs. value by 1.355, or the in.-lbs. value by 0.113.

50950233/G0221

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INDEX A Accessory Plug . . . . . . . . . . . . . . . 29 Adjusting Chain Tension . . . . . . . . 79 Adjustments. . . . . . . . . . . . . . . . . . 75 Alternator Belt . . . . . . . . . . . . . . . 105 ANSI-Style Safety Decals in the Engine Compartment. . . . . . . . . . . . . 13

Changing Hydraulic Oil Filter . . . 104 Checking and Adding Oil . . . . . . . 78 Checking Chain Tension. . . . . . . . 79 Checking Coolant Level . . . . . . . 106 Checking Engine Mounting Hardware . . . . . . . . . . . . . . . . . . . 83 Checking Engine Oil Level . . . . . . 83

ANSI-Style Safety Decals inside the ROPS/FOPS . . . . . . . . . . . . . . . . . 10

Checking Hydraulic Oil Level . . . 103

ANSI-Style Safety Decals on the outside of the Machine . . . . . . . . . . . . 11

Checking Tire Pressure . . . . . . . 108

Attachment Mounting . . . . . . . . . . 34

Cold-Starting . . . . . . . . . . . . . . . . . 52

Auxiliary Hydraulic System . . . . . . 48

Checking the Water Separator . . . 84 Cleaning the Cooling System . . . 106 Cold-Starting Procedure . . . . . . . . 52 Common Materials and Densities . 23

B

Connecting Attachments. . . . . . . . 55

Back-Up Alarm . . . . . . . . . . . . . . . 65

Connecting Auxiliary Hydraulic Couplings . . . . . . . . . . . . . . . . . . . 56

Battery . . . . . . . . . . . . . . . . . . . . . 110

Control Buttons/Switches . . . . . . . 41

Battery Disconnect Switch. . . . . . . 49

Control Handles . . . . . . . . . . . . . . 75

Beacon/Position/Work Lights . . . . 30

Control/Indicator Symbols. . . . . . . . 3

Before Starting the Engine . . . . . . 51

Controls and Safety Equipment . . 25

Brake Release Operation (option). 53

Cooling System. . . . . . . . . . . . . . 106

Bucket Cutting Edge . . . . . . . . . . 105 Bucket Selection . . . . . . . . . . . . . . 24

C Camera Observation System . . . . 64 Capacities and Ratings . . . . . . . . . 22 Chaincases . . . . . . . . . . . . . . . . . . 78 Changing Attachments . . . . . . . . . 55 Changing Engine Oil and Filter . . . 83 Changing Fuel Filter . . . . . . . . . . . 84 Changing Hydraulic Oil . . . . . . . . 104 50950233/G0221

D Dealer Services. . . . . . . . . . . . . . . 71 DEF Dosing Unit Filter Replacement . . . . . . . . . . . . . . . 111 Diesel Exhaust Fluid (DEF) Level . . . . . . . . . . . . . . . . . . . . . 111 Diesel Exhaust Fluid (DEF) Service. . . . . . . . . . . . . . . . . . . . 111 Digging with a Bucket . . . . . . . . . . 57 Dimensional Specifications . . . . . . 21 Dome Light . . . . . . . . . . . . . . . . . . 30 129

Draining Oil . . . . . . . . . . . . . . . . . . 78 Draining/Flushing the Cooling System . . . . . . . . . . . . . . . . . . . . 107 Drive Chains . . . . . . . . . . . . . . . . . 79 Drive Controls . . . . . . . . . . . . . . . . 46

H Heater and/or Air Conditioner (option) . . . . . . . . . . . . . . . . . . . . 31 Heater/Air Conditioner Filters . . . 108

Driving on an Incline . . . . . . . . . . . 57

High-Flow Auxiliary Hydraulic Control. . . . . . . . . . . . . . . . . . . . . 49

Driving over Rough Terrain. . . . . . 57

High-Flow Auxiliary Hydraulics. . . 56

Dumping the Load into a Truck (or Hopper). . . . . . . . . . . . . . . . . . . . . 58

Highway Travel. . . . . . . . . . . . . . . 61

Dumping the Load onto a Pile . . . 58

Hydraglide™ Ride Control System . . . . . . . . . . . . . . . . . . . . 33

Dumping the Load over an Embankment . . . . . . . . . . . . . . . . 58

E Electrical System . . . . . . . . . . . . 109 Engine Air Cleaner . . . . . . . . . . . . 80 Engine Compartment Access . . . . 73 Engine Diagnostic Chart . . . . . . . . 86 Engine Service . . . . . . . . . . . . . . . 82 Engine Speed Control. . . . . . . . . . 32 Engine/Machine Diagnostic Charts . . . . . . . . . . . . . . . . . . . . . 85

F

Horn . . . . . . . . . . . . . . . . . . . . . . . 28

Hydraulic System . . . . . . . . . . . . 103

I Indicator Panel . . . . . . . . . . . . . . . 42 Inner Element . . . . . . . . . . . . . . . . 81 Instrument Panels . . . . . . . . . . . . 44 ISO-Style (used Internationally) Safety Decals in the Engine Compartment. . . . . . . . . . . . . . . . 17 ISO-Style (used Internationally) Safety Decals inside the ROPS/FOPS . . . . . . . . . . . . . . . . 14 ISO-Style (used Internationally) Safety Decals on the outside of the Machine. . . . . . . . . . . . . . . . . . . . 15

