Gehl V420, Mustang 4200V Skid Steer Loader Service Manual 50950421 - PDF DOWNLOAD

Gehl V420 Mustang 4200V

Form No. 50950421 Revision A 12/18

Service Manual

SKID-STEER LOADERS

I NT R OD UC T I O N With correct maintenance and proper use, the Gehl V420 and Mustang 4200V skid-steer loaders will give years of dependable service. This service manual is intended to be a guide in the assembly and disassembly, installation and removal, adjustment and testing, troubleshooting and replacement of components that together make up the Gehl V420 and Mustang 4200V skid-steer loaders.

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

The Table of Contents and the Index can be used to make finding a procedure easier. Many schematics, photographs and line art drawings are used to help perform the necessary repairs, tests and adjustments that the skid-steer loader needs to keep it in good running condition.

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

GEHL V420 / MUSTANG 4200V

TABLE OF CONTENTS

TABLE OF CONTENTS Specifications Page SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety

Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Potential Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Machines Equipped with Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Arm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Arm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ROPS/FOPS – Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ROPS/FOPS – Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Relieving Hydraulic Pressure - Joystic Controls - Lift/Tilt/Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Loader Raising Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Lubrication

Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Grease Fitting Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cooling System Drain Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Mainframe

Page

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Mainframe - Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Mainframe - Rear Grille Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Mainframe - Engine Cover Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine Access Cover - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS Interior . . . . . . . . . . . . . . . . . . . 19 Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS Exterior . . . . . . . . . . . . . . . . . . . 20 ROPS/FOPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Seat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Cab Heater Assembly - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 HVAC Assembly - Front - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 HVAC Assembly - Rear - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 HVAC Assembly - Routing - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 PRINTED IN USA

1

TABLE OF CONTENTS

GEHL V420 / MUSTANG 4200V

HVAC Assembly - Compressor - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Seat Slide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Side Console Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Air Duct Louver Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ROPS/FOPS Rear Window Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Restraint Bar Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 All-Tach® Hitch Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Power-A-Tach® Components - Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Power-A-Tach® Components - Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Restraint Bar Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 All-Tach® and Power-A-Tach® Hitch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Lift Arm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Rear Link Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Timing Link Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Lift Arm, Rear Link, Hose Pivot and Timing Link Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Control Cover Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Control Console Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Floor Plate, Battery Access Cover and Kickplate Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 51 Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Fuel Sensor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Wheel Drives

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Wheel Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Axle Housing Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Drive Chain Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Axle Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Axle and Wheel Bearing Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Controls

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Control Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Wheel Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Lift and Tilt Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Control Handle Removal and Installation - Electrical Auxiliary Grip / Left Control . . . . . . . . . . . . . . . . . . . . . . . 70 Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Control Handle Tracking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Neutral Centering Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Electrical Foot Throttle Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Electrical Foot Throttle Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

2

PRINTED IN USA

GEHL V420 / MUSTANG 4200V Hydrostatic System

TABLE OF CONTENTS Page

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Hydrostatic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Charge Pressure Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Hydrostatic Pump Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Hydrostatic Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Hydrostatic Pump Drive Coupling Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Drive Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Hydrostatic/Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Hydraulic System

Page

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Hydraulics - Standard Chassis Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Hydraulics - High-Flow Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Hydraulics - Standard Auxiliary Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Hydraulics - Standard Auxiliary Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Hydraulics - High-Flow Auxiliary Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Hydraulics - High-Flow Auxiliary Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Hydraulics - Hydraglide™ Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Pressure and Load-Sense Check, Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Tilt Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Tilt Circuit Spool Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Self-Leveling Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Lift Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Lift Circuit Spool Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Solenoid Valve Test - Joystick Drive Supply, All-Tach/Fan, Brake/Two-Speed, Safety Locks and Ride Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Lift Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Tilt Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Tilt Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Lift/Tilt Cylinder Disassembly / Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Auxiliary (Fan) Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Load-Sense Axial Piston Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Self-Leveling Valve Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Self-Leveling Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Brake/Two-Speed and Safety Lock Solenoid Valves - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 127 Joystick Drive Supply, All-Tach/Fan and Hydraglide™ Ride Control Solenoid Valves - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Lift/Tilt, Joystick Drive Supply, Brake/Two-Speed, All-Tach/Fan and Hydraglide™ Ride Control Solenoid Valves - Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Main Control Valve Components - High-Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Control Valve Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Control Valve Solenoid Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Inlet Relief Valve and Drain Orifice Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Hydraulic Oil Reservoir Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Fan Guard and Fan Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 PRINTED IN USA

3

TABLE OF CONTENTS Electrical System

GEHL V420 / MUSTANG 4200V Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Power Distribution Panel Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Fan Control Module Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Chassis Electrical - Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Chassis Electrical - Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 ROPS/FOPS Electrical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 J1939 Data Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Main Control Unit LEDs/Pins Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Controller Area Network (CAN) Functional Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Restraint Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Electrical Lights Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 LED Electrical Lights Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Electrically-Controlled Standard Auxiliary and High-Flow Hydraulic Flow System Test and Operation . . . . . 181 Engine Throttle Test and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Seat Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Restraint Bar Switch Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Master Disconnect Switch - Remote Battery Terminal Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 185 Front and Rear Work Light Bulb Replacement (Halogen Bulbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Dome Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Engine

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Engine Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Air Cleaner and Exhaust Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Radiator/Cooler Components - Main. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Radiator/Cooler Components -Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Fuel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Diesel Exhaust Fluid (DEF) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Air Cleaner Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Air Filter Element Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Batteries Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Diesel Exhaust Fluid (DEF) Service (If So Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Selective Catalytic Reduction (SCR) Standstill Regeneration (If So Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . 209 Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 Exhaust Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 Alternator Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Radiator/Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Charge Air Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Fan Shroud Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Fan Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Engine Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Engine Diagnostic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Engine Diagnostic Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

INDEX 4

247 PRINTED IN USA

GEHL V420 / MUSTANG 4200V

SPECIFICATIONS

SPECIFICATIONS Model

V420 / 4200V

Engine Make Engine Model Fuel Displacement Horsepower - Net Peak Torque Rated Operating Capacity* Operating Weight Shipping Weight

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

90 kW (121 hp) @ 2200 rpm 480 N·m (354 ft.-lb.) @ 1600 rpm 1905 kg (4200 lbs.)

5291 kg (11665 lbs.)

4837,5 kg (10665 lbs.)

Capacities Engine Oil Fuel Tank Chaincase (each) Bare Hydraulic Reservoir Entire Hydraulic System Engine Coolant

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

144 L (38 U.S. gal.)

11,4 L (12 U.S. qts.)

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

79 L (21 U.S. gal.)

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

Electrical System Batteries (2) Starter Alternator

12 Volt DC, 750 CCA, Group 24 4.0 kW (12 Volt DC) 120 A

Hydraulic System Hydraulic System Relief Pressure High-Flow System Relief Pressure Standard Auxiliary Flow Rate High-Flow Auxiliary Flow Rate Maximum Travel Speed - Low Maximum Travel Speed - High

238 bar (3450 psi) 238 bar (3450 psi) 114 L/min (30.1 gpm) 155 L/min (41.0 gpm) 10,5 kph (6.53 mph) 18,7 kph (11.6 mph)

Tire Options 14 x 17.5 Heavy-Duty 12-Ply 14 x 17.5 Heavy-Duty 12-Ply 14 x 17.5 Severe-Duty 14-Ply 14 x 17.5 Severe-Duty 14-Ply 14 x 17.5 Solid-Flex

Flotation Flotation, Foam-Filled Flotation Flotation, Foam-Filled Solid, Foam-Filled

Buckets and Capacities Width - Description 84 inches (2134 mm) - Dirt/Construction 84 inches (2134 mm) - Landscaping/Grading 90 inches (2286 mm) - Dirt/Construction 90 inches (2286 mm) - Light Material 15.75-19.68-24 inches (400-500-610 mm) Pallet

27.0 cubic feet; (0,76 cubic meters) 23.3 cubic feet; (0,66 cubid meters) 29.0 cubic feet; (0,82 cubic meters) 37.0 cubic feet; (1.05 cubic meters) Not Applicable

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

PRINTED IN USA

50950421/A1218

1

SPECIFICATIONS

GEHL V420 / MUSTANG 4200V

V420 and 4200V1

Dimensional Specifications

in.

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

Overall operation height - fully raised Height to hinge pin - fully raised Overall height - top of ROPS Overall length - bucket down Dump angle @ full height Dump height Dump reach - bucket (full height) Rollback at ground Rollback angle @ full height Seat-to-ground height Wheelbase - nominal Overall width - less bucket2 Overall bucket width Ground clearance to chassis (between wheels) Overall length (less bucket) Departure angle Clearance circle - front (with bucket) Clearance circle - front (less bucket) Clearance circle - rear

187.25 143.8 81.5 159

mm 4756 3653 2070 4039

31º 114.5 37.5

2908 952

30º 98º 41.2 54.5 81 84 7.7 123

1046 1384 2057 2134 197 3124

18º 97.8 55.5 74

2484 1410 1880

1 - Models: w/ 27.0 cu. ft. bucket and 14 x 17.5 NHS tires 2 - Overall width (Q) is dependent upon the amount of wheel offset.

2

50950421/A1218

PRINTED IN USA

GEHL V420 / MUSTANG 4200V

SAFETY Signal Words

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

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

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

The use of skid-steer loaders is subject to certain hazards that cannot be eliminated by mechanical means, but only by exercising intelligence, care and common sense. Such hazards include, but are not limited to, hillside operation, overloading, instability of the load, poor maintenance and using the equipment for a purpose for which it is not intended or designed.

Manitou Americas ALWAYS consider the operator’s safety when designing 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. The Operator’s Manual and the decals on the machine warn of additional hazards and should be read and observed closely.

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

PRINTED IN USA

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

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

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

Doors, Guards and Shields - Some photographs in this manual may show doors, guards and shields open or removed for illustrative purposes only. BE SURE all doors, guards and shields are in their proper operating positions before starting engine to operate unit.

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

Attachments - Gehl and Mustang loaders are designed and intended to be used only with Manitou Americas attachments or approved referral attachments. Manitou Americas cannot be responsible for safety if the loader is used with a non-approved attachment.

Battery Safety - To avoid injury from a spark or short circuit, turn the electrical disconnect switch to the OFF position before servicing any part of the electrical system. Do not tip the battery more than 45º.

50950421/A1218

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SAFETY

GEHL V420 / MUSTANG 4200V

Loader Stability - A skid-steer loader’s stability is determined by its wheelbase and tread width. The following elements can affect stability: terrain, speed, load being carried or dumped, and sudden control movements. DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE LOADER TO TIP, POSSIBLY RESULTING IN DEATH OR SERIOUS INJURY. Therefore, ALWAYS have the operator restraint bar lowered and wear the seat belt. Operate the controls only from the operator’s seat. Operate the controls smoothly and gradually at an appropriate engine speed that matches the operating conditions.

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

ALWAYS look to the rear before backing up.

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

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

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

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

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

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

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

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

strength to support the weight of the loader and the load.

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

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

Engine - NEVER use ether or starting fluid.

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

BE SURE all persons are away from the machine and warn others in the area before starting the engine.

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

Wear appropriate ear protection for prolonged exposure to excessive noise.

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

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

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

Potential Hazards 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.

DO NOT drive too close to an excavation or ditch. BE SURE that the surrounding ground has adequate 4

50950421/A1218

PRINTED IN USA

GEHL V420 / MUSTANG 4200V

SAFETY

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.

Mandatory Safety Shutdown Procedure BEFORE cleaning, adjusting, lubricating or servicing the unit or leaving it unattended: 1. Move 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.

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 controls do not cause movement of the lift arm or hitch.

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

Lift Arm Support Device

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

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

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

BE SURE to engage the lift arm support device whenever the lift arm is raised. When the device is not being used, secure it to the left rear of the lift arm using the lynch pin provided.

The lift arm support device is a safety device which must be kept in proper operating condition at all times with decals in place.

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

Lift Arm Support Device Engagement 1. Remove attachment from lift arm.

2. Raise the lift arm fully.

3. Turn keyswitch to OFF position to stop engine.

4. Have an assistant remove the lift arm support device from its storage location and place the lift arm support device on the left cylinder rod and secure with chain provided.

Lynch Pin and Chain

PRINTED IN USA

50950421/A1218

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SAFETY

GEHL V420 / MUSTANG 4200V 3. To store the lift arm support device, have an assistant remove it from the left lift cylinder rod and return it to its storage location. Secure the support device under the lift arm with the lock pin.

Lynch Pin and Chain

5. Restart the engine.

6. Slowly lower the lift arm until the support device contacts the top end of the lift cylinder.

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

Lift Arm Support Device Disengagement

ROPS/FOPS – Raising For service, the ROPS/FOPS can be unbolted in front and tilted back. Two gas-charged springs are used to tilt it back. A self-actuating lock mechanism engages to lock the ROPS/FOPS in a tilted-back position.

1. The lift arm should be either fully lowered or locked in the raised position per the “Lift Arm Support Device Engagement” procedure in this chapter.

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

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

3. Leave the operator’s compartment.

To return the lift arm support device to its storage position, proceed as follows:

WARNING

1. Raise the lift arm fully.

2. Turn the keyswitch to the OFF position to stop the engine and remove the key.

WARNING

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

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

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SAFETY

4. Remove one hex nut, washer and capscrew on each side of the ROPS/FOPS lower corners.

ROPS/FOPS – Lowering 1. Slightly raise the ROPS/FOPS until tension on the ROPS/FOPS lock mechanism releases.

2. Return the self-actuating lock mechanism to the unlocked position.

5. Grip the front grab handles at the front of the ROPS/FOPS and push up and back until the selfactuating lock mechanism engages. The lock mechanism locks the ROPS/FOPS in a tilted-back position.

Lock Mechanism Engaged

Lock Mechanism Disengaged

3. Grip the front grab handles and pull down on the ROPS/FOPS to lower. The ROPS/FOPS will lower slowly.

IMPORTANT Avoid damaging control handles by slowly lowering the ROPS/FOPS. BE SURE the control handles clear the ROPS/FOPS. 4. Be sure control handles clear the ROPS/FOPS. 5. Reinstall the two capscrews, nuts and flat washers that secure the ROPS/FOPS forward uprights to the chassis.

Relieving Hydraulic Pressure - Joystic Controls - Lift/Tilt/Auxiliary

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

The following procedure should be used to relieve pressure in the hydraulic system before performing service procedures on joystick hydraulic system components.

1. Remove attachment from lift arm and lower the lift arm to the lift arm stops. Be sure the hitch is level on the ground.

2. Turn the keyswitch to the “OFF” position to shut off the engine.

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

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4. Depress the float switch to relieve pressure in the lift circuit.

WARNING

Float

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

Auxiliary and Lift/Tilt

1. To raise and block the skid-steer loader, obtain enough suitable blocks of sufficient strength and stability to support the loader.

5. Actuate the standard auxiliary function. This will relieve pressure in the lift and auxiliary circuit.

6. The tilt circuit should have minimal pressure because the hitch rests on the ground.

Note: If servicing the tilt circuit, carefully loosen an accessible fitting and relive any pressure, if present.

CAUTION

2. Using a jack or hoist capable of raising the fullyequipped loader (with all attached options), lift the loader until the tires are off the ground.

3. Place the blocks under the flat part of the loader chassis. Place them parallel with, but not touching, the tires.

4. Slowly lower the loader so that its weight rests on the blocks.

5. When the procedure is finished, all four tires will be off the ground, and the wheels can be removed as necessary.

If removing hydraulic tubes or hoses, wear safety goggles.

Loader Raising Procedure The following procedure is used to raise the skid-steer loader so that all four tires are off the ground.

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

Loader Lowering Procedure When the service procedures are complete, the skidsteer loader can be taken down from the “raised” position. To lower the loader onto its tires: 1. Using a jack or hoist, raise the loader until its weight no longer rests on the reinforced blocks.

2. Carefully remove the reinforced blocks under the loader.

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

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LUBRICATION

General Information

Hydraulic Oil Reservoir

WARNING NEVER service this unit when any part of the machine is in motion. ALWAYS BE SURE to exercise the “Mandatory Safety Shutdown Procedure” (see Safety chapter) BEFORE servicing this equipment.

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

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

Hydraulic System Reservoir Use XPRT™, or PetroCanada Premium HVI60, Mobil DTE 15M or equivalent that contains antirust, anti-foam, and antioxidation additives and conforms to ISO VG46.

Capacity: 15.8 Gallons (59,84 L)

PRINTED IN USA

The oil reservoir for hydraulic and hydrostatic systems has a capacity of 15.8 U.S. gallons (59,8 liters). An oil level dipstick is located left of the air cleaner, which can been seen with the engine cover raised for convenient checking of the hydraulic oil level.

Hydraulic Oil Level Dipstick

Hydraulic Oil Level Fill Tube under cover shown

The hydraulic oil reservoir (located under the engine) should be drained and refilled after every 1000 hours of operation or annually (whichever occurs first). To drain, remove a cover from the bottom left rear of the chassis.

Grease Fittings

Chaincases Use SAE grade 15W40 or 10W-30 motor oil.

Capacity (each side): 12.0 Quarts (11,4 L)

Use lithiumbased grease

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Hydraulic Oil Drain

Crankcase Oil

Anti-Freeze Coolant

SAE Grade* 5W-30 synthetic (see manufacturers engine manual)

Premix CB-14 Deutzapproved

*Service Classification: API - CK-4 Capacity (w/ filter change): 10.0 Quarts (9,5 L)

Capacity: 20.0 Quarts (18,9 L)

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Use XPRT™, or Petro-Canada Premium HVI60 or Mobil DTE 15M hydraulic oil (or ISO VG46 equivalent) that contains anti-rust, anti-foam and antioxidation additives. Hydraulic oil filter element should be replaced after every 500 hours of operation or annually (whichever occurs first). For details, refer to “Hydraulic Oil Filter Element Replacement” procedure in the Hydraulics System chapter.

Crankcase Oil The Deutz four-cylinder diesel engine crankcase has a capacity of 10.0 U.S. quarts (9,5 liters). The chart below lists recommended oil viscosity for the Deutz engine.

Hydraulic Filter Location

Engine Oil Dipstick

Engine Oil Fill

Ambient Temperature All temperaturers

Viscosity SAE 5W-30 synthetic

Service classification: API-CK-4 (see manufacturers engine manual)

Engine oil should be changed and filter element replaced every 250 hours of service. Access to the engine oil filter is behind the left rear engine access panel and a remote drain plug is located behind the left rear tire. Use an allen wrench to remove plug.

Additionally, there is a fumoto valve at the oil pan.

Remote Engine Oil Drain

Hydraulic Filter

NOTE: Refer to the operator’s manual for additional information on hydraulic oil filter element change intervals.

NOTE: Refer to the engine’s operator’s manual for additional information on engine oil and filter element change intervals, including the 50-hour initial oil change.

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LUBRICATION

The engine oil filter is located on the left side of the engine.

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.

Engine Oil Filter Location

2. Reinstall the chaincase drain plug.

3. Remove the chaincase check plug.

4. At the front of each chaincase and on top of the chaincase there is a fill location underneath a boltin cover. Unbolt the cover to access the fill spot.

Refer to operator’s manual for details on changing oil, and to “Oil Filter Removal” and “Oil Filter Installation” procedures in the Engine chapter of this manual.

Chaincases Each chaincase requires 12.0 quarts (11,4 L) of motor oil. This quantity of oil should be maintained at all times. The oil in both chaincases should be drained and refilled every 1000 hours of operation or annually, whichever occurs first.

5. Remove the (left or right) oil fill plug.

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

Chaincase Oil Fill Plug

Change Chaincase Oil 1. Remove the left or right drain plug located at the front, low and inside on the chassis and drain the oil.

Chaincase Check Plug

6. Add 12.0 quarts (11,4 L) of motor oil through the fill plug, or until oil is seen at the chaincase check plug. The oil level should be at the plug level or no more than 3/4 in. (19 mm) below it.

7. Reinstall the check plug and the fill plug.

Chaincase Drain Plug

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Grease Fitting Locations

4. Grease lift cylinder base pivots.

Use lithium-based grease on all grease fittings.

Lift Cylinder Pivot

Grease every 10 hours of operation (or daily) 1. Grease hitch latch pin.

Hitch Latch Pin

5. Grease the lower rear link pivots.

Lower Rear Link Pivot

2. Grease attachment grease cap pivots.

Attachment pivot

Grease every 250 hours of operation 1. Grease the upper rear link pivots.

3. Grease tilt cylinder pivots.

Tilt Cylinder Pivot

Upper Rear Link Pivot

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LUBRICATION

Cooling System Drain Procedure Gehl V420 and Mustang 4200V model skid-steer loaders use a hydraulic oil cooler/radiator design to help keep the hydraulic oil and engine coolant from overheating. Many procedures in this service manual require partially or fully draining the radiator/cooler to perform the procedures.

4. Place a catch pan with a capacity of at least 5.0 gallons (18,9 L) underneath the petcock.

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

Radiator Drain Petcock

• Lower the lift arm.

• Shut off the engine and allow it to cool.

5. Crack open the pressurized cap on the recovery tank.

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

Radiator Drain Procedure 1. Raise the engine cover and lock open the rear grille.

2. Pull up on the oil cooler/radiator lock pin and put it in its placeholder, then swing the oil cooler/radiator out.

Recovery Tank Cap

6. Fully open the petcock to drain the anti-freeze.

7. Close the petcock on the radiator when it is finished draining.

Radiator Latch Pin Placeholder

3. The coooler/radiator can be locked into an open position left of the cooler on the rear bumper.

8. Add 5.0 gallons (18,9 L) of premix Deutzapproved CB-14 to the remote tank. Coolant level should be visible in the sight glass - midway on the glass. Use an extended-life coolant with CB-14 Deutz approval. Find an approved listing avaiable at Deutz.com.

9. Retighten the pressurized cap onto the recovery tank.

10. Bring the engine to operating temperature, shut off the engine and recheck the level after the engine cools off.

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Hydraulic Oil Cooler Drain Procedure 1. Raise the engine cover and lock open the rear grille.

2. Pull up on the oil cooler/radiator lock pin and put it in its placeholder, then swing the oil cooler/radiator out.

catch pan with a capacity of at least 17 gals. (64,3 L) underneath the location that the oil flows out.

5. On the cooler side, pull the red clip out, push the hose up and then pull it down and out. Plug/cap both the hose and fitting.

Red Clip to Remove Radiator Latch Pin Placeholder

NOTE: Plugging or capping the hose fittings will help 3. The coooler/radiator can be locked into an open position left of the cooler on the rear bumper.

prevent hydraulic oil from spilling onto the floor of the chassis if removal of the radiator/cooler is required.

6. Turn the vacuum ON to lessen the amount of hydraulic oil leakage for this procedure.

7. Place a catch pan below the lower cooler connection. Pull the red clip out, push the hose down and then pull it up and out. Plug/cap both the hose and fitting. Turn the vacuum OFF. Red Clip to Rremove

4. Remove the breather cap on the hydraulic reservoir and install a wet/dry Shop•Vac hose into the tube.

Hydraulic Reservoir Breather Cap

8. After the oil has drained from the cooler, place plugs/caps in the upper and lower ports.

NOTE: If a situation arises where the hydraulic reservoir needs to be completely drained, remove a belly plate underneath the left rear chassis area. Place a

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MAINFRAME

Introduction

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

Gehl V420 and Mustang 4200V model skid-steer loaders have a welded steel chassis. Maintenance, service and repair may be performed through standard access panels.

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

Two side chaincases provide mounting for the drive motors and for the front and rear axles. The side cases also serve as sealed housings for the drive chains and Mainframe - Chassis Components

3 4 5 7 9 11 14 15 25 26 34 35 38 39 40 43 46 55 56 57 58 59 60 63 64 65 69 72 73 76 78 81 85

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LN 5/16 CBZY CS FL LOCK 3/8X1 C5ZY CS FL LOCK 5/16X3/4 C5ZY CS FL LOCK 1/2X1-1/4 C5ZY PLUG MORB12 COVER/TOEPLATE BREATHER/ 3/4"NPT WLDMT/STEP CAP/FUEL FILLER STRAINER/FUEL ASSY/COVER/REAR RH ASSY/COVER/FRONT RH COVER/CHASSIS ASSY/COVER/FRONT LH COVER/FLOOR PLATE ASSY/COVER/REAR LH BRACE/TOWER WLDMT/SEAL/RT WLMT/SEAL/LEFT SECTION/RETAINING RING SEAL/PAD SEAL/PAD SEAL/CHASSIS PLATE/FLOOR HOLD DOWN/BATTERY LH HOLD DOWN/BATTERY RH CS 1/2X1-1/4 C5ZY HWHMS 3/8X3/4 C2ZY CS FL 5/16X2 C8ZY BHSCS 1/2X 1-1/2 C8 OCB HWHTRS TAP/R 5/16X3/4 CZY CS FL 5/16X1 C5ZY PLUG MP08

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GEHL V420 / MUSTANG 4200V

Mainframe - Rear Grille Components

1 2 3 4 5 6 8 10 12 13 16 17 18 19 20 21 22 23 24 27 28 29 30 31 32 33 36 37 41 42 44 45 47 48 49 50 51 52 53 54 61 62 66 67 68 70 71 74 75 77 79 80 82 83 84

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SCREW/SHOULDER 3/8X3/8 HLN INST 1/4 CZY LN 5/16 CBZY CS FL LOCK 3/8X1 C5ZY CS FL LOCK 5/16X3/4 C5ZY HLN INST #1024 CZY CLEVIS PIN BUMPER NUT/SPIRALOCK 3/8-16 CLIP/RETAINING PIN/LOCK HOLE PLUG/.50 DIA. LN FL SERR 5/16 CZY LN FL CTR 3/8 CZY TUBE/1/2 O.D. X .120 WA. LATCH/DOOR SCREEN SEAL/FOAM STOP/DOOR SEAL/FOAM SEAL/FOAM SEAL/FOAM HINGE/UPPER WLDMNT HINGE/LOWER WLDMNT CS FL LOCK 1/2X3/4 C5ZY SPRING/EXTENSION PLUG HH MORB08 PLUG HH MP08 WLDMT/PANEL/LT CHECK VALVE/BAFFLE WELDMENT/RAIL LH WLMT/RAIL/RH WLDMT/PANEL/RT EXTENSION/LATCH HANDLE/DOOR LATCH HANDLE/LATCH CROSSMEMBER/TOWER WLDMT/DOOR STIFFENER STOP/LATCH/COOLER WLMT/STRIKER DOOR/REAR WLDMT BUSHING/FLANGE BHSCS 1/2X 1 C8 OCB BHSCS M10-1.50x30 C12.9 BHSCS #1024x3/4 C8 OCG CB 5/16X3/4 C5ZY CS 1/4X1 C5ZY PHMS CR 1/4X1/2 OCB CS M10-1.5x30 C10.9 ZY BHSCS 5/16x3/4 C8 OCG BHSCS 3/8x3/4 C8 OCG CS FL M6-1.0x30 8.8 ZY HJN 5/16 C2ZY FW 1/4 AWZY CP EPSC 1/8x1 Z

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MAINFRAME

Mainframe - Engine Cover Components

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

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LN LG FL SERR 1/4 CZ CS FL LOCK 3/8X1 C5ZY CS FL LOCK 5/16X3/4 DRAW LATCH/T-HANDLE BUMPER HANDLE/MOLDED GRAB SCREEN KNOB/CLAMPING STUD STRIP/TRIM SEAL/BULB .07 X 24.5IN HINGE/PIANO 29.5 INCH WLDMT/FRAME/SCREEN WLDMT/FRAME/SCREEN COVER WASHER BOTTLE WLDMNT PANEL RH WLDMT/HOOD EXHAUST OUTLET WELDMENT/PANEL LH PANEL/LOWER RH PANEL/LOWER LH WLMT/COVER COVER/HYD FILL WLMT/COVER/LEFT PANEL/SIDE WELDMENT/PANEL RH PANEL/SIDE STRIP/TRIM STRIP/TRIM WIPER STRIP HN FL 1/4 FZY CS 5/16X1 C5ZY RHMS SLT #1024X1/2 CB 1/4X3/4 C5ZY CB 1/4X1/2 C5ZY PHMS CR 1/4X3/4 OCB BHSCS 3/8x1-1/4 C8 OCG BHSCS 5/16x1 C8 OCG BHSCS 5/16x3/4 C8 OCG BHSCS 1/4x1 C8 OCG CS FL 5/16X1 C5ZY HJN 5/16 C2ZY FW 5/16 AWZY HN M6-1.00 C8 ZY CS M6-1x16 C8.8 ZY

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GEHL V420 / MUSTANG 4200V

Engine Access Cover - Removal and Installation

3. If equipped with air conditioning, disconnect the condensor fan electrical connector and lines.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: • Shut off the engine and allow to cool.

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

Removal Procedure

4. Unbolt four carriage bolts and locknuts securing the engine access cover to the top engine cover at the piano hinge.

1. Open the rear grille and lock it open.

Rear Grille Lock Mechanism

2. Open the engine access cover until the gas spring is completely extended.

CAUTION

5. Support the engine access cover and disconnect the two gas springs from the engine access cover by removing the gas spring clips at both ends of the gas springs.

DO NOT remove any air conditioning lines. If the condensor must be removed from the engine cover, the freon must first be evacuated.

6. Remove the engine access cover.

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

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Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS Interior

10 15 16 17 18 20 28 29

PAD/ACOUSTIC REAR DECK COVER/B-PILLAR RH COVER/B-PILLAR LH PANEL/ACCESS CONSOLE/FRONT LH LOUVER/SNAP-IN PANEL PLUG/1.50 GROOV CONSOLE/SIDE RH

PRINTED IN USA

30 34 40 44 45 46 49

CONSOLE/FRONT RH/AUXUSB LN/ACORN 1/4 COCB CONSOLE/SIDE LH PHMS CR 1/4X1/2 OCB PHMS CR 1/4X3/4 OCB BHSCS 5/16x3/4 C8 OCG CS M10-1.5x30 C8.8 ZB

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GEHL V420 / MUSTANG 4200V

Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS Exterior

1 2 3 4 5 6 7 8 9 11 12 13 14 19

20

FW 17/32 ZY HLN INST 5/8 CZY HLN INST 1/4 CZY ISOLATOR/ROPS TAG/RIP CORD RING LN FL CTR 1/4 CZY WEATHERSTRIP/WINDOW BULB SEAL MOUNT/ISOLATOR 22002-13 SEAL/ROPS TO CHASSIS RIPCORD/WEATHERSTRIP TRIM/EDGE WINDOW/REAR

21 22 23 24 25 26 27 31 32 33 35 36 37 38

SCREW/SHOULDER M12X20 OCG SPRING/GAS SUPPORT/SEAL CS FL LOCK 5/16X3/4 C5OCB DECAL/HOLE/GREY ROPS WELDMENT PHMS CR 1/4X3/4 COCB SEM PLATE/BULKHEAD CONN WINDOW/TOP GROMMET .69ID .140GW 1.00GD RETAINING RING/EXT .875 GAS SPRING MNT WLDMT SCREW/SHOULDER M12X25 OCG FLIPPER/ROPS LOCK

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ROPS LOCK WLDMT CS 1/4X1-3/4 C5ZY CB 1/4X5/8 C5ZY CS 5/8X5 C5ZY PHMS CR 1/4X1/2 OCB PHMS CR 1/4X3/4 OCB FW M10.5x20x2.0 ZB HARDND CS 1/2X3-1/2 C8ZY CS M10-1.5x30 C8.8 ZB HN 1/2 C2ZY FW 1/4 AWZY FW M12 ZY DIN125

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MAINFRAME

ROPS/FOPS Removal and Installation

4. Remove the two locknuts (C, Fig. 2) that secure the heater valve bracket to the ROPS/FOPS.

WARNING

C

BEFORE beginning this service procedure, perform the following SAFETY procedure: • Shut off the engine.

• BE SURE the engine electrical disconnect switch is in the OFF position.

C

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

Removal Procedure

Fig. 2 – Remove Heater Valve Bracket Locknuts

1. Raise the ROPS/FOPS per the procedure in the Safety chapter of this manual.

5. After evacuating the air conditioning hoses of freon, tag and disconnect the two air conditioning hoses (D, Fig. 3) from the ROPS/FOPS. Close all openings using caps and plugs.

2. With the ROPS/FOPS tilted back and locked, attach a hoist so that it is supporting the weight of the ROPS/FOPS. 3. Tag and disconnect the two heater hoses (B, Fig. 1) located at the right rear corner of the ROPS/FOPS. Close all openings using caps and plugs.

D

B

Fig. 3 – Disconnect Air Conditioning Hoses

6. Tag and disconnect the window washer fluid hose at the hose barb (E, Fig. 4). Close all openings using caps and plugs.

Fig. 1 – Disconnect Heater Hoses

E

Fig. 4 – Disconnect Window Washer Hose

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7. Tag and disconnect the ROPS/FOPS main harness electrical connector (F, Fig. 5). Remove and note the location of tie bands as necessary.

9. Remove the capscrew (G, Fig. 7) and remove the ROPS/FOPS support cylinder (H). Repeat this step for the opposite side.

G

F H Fig. 7 – Remove Support Cylinders Fig. 5 – Disconnect Main Electrical Connector

8. Support the ROPS/FOPS with an appropriate lifting device, using a suitable hoist of adequate capacity and a positive locking mechanism able to support the ROPS/FOPS or equivalent.

10. Remove the snap ring (I, Fig. 8) and ROPS/FOPS safety lock (J).

I

WARNING

J

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

NOTE: The ROPS/FOPS weighs approximately 700 lbs. (318 kg).

Fig. 8 – Remove Safety Lock

11. Remove the four capscrews (K, Fig. 9) and remove the exhaust tip (L).

L K

Fig. 6 – Support ROPS/FOPS

22

Fig. 9 – Remove Exhaust Tip

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12. Remove the ROPS/FOPS hinge capscrew and locknut (M, Fig. 10). Repeat this step for the opposite side.

2. Release the lock mechanism and lower the ROPS/ FOPS. 3. Slide the seat forward and disconnect the seat switch from the wiring harness.

M

Fig. 10 – Remove Mounting Capscrews

13. Remove the ROPS/FOPS from the machine.

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

4. If there is a three-point restraint seat belt, remove the capscrew and locknut attaching the seat to the restraint belt on the left side.

Seat Removal and Installation

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Shut off the engine.

• Tilt back ROPS/FOPS until lock engages.

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

5. Lift the seat from the seat pan.

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

Removal Procedure 1. Remove four nuts from the studs attaching the seat to the seat pan underneath the ROPS/FOPS.

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Cab Heater Assembly - ROPS/FOPS

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TIE/CABLE .19X7.50 TIE/CABLE .30X14.50 LN FL SERR 3/8 CZY CLAMP/HOSE #10 LN FL SPIRALOCK 5/16 DRIP CAP PLUG/RUBBER SCREW/#8 X .5 SM/PHIL FILTER/HVAC FRESH AIR LN FL SERR 5/16 CZY PLATE/HEATER TUBES HOSE/HEATER PLATE/COVER VENT PLUG/PASS-THROUGH TUBE/FORWARD HVAC COVER/RECIRC FILTER/RECIRC PAD/SEALING FILTER GROMMET .62ID .188GW PAD/HOUSING TOP GROMMET .69ID .250GW PAD/HOUSING LH PAD/HOUSING RH PAD/HEADLINER SEAL CLIP/HOSE RETAINING HOSE/MOLDED (SUPPLY) HOSE/MOLDED (RETURN) HEATER TUBE TUBE/DRAIN HVAC COVER/DRAIN HVAC RH COVER/DRAIN HVAC LH HOSE/MENDER .50 HOSE CLAMP/HOSE WIRE 0.75 VALVE/HEATER HEATER VALVE BRKT HOSE/HEATER -10 X 7.75 HARNESS/HEAT CHASSIS ASSY/HEATER HOUSING HOSE/HEATER/.63 HOSE/HEATER/.63 PLENUM/RECIRC AIR GASKET/TUBE PLATE CB SN 5/16X5/8 C5ZY PHMS CR 1/4X1/2 PHMS CR 1/4X3/4

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MAINFRAME

HVAC Assembly - Front - ROPS/FOPS

19 SCREW/#8 X .5 SM/PHIL FH 32 VENT 34 PLUG/PASS-THROUGH TUBE 35 TUBE/FORWARD HVAC 36 COVER/RECIRC 46 CLIP/HOSE RETAINING 100 PHMS CR 1/4X3/4 OCB

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GEHL V420 / MUSTANG 4200V

HVAC Assembly - Rear - ROPS/FOPS

6 7 9 10 18 24 25 27 28 29 30 33

26

TIE/CABLE .30X14.50 BLACK LN FL SERR 3/8 CZY CLAMP/HOSE #10 LN FL SPIRALOCK 5/16 CZY DRIP CAP FILTER/HVAC FRESH AIR LN FL SERR 5/16 CZY PLUG/PASS-THROUGH PLATE/HEATER TUBES HOSE/HEATER PLATE/COVER LOUVERED KNOB/CLAMPING .31 STUD

39 40 41 42 47 48 49 50 51 52 53 54

GROMMET .62ID .188GW 1.2 PAD/HOUSING TOP PAD/HOUSING LH PAD/HOUSING RH HOSE/MOLDED HTR (SUPPLY) HOSE/MOLDED HTR (RETURN) HEATER TUBE WLDMNT TUBE/DRAIN HVAC COVER/DRAIN HVAC RH COVER/DRAIN HVAC LH HOSE/MENDER .50 HOSE CLAMP/HOSE WIRE 0.75 OD

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55 VALVE/HEATER 56 HEATER VALVE BRKT WLDMT 59 HOSE/HEATER -10 X 7.75 60 ASSY/MAIN HVAC HOUSING 73 HOSE/HEATER/.63 74 HOSE/HEATER/.63 75 PLENUM/RECIRC AIR 81 GASKET/HEATER TUBE PLATE 96 CB SN 5/16X5/8 C5ZY 99 PHMS CR 1/4X1/2 OCB 100 PHMS CR 1/4X3/4 OCB

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MAINFRAME

HVAC Assembly - Routing - ROPS/FOPS

3 CLAMP/HOSE .75X.41 4 CLAMP/HOSE .88X.41 11 RECEIVER/DRYER/AC 12 CLAMP/RECEIVER DRYER 14 O-RING/AC/#6 FITTING 15 O-RING/AC/#8 FITTING 16 O-RING/AC/#10 FITTING 20 TUBE/AC #10 21 TUBE/AC/#6 22 HOSE/#6/AC 23 HOSE/#10/AC 26 LN FL CTR 1/4 CZY 33 KNOB/CLAMPING .31 44 CUSHION/TUBE .62-.50 45 FAN/CONDENSER 57 HOSE/AC -06 X 33.25 58 HOSE/AC -06 X 42 60 MAIN HVAC HOUSING 61 SLEEVE 62 HINGE/PIANO 63 COVER/CONDENSOR 66 TUBE/AC/LOW PRESSURE 67 TUBE/AC/HIGH PRESSURE 68 HOSE/AC -10 X 32.00 71 MOUNT/FAN 80 WLMT/COVER 83 A/C COMPRESSOR 84 PAD 86 CS 1/4X1-3/4 C5ZY 85 SUPPORT/CONDENSER 94 FW 1/4 ANZY 95 SCREW THM CR 1/4X1/2 97 CS 1/4X3 C5ZY 98 HJN 1/4 C2ZY 101 BHSCS 3/8x1-1/4 C8 OCG 102 P TORX HTF #1032X1/2 105 HN 3/8 C2ZY 109 CONDENSER COIL

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HVAC Assembly - Compressor - ROPS/FOPS

8 CS FL LOCK 1/2X1-1/4 17 TIE/CABLE 7.9 SS 65 SPACER/PULLEY 70 PULLEY/VEE/W/BEARING 72 BELT/AC 77 WLMT/PLATE/IDLER 78 WLMT/BRKT/COMP 79 MOUNT/COMPRESSOR 82 MOUNT/HOSE 88 CS 3/8X1-1/4 C5ZY 92 CS 3/8X5 C5ZY 93 CS 1/2X2-3/4 C5ZY 105 HN 3/8 C2ZY 106 CS M16-2x55 C10.9 107 FW M10 ZY DIN125 108 SHCS M10-1.5x25 C12.9 110 WASHER/HARD .50

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Seat Slide Replacement

Side Console Removal and Installation

Replacement Procedure

Removal Procedure

1. Remove the seat per the procedure in this chapter.

2. Remove the four screws attaching the seat slides to the seat.

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

Standard Seat

• Roll back ROPS/FOPS until lock engages (For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the four capscrews (A, Fig. 11) from the outside of the rollover protection structure (ROPS)/ falling object protection structure (FOPS).

Air Suspension Seat

A

Fig. 11 – Side Console Outside Capscrews

3. Replace with new slides using the existing screws.

2. Remove the capscrew (B, Fig. 12) that secures the front of the side console to the inside of the ROPS/ FOPS. Remove the side console.

NOTE: The side console can be removed with the information display panel in place.

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GEHL V420 / MUSTANG 4200V Air Duct Louver Replacement The headliner and forward side consoles with air ducts in the ROPS/FOPS are optional and used when heating and heating/air-conditioning options are installed.

Replacement Procedure 1. Using a thin flat-tipped screwdriver, insert the screwdriver between the face of the louver and the louver’s bezel.

B

Fig. 12 – Side Console Inside Capscrew

Installation Procedure - Reverse the removal steps.

2. Rotate the screwdriver to lift the face and pop it off the bezel to release the louver.

3. Pop new louver into existing bezel until a “click” sound indicates it is seated.

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ROPS/FOPS Rear Window Removal and Installation

3. Slowly pull weatherstrip away from window frame.

Weatherstrip

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: • Shut off the engine.

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

Removal Procedure 1. Grab and pull emergency exit tag until the ripcord pulls free of rubber seal.

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

NOTE: To install the rear window, obtain two insert tools from your glass dealer.

Pigtail Hook

L-Hook

2. With an assistant outside the ROPS/FOPS to catch the window, push window outward.

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

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3. Start at top of window frame and install weatherstrip with the ripcord lip facing inside the ROPS/ FOPS and the glass lip facing out.

4. Spray soap solution between glass window and inside edge of rear window.

5. Carefully use the L-hook tool between glass and weatherstrip and work it underneath the glass. Lift the glass lip over the weatherstrip. Use caution to avoid breaking the glass.

6. Use the pigtail hook tool to “pull down” the weatherstrip seal on the outside of the ROPS/FOPS to secure the window.

7. On the inside of the ROPS/FOPS, install the ripcord in the ripcord lip, starting at top of weatherstrip. Be sure to have emergency exit tag slipped over the ripcord before performing this step.

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

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

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Restraint Bar Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

PRINTED IN USA

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HLN INST 3/8 CZY RING/RETAINING HLN INST 1/4 CZY BEARING LN FL 5/16 NUT/LOCK 3/8-16 PIN/PIVOT GROOVED NUT/NYLON INSERT SWITCH/PROXIMITY MAGNET/ACTUATOR LN LG FL CTR 1/2 LH/ARMREST TUBE/1/2 O.D. X .120 SPRING/EXTENSION RAIL/ARMREST STOP/TRAVEL BAR/PIVOT SPRING/COMP PIVOT/ARM SPACER/PIVOT BAR/RESTRAINT PLATE/SLIDER TOP LEVER/ADJUSTER LEVER/ADJUSTER CB 5/16X5/8 C5ZY CS 1/2X1-1/2 C5ZY CS 3/8X1 C5ZY CS 3/8X2 C5ZY CS 3/8X2-1/4 C5ZY RHMS SLT #1024X1/2 HN MS #1024 CZY CS 5/16X7/8 C5ZY FW 1/4 ANZY CB 1/4X1-1/4 C5ZY FW #4 BRZY FW 1/2 AWZY FW 3/8 ANZY

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All-Tach® Hitch Components

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

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HLN INST 3/8 CZY HLN INST 3/4 CZY FW 3/8 HT ZY PIN/TILT CYL END SHIM/2.03 ID .06 THK SHIM/2.03 ID .13 THK PIN LINK LATCH LINK LATCH PIN CAP/GREASE PIN/SPRING PIN/ALLTACH PIVOT WLDMT/ALL-TACH PIN/CLEVIS 7/16 X 1 5/8 FITTING/GREASE 1/8 PTF CS 3/8X3-1/4 C5ZY SHCS HS 1/4X7/8 C5 OCG FW 3/4 HT ZY CS 3/4X7 C8ZY CS 3/8X3-1/2 C8ZY CP EPSC 1/8x1 Z

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MAINFRAME

Power-A-Tach® Components - Chassis

1 2 3 4 5 7 9 10 12 13 17 18 19 20 21 22 26 27 28 29 30 31 33 42 44 46 47 48

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HLN INST 5/16 CZY HLN INST 1/4 CZY ST MJ08-MORB06 CS FL LOCK 3/8X3/4 C5ZY PLATE/TOP SIZE 2 TWIN CLAMP/TUBE .50 TWIN BAR/HOSE PIVOT LINKAGE TIE/CABLE .50X12.90 BLACK SPACER/CLAMP HOSE/ASSY/.50 X 76.50 WLDMT/TUBE MOUNT TUBE/ALLTACH/HYD TUBE/ALLTACH/HYD WLDMT/HOSE PIVOT BAND TUBE/HOSECARRIAGE WLDMT/ARM/CARRIAGE ALLTACH/COIL KIT CLAMP/HYD HOSE BAND/HYD HOSE BAND/HYD HOSE/BASE BUSHING/0.275X0.118 BUSHING/.313X.75 CS 5/16X2 C5ZY CS 5/16X2-1/2 C5ZY CS 1/4X3-3/4 C5ZY CB 1/4X2-1/4 C5ZY CB 1/4X3-3/4 C5ZY

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Power-A-Tach® Components - Lift Arm

1 5 6 7 8 11 14 15 16 23 24 25 32 34 35 36 37 38 40 43 44 45 49

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HLN INST 5/16 CZY8 PLATE/TOP SIZE 2 TWIN FL11 CLAMP/TUBE .62 TWIN1 CLAMP/TUBE .50 TWIN9 90 MJ08-MAORB062 CYLINDER/HYD POWER F-A-T1 TUBE/LIFTARM ALL TACH1 TUBE/LIFTARM ALL TACH1 Screw Self Tapping3/8-167 COVER/PWR ALL-TACH1 COVER/BOTTOM PWR TACH1 ASSY/HOSE/SLEEVE1 COVER/TUBE1 BRKT/STOP1 BRKT/STOP1 WLDMT/FLAG/STOP/RH1 WLDMT/FLAG/STOP/LH1 GUARD/TUBE1 LINK/SPRING SLIDE2 CS 5/16X1-3/4 C5ZY5 CS 5/16X2-1/2 C5ZY3 THWH TC USL 3/8X1 CZY4 HJN 3/4 F2ZY2

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MAINFRAME

Restraint Bar Removal and Installation Removal Procedure

4. Lift the restraint bar assembly off the console and remove from the ROPS/FOPS.

1. Remove two machine screws on the access panel located beneath the restraint bar.

5. The arm rest on the other console has two locknuts securing it to the console and can be removed like the restraint bar assembly.