14-Pin Auxiliary Connector . . . . . . 66 Fan Reverse . . . . . . . . . . . . . . . . . 67 Float Control . . . . . . . . . . . . . . . . . 33

J

Fuel . . . . . . . . . . . . . . . . . . . . . . . .51

Joystick Controls . . . . . . . . . . . . . 46

Fuse Panels . . . . . . . . . . . . . . . . 109

Jump-starting . . . . . . . . . . . . . . . . 53

G

L

Guards and Shields . . . . . . . . . . . 25

Left Panel . . . . . . . . . . . . . . . . . . . 44 Leveling the Ground . . . . . . . . . . . 59 Lift Arm Pivots . . . . . . . . . . . . . . 105

130

50950233/G0221

Lift Arm Support Device . . . . . . . . 28 Lift/Tilt Control . . . . . . . . . . . . . . . . 47 Lifting the Machine . . . . . . . . . . . . 64 Loader Specifications . . . . . . . . . . 19 Loading a Bucket. . . . . . . . . . . . . . 57 Lubrication. . . . . . . . . . . . . . . . . . . 76

M

P Parking Brake . . . . . . . . . . . . . . . . 27 Parking the Machine . . . . . . . . . . . 53 Potential Hazards . . . . . . . . . . . . . . 8 Power-A-Tach® System . . . . . . . .34 Product and Component Plate Locations . . . . . . . . . . . . . . . . . . . 18

Machine Identification . . . . . . . . . . . 2

R

Machine Lowering Procedure . . . . 73

Rear Window Emergency Exit . . . 28

Machine Raising Procedure . . . . . 72

Removing Attachments. . . . . . . . . 56

Machines Equipped with Air Conditioning . . . . . . . . . . . . . . . . . . 9

Removing Foreign Material. . . . . . 75

Maintenance . . . . . . . . . . . . . . . . 115

Right Panel . . . . . . . . . . . . . . . . . . 44

Maintenance Log. . . . . . . . . . . . . 116 Mandatory Safety Shutdown Procedure. . . . . . . . . . . . . . . . . . . . 6 Multi-Function Display . . . . . . . . . . 35 Multi-Function Display Screens. . . 37 Multi-Function Display Symbols . . 36

Removing Machine from Storage . 62 ROPS/FOPS. . . . . . . . . . . . . . . . . 27

S Safety . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Decals . . . . . . . . . . . . . . . . . 9 Safety Interlock System . . . . . . . . 26

N New Decal Application . . . . . . . . . . 9

O Operation. . . . . . . . . . . . . . . . . . . . 51 Operator Restraint Bar . . . . . . . . . 25

Safety Reminders . . . . . . . . . . . . . . 6 Scraping with a Bucket . . . . . . . . . 58 Selective Catalytic Reduction (SCR) Standstill Regeneration. . . . . . . . . 68 Self-Leveling . . . . . . . . . . . . . . . . . 56 Self-Leveling Cancel . . . . . . . . . . . 56 Service . . . . . . . . . . . . . . . . . . . . . 71

Operator’s Seat . . . . . . . . . . . . . . . 26

Sliding Side Window Removal Procedure . . . . . . . . . . . . . . . . . . 71

Optional Features . . . . . . . . . . . . . 20

Specifications . . . . . . . . . . . . . . . . 19

Outer Element . . . . . . . . . . . . . . . . 81

Standard Features . . . . . . . . . . . . 20 Standard-Flow Auxiliary Hydraulic Control . . . . . . . . . . . . . . . . . . . . . .48 Standard-Flow Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . 56

50950233/G0221

131

Starting the Engine . . . . . . . . . . . . 51 Stopping the Machine . . . . . . . . . . 52 Storing the Machine . . . . . . . . . . . 61 Switch / Pin Assignments . . . . . . . 66

T Testing the Safety Interlock System . . . . . . . . . . . . . . . . . . . . . 27 Tilting Back the ROPS/FOPS . . . . 74 Tires . . . . . . . . . . . . . . . . . . . . . . 107 Torque Specifications . . . . . . . . . 127 Transporting/Towing the Machine 62 Troubleshooting . . . . . . . . . . . . . 119 Two-Speed Drive (Travel Mode Only) . . . . . . . . . . . . . . . . . 32

U Upper-Torso Restraint . . . . . . . . . 26 Using a Bucket . . . . . . . . . . . . . . . 57

V Vibration Information. . . . . . . . . . . 59 Vibration Levels . . . . . . . . . . . . . . 61 Vibration Measurement and Actions . . . . . . . . . . . . . . . . . . . . . 60

W Wheel Nuts . . . . . . . . . . . . . . . . . 105

132

50950233/G0221

WARNING THIS OPERATOR’S MANUAL IS PROVIDED FOR OPERATOR USE DO NOT REMOVE FROM THIS MACHINE Do not start, operate or work on this machine until you carefully read and thoroughly understand the contents of this Operator’s Manual.

Failure to follow safety, operating and maintenance instructions can result in serious injury to the operator or bystanders, poor operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or maintenance of this machine, contact your dealer or the Manitou Group Service Department before starting or continuing operation.

For Support and Service, Contact Your Dealer www.gehl.com/dealer-locator

Manitou Group One Gehl Way, West Bend, WI 53095-0179 U.S.A. www.gehl.com © 2021 All rights reserved