2. Unplug the restraint bar switch wire from the ROPS/FOPS wire harness.

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

Installation Procedure - Reverse the removal steps.

3. Underneath the restraint bar, through holes cut in the side console, remove locknuts securing the restraint bar to the side console.

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GEHL V420 / MUSTANG 4200V 10. Disconnect the two hydraulic hoses (C, Fig. 14).

Close all openings using caps and plugs.

All-Tach® and Power-A-Tach® Hitch Removal and Installation Removal Procedure

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

C

• Shut off the engine.

• Relieve hydraulic system pressure.

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

NOTE: Label all hoses and note their locations before disconnecting them, to ensure correct installation.

NOTE: Some loss of hydraulic oil will occur when disconnecting hydraulic hoses. Use absorbent mats to catch any dripping oil when disconnecting hoses. Cap and plug hydraulic lines after disconnecting.

Fig. 14 – Power-A-Tach® Hydraulic Hoses

11. Remove the capscrew and locknut (D, Fig. 15) that secure the tilt cylinder pin (E) to the Power-ATach® and remove the tilt cylinder pin. Repeat this step on the other side.

IMPORTANT: Always dispose of hydraulic fluids according to environmental laws or take to a recycling center for proper disposal. DO NOT pour onto the ground or down a drain.

6. Remove the attachment.

7. Rotate the Power-A-Tach® so that it is in contact with a solid work surface.

8. Complete the mandatory safety shutdown procedure.

D

E

Fig. 15 – Tilt Cylinder Pin, Capscrew, and Locknut

9. Remove the two capscrews (A, Fig. 13) that secure the lower cover (B) to the Power-A-Tach®.

12. Start the machine and slowly retract the tilt cylinders.

13. Shut off the engine.

B

14. Using the auxiliary button and with the engine off and the power on, operate the controls to relieve the hydraulic pressure.

A

Fig. 13 – Power-A-Tach® Lower Cover Capscrews

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15. Remove the three capscrews (F, Fig. 16) that secure the grease cap (G) to the Power-A-Tach®. Repeat this step for the opposite side.

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

F

Installation Procedure - Reverse the removal steps.

G

Fig. 16 – Grease Cap and Capscrews

16. Remove the pivot pin locknut (H, Fig. 17) from the capscrew. Repeat this step for the opposite side.

H

Fig. 17 – Swivel Pin Locknut and Capscrew

17. Install a 5/8-11 slide hammer insert into the swivel pin and use the slide hammer to remove the swivel pin. Repeat this step for the opposite side.

18. With an appropriate lifting device, remove the Power-A-Tach® from the lift arm.

NOTE: The Power-A-Tach® weighs approximately 150 lb. (68 kg).

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Lift Arm Components

1 2 3 4 5 6 7 8 9 10 11

40

HLN INST 3/8 CZY HLN INST 3/4 CZY PIN/KLIK WASHER 5/8 HT PIN/TIMING LINK PIN/LOWER REAR LINK PIN/REAR ARM PIVOT THRUST WASHER PAD PIN/FLAG WLDMN'T WELDMENT/ LIFT ARM

12 13 14 15 16 17 18 19 20 21 22

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WELD/TIMING LINK SUPPORT ASSY PIN/PIVOT 1.75 LINK/REAR TIMING WLDMNT FITTING/GREASE 1/8 PTF FITTING/GREASE 1/8 PTF 3 CS 3/8X1/2 C5ZY CS 3/8X3-3/4 C5ZY CS 5/8X2 C8ZY CS 3/4X2 C8ZY CS 3/4X5 C8ZY

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MAINFRAME

Lift Arm Removal and Installation Removal Procedure 1. Lower the lift arm.

2. Remove the bucket or attachment from the loader.

3. Remove the hitch (if replacing) per the procedure in this chapter.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: • Shut off the engine.

• Relieve hydraulic system pressure.

Fig. 18 – Pin Clearance

• Note and record the location and stacking order of all the lift arm hoses and tubes.

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

5. Complete the mandatory safety shutdown procedure.

6. Attach an appropriate lifting device.

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

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

4. Raise the lift arm high enough for the lift arm pins to clear the engine access cover. Support the lift arm with an appropriate lifting device, using a suitable hoist of adequate capacity and a positive locking mechanism able to support the lift arm or equivalent.

Fig. 19 – Lifting Device

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7. Tag and disconnect the five left side hydraulic hoses (A, Fig. 20). Close all openings using caps and plugs.

9. Remove the two tube clamps (D, Fig. 22) that secure the hydraulic lines to the lift arm. .

D

A

Fig. 20 – Left Side Hoses Fig. 22 – Tube Clamps

8. Tag and disconnect the five right side hydraulic hoses (C, Fig. 21). Close all openings using caps and plugs.

10. Remove the 14-pin electrical connector locknut (E, Fig. 23) that secures the connector to the mounting bracket.

C

E

Fig. 21 – Right Side Hoses

Fig. 23 – 14-Pin Electrical Connector

11. Route the 14-pin electrical connector through the hydraulic tubes.

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12. Remove the three P-clips (F, Fig. 24) that secure the 14-pin electrical connector harness to the underside of the lift arm.

H

Fig. 26 – Lift Cylinder Pin Capscrew and Washer

F

15. Support the lift cylinders and remove the two upper lift cylinder pins.

Fig. 24 – Three P-clips

13. Remove the two P-clips (G, Fig. 25) that secure the 14-pin electrical harness to the inside of the lift arm.

16. Remove the two capscrews and washers that secure the timing link upper pivot pins (I, Fig. 27) to the lift arm.

G I

Fig. 27 – Timing Link Capscrew and Washer

Fig. 25 – Two P-clips

14. Remove the two capscrews (H, Fig. 26) and washers that secure the two upper lift cylinder pivot pins to the lift arm.

PRINTED IN USA

17. Support the timing links and remove the timing link upper pivot pins (J, Fig. 28).

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L

Fig. 30 – Rear Link Capscrews and Nuts

J Fig. 28 – Timing Link Upper Pivot Pin

18. Remove the two capscrews and washers that secure the rear timing link upper pivot pins (K, Fig. 29) to the lift arm.

20. Using a slide hammer, remove the two rear timing link upper pins. Protecting the paint, pivot the rear link back to rest on the housings.

21. Raise the lift arm high enough to clear the rollover protection system (ROPS)/falling object protection system (FOPS) and remove the lift arm from the machine.

NOTE: The lift arm weighs approximately 1900 lb.

(861 kg).

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

K

Fig. 29 – Rear Link Capscrew and Washer

19. Remove the two rear timing link upper capscrews and lock nuts (L, Fig. 30).

WARNING Lift arm may shift or move when the rear arm pivot pins are removed.

22. At the rear of the lift arm, pull the interior hoses out of the lift arm on both sides of the lift arm, if a high-flow model.

23. Remove the many hydraulic line clips and plates that secure the hydraulic tubes to the lift arm, if necessary.

Installation Procedure - Reverse the removal steps.

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NOTE: After removing/replacing any components of the lift and tilt system, ALWAYS prime hydraulic system by operating the lift arm and attachment (NO LOAD) slowly up and down for several cycles. Check system for hydraulic oil leaks. Fill the hydraulic reservoir until fluid becomes visible on the hydraulic oil dipstick.

A

B

NOTE: Refer to the lift arm bushing installation procedure in replacement.

this

chapter

if

bushings

require

Rear Link Removal and Installation Fig. 31 – Rear Link Capscrews and Locknuts

5. Remove the capscrew and washer (C, Fig. 32) from the upper rear timing link pivot pin. Repeat this step for the opposite side.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: • Shut off the engine and remove the key.

• Raise the loader, block and remove the tires.

• Procure two suitable hoist systems.

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

Removal Procedure C

1. Raise the lift arm to a height of 6 ft. (1.8 m) and secure it in place with an appropriate lifting device.

2. Complete the mandatory safety shutdown procedure.

Fig. 32 – Pivot Pin Capscrew and Washer

3. Raise and support the rear of the machine with an appropriate supporting device. Remove the rear wheels from the machine.

4. Attach an appropriate lifting device to the rear link (A, Fig. 31) and remove the two capscrews and locknuts (B).

PRINTED IN USA

WARNING Lift arm may shift or move when the rear arm pivot pins are removed.

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6. Remove the upper rear timing link pivot pin (D, Fig. 33) from the rear link and lift arm using a slide hammer. Repeat this step for the opposite side.

8. Remove the lower rear timing link pivot pin (G, Fig. 35). Repeat this step for the opposite side.

D G

Fig. 35 – Lower Pivot Pin Fig. 33 – Upper Rear Timing Link Pivot Pin

7. Remove the locknut (E, Fig. 34) from the flag pin (F) that secures the lower rear timing link pivot pin.

Repeat this step for the opposite side.

9. With the aid of an assistant, remove the rear link from the machine.

NOTE: The rear timing link weighs approximately 400 lb. (181 kg).

Installation Procedure - Follow as warnings first, then reverse the removal steps* * Coat the pin hubs with anti-seize lubricant before reinstalling.

E

F

Fig. 34 – Flag Pin and Locknut

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Timing Link Removal and Installation Removal Procedure 1. Raise the lift arm until the rear of the timing link (A, Fig. 36) clears the engine access cover and the rear timing link pin (B) can be removed.

2. Complete the mandatory shutdown procedure.

D B

A

C

Fig. 37 – Hydraulic Hose Retainer and Capscrew

6. Remove the capscrew and washer (E, Fig. 38) from the upper timing link pin and remove the upper timing link pin.

Fig. 36 – Upper Timing Link Pin

3. Attach an appropriate lifting device to the lift arm.

Support the lift arm with an appropriate lifting device, using a suitable hoist of adequate capacity and a positive locking mechanism able to support the lift arm or equivalent.

4. The timing link weighs approximately 50 lb. (23 kg).

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

E

Fig. 38 – Upper Timing Link Pin Capscrew

• Shut off the engine and remove the key.

• Tilt back ROPS/FOPS until lock engages.

• Relieve hydraulic system pressure.

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

5. Remove the four capscrews (C, Fig. 37) that secure the hydraulic hose retainers (D) to the machine.

Repeat this step for the other hydraulic hose retainer.

NOTE: Two capscrews are used on each hydraulic hose retainer.

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7. Remove the locknut and capscrew (F, Fig. 39) from the lower timing link pin (G) and remove the lower timing link pin while supporting the timing link (H).

Lift Arm, Rear Link, Hose Pivot and Timing Link Bushing Replacement

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

F

H

Replacement Procedure 1. If replacing the lower lift arm bucket pivot bushings, remove the hitch per the procedure in this chapter.

G Fig. 39 – Lower Timing Link Pin

8. Remove the timing link from the machine.

9. If needed, replace bushings in the timing link or hose pivot weldment per the procedure in this chapter.

Installation Procedure - Reverse the removal steps

2. If replacing rear link or timing link bushings, attach a suitable hoist to the lift arm.

3. If replacing hose pivot bushings, refer to the Timing Link Removal and Installation procedure in this chapter.

4. If replacing lift arm bushings, remove the lift arm per the procedure in this chapter.

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

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Control Cover Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

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CS FL LOCK 5/16X1 CS FL LOCK 1/4X3/4 CS FL LOCK 5/16X5/8 CS FL LOCK 3/8X1 CS FL LOCK 5/16X1/2 NUT/SPIRALOCK 1/4-20 SPACER HARNESS/THROTTLE LN FL SERR 5/16 CZY KNOB/CLAMPING .31 MOUNT/FLOOR PAN SEAL/FOAM SEAL/BULB WDMT/FLOOR FOOT REST SEAL/FLOORPAN MAT/APRON/JS PANEL/ACCESS/PEDAL BOOT/ACC PEDAL BEZEL/BOOT SEAL/ACCESS COVER RIGHT III WLMT/BRKT/JS COVER LEFT III WLMT/BRKT/JS/ LH WDMT/APRON/JS/HF BRACKET SUPPORT BRACKET SUPPORT BRACKET COVER BRACKET COVER BACK PLATE MAT/FLOOR/JS PLATE/SEAL SEAL/TOWER SEAL/BULB/.38 SEAL/BULB/.38 SEAL/FOAM/RT PAD/FOAM/SEAL SEAL/BULB PAD/FOAM/SEAL SEAL/TOWER/LF SEAL/FOAM/LF FOAM/FOILBACKED FOAM/FOILBACKED PANEL/ACCESS CS 1/4X1-1/4 CB 5/16X3/4 THWH TC US 1/4X3/4 NUT/RETAINING 3/8-16

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5. Use a punch to drive out bushings. There are four bushings used on each rear link; two large bushings and four small bushings used on each timing link; four bushings used on the hose pivot; and two bushings used (one on each side) on the front lower lift arm.

Control Console Removal and Installation The upper and lower control consoles may be removed for access to control handle assemblies.

WARNING

Timing Link Bushing

BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Tilt back ROPS/FOPS until lock engages.

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

Timing Link and Hose Pivot Bushing

Removal Procedure 1. Remove four screws securing the control handle tower covers on both the left and right control handles. If equipped with a 14-pin electrical auxiliary connection, the handle will need to be removed.

Rear Link Bushings

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

NOTE: Before lifting off the tower covers, push the

7. Press new bushings into place or use a rubber mallet to drive them into the lift arm or links.

2. Lift up and remove the tower covers.

8. Reinstall the hitch or the lift arm on the loader per the procedures in this chapter.

3. Lift the apron (A, Fig. 40) to access the rear thumbscrew.

50

rubber boots into the tower covers.

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MAINFRAME Floor Plate, Battery Access Cover and Kickplate Cover Removal and Installation The floor plate, battery cover and kickplate may be removed for access to: 1) remove debris from the loader, 2) foot throttle control components, and 3) the two batteries.

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

A

• Remove attachment from lift arm.

Fig. 40 – Apron

4. Remove the two thumbscrews (B, Fig. 41) and remove the lower control console.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Tilt back ROPS/FOPS until lock engages.

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

Removal Procedure 1. Remove the lower control consoles per the procedure in this chapter.

2. To remove the floor plate, begin with removing three self-tapping screws at the front of the loader, just beneath the front step.

B

3. Remove three self-tapping screws on the kickplate cover at the front of the chassis.

Fig. 41 – Console Thumbscrews Floor Plate Screws

Kickplate Cover

4. Inside the ROPS/FOPS, carefully pull up on and remove the rubber floor mat.

Covers Shown Removed

Installation Procedure - Reverse the removal steps.

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5. Reach into the kickplate opening from the front and disconnect the electrical connector on the foot throttle.

8. Remove the four nuts (B, Fig. 42) and washers that secure the powertrain control module (PCM) (C) to the right side mounting panel. Remove the PCM.

C

B

6. To gain access to the dual batteries, pull up on the center foam pad between the control handles until it frees from Velcro strips.

Fig. 42 – PCM, Nuts, and Washers

9. Remove the two capscrews that secure the fuse block. Remove the fuse block (D, Fig. 43) from the mounting panel.

10. Remove the two mounting panel capscrews (E, Fig. 43) and remove the mounting panel.

E

7. Remove four locking capscrews on the battery access plate.

D Fig. 43 – Fuse Block and Mounting Panel

11. Remove the fan module and solenoids on the left side foot well.

Battery Access Plate

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12. Remove the right and left side lower console mounting brackets (F, Fig. 44).

Crossmember Removal and Installation The crossmember, or apron, can be removed as a complete unit with the control handles to facilitate work on the gear pump/load-sensing pump beneath it, or to perform work on the control handles.

Removal Procedure

WARNING

F

BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

Fig. 44 – Lower Console Brackets

• Shut off the engine.

13. Remove the two ROPS/FOPS weatherstrip brackets (H, Fig. 45) on the right and left sides of the chassis.

• Tilt back ROPS/FOPS until lock engages.

14. Remove the four capscrews (I, Fig. 45) located at the back of the floorplate.

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

• BE SURE the engine electrical disconnect switch is in the OFF position.

1. Remove the control consoles per the procedure in this chapter.

2. Remove the lift/tilt control handle per the procedure in the Controls chapter.

H

3. Remove the drive control handle per the procedure in the Controls chapter.

4. Remove the foot plate and battery access cover per the procedure in this chapter.

5. Remove three locking capscrews securing the left and right ROPS/FOPS seal plates inside the chassis and remove the plates.

I Fig. 45 – Rear Floorplate Capscrews

15. Tilt back and remove the floorplate.

Installation Procedure - Reverse the removal steps.

ROPS/FOPS Seal Plates

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6. Remove the three capscrews and nuts (A, Fig. 46) (two shown) and bracket (A, Fig. 46) that secure the battery disconnect bracket.

A

C

C

A

A

Fig. 48 – Fuse and Relay Block Capscrews

9. Remove the two capscrews and nuts (D, Fig. 49) that secure the hose support bracket to the crossmember.

Fig. 46 – Battery Master Switch Bracket Capscrews and Nuts

7. Remove the two capscrews (B, Fig. 47) that secure the left mounting panel.

10. Remove the eight capscrews (E, Fig. 49) that secure the crossmember to the chassis.

D E

E

B

Fig. 49 – Hose Support Capscrews and Crossmember Capscrews

Fig. 47 – Left Mounting Panel Capscrews

8. Remove the four capscrews (C, Fig. 48) that secure the fuse and relay blocks. Push the blocks and harnesses back.

11. Pull the crossmember forward to access the electrical harness. Cut and remove the tie bands that secure the harness to the crossmember. Note the locations of the tie bands for installation.

12. Lift the crossmember. Route all of the electrical components, wiring, and hoses through the cutouts in the crossmember. Remove the crossmember from the machine.

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

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Fuel Sensor Removal and Installation

Rear Grille Removal and Installation

Removal Procedure

The rear grille is pinned onto the chassis and can be removed to perform work on the cooling system, engine, engine fan and shrouds.

WARNING

Removal Procedure

BEFORE beginning this service procedure, perform the following SAFETY procedures: • Shut off the engine and allow it to cool.

1. Raise the engine access cover.

2. Push down the rear grille latch (A, Fig. 50) and open the rear grille.

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

1. Remove the lower right radiator hose from the engine and unplug the sensor (below).

2. Remove the five screws securing the bracket and sensor, then remove the sensor and gasket from the tank.

A

Fig. 50 – Rear Grille Latch

3. Disconnect the taillight electrical connector (B, Fig. 51), located between the charge air cooler and the lower rear grille hinge.

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

2. Install new gasket using Form-A-Gasket #7651211 (or equivalent) to seal sensor opening on fuel tank.

B

3. Install the sensor in the fuel tank.

4. Install the sensor electrical plug to the sensor.

5. Install the five screws through the sensor into the fuel tank. DO NOT OVERTIGHTEN.

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Fig. 51 – Taillight Electrical Connector

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4. Attach an appropriate lifting device (C, Fig. 52) to the rear grille (D).

6. Remove the three capscrews (F, Fig. 54), that secure the upper grille hinge to the rear grille.

NOTE: The rear grille weighs approximately 150 lb. (69kg).

D

F

C

Fig. 54 – Upper Rear Grille Hinge

7. Remove the rear grille from the machine.

Fig. 52 – Rear Grille Lifting Device

Installation Procedure - Reverse the removal steps.

5. Remove the three capscrews (E, Fig. 53) that secure the lower rear grille hinge to the rear grille.

Rear Grille Latch Removal and Installation Removal Procedure

E

1. Open the engine access cover, pull up on the rear grille latch and swing the rear grille fully open to its locked-in position.

Fig. 53 – Lower Rear Grille Hinge

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2. Remove the two capscrews and locknuts securing the latch extension to the door latch.

3. Remove four capscrews and washers securing the door latch to a welded tab on the chassis.

4. Remove the door latch from the loader.

Installation Procedure - Reverse the removal steps.

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CHAPTER NOTES

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WHEEL DRIVES

Introduction

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

This chapter covers removal, installation, assembly and adjustment procedures for wheel drive system components on Gehl V420 and Mustang 4200V model skid-steer loaders. Wheel drive components covered in this chapter are shown below.

Service procedures for the hydrostatic pumps and drive motors are in the Hydrostatic System chapter.

Gehl V420 and Mustang 4200V model skid-steer loaders are equipped with a hydrostatic pump assembly coupled to the diesel engine, providing hydrostatic Wheel Drive Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

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HLN INST 3/8 CZY SPROCKET ASSY 16T WASHER/SPC MOTOR/DRIVE RT MOTOR/DRIVE LT ASSY/SPROCKET 100-32 COVER/CHAINCASE STOP/AXLE SPROCKET CHAIN/ROLLER 100-68 CB 3/4-10 X 2.00 GD8 NUT/WHEEL LG FLANGE AXLE ASSY LN FL TOP 3/4 CGZY WELDMENT/CHASSIS HWHMS 3/8X1 C2ZY FW 7/8 SAE ZB HARD HN 7/8 C8ZB SHCS HS 7/8X2-1/2 C8 OCB FW 3/4 HT ZY FW 3/8 AWZY SHCS M10-1.5x20 C12.9

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Drive Chain Adjustment Skid-steer loader drive chain tension should be checked every 250 hours of operation.

5. To adjust chain tension, loosen the eight locknuts on the two axles on one side of the loader. Using a spreader bar, push the axles outward in their slots to tighten the chain.

Adjustment Procedure - Two Methods

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Shut off the engine.

• Raise and securely block the loader so all four tires are off the ground.

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

6. After the proper chain tension is obtained, retighten the locknuts on the axle. Axle housing locknuts should be torqued to 280 lbf. (380 N•m).

Method One 1. Raise and support the machine.

2. Rotate the tire by hand. If there is more than 0.75” (19.05 mm) of wheel movement, adjustment is required, see steps 5 & 6 in the step two method.

IMPORTANT: The drive chain must have a

Method Two

minimum of 1/8-1.00" (3.175-25.4 mm) deflection; overtightening causes premature drive chain and sprocket wear.

1. Remove the wheels and tires on the side of the loader to be serviced.

7. Scrape off the old oil-resistant RTV and apply new RTV. Reinstall the access cover.

2. Remove 18 machine screws on the chaincase access cover (between tires) to access the drive chain.

Chaincase Access Cover Screws

8. Refill the oil in the chaincase. See the procedure in the Lubrication chapter.

3. Drain the oil from the chaincase. See the procedure in the Lubrication chapter.

4. Correct chain deflection is ½” @ 20 lbs. force (13 mm @ 89 N) - midway between the sprockets.

60

9. Reinstall the wheels and tires. Wheel nut torque is: 240 lbf. (325 N•m).

10. Repeat the adjustment procedure for the other side.

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Axle Housing Assembly Removal and Installation Removal Procedure

Installation Procedure 1. Support the axle housing assembly with a suitable hoist.

2. Clean the side of the chassis where installing.

3. Install a new o-ring on the axle housing assembly and secure it with grease.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Shut off the engine.

• Raise and securely block the loader so all four tires are off the ground.

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

1. Remove the wheels and tires on the side of loader being serviced.

2. Drain the oil from the chaincase. See the procedure in the Lubrication chapter.

3. Remove 18 machine screws on the chaincase access cover (between tires) to access the drive chain.

4. Attach a suitable hoist to the axle assembly to support the weight of the assembly. Remove the eight locknuts and washers attaching the axle housing to the chassis.

4. Align the holes in the axle housing with studs in the chassis and push it in place.

5. Install the eight washers and locknuts securing axle housing to chassis (hand tighten at this point).

6. Install and adjust the drive chains per the procedure in this chapter. Axle nut torque is 280 lbf. (380 N•m).

7. Reinstall the chaincase access cover using oilresistant RTV sealant between cover and chaincase.

8. Refill the oil in the chaincase. See the procedure in the Lubrication chapter.

9. Reinstall the wheels and tires. Wheel nut torque is: 240 lbf. (325 N•m).

5. Pull axle housing away from the chassis, allowing the axle housing sprocket to drop inside the chaincase.

NOTE: It may be necessary to carefully insert a pry bar or chisel between the chassis and axle housing to loosen the axles.

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Drive Chain Removal and Installation Removal Procedure Accessible

-

Connecting

Link

Not

Installation Procedure - Follow the Removal Procedure warnings first, then:

NOTE: When installing the left and right side drive chains, install the inside chain first.

1. Wrap the chain around sprocket of the axle.

WARNING

2. Wrap the chain around the drive motor sprocket.

BEFORE beginning this service procedure, perform the following SAFETY procedures: • Shut off the engine.

• Raise and securely block the loader so all four tires are off the ground.

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

1. Remove the wheels and tires on the side of the loader being serviced.

2. Drain the oil from the chaincase. See the procedure in the Lubrication chapter.

3. Remove 18 screws on the chaincase access cover (between tires) to access the drive chain.

3. Adjust the drive chain to the proper tension per the “Drive Chain Adjustment” procedure in this chapter.

Removal Procedure - Connecting Link Accessible 1. Drain the oil from the chaincase. See the procedure in the Lubrication chapter.

2. Remove 18 screws on the chaincase access cover (between tires) to access the drive chain.

3. Rotate the tires to access the connecting link.

4. Remove two cotter pins securing the connecting link to the drive chain and disconnect the link.

Connecting Link Cotter Pins

4. For each drive chain: Loosen the eight locknuts on axle assembly attached to the chain. Slide the axle assembly in its slots to loosen the chain tension.

5. Supporting the axle with a suitable hoist, pull the axle housing out of the chaincase to allow the axle housing sprocket to drop inside the chaincase.

5. Slip the drive chain off the axle housing sprocket.

Then, slip the drive chain off the drive motor sprocket.

6. Remove the drive chain from the chaincase.

Installation Procedure - Reverse steps 6-4 and perform the “Drive Chain Adjustment” procedure in this chapter.*

Axle Housing Sprocket

6. Slip the drive chain off the axle housing sprocket.

Then, slip the drive chain off the drive motor sprocket.

*NOTE: When installing the left and right side drive chains, install the inside chain first.

7. Remove the drive chain from the chaincase.

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Axle Assembly Components

1 2 3 4 5 6 7 8

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BEARING CUP BEARING CONE HOUSING/AXLE ASSEMBLY/AXLE & BOLT RETAINING RING/EXTERNAL O-RING 369 N70 WASHER/SPECIAL WASHER/SPECIAL

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WASHER/SPECIAL WASHER/SPECIAL WASHER/SPECIAL WASHER/SPECIAL WASHER/SPECIAL WASHER/SPECIAL SEAL/AXLE Bolt/Wheel 5/8x2-3/8 F8ZY

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Axle and Wheel Bearing Disassembly and Assembly

1. Install the bearing cup in the axle housing with a force of 6000 lbf. (26,7 kN) using a bearing press.

Disassembly Procedure 1. Move axle housing assembly to a workbench and clamp it in a vise. Use caution not to clamp cast web members in a way that they might be damaged.

2. Using a retaining ring pliers, remove external retaining ring and washers from axle shaft.

3. Remove the inner bearing cup and cone from axle shaft.

4. Remove axle from axle housing.

Bearing Cup

5. Remove the axle seal from the axle housing.

6. Remove the inner bearing cone from axle shaft.

7. Turn housing assembly over and remove the inner bearing cup from the axle housing assembly.

8. Thoroughly clean/flush all the disassembled parts.

2. Install the axle seal (do not crush) in the axle housing with a seal install tool, until it is flush with the surface of the axle housing.

Axle Seal

Assembly Procedure

NOTE: Pack the tapered bearing cones with synthetic grease before assembling. Use suitable drivers or a press to countersink components until they bottom out.

3. Turn the axle housing over and press an additional bearing cup into the other side of the axle housing with a force of 6000 lbf. (26,7 kN) using a bearing press.

Bearing Cup

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4. Place the axle shaft on a flat surface with the shaft in a vertical position. Press the inner bearing cone onto the axle shaft with a suitable driver or a press at a force of 6000 lbf. (26,7 kN). Note the proper orientation of the first bearing cone.

6. Press another inner bearing cone onto the axle shaft. Note the proper orientation of the second inner bearing cone.

Bearing Cone

7. Spread the bearing grease around the cone surface.

8. Install a new o-ring on the axle housing assembly and secure it with grease.

5. Place axle housing onto axle shaft.

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9. Install the special washer(s) and the retaining ring.

CHAPTER NOTES

Special Washer

NOTE: Allowable end play tolerance on axle shaft is 0.000” to 0.005” (0.0 mm to 0.127 mm) with axle turning freely. Add special washers to increase end play or remove special washers to decrease end play.

10. Seat the external retaining ring in axle shaft groove.

Retaining Ring

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Introduction

Two-Speed Control

This chapter covers the removal, installation, assembly and adjustment procedures for standard and optional controls on Gehl V420 and Mustang 4200V model skidsteer loaders.

Equipment Identification Because there are a variety of control options available for Gehl V420 and Mustang 4200V models, it is necessary to properly identify the controls before beginning the service procedures. Illustrations and photographs are provided with procedures to aid in servicing this equipment.

Dual Joystick Controls

Skid-steer loaders have a high and low speed setting. It is controlled by a button switch in the left control handle, which lights a panel indicator light.

Hydraglide™ Ride Control The Hydraglide™ Ride Control is controlled by a button switch in right control handle, which lights a panel indicator light.

Power-A-Tach® (P-A-T) Hitch Control (Optional) The Power-A-Tach hitch control on skid-steer loaders is controlled by one switch. In the right instrument panel is a two-position switch to engage the system. Press the top of the switch to retract (release) the hitch pins; press the bottom of the switch to extend (engage) the hitch pins.

The left control handle operates the drive wheels, and the right control handle operates lift and tilt functions of the lift arm and attachment. Engine speed is controlled with a foot throttle pedal and dial in the right instrument panel. A rocker switch in the right control handle controls standard auxiliary hydraulics in tandem with a lock-on button switch. On high-flow models, a rocker switch in the left instrument panel activates the high-flow hydraulics.

Float Control The float control on skid-steer loaders is controlled by a momentary button switch in the right control handle, which lights a panel indicator light.

Control Locations

4, 12 11

5 1, 7, 10

1 - Drive Control 2 - Lift Control 3 - Tilt Control 4 - Hand Throttle

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2, 3, 6, 8, 9

5 - Foot Throttle 6 - Standard Auxiliary Hydraulics Control 7 - Two-Speed Button Switch 8 - Hydraglide™ Ride Control Switch

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Wheel Drive Components

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

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FITTING/TEE RING/RETAINING FITTING/90 CS FL LOCK 5/16X3/4 TIE/CABLE .30X14.50 BEARING 90 MJ06-MAORB04 VALVE/SOLENOID HANDLE/RATCHET FITTING/ST W/SCREEN PIN/TILT CONSOLE LN FL SERR 1/4 CZY JOYSTICK/TOWER COVER/TOWER BRKT/GROMMET BRKT/MTG/VALVE WLMT/HOSE BRKT HOSE/HYD -06 X 28 VALVE BODY MOUNT/PIVOT FITTING/RW826_0609 FITTING/RW826_0409 TUBE/HYD -06 DRAIN HOSE/HYD -04 X 41 HOSE/HYD -06 X 29 HOSE/HYD -04 X 52.38 GROMMET/HOSES CS 1/4X1-3/4 C5ZY CS 5/16X1 C5ZY CB 5/16X1 C5ZY PHMS CR 1/4X3/4 OCB HWHTRS 1/4X1-1/4 FW 5/16 AWZY

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CONTROLS

Lift and Tilt Components

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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RING/RETAINING 90 MJ06-MAORB06 45 MJ06-MAORB06 CS FL LOCK 5/16X3/4 90 MJ08-MAORB06 BEARING HANDLE/RATCHET CLAMP/TUBE .38 TWIN PLATE/TOP SIZE 1 TWIN 90-LL MJ06-MAORB06 PIN/TILT CONSOLE LN FL SERR 1/4 CZY JOYSTICK/TOWER COVER/TOWER BOOT/CONTROL VALVE BRKT/GROMMET HOSE/TUBE -04/-06 HOSE/TUBE -04/-06

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HOSE/TUBE -04/-06/-06 HOSE/TUBE -04/-06/-06 FITTING/RW826_0609 FITTING/RW826_0409 MOUNT/PIVOT RH HOSE/HYD -06 X 30 HOSE/HYD -06 X 27 GROMMET/HOSES JOYSTICK/KAWASAKI LEVER/GRIP RH GRIP/CTRL CB 5/16X1 C5ZY CS 1/4X1-1/2 C5ZY PHMS CR 1/4X3/4 OCB HWHTRS TAP/R 1/4X1-1/4 FW 5/16 AWZY HJN M14-2.00 C4

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Control Handle Removal and Installation Electrical Auxiliary Grip / Left Control

4. Disconnect the electrical connector in the control handles at the end of the wire. Note the wire terminal connections for assembling the control handles if replacing the handle’s electrical cable.

WARNING BEFORE beginning this Service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Tilt back ROPS/FOPS until lock engages.

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

Removal Procedure 1. Loosen the ratchet handle on the joystick tower and tilt the right/left control handles forward.

2. Pull the joystick boot up and off the joysticks.

5. Remove six hoses attached at the bottom of the joystick tower by removing the lock clip or turn out. Mark the hoses with their corresponding port numbers for reinstallation.

Lock Clip

3. Remove screws securing the tower covers to the tower and remove the covers.

6. Remove four self-tapping thread screws securing the joysticks to the stand.

Ratchet Handle

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7. Pull the joysticks up and out of the joystick tower.

Loosen the locking hex nut and unscrew the grip from the joysticks.

Locking Hex Nut

Control Handle Assembly The left control handle operates the drive wheels, and the right control handle operates lift and tilt functions of the lift arm and attachment. Engine speed is controlled with a foot throttle pedal and dial in the right instrument panel. A rocker switch in the right control handle controls standard auxiliary hydraulics in tandem with a lock-on button switch. On high-flow models, a keypad button activates the high-flow hydraulics.

Assembly Procedure 1. Using a rubber mallet, hammer two bronze bearings into the lower portion of the joystick tower.

8. Pull the connectors out of the joystick towers.

NOTE: Pins may need to be removed from the electrical auxiliary connector (right side).

9. Remove the grips from the skid-steer loader.

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

2. Insert the tilt console pin into the bronze bearings and secure with external retaining rings.

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3. Attach the ratchet handle to the joystick tower with a flat washer and carriage bolt.

6. Route the electrical wire in the control grip through a slot in the joystick.

4. Screw six adapters into the bottom of the joystick.

There are four smaller of one size and two larger of another size. Consult the illustrations in this manual or the parts manual for correct installation of these adapters.

7. Slip the entire assembly into the joystick stand.

8. Bolt the joystick onto the joystick stand.

9. View of joystick secured onto the joystick stand.

5. Screw down and attach the control grip to the top of the joystick.

10. Connect the tower cover to the joystick stand with four machine screw.

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11. Pull the boot down over the control grip and top of the joystick stand.

Control Handle Tracking Adjustment When to Adjust Tracking: With joystick drive engaged (FORWARD or REVERSE), unit turns slightly left or right (won’t drive in a straight line.)

Forward or Reverse Speed Adjustment Procedure

WARNING BEFORE beginning this Service procedure, perform the following SAFETY procedures: 12. View of correctly orientated control handles.

• Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Tilt back ROPS/FOPS until lock engages.

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

1. Decide which side needs to be adjusted. If the loader turns right while going FORWARD, the left side speed must be reduced, and vice versa. DO NOT attempt to increase speed of either side, because it may damage the hydrostatic pump.

FORWARD Adjusters

NOTE. FORWARD adjustment points are on the right side of the pump; REVERSE adjustment points are on the left side of the pump.

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2. If the loader turns right in FORWARD position, remove a front plastic cap on the hydrostatic pump with pliers. Use an allen wrench to hold the stud in place while loosening the locknut. With the allen wrench in clockwise motion, tighten 1/4 turn.

Retighten the locknut.

Neutral Centering Test and Adjustment

3. If the loader turns right in REVERSE position, use the adjustment points opposite the FORWARD position adjustment points in step 2.

Test and Adjustment Procedure

Dual Joystick machines use a control piston which has strong centering springs to ensure that when the hydrostatic pump is adjusted for the NEUTRAL position it will always return to NEUTRAL.

WARNING

REVERSE Adjusters

BEFORE beginning this Service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise and block the skid-steer loader so that the tires are off the ground.

• Raise lift arm; engage lift arm support device.

• Tilt back ROPS/FOPS until lock engages.

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

4. If the loader turns left in FORWARD position, remove a rear plastic cap on the hydrostatic pump with pliers. Use an allen wrench to hold the stud in place while loosening the locknut. With the allen wrench in clockwise motion, tighten 1/4 turn.

Retighten the locknut.

5. If loader turns left in REVERSE position, use the adjustment points opposite the FORWARD position adjustment points in step 4.

6. Lower and secure ROPS/FOPS. Start the loader.

Test loader tracking; repeat the adjustment as needed.

1. Mark and disconnect the pilot lines going into the top of the pump for the section being tested.

2. Plug the end of the hoses. Do not cap the fittings on the transmission.

3. Disconnect the drive hoses from the section being tested.

4. Plug the drive hoses and cap the fittings on the transmission.

5. Connect X1 and X2 ports together by means of 1/4” internal diameter hose or tubing.

X1

MB

X2

MA

6. Install 8702 psi (600 bar) pressure gauges in MA and MB of the section being tested.

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7. Block ports A and B ports and apply the parking brake.

Electrical Foot Throttle Removal and Installation

8. Start the machine observing safety practices.

Gehl V420 and Mustang 4200V machines have an electric foot throttle located beside the right foot rest for increasing/decreasing the engine speed.

9. Loosen the jam nuts on the neutral adjustment screws.

10. Turn the mechanical centering adjusting screw until 1000 psi (70 bar) is read on the pressure ports.

Removal Procedure

11. Turn the screw back, splitting the distance between the previous two positions.

WARNING

Note: Pressure on MA and MB should be equal.

12. Tighten the jam nut on the adjustment screws when equal pressure is measured on both gauges.

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

13. Stop the pump drive.

• Remove attachment from lift arm.

14. Remove the hose connecting ports X1 and X2.

Reinstall plugs where MA and MB were checked.

• Raise lift arm; engage lift arm support device.

15. Adjust NEUTRAL in the other section, if necessary.

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

• Shut off the engine.

1. Remove the front kickplate cover just below the cab entry step.

Kickplate Cover

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2. Through the kickplate opening, unplug the electrical connector on the electric foot throttle.

3. Inside the ROPS/FOPS, unbolt the top pedal assembly from the throttle pedal.

4. Remove the floor mat.

5. Remove five capscrews securing the foot throttle assembly to the floorplate.

6. Remove the entire electric foot throttle assembly from the skid-steer loader.

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

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CONTROLS

Electrical Foot Throttle Components

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

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BALL/JOINT ASSY FW 25/32 Z CS 5/16X1-1/2 C8 PIN/ROLL 5/16 X 1.25 CS FL LOCK 5/16X5/8 C5ZY BEARING NUT/SPIRALOCK 1/4-20 ROD/THREADED/.25-28UNF WLDMNT/THROTTLE LINK LN FL SERR 1/4 CZY SPRING WLDMT/TRAVEL STOP WLDMT/PEDAL/THROTTLE WLDMT/THROTTLE ASSY ASSY/PEDAL/TOP SENSOR/THROTTLE SHSS CP 1/4X5/16 C CS 1/4X1-1/4 C5ZY HN 1/4 F2ZY HJN 5/16 C2ZY

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CHAPTER NOTES

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HYDROSTATIC SYSTEM

Introduction

on each side of the loader through a chain-and-sprocket system. The pumps and motors are controlled individually, allowing complete flexibility in forward, reverse, gradual, pivot and spin turns.

This chapter covers troubleshooting, testing, removal, installation and adjustment procedures for the tandem pump system on Gehl V420 and Mustang 4200V model skid-steer loaders.

A hydrostatic tandem pump assembly coupled to the engine provides power to two fixed-displacement hydrostatic drive motors. The motors drive the wheels

For detailed information on pump and motor internal repairs, consult the Gehl-Mustang Service Department or the component manufacturer’s service manual.

Related hydraulic components are covered in the Hydraulic System chapter of this manual.

USE SPACE BELOW FOR ANY FOR SERVICE NOTES

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Hydrostatic Components

1 ST MJ08-MORB08 2 ST MJ16-MORB12 3 TEE BR MJ06-MJ06-MAORB06 4 ST MJ16-MORB16 5 90 MJ10-MAORB10 6 90 MJ06-MAORB06 7 ST MJ10-MORB10 8 45 MJ16-MAORB16 9 90 MJ08-FJS08 10 CS FL LOCK 1/2X1-1/4 C5ZY 11 90 MJ08-MAORB06 12 ST MORB08-FORB06 13 45 MJ12-MAORB10 14 NUT/SPIRALOCK 1/2-13 15 SPLIT FLANGE KIT/C62-12 16 VALVE/RELIEF MJ10-MORB10 17 PUMP TANDEM/REXROTH JS

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18 TEE RUN MJ08-MAORB06-MJ0 19 ST SA08 FL06 W/SCREEN 20 WASHER/M16 HARD 21 TEST PORT-9/16-18 UNF 22 LN FL SERR 1/4 CZY 23 TUBE/2-SPEED CROSS 24 ST MC20-MORB12-S 25 45 MC20-MAORB12-S 26 HOSE/HYD -10 X 21.25 27 HOSE/HYD -10 X 22.00 28 HOSE/HYD -06 X 20.25 29 TUBE/HYD/CASE DRAIN 30 TUBE/HYD/CASE DRAIN 31 HOSE/HYD -12 X 22.00 32 HOSE/HYD -12 X 36.30 33 HOSE/HYD -12 X 38.50 34 HOSE/HYD -12 X 42.75

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35 TUBE/BRAKE CROSS 36 HOSE/HYD -12 X 24.00IN 37 PUMP SUPPORT 38 WLMT/SUPPORT 39 STOP/RIGHT/BACK 40 STOP/RIGHT/FRONT 41 STOP/LEFT/BACK 42 STOP/LEFT/FRONT 43 HOSE/SUCTION 44 HOSE/SUCTION 45 HOSE/DRAIN 46 HOSE/BRAKE 47 CS 1/4X1-1/4 C5ZY 48 CS 1/4X2-1/2 C5ZY 49 CS 5/8X2 C8ZY 50 SHCS HS 5/8X2 C8 OCB 51 CS M10-1.5x60 C10.9 ZY DIN931

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Charge Pressure Test and Adjustment Gehl V420 and Mustang 4200V model skid-steer loaders have, as standard equipment, two charge pressure test ports as part of the hydrostatic pump system. Before performing the following test, run the skid-steer loader to be sure the hydraulic oil is at normal operating temperature, around 140° F (60° C).

High Pressure Relief Valve

NOTE: This test requires a minimum of a 500 psi (34.5 bar) pressure gauge.

Charge Relief Valve

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Shut off the engine.

• Tilt back ROPS/FOPS until lock engages.

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

Test Procedure 1. Locate the two test ports on top of the hydrostatic pump.

2. Remove the metal cap from one of the test ports (ISO 15171-2, coupling with M16x2 end for connections under pressure.)

3. Install a pressure gauge on the charge pressure test port.

4. Restart the engine and allow it to run until the hydraulic oil is at operating temperature, around 140° F (60° C) and check the pressure reading on the gauge. The gauge should read as follows: Dual Joystick Controls: 363 psi (25 bar) 5. If the pressure reading on the gauge is either lower or higher than specified, refer to the manufacturer’s service manual for the hydrostatic pump, and the charge pressure adjustment procedure that follows.

6. Next, install a pressure gauge on the other charge pressure test port and repeat steps 4 and 5. Both pumps must be checked.

Charge Pressure Test Ports

7. When finished, reinstall the metal cap on the test port.

Adjustment Procedure Add or remove shims on the charge pressure relief valve (on the hydrostatic pump, see next section) to adjust the charge pressure. Add shims to increase the charge pressure; remove shims to decrease the charge pressure.

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Hydrostatic Pump Relief Valves Each hydrostatic pump is equipped with two highpressure relief valves, for a total of four hydrostatic pump relief valves in the hydrostatic drive system. The two front relief valves on the hydrostatic pump assembly control the front hydrostatic pump, which drives the right side of the skid loader. The two rear relief valves on the hydrostatic pump assembly control the rear hydrostatic pump, which drives the left side of the skid-steer loader. Refer to the manufacturer’s manual for service procedures.

High Pressure Relief Valves

Hydrostatic Pump Removal and Installation

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Tilt back ROPS/FOPS until lock engages.

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

Removal Procedure 1. Drain the oil from the hydraulic reservoir per the procedure in the Lubrication chapter.

2. Remove the control consoles, floor plate and crossmember per their procedures in the Mainframe chapter.

3. Remove the auxiliary pump per the procedures in the Hydraulic System chapter.

4. Label all hoses and note their locations before disconnecting them to ensure correct installation.

5. Remove the control valve return hose (A, Fig. 1).

Close all openings.

A

Fig. 1 – Control Valve Return Hose

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6. Disconnect the hydraulic hose fittings (B, Fig. 2) and remove the flange clamps from the top and sides of the hydrostatic pump. Close all openings.

E

B

Fig. 4 – Pump Cradle Capscrews

9. Disconnect the two suction hoses (one shown) (F, Fig. 5) from the bottom of the pump. Close all openings.

Fig. 2 – Hydrostatic Pump Hoses

7. Remove the capscrews and nuts (D, Fig. 3) that secure the support bracket to the support cradle.

F

D

Fig. 5 – Suction Hose

10. Support the hydrostatic pump with an appropriate lifting device.

Fig. 3 – Pump Support Bracket and Capscrews

NOTE: The hydrostatic pump weighs approximately 100 lb. (46 kg).

8. Remove the four capscrews (E, Fig. 4) that secure the support cradle to the pump adapter (right side shown). Lower the cradle.

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11. Remove the two capscrews and washers (G, Fig. 6) that secure the hydrostatic pump to the pump adapter.

Hydrostatic Pump Drive Coupling Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm, engage lift arm support device.

• Shut off the engine.

• Tilt back ROPS/FOPS until lock engages.

G

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

Fig. 6 – Hydrostatic Pump Capscrews

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

12. Remove the hydrostatic pump and the pump cradle from the machine.

2. Remove the socket-head capscrews (39 lbf.) (53 N•m) securing the flywheel housing to the engine.

Use Loctite™ 242 or equivalent to reinstall.

13. If necessary, remove the splined coupler from the pump. Remove two socket-head screws (25 lbf.)

(34 N•m) on the coupler and slip it off the pump shaft. Before doing so, measure the distance (0.22”) (5,6 mm) between the face of the splined coupler and the pump for reinstallation purposes.

Measure This Distance

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

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3. Remove the capscrews (35 lbf.) (47 N•m) attaching the flexible coupling plate to the engine. Use Loctite™ 242 or equivalent to reinstall.

Drive Motor Removal and Installation

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise and securely block the loader so all four tires are off the ground.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Tilt back ROPS/FOPS until lock engages.

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

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

Removal Procedure 1. Underneath the skid-steer loader, remove the capscrews securing the belly pans and then remove both pans from the chassis.

2. Remove the drive chains per the procedure in the Wheel Drives chapter.

3. If necessary, drain oil from the hydraulic reservoir and chaincases per their procedures in the Lubrication chapter.

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

4. BEFORE disconnecting hydraulic hoses and tubes from the drive motor, mark each hose/tube and the port where it attaches to the drive motor (so that PRINTED IN USA

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hoses/tubes can be correctly reattached during installation).

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

5. Disconnect all hydraulic hoses and tubes on each drive motor.

NOTE: It is recommended that new o-rings for pressure hoses and flat-faced fittings (on or attaching to the drive motor) should be installed prior to the reinstallation of the drive motor. It is also recommended that a new o-ring on the mating surface of the drive motor is installed before reinstallation of the drive motor to the chassis. Scrape off old gasket material and apply new sealant to mating surface of the drive motor, and before reassembly to the chassis.

CHAPTER NOTES

6. Support the drive motor with a suitable hoist and remove eight socket-head capscrews (200 lbf.)

(271 N•m) and washers attaching the drive motor to the chaincase.

7. Carefully lower the drive motor through the belly opening and out of the chassis.

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Troubleshooting Guide The troubleshooting guide lists potential hydrostatic system problems, as well as possible causes and remedies.

If you cannot locate a particular hydrostatic system problem in this chart, consult the troubleshooting chart in the Hydraulic System chapter.

When a problem occurs, don’t overlook simple causes.

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

Problem

Possible Cause

Remedy

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

Restraint bar/seat switch malfunction

Check switches and interlock module.

Hydraulic oil viscosity too high

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

Hydraulic oil supply too low

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

Hydrostatic pump drive disconnected Drive coupling failure

Check for broken or worn pump Drive Coupling and replace, as needed.

Electrical malfunction

Troubleshoot electrical system.

Low or no charge pressure

See hydrostatic pump manual.

Parking brake engaged

Disengage parking brake.

Hydraulic oil supply too low

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

Low or no charge pressure

See hydrostatic pump manual.

Hydrostatic pump relief valves malfunctioning

Inspect and clean the relief valves.

Replace them as needed.

Inadequate pilot supply oil pressure to joystick control

Check pilot supply oil pressure. Check pilot supply cut-out solenoid.

Restraint bar raised

Lower the restraint bar.

Restraint bar or seat switch malfunctioning

Replace malfunctioning switch. Check indicator light on the interlock module.

High pressure hydraulic hoses between hydrostatic pump and drive motors connected incorrectly

Reconnect hoses to proper ports on the drive motors. Refer to schematic and figures in the Hydrostatic System chapter.

Joystick pilot controller hoses connected incorrectly

Reconnect hoses to proper ports on hydrostatic pump. Refer to schematic and figures.

Traction drive will not operate in either direction

Drive wheels do not turn in proper direction

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Problem

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Possible Cause

Remedy

Neutral centering mechanism(s) out of adjustment

Adjust neutral centering mechanism(s).

Hydrostatic pump out of adjustment

See hydrostatic pump manual.

Joystick control valve malfunction

Replace joystick control valve.

Air in the hydraulic system

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

Check hydraulic oil reservoir, fill as needed.

Hydraulic oil supply too low

Check hydraulic oil reservoir. Add oil, if necessary.

Low hydrostatic system charge pressure

See hydrostatic pump manual.

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

Refer to component manufacturer’s service manual.

Engine not responding under load

Troubleshoot engine.

Automatic Parking Brake is partially engaged

Contact you dealer.

Drive system overloaded continuously.

Improve efficiency of operation.

Lift and tilt system overloaded continuously.

Improve efficiency of operation.

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

Refer to component manufacturer’s service manual.

Oil cooler plugged with debris

Clean oil cooler fins.

Fan malfunctioning

Check fan operation.

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

Reduce duty cycle and improve air circulation.

High pressure relief malfunctioning

See hydrostatic pump manual.

Creeps in NEUTRAL

Hydrostatic pump needs adjustment

Refer to the “Neutral Centering Adjustment” procedure in the Controls chapter.

Turns slightly left or right in FORWARD or REVERSE position when using the traction drive control handle

Hydrostatic pump needs adjustment

Refer to the “Control Handle Tracking Adjustment” procedure in the Controls chapter.

Neutral difficult to maintain

Sluggish acceleration

Hydrostatic drive overheating

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Problem Hydrostatic (drive) system noisy

Right side doesn’t drive in either direction. Left side operates normally

Right side doesn’t drive in one direction

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Possible Cause

Remedy

Hydraulic oil viscosity too high

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

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

Refer to component manufacturer’s service manual.

Air in hydraulic system

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

Check oil level in reservoir; fill as needed.

Chain or bearing damage

Repair or replaced as needed.

Excessive internal leakage in right drive motor

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

Excessive leakage in hydrostatic pump

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

Relief valves on hydrostatic pump malfunctioning

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

Low charge

Check charge.

Pilot supply oil not reaching servo piston

Troubleshoot the drive control and servo.

Relief valve on hydrostatic pump malfunctioning

Switch one relief valve with the other relief valve on rear pump; problem should switch to reverse direction.

Clean or replace the faulty valve as needed.

Hydrostatic pump malfunctioning

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

Joystick control valve malfunction

Replace joystick control valve.

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Problem

Possible Cause

Remedy

Left side doesn’t drive in either direction. Right side operates normally

Excessive internal leakage in left drive motor

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

Excessive leakage in engine-end hydrostatic pump

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

Relief valves on engine-end hydrostatic pump malfunctioning

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

Low charge

Check charge.

Pilot supply oil not reaching servo piston

Troubleshoot the drive control and servo.

Relief valve on engine-end hydrostatic pump malfunctioning

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

Engine-end hydrostatic pump malfunctioning

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

Hydraulic oil viscosity too high

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

Hydraulic oil level low

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

No pilot supply oil

Check charge pressure.

Restraint bar or seat switch malfunction

Check switches and interlock module.

Lift/Tilt control malfunctioning

Repair or replace as needed.

Auxiliary pump coupler broken

Repair or replace as needed.

Left side doesn’t drive in one direction

Lift/tilt controls fail to respond

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HYDROSTATIC SYSTEM Hydrostatic/Hydraulic Schematic

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Introduction

The following troubleshooting guide lists potential hydraulic system problems, as well as possible causes and remedies, for Gehl V420 and Mustang 4200V skidsteer loaders.

This chapter covers troubleshooting, testing, removal, installation and adjustment procedures for hydraulic system components on Gehl V420 and Mustang 4200V model skid-steer loaders.

Power for the lift arm functions and auxiliary hydraulics is provided by a axial piston pump attached to the front of the tandem pump. An additional gear pump provides oil for fan and All-Tach® functions.

Machines include a standard-flow auxiliary hydraulics system with connections on the lift arm for attachment hookup. They are also equipped with high-flow hydraulics, which includes connectors on the right side of the lift arm, for operating attachments that require higher hydraulic flow.

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

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

When a problem occurs, don’t overlook simple causes.

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

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

Troubleshooting Guide

Problem Lift/tilt controls fail to respond

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Possible Cause

Remedy

Hydraulic oil viscosity too heavy

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

Hydraulic oil level low

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

Hydraulic oil flow to the pump blocked

Inspect suction hose. Clean or replace as needed.

Inlet relief valve malfunctioning

Adjust or replace relief valve as needed in the control valve.

Drive disconnected

Check for broken or worn pump drive coupling. Replace as needed.

Sheared spline or broken shaft in hydrostatic pump assembly

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

Sheared spline or broken shaft in pump

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

Restraint bar switch or seat switch not closing

Check switches and wiring. Replace as needed. Check indicator light on the interlock module.

Solenoid lock valve(s) malfunctioning

Check electrical connections to solenoid. Replace as needed.

Low or no charge

Check charge.

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Troubleshooting Guide Problem Hydraulic cylinder action slow for lift/tilt function

Lift arm does not raise; bucket tilt works properly

Standard-flow auxiliary hydraulics function slowly

96

Possible Cause

Remedy

Bleed orifice plugged

Remove orifice and clean.

Low engine speed

Operate engine at higher speeds.

Hydraulic oil viscosity too heavy

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

Hydraulic oil leaking past cylinder piston seals

Replace cylinder seals and o-rings as needed.

Hydraulic oil level low

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

Lift or tilt solenoid lock valve malfunctioning

Check electrical connections to solenoid. Replace as needed.

Inadequate pilot supply oil pressure to joystick controls

Check pilot supply oil pressure.

Inadequate pilot signal from control to the main control valve

Check signal pressure.

Pump damage

Check pressure and flow.

Lift spool in control valve not actuated or leaking

Check hose or tube connection to valve. Check pressure and flow. Check linkage connection at control levers.

Supply pressure not getting to main valve

Check the charge pressure at the manifold.

Stuck spool on control valve

Replace the control valve.

Lift solenoid lock valve malfunctioning

Check electrical connections to solenoid. Replace as needed.

Low engine speed

Operate engine at higher engine speeds.

Hydraulic oil level low

Add oil to reservoir.

Hydraulic oil viscosity is heavy

Allow long warm-up period.

Auxiliary spool in control valve leaking or not fully activated

Repair any leak found.

Control handle malfunction

Repair.

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Troubleshooting Guide Problem

Possible Cause

Lift arm doesn’t maintain raised position with lift control in NEUTRAL

Oil leaking past lift cylinder seals (internal or external)

Check cylinder tube bore condition.

Replace seals or cylinder tube as needed.

Oil leaking past lift spool in control valve

Check valve body for scores or cracks.

Replace control valve as needed.

Self-leveling valve malfunctioning

Repair or replace as needed.

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

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

Hydraglide/Float control with internal leakage.

Repair or replace as needed.

Float control activated

Deactivate float control by pressing the button on the control handle.

Port relief malfunctioning

Check for debris in control valve port relief.

Lift cylinder lift arm support device engaged

Raise lift arm and disengage the lift arm support device.

Restraint bar not lowered

Lower restraint bar.

Restraint bar switch or seat switch malfunction

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

Check indicator light on the interlock module.

Blown fuse or relay

Replace fuse or relay.

No hydraulic oil flow

Check that pump is pumping oil. Check that relief on control valve is not stuck open.

Lift solenoid valve malfunctioning

Check electrical connections to solenoid. Replace as needed.

Oil leaking past tilt cylinder seals (external or internal)

Check cylinder tube bore condition.

Replace seals, o-rings or cylinder as needed.

Self-leveling valve malfunctioning

Repair or replace as needed.

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

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

Pilot control lines have air in them

Bleed pilot control line from the main control valve.

Low or no pilot pressure

Check pilot pressure at the control valve.

Tilt solenoid valve malfunctioning

Check electrical connections to solenoid. Replace as needed.

Lift arm will not lower or raise

Bucket drifts downward with tilt control in NEUTRAL

Slow or no response for bucket tilt; lift works properly

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Remedy

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Troubleshooting Guide Problem

Possible Cause

Remedy

Lift arm will not raise a heavy load or any load

Lift port relief in control valve malfunctioning

Replace lift port relief or contact GehlMustang Service Department.

Float control activated

Deactivate float control by pressing button on control handle.

Inlet relief valve malfunctioning

Check pressures in relief valve. Repair or replace as needed.

High-pressure compensator on pump is malfunctioning

Contact the Gehl-Mustang Service Department.

Control valve in “float” position

Take control out of “float” position.

Tilt cylinders malfunctioning

Check condition of cylinder tube bore.

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

Float control activated

Deactivate float control by pressing button on control handle.

Bucket does not level on the lift cycle

Self-leveling valve misadjusted or malfunctioning

Self-leveling valve turned OFF. Repair or replace valve as needed.

Bucket will not tilt; lift arm works properly

Tilt spool in control valve not actuated or leaking

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

Tilt solenoid lock valve is malfunctioning

Check electrical connections to solenoid. Replace as needed.

Solenoid valves on main control malfunctioning

Check electrical connections to solenoid. Repair or replace solenoid.

Restraint bar raised

Lower restraint bar. Check indicator light on the interlock module.

Restraint bar switch or seat switch malfunctioning

Replace malfunctioning switch. Check indicator light on the interlock module.

Control modules malfunctioning

Check indicator lights on module. Contact your authorized Gehl-Mustang dealer.

Load-sense signal line loose or broken

Check line, tighten or replace.

High-pressure compensation on pump malfunctioning

See load-sensing pump manual.

Replace if necessary.

High-flow button malfunctioning

Replace keypad.

Low engine speed

Operate engine at higher speeds.

Hydraulic oil level low

Add oil to reservoir.

Hydraulic oil viscosity too heavy

Allow for longer warm-up period.

Control valve relief pressure low

Check pressure at control valve. Readjust if necessary.

Low or no pilot pressure

Check pilot pressure at the control valve.

Bleed orifice plugged

Remove orifice and clean.

No downward pressure on bucket

High-flow auxiliary does not function

Standard auxiliary or high-flow auxiliary functions slowly

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Troubleshooting Guide Problem Standard-flow auxiliary hydraulics do not function

Hydraulic system noisy

Jerky lift arm and bucket action

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Possible Cause

Remedy

Restraint bar raised

Lower restraint bar. Check indicator light on the interlock module.

Restraint bar switch or seat switch malfunctioning

Replace malfunctioning switch. Check indicator light on the interlock module.

Faulty electrical connections

Check electrical connections for security, broken or damaged wires. Replace as needed.

Pilot control handle malfunctioning

Repair or replace as needed.

Load-sense signal line loose or broken, load-sense compensation malfunctioning

See load-sensing pump manual.

Replace if necessary.

High-pressure compensation on pump malfunctioning

See load-sensing pump manual.

Replace if necessary.

Hydraulic oil viscosity too heavy

Allow for longer warm-up period.

Air in hydraulic system

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

Restraint bar switch or seat switch malfunction

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

Air in hydraulic system

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

Oil in hydraulic reservoir low

Check and add oil to reservoir as needed.

Damaged pump

Replace pump or contact the GehlMustang service department.

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Hydraulics - Standard Chassis Components

6 13 16 21 23 26 40 41 43 52

100

HLN INST 5/16 CZY CS FL LOCK 3/8X1 C5ZY CLAMP/TUBE .62 TWIN 45 MJ10-FJS10 CAP/HYD RESERVOIR LN FL SPIRALOCK 5/16 CLAMP/TUBE 1.00 TWIN REDUCER FJ06-MJ08 BRKT/HARNESS HOSE/SUCTION/MOLDED

53 55 68 76 78 80 81 82 83 93

VALVE/SELF LEVEL CLAMP/HOSE 1.56X.41 90 MAORB12-FORB16 HOSE/HYD -10 X 25.25IN SPACER/.63X.083X1.14 TUBE/HYD -10 TUBE/HYD -10 BRKT/HOSE TUBE/HYD -06 HOSE/TUBE/COOLER

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94 HOSE/TUBE -16/-16 95 TUBE/HYD -24 FILL NECK 105 PLATE/MOUNT/TUBE 112 VALVE/SOLENOID 122 CB 5/16X1-3/4 C5ZY 123 CS 5/16X2-1/4 C5ZY 128 FW 5/16 ANZY 132 CS FL 5/16X2 C8ZY 139 TEE BLKHD RUN

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HYDRAULIC SYSTEM

Hydraulics - High-Flow Chassis Components

1 2 3 4 5 6 7 8 9 10 11 12 13 14

ST MJ16-MORB12 ST MJ06-MORB06 HLN INST 5/16 CZY ST MJ16-MORB16 ST MJ12-MORB12 ST MJ10-MORB12 90 MJ10-MAORB12 45 MJ06-MAORB06 CLAMP/TUBE .75 TWIN PLATE/TOP SIZE 2 TWIN FL CLAMP/TUBE .62 TWIN 90 MJ16-FJS16 90-LL MJ12-MAORB12 TEE RUN MJ08-MAORB06-MJ0

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15 16 17 18 19 20 21 22 23 24 25 26 27 28

ST MJ04-MORB06 90 MFS16-MAORB16 CLAMP/TUBE 1.00 TWIN 90-LL MJ16-MAORB12 HOSE/HYD -16 X 26.75 HOSE/HYD -04 X 31.10 VALVE/DPX160 TUBE/HYD -12 JOY STICK WLDMT/VALVE BRKT TUBE/HYD -08 DRAIN HOSE/HYD -06 X 19 TUBE/HYD -10 JOY STICK TUBE/HYD -10 JOY STICK TUBE/HYD -10 JOY STICK

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TUBE/HYD -16 JOY STICK TUBE/HYD -12 JOY STICK TUBE/HYD -12 JOY STICK TUBE/HYD -16 JOY STICK TUBE/HYD/-10 TUBE/HYD/-10 HOSE/HYD -16 X 20 PLATE/CLAMP BASE CLAMP/TUBE SINGLE RELIEF PLATE/COVER HN LG FL 5/16 C2ZY CS 5/16X3-3/4 C5ZY CS 5/16X3 C5ZY CS M10-1.5x16 C8.8 ZY DIN933

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Hydraulics - Standard Auxiliary Lift Arm Components

Parts Listing For Previous Drawing

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

90 MJ08-MAORB08 HLN INST 5/16 CZY HLN INST 1/2 C2ZY LN LG FL SERR 5/16 CZ HLN INST 1/4 CZY ST MJ08-MORB06 CS FL LOCK 3/8X3/4 C5ZY CLAMP/TUBE .75 TWIN PLATE/TOP SIZE 2 TWIN FL CLAMP/TUBE .62 TWIN CLAMP/TUBE .50 TWIN LN FL SPIRALOCK 5/16 CZY WASHER 5/8 HT PIN/TILT CYLINDER BAR/HOSE PIVOT LINKAGE HOSE/MP .50 X 24 TUBE/LIFT CYL BASE TUBE/LIFT CYL ROD CLAMP/HOSE #80 TIE/CABLE .50X12.90 DUAL BLACK PLATE/COVER ASSY/PIN PLATE/TWIN COVER T4 PLATE/SPACER TUBE/FRONT AUX TUBE/FRONT AUX TUBE/FRONT AUX DRAIN COVER/AUX COUPLER TUBE/TILT LOWER ARM TUBE/CROSSMEMBER REAR CYLINDER/LIFT W/CUSH CYLINDER/TILT W/CUSHION

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33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

WLDMT/HOSE PIVOT BAND TUBE/HOSECARRIAGE HOSE/ASSY/.50 X 19.00 WLDMT/ARM/CARRIAGE TUBE/REAR AUX TUBE/REAR AUX DRAIN TUBE/REAR TILT HOSE/ASSY/.75 X 73.00 HOSE/ASSY/.63 X 73.00 HOSE/ASSY/.50 X 76.00 STUD/THREADED 5/16X6.25 PLATE/TUBE CLAMP STRIP/TRIM 20.75 HOSE/ASSY/.63 X 68.00 HOSE/ASSY/.75 X 68.00 BUSHING/.313X.75 PIN/LIFT CYLINDER BLOCK/COUPLER CLAMP/TUBE SINGLE RELIEF PLATE/COVER TUBE/TILT LOWER ARM TUBE/CROSSMEMBER REAR CS FL 3/8X3-1/2 C5ZY CS 5/16X2-1/4 C5ZY CS 5/16X4 C5ZY CB 1/2X1-1/2 C5ZY CS 5/8X2 C8ZY CS 1/4X3-3/4 C5ZY CS 5/8X5 C8ZY PLATE/TOP SIZE 2 TWIN

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Hydraulics - High-Flow Auxiliary Lift Arm Components

Parts Listing For Previous Drawing

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

ST MJ16-MORB12 HLN INST 5/16 CZY HLN INST 1/4 CZY ST MJ08-MORB06 CS FL LOCK 3/8X3/4 C5ZY 90 MJ16-FJS16 BAR/HOSE PIVOT LINKAGE TIE/CABLE .50X12.90 DUAL BLACK CLAMP/TUBE 1.00 TWIN PLATE/TWIN COVER T4 BLOCK/COUPLER COVER/HI FLOW COUPLER TUBE/HI-FLOW TUBE/HI-FLOW TUBE/FRONT HI FLO DRAIN PLATE/SPACER TUBE/REAR HI FLO HOSE/ASSY/1.00 X 73.00 90-LL MJ16-MAORB12 VALVE/DPX160 TUBE/HYD -08 DRAIN

PRINTED IN USA

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

WLDMT/HOSE PIVOT BAND TUBE/HOSECARRIAGE TUBE/HYD -08 DRAIN PLATE/TWIN COVER/ASSY WLDMT/ARM/CARRIAGE TUBE/HYD -16 JOY STICK TUBE/HYD -16 JOY STICK HOSE/ASSY/.50 X 76.00 PLATE/CLAMP BASE STRIP/TRIM 20.75 HOSE/ASSY/1.00 X 71.00 BUSHING/.313X.75 TIE/CABLE .50X19.20 DUAL CLAMP/TUBE SINGLE RELIEF PLATE/COVER CS FL 3/8X3-1/2 C5ZY CS 5/16X3-3/4 C5ZY CS 5/16X4-1/2 C5ZY CS 1/4X3-3/4 C5ZY

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Hydraulics - Hydraglide™ Components 1 2 3 4

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Assy/Manifold Coil Cartridge Cartridge

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HYDRAULIC SYSTEM

Pressure and Load-Sense Check, Test and Adjustment The control valve on the skid-steer loader controls lift and tilt functions of the lift arm and standard and highflow auxiliary hydraulics. It is located on the right side of the chassis. There is also an inlet relief in the control valve for the load-sense signal.

There are two adjustable pressure compensators on the axial piston load-sensing pump. One is used to set maximum system pressure, the other, to set load-sense standby pressure.

System Pressure Check Procedure The hydraulic oil must be at normal operating temperature, around 140° F (60° C).

It is possible to perform a system pressure reading check at the auxiliary hydraulic couplers located on the left lift arm. Install a pressure gauge in the end of the male coupler and activate the auxiliary hydraulics to pressurize the line.

Load-Sense Standby Check Procedure The hydraulic oil must be at normal operating temperature, around 140° F (60° C).

1. Install the low pressure gauge in the pump output port. DO NOT OPERATE / Acutate any machine functions.

2. Se the engine speed aty 1800-2000 rpm and monitor the gauge. It should read between 290 to 330 psi.

System Pressure and Load-Sense Test Procedure and Adjustment The hydraulic oil must be at normal operating temperature, around 140° F (60° C).

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Shut off the engine.

• Relieve hydraulic system pressure.

• Tilt back ROPS/FOPS until lock engages.

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

Standard Auxiliary Couplers

1. At the Hydraulics Couplers: Climb into the operator’s seat, lower the restraint bar and start the engine.

2. Activate the standard control function of the standard auxiliary, or high-flow auxiliary if checking that.

3. Slowly increase the engine speed to high idle.

4. Have assistant observe the pressure reading on the gauge. The pressure reading on the loader should be:

IMPORTANT: A small number of of early machines were manufactured with an older style axial pump.

Early pumps had the load-sense and high pressure standby adjustment sensor flipped. BE SURE to identify which pumps you have on your machine.

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

1. What you’ll need: an assistant, two minimum 5000 PSI (345 bar) pressure gauges, and a lower pressure gauge 600 or 1000 PSI (41,3 or 69 bar), and hoses. You may purchase a kit, PN 50353020, that includes the hoses, caps, fittings and test ports.

Gauges are not included.

2. Warm hydraulic oil to 140° F (60° C).

a. for standard flow, at least 3450 PSI ± 25 PSI (238 bar ± 1,7 bar), and b. for high-flow, at least 3450 PSI ± 25 PSI (238 bar ± 1,7 bar).

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3. Install pressure gages to the fittings on the pump output and load sense lines. Gages must be capable of 4000 psi at minimum.

4. Bottom/turn in the inlet relief on the main valve. A metric Allen and ratchet seem to work best for this operation. The locknut must be loosened.

5. Identify the high pressure standby adjustment screw and loosen locknut. Set engine speed to 1800 rpm and slowly engage/deadhead the standard auxiliary system.

screw in or out to achieve desired setting.

Return to low idle speed. Tighten the locknut.

7. Set low pressure standby by monitoring pressure in both the load-sense line and pump output line. Install a loop line with a needle valve on the standard auxiliary circuit. You will want to run the engine at 2000-2200 rpm.

Open needle valve and engage aux circuit.

Turn needle valve inward to achieve 1800 psi pump output pressure. Then turn the low pressure standby screw outward until you see a difference of approximately 50-100 psi between the pump output and load-sense line. Then turn the low pressure adjustment screw inward until you achieve a difference of 300-340psi between pump output and load-sense line. Disengage the auxiliary. Tighten the locknut.

8. Run the engine at high idle and record the

pump output pressure without having the standard auxiliary engaged, should be 310 psi +/20 psi. Return to low idle speed.

9. Engage/deadhead the standard auxiliary and adjust engine speed to approximately 1800 rpm. Adjust the inlet relief on the main valve to achieve a pump output pressure of 3450 psi+/-25. Load-sense line will be approximately 3120-3160 psi.

10. Double check pump output pressure (dead head function) (approximately 3450 psi) and low pressure standby (high idle no aux, not dead-headed) (approximately 290-330 psi).

6. Monitor pump output pressure and set high

pressure standby at 3550 +/-25 psi by turning

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

NOTE: When checking for drifting, BE SURE the ignition key is in the ON position, with the operator in the seat, and the restraint bar lowered. The maximum allowable tilt cylinder circuit drifting with a loaded bucket is 0.4" (10 mm) of cylinder extension in 15 minutes.

Test Procedure

tested, and cap or plug the hose. Caps/plugs MUST BE able to withstand full hydraulic pressure.

3. Install an extra hose to the upper cylinder port and place the other end of this hose into an empty bucket.

4. Climb back into the operator’s seat, lower the restraint bar, and start the engine. Have an assistant watch the hose in the bucket.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Roll (Curl) the hitch in towards the loader until the tilt cylinders bottom out.

5. Slowly actuate the roll back (curl) function of the hitch. If oil streams into the bucket, the cylinder seals are malfunctioning. Replace the cylinder seals.

• Shut off the engine.

6. After the tilt cylinder has been tested, be sure to reconnect the tilt cylinder hydraulic hose removed in step 1.

• Relieve hydraulic system pressure.

7. Repeat steps 1 - 5 for the other side.

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

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

1. Make sure the cylinder is bottomed out.

2. Checking one tilt cylinder at a time, remove the upper hydraulic hose from the cylinder being

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Tilt Circuit Spool Leakage Test The following test procedure indicates what would be regarded as normal leakage through the spool valve. If the cylinders move substantially more than the amount of movement indicated, further testing will be required to determine the source of the leakage. Prior to conducting the valve leakage test, disable the self level valve.

5. Add weight to the bucket until the pressure gauge reads 1400-1500 psi (96,5 - 103 bar).

6. Roll back the bucket fully. Find a position that can be easily measured between the barrel of the cylinder and the rod. Record this dimension.

WARNING

Test Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Shut off the engine.

• Relieve hydraulic system pressure.

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

1. Required Equipment: Pressure Gauge (0-5000 psi) (345 bar), infrared thermometer, two people, tape measure or caliper, stop watch.

2. Install the pressure gauge into the hydraulic circuit of the rod end of the tilt cylinder. The gauge can be installed anywhere between the cylinder and the control valve.

BEFORE raising a loaded bucket, BE SURE no personnel are near the loader. Serious personal injury can result if the bucket drops suddenly or its contents spill out.

7. Shut the machine off. Have the operator turn the key to the ON position and remain in the seat with the restraint bar down. (This is done to ensure the additional hydraulic locks remain open for the test period).

8. Begin recording time on the stop watch.

9. After a period of ten minutes, record the amount that the cylinder had moved.

10. Compare to the allowable movement of 0.72” (18,3 mm) of cylinder movement in a 10 minute period.

This is the highest allowable leakage value per the valve manufacturers specifications.

3. Idle the machine until the hydraulic oil is stabilized at 120° F (49° C). The oil temperature can be determined by using the infrared thermometer. The temperature area of the cooler is shown below. Once the temperature of the cooler has not varied 2° in a ten minute period, the test can be conducted.

4. Attach a dirt/construction bucket to the machine.

Position the bucket so that approximately 0.5" (12,7 mm) of the rod is exposed.

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Self-Leveling Valve Test

Lift Cylinder Test

Test Procedure

If the lift arm drifts with the lift control in NEUTRAL position, and the ignition key OFF, first check the lift cylinders for external leakage. If external leakage is evident, a new seal kit should be installed in the leaking cylinder(s). If no external leakage is evident, check the lift cylinders for internal leakage according to the following procedure.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Shut off the engine.

• Relieve hydraulic system pressure.

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

1. With the engine OFF and the ROPS raised and locked, loosen the jam nut on the self-leveling valve adjuster screw.

NOTE: When checking lift arm for drifting, BE SURE the ignition key is in the ON position, with the operator in the seat, and the restraint bar lowered. The maximum allowable lift cylinder drifting is 0.75" (19 mm) of cylinder retraction in 15 minutes.

Test Procedure

WARNING

Self-Leveling Valve Adjuster Screw

BEFORE continuing this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Relieve hydraulic system pressure.

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

NOTE: For step 2, BE SURE to count and record the number of turns, so the adjuster screw can be returned to its original setting after the test.

2. With an allen wrench, turn the adjuster screw in (clockwise) until it bottoms out. The self-leveling valve is now disabled and will not affect the tilt operations.

5. Remove the clamp securing the hydraulic tubes to the lift cylinder on the side being tested.

IMPORTANT: To prevent contamination, ALWAYS clean around hydraulic fittings before disconnecting any hydraulic lines.

6. Disconnect the hydraulic tube from the rod end port of the lift cylinder to be tested.

3. Perform steps 3-5 in the “Tilt Cylinder Test” procedure. If the bucket no longer drifts, the self-leveling valve is defective. If the bucket continues to drift, the control valve is defective and in need of repair or replacement.

4. Refer to the “Self-Leveling Valve Adjustment” procedure in this chapter for correct adjustment of the self-leveling valve.

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7. Install a plug on the hydraulic tube. Attach a hose to the rod end port of the cylinder and run the other end of the hose into a suitable container.

8. Climb into the operator’s seat, lower the restraint bar and start the engine.

9. Hold the lift control in the RAISE position to extend both cylinders (a small amount of oil will exit the hose initially). If the seals in the cylinder are defective and leaking, oil will flow out of the rod end port.

10. Slowly lower the lift arm until the support device contacts the lift cylinder. Shut off the engine and relieve hydraulic pressure with the lift control.

11. Reconnect the tube to the cylinder, then reattach the clamp around the hydraulic tube and cylinder.

12. The other cylinder can be checked the same way.

NOTE: If neither lift cylinder shows signs of external or internal leakage, and the lift arm still drifts, the problem could be due to leaking hydraulic tube fittings between the control valve and the lift cylinders. Check all hydraulic tube fittings thoroughly. The fault could also be in either the control valve or the ride control manifold. Continue the test procedure with step 13.

Also refer to the Troubleshooting Guide in this chapter.

13. Relieve hydraulic pressure. Disconnect the ride control tubes to port A & B of the ride control manifold. Cap the fittings on the hydraulic tubes.

Lift Circuit Spool Leakage Test The following test procedure indicates what would be regarded as normal leakage through the spool valve. If the cylinders move substantially more than the amount of movement indicated, further testing will be required to determine the source of the leakage. Prior to conducting the valve leakage test, disable the self level valve.

Test Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Shut off the engine.

• Relieve hydraulic system pressure.

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

1. Required Equipment: Pressure Gauge (0-5000 psi) (345 bar), infrared thermometer, two people, Tape measure or caliper, stop watch.

2. Install the pressure gauge into the hydraulic circuit of the base end of the lift cylinder. The gauge can be installed anywhere between the cylinder and the control valve.

3. Idle the machine until the hydraulic oil is stabilized at 120° F (49° C). The oil temperature can be determined by using the infrared thermometer. The temperature area of the cooler is shown below. Once the temperature of the cooler has not varied 2° in a ten minute period, the test can be conducted.

14. Raise the lift arm and check for drifting.

15. With an operator in the seat, the keyswitch set to the ON position and the restraint bar lowered, check to see if drifting has subsided, if so, then the solenoid valve nearest port A of the ride control manifold should be replaced.

16. If drifting remains after disconnecting the ride control manifold, then the control valve is at fault and should be replaced.

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4. Attach a bucket to the machine. Position the bucket so that 5.00"-6.00” (127 - 152 mm) of rod is exposed.

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5. Add weight to the bucket until the pressure gauge reads 1400-1500 psi (96,5 - 103 bar).

6. Roll back the bucket fully and raise the lift arm so that 5.00"-6.00” (127 - 152 mm) of the rod is exposed.

Find a position that can be easily measured between the barrel of the cylinder and the rod. Record this dimension.

» Brake light.

Joystick Drive Supply, Brake, Lift/Tilt Safety Locks and Two-Speed Test Procedure 1. Climb into the operator’s seat, lower the restraint bar and start the engine.

2. BE SURE the parking brake button on the instrument keypad is OFF. 3. Raise the restraint bar. Use the drive controls to see if the tires will move.

WARNING BEFORE raising a loaded bucket, BE SURE no personnel are near the loader. Serious personal injury can result if the bucket drops suddenly or its contents spill out.

» If the skid loader moves forward or backward, check to see if the joystick drive supply. solenoid, seat switch, restraint bar switch or the brake solenoid is malfunctioning.

Two-Speed

7. Shut the machine off. Have the operator turn the key to the ON position and remain in the seat with the restraint bar down. (This is done to ensure the additional hydraulic locks remain open for the test period).

All-Tach

8. Begin recording time on the stop watch.

Fan

9. After a period of ten minutes, record the amount that the cylinder had moved.

Compare to the allowable movement of 0.42” (10,7 mm) of cylinder movement in a 10 minute period. This is the highest allowable leakage value per the valve manufacturers specifications.

Solenoid Valve Test - Joystick Drive Supply, All-Tach/Fan, Brake/Two-Speed, Safety Locks and Ride Control During normal operation, the Hydraglide™ solenoid valve provides two functions: a float function for the lift arm and a ride control function for the lift arm. The float function allows the bucket to follow the contours of the ground during back-dragging applications. The ride control function is a cushioning effect for the lift arm when driving over uneven surfaces.

Joystick Drive Supply

» If the lift arm can be raised or lowered, check to see if the seat switch, restraint bar switch or the lift solenoid is malfunctioning.

During normal operation, the lift and tilt lock valves should prevent operation of the lift arm and the hitch, if the operator is not in the seat with the restraint bar lowered.

Lift Lock

During normal operation, the joystick drive supply and brake valves should prevent operation of the drive functions if any of the safety interlock system switches are open, for example: » Operator not sitting on the seat. » Restraint bar not lowered.

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» If the hitch can be tilted, the tilt solenoid is malfunctioning.

arm height and a light in the instrument keypad should illuminate.

Hydraglide™ Solenoid

Tilt Lock

3. Lower the lift arm.

4. If any solenoid in the tests appears to be malfunctioning, test the solenoid coil(s) as follows:

4. If the Hydraglide™ solenoid valve in the test appears to be malfunctioning, test the solenoid coils as follows:

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

WARNING

• Remove attachment from lift arm.

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

• Raise lift arm; engage lift arm support device.

• Remove attachment from lift arm.

• Shut off the engine.

• Raise lift arm; engage lift arm support device.

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

• Shut off the engine.

» Have an assistant sit in the operator’s seat, lower the restraint bar and turn the keyswitch to ON. DO NOT start the engine.

• Tilt back ROPS/FOPS until lock engages.

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

» Using a thin strip of steel (such as a pocket ruler), check the suspected solenoid by moving the steel strip close to the solenoid coil.

5. Lower the restraint bar, turn the keyswitch to ON (DO NOT start the engine). Compress the operator’s seat and hold to temporarily bypass the interlock safety system.

» If the steel strip is magnetically attracted to the solenoid coil, the coil works and the solenoid cartridge may be causing the malfunction.

6. Actuate the Hydraglide™ button to see if the coil magnetizes.

5. For service procedures, refer to “Solenoid Valve Removal and Installation/Disassembly and Reassembly” procedure in this chapter.

Ride Control Test Procedure 1. Climb into the operator’s seat, lower the restraint bar and start the engine.

1. Clear the area of bystanders and raise the lift arm half way up.

2. Actuate the ride control button on the right control handle. If the solenoid is functioning properly, there should be a slight (minimal) drop in the lift

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7. Have an assistant do the metal ruler test: » Using a thin strip of steel (such as a pocket ruler), check the suspected solenoid by moving the steel strip close to the solenoid coil. » If the steel strip is magnetically attracted to the solenoid coil, the coil works and the solenoid cartridge may be causing the malfunction 8. For service procedures, refer to “Solenoid Valve Removal and Installation/Disassembly and Reassembly” procedure in this chapter and the Electrical System chapter Troubleshooting Guide. Also look at the module test procedures and LED truth tables in the Electrical System chapter.

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Hydraulic Oil Filter Element Replacement Gehl V4200 and Mustang 4200V model skid-steer loaders have one hydraulic oil filter. The filter needs to be replaced when the restriction indicator light on the right instrument keypad comes on, indicating the return filter is restricted or, at the regular maintenance interval.

The filter element should be replaced after every 500 hours of operation or annually (whichever occurs first).

4. Pull up on the filter element and remove it from the reservoir.

NOTE: There is an initial 50-hour element replacement schedule for new skid-steer loaders with original filters.

Replacement Procedure

WARNING

5. Install the new filter element in the reservoir.

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

6. After properly positioning the spring, reinstall the cover plate and its hardware.

• Remove attachment from lift arm.

7. Refill the hydraulic reservoir. Refer to the Lubrication chapter in this manual for the hydraulic fluid requirements and specifications.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Tilt back ROPS/FOPS until lock engages.

WARNING

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

1. At the left side of the chassis, remove the left side access cover.

2. Clean any dirt/debris off the surface of the filter housing.

3. Remove four bolts on the cover plate and remove the plate and spring.

NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

8. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

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Lift Cylinder Components 2 3 4 5 6 7 8 9 10 11 12 13

SCREW/SET NUT/LOCK WELDMENT/ROD BUSHING/COMPOSITE GLAND/HEAD PISTON CAP/HEAD GLAND WELDMENT/TUBE BUSHING/SPRING FITTING/GREASE BUSHING/COMPOSITE SCREW/SET

Tilt Cylinder Components 2 3 4 5 6 7 8 9 10 11 12

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Tilt Cylinder Removal and Installation Removal Procedure

lower tilt cylinder pivot pin. Then drive the pivot pin out to release the lower end of the tilt cylinder.

NOTE: Refer to the “Lift Arm Removal/Disassembly” procedure in the Mainframe chapter for instructions on removing the complete lift arm assembly, including the tilt cylinders.

1. Remove the bucket or attachment.

2. With the engine running, lower the lift arm until it is in contact (or near contact) with the lift arm stops (on front of chassis).

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: • Shut off the engine.

• Relieve hydraulic system pressure.

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

5. Loosen the capscrew on the end of the upper tilt cylinder pin by two to three counterclockwise turns. Strike the bolt head to drive the pin into the lift arm and break the pin free of the taper. Remove the capscrew and flat washer. Remove the upper tilt cylinder pin while supporting the tilt cylinder.

3. Disconnect the upper and lower tilt cylinder hoses from the tubes on the crossmember. BE SURE to plug the hoses and cap the fittings to prevent fluid loss and contamination of the hydraulic system.

6. Remove upper and lower hoses from the cylinder.

Installation Procedure 1. Connect the upper and lower hoses to the tilt cylinder.

4. While supporting the weight of the tilt cylinder, remove the capscrew and locknut securing the

2. Install the base end of the tilt cylinder in position on the lift arm and insert the pivot pin. Use Loctite® 242 (or equivalent) on the capscrew before reinstalling and torque to 80 ft.-lbs. (108 N•m).

3. Position the rod end of the tilt cylinder and insert the pivot pin through the cylinder and attachment mount. Secure the pivot pin with a capscrew and locknut.

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NOTE: The grease fitting on the rod end of the tilt cylinder should face inward as installed.

Lift Cylinder Removal and Installation Removal Procedure 1. Remove the bucket or attachment.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: • Shut off the engine.

• Relieve hydraulic system pressure.

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

4. Remove plugs/caps and attach the upper and lower tilt cylinder hoses to the cylinder, and then reconnect hoses to the tubes on top of the crossmember.

NOTE: After removing/replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary.

Refer to the Lubrication chapter in this manual for the hydraulic fluid requirements and specifications.

2. Raise and block the tire on the working side of the loader, then remove the tire to access the lower lift cylinder pin.

3. Raise the lift arm to a position where access to the tubes and hoses on the lift cylinder is maximized and attach a suitable hoist to the hitch.

4. Remove the clamp that secures the hydraulic tube to the lift cylinder.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

NOTE: To aid in correct reassembly of the hydraulic hoses/tubes, mark the hoses/tubes to be removed BEFORE disassembly.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

5. Disconnect the two hydraulic hoses at the base end of the lift cylinder. BE SURE to install plugs/caps in the hoses/tubes to prevent fluid loss and contamination of the hydraulic system.

5. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

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HYDRAULIC SYSTEM 2. Install the lift cylinder on the chassis so the rod end is facing forward and the hydraulic tube ports on the cylinder are facing forward.

CAUTION The lift cylinder hydraulic hoses can contain trapped hydraulic pressure inside them. Wear appropriate safety gear when disconnecting these lines.

6. Remove the capscrew and washer securing the top lift cylinder pivot pin. Screw in a 5/8” x 6” capscrew and hammer the pivot pin out to release the rod end of the lift cylinder.

3. Apply anti-seize grease on pin ends and insert the lower and upper pivot pins through the cylinder pivots and secure them with carriage bolts, capscrews, washers and locknuts.

4. Remove the plugs/caps and connect the two hydraulic hoses to the lift cylinder according to the markings made at removal. If no markings were made or new parts were installed, refer to the Hydraulic System chapter exploded views.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter in this manual for the hydraulic fluid specifications.

Pivot Pin

WARNING

7. While supporting the weight of the lift cylinder, remove the carriage bolt, pin assembly and locknut securing the lower lift cylinder pivot pin. Drive the pivot pin out the hole on the outside of the chassis.

Remove the lift cylinder from the chassis.

NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

5. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

8. Remove hydraulic tube from the cylinder

6. Remove the hoist.

Installation Procedure 1. Attach a suitable hoist to the hitch and raise the lift arm to a position where access to the tubes and hoses on the lift cylinder is maximized.

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Lift/Tilt Cylinder Disassembly / Assembly Disassembly Procedure

5. Remove the rod assembly and inspect both the cylinder rod and the tube for dents or nicks that may cause damage to the o-rings and seals.

Remove the cylinder from the skid-steer loader. See “Lift Cylinder Removal” or “Tilt Cylinder Removal” in this chapter.

1. Use an Allen wrench to loosen the set screw on the cylinder collar.

2. Purge the oil from the cylinder by facing the ports downward and pumping the cylinder rod back and forth several times.

3. Clamp a suitable shaft in a vise and slide the cylinder onto the shaft to prevent the cylinder tube from turning.

6. Use an air wrench and socket to loosen and remove the locknut (see Important note below) that secures the head gland, seal kit and piston on the cylinder rod.

7. Remove the piston assembly.

8. Slide the piston, head gland, seals, and o-rings off the cylinder rod and inspect them for wear.

4. Use a clamp wrench or suitable pipe wrench to loosen cylinder collar from the cylinder tube.

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HYDRAULIC SYSTEM Auxiliary (Fan) Pump Removal and Installation

IMPORTANT Have a new locknut available for reassembly if the existing locknut is removed. A crimping feature on the locknut will be compromised on the existing locknut after its removal from the cylinder rod.

Removal Procedure

9. Change the seals as needed.

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

NOTE: Soaking the seals in warm water prior to installation will make them pliable and easier to install.

However, BE SURE to dry them and coat with hydraulic oil for proper installation.

Assembly Procedure

WARNING • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Relieve hydraulic system pressure.

1. Slide the collar onto the cylinder rod (threaded end of the collar should face the threaded end of the cylinder rod).

2. Slide the piston, head gland, seals, and o-rings on the cylinder rod in the reverse order the came off the rod.

3. Slide the head gland, larger diameter first, onto the cylinder rod.

4. Install the piston on the cylinder rod.

5. Secure the head gland and piston on the cylinder rod with a new locknut (see Important note in the disassembly procedure). The locknut should be torqued to 350 ft.-lbs. (474 N•m).

6. Install the cylinder rod into the tube.

• Tilt back ROPS/FOPS until lock engages.

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

1. If necessary, drain the hydraulic oil tank per the procedure in the Lubrication chapter.

2. If necessary, remove control consoles and floor cover per their procedures in the Mainframe chapter.

3. If necessary, remove the crossmember per the procedure in the Mainframe chapter.

4. Disconnect one hydraulic hose from its fitting on the auxiliary pump and remove a hose clamp on the other hydraulic hose.

7. Slide the collar down to the cylinder tube; thread it onto the tube and tighten with a chain clamp wrench. Tighten the set screw on the collar.

8. Install the cylinder on loader. See the “Lift Cylinder Installation” or the “Tilt Cylinder Installation” procedure in this chapter.

IMPORTANT: Cap or plug hydraulic hoses and fittings to prevent fluid loss/contamination of hydraulic system.

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5. Remove two capscrews and washers attaching the auxiliary pump to the load-sensing pump.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

6. Pull the auxiliary pump forward and out of the load-sensing pump. BE CAREFUL not to lose the o-ring.

Installation Procedure 1. Install the o-ring on the mating surface of the auxiliary pump.

2. Attach the auxiliary pump to the load-sensing pump (BE SURE the auxiliary pump shaft engages the splined coupler). Install two capscrews to secure the auxiliary pump to the load-sensing pump.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

7. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

3. Remove the caps/plugs and connect the hydraulic hoses to the auxiliary pump.

4. If performed at removal, reinstall the crossmember, floor plate and control consoles per their procedures in the Mainframe chapter.

5. If performed at removal, reinstall the hydraulic reservoir drain plug.

6. If performed at removal, replace the hydraulic oil drained out of the reservoir in step 1.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of the hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for the hydraulic fluid specifications.

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Load-Sense Axial Piston Pump Removal and Installation

6. Remove two capscrews and washers attaching the axial piston pump to the hydrostatic pump.

Remove Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Relieve hydraulic system pressure.

• Tilt back ROPS/FOPS until lock engages.

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

1. If necessary, drain the hydraulic oil tank per the procedure in the Lubrication chapter.

2. If necessary, remove control consoles and floor cover per their procedures in the Mainframe chapter.

7. Pull the axial piston pump forward and out of the hydrostatic pump. BE CAREFUL not to lose the oring.

Installation Procedure 1. Install the o-ring on the mating surface in the rear housing of the tandem pump.

3. If necessary, remove the crossmember per the procedure in the Mainframe chapter.

2. Attach the axial piston pump to the hydrostatic pump (BE SURE the axial piston pump shaft engages the splined coupler). Install two washers and capscrews to secure the axial piston pump to the hydrostatic pump.

4. Remove the auxiliary pump per the procedure in this chapter.

3. Remove the caps/plugs and reconnect the hydraulic hoses to the their fittings on the axial piston pump.

5. Disconnect the hydraulic hoses from their fittings or split flange kits on the axial piston pump.

4. If performed at removal, reinstall the crossmember, floor cover and control consoles per their procedures in the Mainframe chapter.

5. If performed at removal, replace the hydraulic oil drained out of the reservoir in the first step of the removal procedure.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of the hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for the hydraulic fluid specifications.

WARNING IMPORTANT: Cap or plug hydraulic hoses and fittings to prevent fluid loss/contamination of hydraulic system.

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penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

Self-Leveling Valve Removal and Installation Removal Procedure

WARNING

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

6. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Relieve hydraulic system pressure.

• Tilt back ROPS/FOPS until lock engages.

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

NOTE: Cap or plug the hydraulic hoses and fittings after disconnecting them to prevent fluid loss and contamination of the hydraulic system.

NOTE: To remove the hydraulic tubes from their fittings on the self-leveling valve, it may be necessary to loosen the hydraulic tube at the other end to provide some free-play.

1. Disconnect the two electrical connectors from the safety lock valve attached to the self-leveling valve. Remove two hydraulic tubes from the safety lock valve.

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2. Remove the two locknuts securing the safety lock valve to the valve mounting plate. Slide the safety lock valve off its mounting plate.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

WARNING

3. Disconnect all the hydraulic tubes from their hydraulic fittings on the self-leveling valve.

ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

6. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

4. Remove the two capscrews and locknuts securing the self-leveling valve to the chassis.

5. Remove the self-leveling valve.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of the hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for the hydraulic fluid specifications.

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

ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

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Self-Leveling Valve Adjustment

6. Loosen the adjuster screw locknut on the self-leveling valve.

Adjustment Procedure 1. Raise and lower the lift arm several times to ensure there is no air in the hydraulic system.

2. Lower the lift arm completely, then fully retract the tilt cylinders (roll back).

3. Raise the lift arm to its maximum height; then lower it to the ground.

4. Measure how far the tilt cylinder rod extends from the tilt cylinder. The distance should be between 81/4 and 8-1/2” (210-216 mm). If measurement is outside this range, the self-leveling valve should be adjusted according to steps 5 - 7 of this procedure.

7. Insert an allen wrench into the adjuster screw on the self-leveling valve and adjust the valve. Turn the screw IN (clockwise) to shorten the cylinder extension. Turn the screw OUT (counterclockwise) to lengthen the cylinder extension.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

8. To check for proper operation, lower the ROPS, climb into the operator’s seat, lower the restraint bar and start the engine. Disengage the lift arm support device and secure it to the lift arm.

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

9. Repeat steps 2 through 4 above to check for proper operation of the self-leveling valve. If further adjustment is needed, perform the safety procedures again and repeat steps 5 through 7.

5. The self-leveling valve can be accessed from the left side of the chassis.

10. After adjustment is complete, tighten the adjuster screw locknut.

• Tilt back ROPS/FOPS until lock engages.

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Brake/Two-Speed and Safety Lock Solenoid Valves - Removal and Installation

tubes from the front of the self-leveling valve and move out of the way. Remove the valve.

Gehl V420 and Mustang 4200V model skid-steer loaders have separate electric solenoids for lift, tilt and brake functions of the hydraulic system. The tilt safety lock valve is located on the left side of the chassis at the self-leveling valve. The lift safety lock valve is located on the right side of the chassis above and behind the main control valve. The brake/two-speed solenoid valve is located forward and below the main control valve.

Tilt Safety Lock

Removal Procedure

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

2. Lift Safety Lock Valve Removal: Disconnect two electrical connectors on the solenoid coils. Remove two hydraulic tubes from their fittings. Remove the valve.

• Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

Lift Lock

• Relieve hydraulic system pressure.

• Tilt back ROPS/FOPS until lock engages.

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

IMPORTANT: Cap or plug the hydraulic hoses, tubes and fittings after disconnecting them to prevent fluid loss and contamination of the hydraulic system.

NOTE: To remove the hydraulic tubes from their fittings, it may be necessary to loosen hydraulic tubes at the other end to provide some free-play.

3. Brake/Two-Speed Valve Removal: Disconnect two electrical connectors on the solenoid coils.

Remove four hydraulic hoses on the lock valve.

Remove two locknuts securing the valve to the chassis. Remove the valve.

1. Tilt Safety Lock Valve Removal: Disconnect two electrical connectors on the solenoid coils. Remove two hydraulic tubes from their fittings. Remove two locknuts securing the valve to the valve mounting plate. Disconnect two forward hydraulic Brake/Two-speed

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

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if PRINTED IN USA

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necessary. Refer to the Lubrication chapter for hydraulic fluid requirements and specifications.

ALWAYS check for hydraulic fluid leaks after assembling any component of the hydraulic system.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

Joystick Drive Supply, All-Tach/Fan and Hydraglide™ Ride Control Solenoid Valves - Removal and Installation Gehl V420 and Mustang 4200V model skid-steer loaders have separate electric solenoids for joystick drive supply, all-tach/fan and ride control functions of the hydraulic system. The joystick drive supply valve is located on the left side of the chassis forward of the self-leveling valve. The all-tach/fan valve is located on the right side of the chassis, low and forward of the main control valve. The ride control/float valve is located in front of the hydraulic oil reservoir.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Raise lift arm; engage lift arm support device.

• Shut off the engine.

WARNING

• Relieve hydraulic system pressure.

ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

4. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

• Tilt back ROPS/FOPS until lock engages.

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

IMPORTANT: Cap or plug the hydraulic hoses, tubes and fittings after disconnecting them to prevent fluid loss and contamination of the hydraulic system.

NOTE: To remove the hydraulic tubes from their fittings on the solenoid valves, it may be necessary to loosen the hydraulic tubes at the other end to provide some free-play.

1. Identify and mark connectors, then disconnect the electrical connectors on the solenoid coil. Identify and mark tubes and hoses, then disconnect the hydraulic tubes or hoses from their fittings on the solenoid valve. Remove the capscrews and lock-

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nuts securing the solenoid valve to the chassis or to its bracket.

ALWAYS check for hydraulic fluid leaks after assembling any component of the hydraulic system.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

Joystick Drive Supply

Hydraglide™ Solenoid

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

3. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

All-Tach/Fan

2. Remove the solenoid manifold from the skid-steer loader.

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

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for hydraulic fluid specifications.

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Lift/Tilt, Joystick Drive Supply, Brake/TwoSpeed, All-Tach/Fan and Hydraglide™ Ride Control Solenoid Valves - Disassembly and Assembly

3. Unscrew cartridge from the valve body.

Lift and tilt, joystick drive supply, two-speed brake, alltach/fan and ride control solenoid valves can be removed from the loader for parts replacement, but it may not be necessary. If it is necessary, refer to the procedure in this chapter.

Disassembly Procedure 1. Remove the nut that secures the coil to the cartridge.

4. Install seal kit (or other new parts). Assemble solenoid valve in reverse order of disassembly.

O-Ring

2. Remove the coil from the cartridge.

O-Ring

O-Ring

Backup Rings

IMPORTANT DO NOT torque coil retaining nut more than 45 in.-lbs. (5.1 N•m).

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Main Control Valve Components - High-Flow

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

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Control Valve Removal and Installation The main hydraulic control valve is located on the right side of the chassis, in front of the engine. This procedure highlights steps for removing the electrical lines, hydraulic hoses and tubes that connect to the control valve to remove the control valve. The control valve ports are numbered for reference.

NOTE: To aid in reassembly of hydraulic hoses and tubes, mark hoses and tubes to be removed before disassembly.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Relieve hydraulic system pressure.

• Tilt back ROPS/FOPS until lock engages.

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

1. If necessary, (see following NOTE), drain oil from hydraulic reservoir. For this procedure refer to “Hydraulic Reservoir” in the Lubrication chapter.

2. Disconnect four electrical connectors on the control valve, two at the front and two more at the rear of the valve.

3. Hydraulic tubes will need to be removed for acces to the control valve. Mark the tubes before their removal to aid in reassembly.

NOTE: If hydraulic hoses and tubes are plugged to prevent oil leakage, it should not be necessary to drain hydraulic reservoir. BE SURE to plug/cap ALL hydraulic hose and tube fittings to prevent contamination of the hydraulic system.

NOTE: Cap or plug ALL hydraulic hoses, tubes, fittings and control valve ports immediately after being disconnected to prevent fluid loss and contamination of the hydraulic system.

NOTE: It may be necessary to loosen hydraulic tubes at the other end of the tubes connected to the control valve to provide some free-play.

4. Ports 1 and 2: Disconnect the pilot drain tube at its straight fitting and the pilot pressure hose at the 90° fitting on the valve.

5. Port 3: Disconnect the hydraulic tube from the 90° fitting on the control valve.

6. Port 4: Disconnect the hydraulic tube from its straight fitting on the control valve.

7. Port 5: Disconnect the hydraulic tube from its straight fitting on the control valve.

8. Port 6: Disconnect the hydraulic tube from its straight fitting on the control valve.

9. Port 7: Disconnect the hydraulic tube from its straight fitting on the control valve.

10. Port 8: Disconnect the hydraulic tube from its straight fitting on the control valve.

11. Ports 9 and 12: Disconnect the hydraulic tube from its 90° fitting on the control valve.

12. Ports 10 and 11: Disconnect the hydraulic tube from the spool connection.

13. Port 13: Disconnect the hydraulic tube from its straight fitting on the control valve.

14. Port 14: Disconnect the hydraulic tube from its straight fitting on the control valve.

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15. Ports 15 and 16: Disconnect the 90° fitting end of the hydraulic hose from the control valve.

8. Port 8: Connect the hydraulic tube to its straight fitting on the control valve.

16. Port 17: Disconnect the load-sense port hose at the 90° fitting on the valve.

9. Port 7: Connect the hydraulic tube to its straight fitting on the control valve.

17. From outside the chassis, remove four capscrews securing the control valve and its mounting bracket to the chassis.

10. Port 6: Connect the hydraulic tube to its straight fitting on the control valve.

18. Lift out the control valve with the mounting bracket. Removal may require loosening the opposite ends of some of the disconnected tubes.

Installation Procedure

11. Port 5: Connect the hydraulic tube to its straight fitting on the control valve.

12. Port 4: Connect the hydraulic tube to its straight fitting on the control valve.

13. Port 3: Connect the hydraulic tube to the 90° fitting on the control valve.

14. Ports 1 and 2: Connect the pilot drain tube at its straight fitting and the pilot pressure hose at the 90° fitting on the valve.

15. Install hydraulic reservoir drain plug and refill with correct type of hydraulic oil. Refer to Lubrication chapter for hydraulic oil specifications.

16. ALWAYS check for hydraulic fluid leaks after reassembling any component of the hydraulic system.

WARNING

1. Secure the control valve and its mounting bracket to the chassis with four capscrews. If straight or 90° fittings are not in the valve, install them at this time.

2. Port 17: Connect the load-sense port hose at the 90° fitting on the valve.

NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

3. Ports 15 and 16: Connect the 90° fitting end of the hydraulic hose to the control valve.

4. Port 14: Connect the hydraulic tube to its straight fitting on the control valve.

5. Port 13: Connect the hydraulic tube to its straight fitting on the control valve.

6. Ports 10 and 11: Connect the hydraulic tube to the spool connection.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

7. Ports 9 and 12: Connect the hydraulic tube to its 90° fitting on the control valve.

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Control Valve Disassembly and Assembly The main control valve is made up of serviceable spool sections. These spool sections may be removed for service. The control valve also contains compensators and port reliefs that may be cleaned and serviced.

5. Grab the spring assembly on the end of the spool and pull the spool out of the control valve. Identify and mark the spools and reinstall them (later) in the same location. Retain any o-rings.

Disassembly Procedure

Spool

Spring Assy

1. Remove the main control valve per the procedure in this chapter and place valve on a flat surface that can retain or collect any hydraulic oil spill.

2. To separate the sections, remove through-bolts and nuts securing the sections together.

3. To access the sections, use an Allen wrench to loosen four socket capscrews, two on each side of the spool cap.

6. Repeat steps 3-5 for all spools that need to be removed from the control valve.

7. To remove any of the port relief valves or the inlet relief valve from the control valve, use a wrench to loosen the valve from the control valve.

Spool Cap

Inlet Relief Valve

4. Pull spool cap off the spool and retain the o-rings, the small o-rings may be found on the valve.

Assembly Procedure - Reverse the disassembly steps.* * Any spools removed from the control valve must be reinstalled in the same location. Identify and mark spools for assembly.

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Control Valve Solenoid Removal and Installation

• Shut off the engine.

The main control valve contains two electrical solenoids for standard flow units or four electrical solenoids for high-flow units.

• Tilt back ROPS/FOPS until lock engages.

• Relieve hydraulic system pressure.

Removal Procedure

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

1. With a wrench, loosen and remove the inlet relief valve or drain orifice from the main control valve.

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

Inlet Relief Valve

• Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Relieve hydraulic system pressure.

• Tilt back ROPS/FOPS until lock engages.

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

Drain Orifice

1. Unplug the electrical connector on the valve solenoid to be serviced.

2. Using an Allen wrench, remove two screws securing the solenoid to the valve.

3. Check the condition of the cartridge and clean off any debris. Check the solenoid output, if necessary (see the Electrical System chapter).

2. Check condition of o-rings and clean off any debris.

Inlet Relief Valve and Drain Orifice Removal and Installation An inlet relief valve and drain orifice are integrated within the standard-flow control and high-flow control valves. A relief valve activates when oil pressure inside the control valve reaches an unacceptable level, to relieve that pressure and prevent damage to valve and hydraulic system. The drain orifice, opposite the inlet relief valve, can be removed for cleaning too, if simultaneous functions of the control valve are suspect.

O-Ring

Removal Procedure O-Rings

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

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

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Hydraulic Oil Reservoir Removal and Installation

6. Disconnect three electrical connectors on the reservoir.

The hydraulic oil reservoir is a self-contained, welded steel reservoir secured to the floor of the chassis located in front and left of the engine.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

• Relieve hydraulic system pressure.

• Tilt back ROPS/FOPS until lock engages.

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

IMPORTANT: Cap or plug ALL hydraulic hoses, tubes, fittings and control valve ports immediately after being disconnected to prevent fluid loss and contamination of the hydraulic system.

1. Drain all the oil from the hydraulic reservoir into a suitable container capable of holding at least 25 gallons (94,7 L). For this procedure refer to “Cooling System Drain Procedure” on page 13 in the Lubrication chapter.

7. Remove four carriage bolts and hex nuts securing the hydraulic tank to the floor of the chassis.

2. Remove the engine cover, ROPS/FOPS and fuel tank per their procedures in the Mainframe chapter.

3. Remove all side engine covers.

4. Remove the hydrostatic pump per the procedure in the Hydrostatic System chapter.

5. Remove the engine per the procedure in the Engine chapter.

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8. Remove the hydraulic hoses from the hydraulic reservoir. Remove hoses from their fittings or loosen the clamps securing them to the reservoir.

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

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for hydraulic fluid specifications.

1. Install hydraulic reservoir drain plug and refill with correct type of hydraulic oil. Refer to Lubrication chapter for hydraulic oil specifications.

2. ALWAYS check for hydraulic fluid leaks after reassembling any component of the hydraulic system.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

9. Using a suitable strap hoist, wrap the strap hoist around the reservoir tower below the hydraulic filter access plate.

10. Slowly lift and slide the hydraulic reservoir rearward, out of the loader.

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Fan Guard and Fan Motor Removal and Installation The hydraulically-driven fan motor powers the engine fan, independent of the engine.

3. Remove six capscrews on the fan guard and speed sensor located above the fan in the engine compartment. .

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine and allow it to cool.

4. Remove two additional capscrews securing the speed sensor bracket to the fan.

• Relieve hydraulic system pressure.

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

IMPORTANT: . Cap or plug ALL hydraulic hoses, tubes, fittings and control valve ports immediately after being disconnected to prevent fluid loss and contamination of the hydraulic system.

1. Disconnect the electrical connector on the speed sensor and release it from its clip on the fan shroud.

2. Remove capscrew securing the speed sensor to its bracket.

Speed Sensor

5. Remove four capscrews (6.6 ft-lbs) (8,9 N•m) on the engine fan. Use Loctite® 242 (or equivalent) when reinstalling.

Engine Fan Capscrews (two shown)

6. Pull up on 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 and latch open.

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7. Disconnect three hydraulic tubes from their fittings on the fan drive motor and swing out of the way.

You may need to loosen the three bulkhead mounts on the lower right side of the shroud.

9. Remove the fan motor and then remove the fan.

10. It is possible to remove the fan and fan motor without removing the radiator/oil cooler, but that is an option. If necessary, see the procedure to remove the radiator/oil cooler in the Engine chapter.

Installation Procedure - Follow all warnings first, then reverse removal steps.* * The fan should be concentric with the shroud with a tip clearance of 0.25” ± 0.06 (6,35 mm ± 1,5). * The face of the fan base should be 0.5” ± 0.06 (12,7 mm ± 1,5) out from the shroud. * Torque the aluminum fan mounting bolts to 6.60 ftlbs. (8,9 N•m) with Loctite® 242 (or equivalent).

8. Remove the left motor mount bracket and unbolt the right bracket from the fan motor.

Left Motor Mount Bracket

* Torque the steel fan mounting bolts to 13.0 ft-lbs.

(17,6 N•m) with Loctite® 242 (or equivalent).

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for hydraulic fluid specifications.

11. ALWAYS check for hydraulic fluid leaks after reassembling any component of the hydraulic system.

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CHAPTER NOTES

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Introduction

• 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

Multi-Function Display The multi-function display (Fig. 1) is located above the ignition switch. It provides the following functionality:

Fig. 1 Multi-Function Display

Table 1: Multi-Function Display

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WARNING 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.

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

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ELECTRICAL SYSTEM 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. 1) to switch between display mode screens.

Table 3: Status and Maintenance Screens

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Table 3: Status and Maintenance Screens

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Table 3: Status and Maintenance Screens

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Table 3: Status and Maintenance Screens

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Control Buttons/Switches

Fig. 2 Buttons/Switches

Table 4: Buttons/Switches

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Table 4: Buttons/Switches

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

Fig. 3 Indicator Panel (Refer to Table 5)

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Table 5: Control Keypad Indicators

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Instrument Panels

Right Panel

Left Panel A

B

A

D C

F

E

G H

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

B. Heat Indicator (option) – Illuminates when the heater is operational.

C. HVAC Button – Turns the fan/heat/cool on/off.

Low, medium and high settings are available.

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

E. Front Windshield Wiper Button (option) – Turns the windshield wiper button on/off. Low, medium 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.

A. Multi-Function Display – See page 141.

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, 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.

B

C

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

D E

Power Distribution Panel Test and Operation Gehl V420 and Mustang 4200V skid-steer loaders utilize power distribution panels in the electrical system to maximize the efficiency of engine, hydraulic, power and electrical operations. Three panels are located below the right control handle, behind a rotary knob cover.

Power Distribution Panels

F

G

H

I

J

K L

D. Indicator Panel - See page 148.

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.

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 function. Illuminates when self-leveling is deactivated.

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

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

J. High-Flow Auxiliary Hydraulics Reverse Flow Button - Press to activate reverse auxiliary hydraulics flow.

K. High-Flow Auxiliary Hydraulics Forward Flow Button - Press to activate forward auxiliary hydraulics flow.

L. 12V Accessory Plug - For multiple uses.

Power Distribution Panel Fuse Test The following procedure can be used to test the fuses found inside the power distribution panels.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

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

1. Using a volt/ohm multimeter or a test lamp, measure between test points and the chassis ground for 12 V with the wiring connected and the keyswitch in the “ON” position. The test lamp lights for functioning fuses, or the volt/ohm multimeter will read 12 V on both sides of the fuses. The covers have decals that identify the fuses.

• Far Right Panel: See the accompanying illustration below the photograph for the function of

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these multiple mini-fuses. The cover has a decal that identifies the fuses.

• Floor Panel: See the accompanying illustration after the photograph for the function of these multiple mini-fuses. The cover has a decal that identifies the fuses.

• Right Panel: See the accompanying illustration below the photograph for the function of these multiple mini-fuses. The cover has a decal that identifies the fuses.

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Grid Heater Fuse: Located on the left side behind a rubberized cover, this 125 A fuse provides power to the grid heater.

Bench Test: The relays can also be tested on a work bench as follows: Power Relays

#86 #30

#87 #85

2. Replace any fuse that did not have power at each test point.

Relays #86

Power Distribution Panel Relay Test There are several power relays inside the distribution panels that supply power to the fuses for individual circuits. The cover has a decal that identifies the relays.

#87a

Machine Test: The relays can be tested in the machine as follows: 1. With an operator in the seat and the restraint bar lowered, turning the keyswitch to the “ON” position should produce an audible “click” from each relay closing.

2. While the keyswitch is in the “ON” position, test each relay individually (functions must be activated), pull one relay out of the panel at a time, listening for the audible “click” of the relay opening.

3. Plug the relay back into the panel and listen for the audible “click” of the relay re-closing, if the circuit is activated.

#87

#30

#85

1. A relay may be tested by removing it and taking it to a work bench. Apply a ground to terminal #85 and a 12 V source to terminal #86. The relay should actuate. There should be continuity between terminal #30 and terminal #87.

2. Replace any relay that does not have continuity between powered terminals.

4. Replace any relay for which there is no discernible “clicking” sound heard at keyed power or opening (removing) of the relay.

• The solenoid lock relay and start safety relay will actuate only with the keyswitch in the “ON” position, the restraint bar down and an assistant in the seat. The horn relay will actuate only when the horn button is actuated.

5. Replace any relay that does not have continuity between powered terminals #85 and #86.

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Solenoid Test There are two solenoids located at the left foot area in the cab, across from the power distribution panels.

• With keyswitch in “OFF” position, there should be 12-VDC on the upper large copper stud of the solenoid.

• Unplug the control current connector and install a test lamp between #85 and #86 in the connector. Have a second operator turn the keyswitch to “ON” position, the test lamp should light if ambient temperature is low enough.

2. For the upper solenoid: • With keyswitch in “OFF” position, there should be 12-VDC on the left large copper stud of the solenoid.

• With the keyswitch in the “ON” position, the red 5 A wire should have 12-VDC and the ground wire should have continuity to the chassis ground. The solenoid should make an audible “click” when the key is turned on.

Load

#85

#86

Live Power

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

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

1. The lower solenoid, the engine glow circuit, will only engage when the engine ECU senses an ambient temperature below 22° F (-6° C). The engine's ECU provides both the control current and ground for the solenoid:

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Fan Control Module Test Check the fan control module by verifying that it powers up with the keyswitch in its “ON” position and the green LED power light is illuminated.

2. The module then sends a signal to the fan control valve from pins 6 and 9 of connector J2. If the connector is unplugged from the fan control valve, the fan will operate at FULL speed. The coil on the fan control valve can be checked by measuring resistance across its terminals. Measure across pins 6 and 9. The resistance should be 7.58 ohms (W) at room temperature.

3. The charge air cooler and hydraulic sensors are hardwired to the module. The coolant temperature is obtained from the Controller Area Network (CAN) system.

4. Charge air cooler and hydraulics can be checked by measuring the resistance across their terminals.

5. Unplug the 12-pin connectors and measure resistance across pins 1 and 2 of each connector. The resistance should be 3.51 ohms (W) at room temperature.

6. Check the main display to check engine temperature.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

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

7. The fan module also monitors fan speed via a sensor mounted near the fan hub. The fan speed is shown on the main display. If the fan speed is not displaying correctly, investigate the sensor and/or connections. May need to review the schematic.

8. Fan reversing is intiated by pressing the self-level and light buttons for 10 seconds. A LED should illuminate on the fan module. The fan reversing solenoid is located in the fan shroud, directly in front of the charge air cooler.

1. The fan module controls the speed of the fan as well as the the fan reverse function. The module monitors the charge air cooler, hydraulic, and coolant temperatures.

Fan Control Module Test Module Illustration

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Chassis Electrical - Battery 1 3 4 5 6 7 8 9 10 12 13 15 16 19 20 22 25 29 32 33 34 35 38 40 41 44 49 52 53 54 55 56 57 58 63 68 69

156

TIE/CABLE .19X7.50 BLACK CLAMP/HOSE .75X.41 HOLE HLN INST 5/16 CZY CS FL LOCK 3/8X1-1/2 C5ZY LN LG FL SERR 1/4 CZ HLN INST 1/4 CZY CS FL LOCK 1/4X3/4 C5ZY CLAMP/HOSE .50X.41 HOLE CLAMP/TUBE .75 TWIN CLAMP/HOSE .56X.41 HOLE TIE/CABLE .30X14.50 BLACK SWITCH DISCONNECT GROMMET .50ID .125GW .75 TERMINAL/REMOTE RED LN FL SERR #1024 CZY HOLDER/FUSE/AMG BATTERY POST/NEG MALE WLMT/PANEL/MTG/FUSE ASSY PLATE MODULE BRKT/CABLE MODULE/FAN CONTROL/GEN2 FUSE/200AMP/AMG CABLE/POWER RELAY/150AMP CABLE/HEATER/GRID SOLENOID CABLE/BATTERY CABLE/GROUND CABLE/GROUND CABLE/POS/0 GA CABLE/HEATER/GLOW PLUG BRK/CABLE CABLE/ALTERNATOR ASSY/BRKT/RELAY BRKT/WIRE CLIP/CONDUIT DIPSTICK BRACKET

70 74 75 76 77 78 79 80 81 82 84 86 87 89 91 92

JUMPER/DIODE CABLE/HEATER/GRID CABLE/POSITIVE CLAMP/TUBE .78 CS 1/4X1-3/4 C5ZY CS 1/4X3/4 C5ZY CS 3/8X3/4 C5ZY CS 5/16X2 C5ZY FW 5/16 ANZY CS 1/4X1 C5ZY LW INT T 3/8 AZY BHSCS 5/16x1 C8 OCG CS M12-1.75x16 C 8.8 ZY HJN 5/16 F2ZY CS M8-1.25x16 C8.8 ZY CS M6-1x16 C8.8 ZY

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Chassis Electrical - Harness

1 2 4 8 9 11 13 14 17 18 20 21 23 24 26 27

TIE/CABLE .19X7.50 BLACK CLAMP/HOSE .50X.41 HOLE HLN INST 5/16 CZY CS FL LOCK 1/4X3/4 C5ZY CLAMP/HOSE .50X.41 HOLE CLAMP/TUBE .62 TWIN TIE/CABLE .30X14.50 BLACK LN FL SERR 3/8 CZY LN FL SPIRALOCK 5/16 CZY TEMPERATURE SWITCH LN FL SERR #1024 CZY HORN-WARNING CLIP/CONDUIT/16MM LN FL SERR 1/4 CZY SWITCH SENDER/TEMP

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30 31 32 34 36 37 39 42 43 44 45 48 50 51 58 59

MOUNT/WLMT/VALVE BRACKET MAIN MODULE ASSY PLATE MODULE MODULE/FAN CONTROL/GEN2 WLMT/PANEL/FUSE SPACER INDICATOR/FILTER/H2O/ELEC SPACER/.63X.083X1.14 WLMT/BRKT SOLENOID MOUNT/HORN BRKT/HOSE PLATE/MTG/HARNESS PLATE/MTG/HARNESS ASSY/BRKT/RELAY HARNESS/CHASSIS/DEUTZ

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BRKT/WIRE WLMT/SHIELD BRKT/WIRE WLMT/BRKT/WIRE MODULE/MCU PLATE/TOP SPACER TUBE CLAMP/TUBE .78 CS 1/4X1-3/4 C5ZY CS 3/8X3/4 C5ZY FW 1/4 ANZY CS FL 5/16X2 C8ZY BHSCS 5/16x1 C8 OCG CS FL 5/16X1 C5ZY CS M6-1x25 C8.8 ZY

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ROPS/FOPS Electrical Assembly

1 2 3 4 5 6 7 8 9

158

NUT/SPEED CLAMP/HOSE .50X.41 HOLE CS FL LOCK 5/16X1/2 C5ZY THWH TR US #1024X3/4 CZY LIGHT SCREW/#8 X .5 SM/PHIL FH CROSSPIECE/INSTR PANEL SWITCH/IGNITION SOCKET/12V

10 11 12 13 14 15 16 17 18

PLATE/DISPLAY MOUNT A-PILLAR COVER RH HARNESS/ROPS PANEL/INSTRUMENT RH PANEL/INSTRUMENT LH DISPLAY/PROGRAMMED PLATE/PLUG MODULE/MAIN KEYPAD THROTTLE/HAND

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RHMS SLT #632X1/2 CZY HN MS #632 CZY PHMS CR 1/4X1/2 OCB PHMS CR 1/4X3/4 OCB PHMS CR 1/4X1-1/8 CZB PHMS CR M5-0.8X10 CY HN MS #832 CZY

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Control Modules

Engine Control Unit (ECU)

The electrical control modules monitor/control several vital functions of the machine.

The engine control unit controls engine control logic and error reporting. It is located underneath the deck of the ROPS/FOPS.

Main Control Unit (MCU) The main control unit (below) provides logic, inputs and outputs for the electrical system. It is located on the right against the inside of the chassis.

J1939 Data Connector

Periodically inspect connectors and terminals for damage. Ensure no pins are bent and no sockets are damaged. Replace damaged components and reconnect both connectors to the control module.

The electrical system uses the SAE J1939 standard for Controller Area Network (CAN) communication and diagnostics. A J1939 data port is provided to the left of the operator's position, for computer diagnostic/ configuration connectivity. Left and right are determined by sitting in the operator’s seat and facing forward.

Refer to “Main Control Unit LEDs/Pins Description” on page 160 and “Controller Area Network (CAN) Functional Detail” on page 165 for more information about the main control unit and controller functional logic.

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

The J1939 data connector port for the machine is located inside the cab behind the seat and on the left side of the operator’s seat.

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Main Control Unit LEDs/Pins Description LEDs

J2 Connector (Pins)

J1 Connector (Pins) Fig. 4 – Main Control Unit LEDs/Pins

Table 6: Main Control Unit LEDs/Pins LED

POWER STATUS

COMM STATUS

AIR FTL CLOG

HYD FTL CLOG

HIGH HYD TEMP

HYDRO GLIDE

160

Description

LED State

Control module power status

Electronic/Controller/Display communication status

Pin

N/A

N/A

Power present on all battery pins and Green system voltage is within the desired range Yellow

Power is absent from one or more power pins, but voltage is within desired range

Red

System voltage is outside desired range

Green

Information Center Display is present on CAN

Yellow

Information Center Display is not present on CAN, but CAN network is active

Red

CAN activity is not present

On

Incoming signal from air filter restriction sensor

Off

No incoming signal from air filter restriction sensor

On

Incoming signal from hydraulic filter restriction sensor

Off

No incoming signal from hydraulic filter restriction sensor

On

Incoming signal from hydraulic overtemperature sensor

Off

No incoming signal from hydraulic overtemperature sensor

On

CAN activity indicates hydraglide ride control is activated

Off

CAN activity indicates hydraglide ride control is deactivated

Air filter clogged

Hydraulic system filter clogged

High hydraulic system temperature

In/Out

Hydraglide ride control

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J1-12

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Table 6: Main Control Unit LEDs/Pins LED

HIGH GEAR SEL

FLOAT

AUX DETENT

Description

LED State On

CAN activity indicates high gear/speed is activated

Off

CAN activity indicates hydraglide ride control option is not available or is deactivated

On

CAN activity indicates attachment float is activated

Off

CAN activity indicates hydraglide ride control is deactivated

On

CAN activity indicates continuous auxiliary hydraulics flow is activated

Off

CAN activity indicates continuous auxiliary hydraulics flow is deactivated

High gear/speed selection

Attachment float

Auxiliary hydraulics flow latching

In/Out

Pin

J1-11

In

J1-10

J1-2

SPARE 2

Unused

J2-30

SPARE 1

Unused

J2-31

On

CAN activity indicates left drive system is in motion; CAN activity also indicates if right drive system is in motion as well

J2-19

Off

CAN activity indicates left drive system is not in motion

On

CAN activity indicates left drive system is in motion; CAN activity also indicates if right drive system is in motion as well

LEFT PROX A

LEFT PROX B

RIGHT PROX A

RIGHT PROX B

ALL TACH UNLK

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Left drive system proximity switch

Left drive system proximity switch

Right drive system proximity switch

Right drive system proximity switch

Off

CAN activity indicates left drive system is not in motion

On

CAN activity indicates right drive system is in motion; CAN activity also indicates if left drive system is in motion as well

Off

CAN activity indicates right drive system is not in motion

On

CAN activity indicates right drive system is in motion; CAN activity also indicates if left drive system is in motion as well

Off

CAN activity indicates right drive system is not in motion

On

CAN activity indicates power-a-tach unlock button is pressed and is activated

Off

CAN activity indicates power-a-tach unlock button is not pressed and is unlock is not activated

Power-a-tach unlock

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J2-21

Out

J2-29

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Table 6: Main Control Unit LEDs/Pins LED

ALL TACH LK

Description

LED State On

CAN activity indicates power-a-tach lock button is pressed and is activated

Off

CAN activity indicates power-a-tach lock button is not pressed and is unlock is not activated

Power-a-tach lock

In/Out

Pin

Out

J2-28

SPARE 1

Unused

J2-27

START

CAN activity indicates the ignition switch is in the start position and an engine start signal is sent to the engine ECU

J2-26

On

CH WORK LTS

MARKER LTS

HIGH FLW REV (PWM)

HIGH FLW FWD (PWM)

SELF LEVEL SOL

HIGH GEAR SOL

TILT & LIFT SOL

162

Engine start Off

CAN activity indicates the ignition switch is not in the start position

On

CAN activity indicates the chassis work lights are turned on

Off

CAN activity indicates the chassis work lights are turned off

On

CAN activity indicates the marker lights are turned on

Off

CAN activity indicates the marker lights are turned off

On

CAN activity indicates high-flow auxiliary hydraulics reverse flow is activated

Off

CAN activity indicates high-flow auxiliary hydraulics reverse flow is deactivated

On

CAN activity indicates high-flow auxiliary hydraulics forward flow is activated

Off

CAN activity indicates high-flow auxiliary hydraulics forward flow is deactivated

On

CAN activity indicates the self-leveling control solenoid is activated

Off

CAN activity indicates the self-leveling control solenoid is deactivated

On

CAN activity indicates the high gear/ speed selection solenoid is activated

Off

CAN activity indicates the high gear/ speed selection solenoid is deactivated

On

CAN activity indicates the attachment lift and tilt lockout solenoids are activated (tilt/lift deactivated)

Off

CAN activity indicates the attachment lift and tilt solenoids are deactivated (tilt/lift activated

Chassis work lights

Marker lights

High-flow auxiliary hydraulics reverse flow

High-flow auxiliary hydraulics forward flow

Self-leveling control solenoid

High gear/speed selection solenoid

Attachment tilt and lift enable solenoids

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J1-4

J1-5

J2-24 Out J2-25

J2-2

J2-3

J2-11

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GEHL V420 / MUSTANG 4200V

ELECTRICAL SYSTEM

Table 6: Main Control Unit LEDs/Pins LED PARK BRAKE

FLOAT SOL

AUX REV (PWM)

AUX FWD (PWM)

GLOW PLUGS

FUEL SHUTOFF

BACK UP ALARM

HYDRO GLD SOL

PRINTED IN USA

Description

LED State On

CAN activity indicates the parking brake is set

Off

CAN activity indicates the parking brake is released

On

CAN activity indicates the attachment float solenoid is activated

Off

CAN activity indicates the attachment float solenoid is deactivated

On

CAN activity indicates auxiliary hydraulics reverse flow is activated

Off

CAN activity indicates auxiliary hydraulics reverse flow is deactivated

On

CAN activity indicates auxiliary hydraulics forward flow is activated

Off

CAN activity indicates auxiliary hydraulics forward flow is deactivated

On

CAN activity indicates the engine glow plugs are activated

Off

CAN activity indicates the engine glow plugs are deactivated

On

CAN activity indicates the engine fuel system is shut off

Off

CAN activity indicates the engine fuel system is not shut off

On

CAN activity indicates the backup alarm is activated

Off

CAN activity indicates the backup alarm is not activated

On

CAN activity indicates the hydraglide ride control solenoid is activated

Off

CAN activity indicates the hydraglide ride control solenoid is deactivated

Parking brake

Attachment float control solenoid

Auxiliary hydraulics - reverse flow

Auxiliary hydraulics - forward flow

Glow plugs (interim tier 4 engine)

Engine fuel system shut-off

Backup alarm

Hydraglide ride control solenoid

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In/Out

Pin J2-12

J2-23

J2-13

J2-1 Out J2-35

J2-34

J2-33

J2-32

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ELECTRICAL SYSTEM

GEHL V420 / MUSTANG 4200V

Table 6: Main Control Unit LEDs/Pins LED

(No LED)

164

Description

LED State

In/Out

Pin

Engine Temperature (+5VDC)

J2-4

Fuel Level (+5VDC)

J2-15

Engine Oil Pressure (+5VDC) (interim tier 4 engine)

J2-16

Alternator pre-excitation (PCI)

J2-14

Spare analog in 1

J2-9

Auxiliary forward/reverse

J2-10

Throttle pedal

N/A

J2-22

CAN high

J2-5

CAN low

J2-17

V-IGN

J1-1

V-IGN

J1-6

V-IGN

J1-3

Ground

J1-9

Signal ground

J1-8

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PRINTED IN USA

GEHL V420 / MUSTANG 4200V

ELECTRICAL SYSTEM

Controller Area Network (CAN) Functional Detail The electrical system uses the SAE J1939 standard for Controller Area Network (CAN) communication and

diagnostics. The following table describes the basic functionality of the CAN system logic.

NOTE: The “Malfunction Indicators” column in the following table contains information about possible causes of function - inputs/conditions - outputs/actions logic disagreement or problems. In some cases, additional information about specific malfunctions is included.

Table 7: Controller Area Network (CAN) Functional Detail Function

Inputs/Conditions • Ignition switch in OFF position.

Activate Dome Light

Power On

• Seat switch CLOSED (seat occupied), or a button on the control keypad is pressed.

• Ignition switch in ON / RUN position.

• Ignition switch in OFF position.

Power Off

• Seat switch OPEN (seat not occupied).

• Dome light OFF.

Outputs/Actions Malfunction Indicators Dome light turns on for 30 seconds or until the ignition • Dome light bulb burned switch is turned on. Pressing any out. button on the control keypad toggles the dome light on/off and • Electrical fault (switch, resets the 30-second timer. components, connections or battery).

NOTE: Dome light gradually dims when turning off.

• Ignition switch All indicator lights, key pad malfunction. button backlights and audible alarm activate for 3 seconds to • Electrical fault (switch, test; test interrupted if the ignition components, connections switch is turned to the START or battery). position. Parking brake is set and • Component / safety parking brake indicator is turned interlock system on. malfunction.

Control keypad enters low-power • Electrical fault (switch, state. components, connections NOTE: Backlights on the control or battery). keypad buttons remain on until • Component / safety inputs/conditions are met. interlock system malfunction.

• Seat switch CLOSED (seat occupied).

Start Engine

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• Ignition switch malfunction.

• Ignition switch malfunction.

• Restraint bar switch CLOSED • Electrical fault (switch, Turns on and holds engine start. (restraint bar down). components, connections Engine start disabled if the or battery).

• If equipped with a door, door ignition is in the START position proximity switch ON (door • Starter malfunction. for longer than 15 seconds. closed).

• Component / safety • Ignition switch in START interlock system position. malfunction.

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Table 7: Controller Area Network (CAN) Functional Detail Function

Inputs/Conditions

Outputs/Actions

Malfunction Indicators • Ignition switch malfunction.

Stop Engine

• Ignition switch in OFF position.

Stops fuel flow.

• Electrical fault (switch, components, connections or battery).

• Solenoid or other component malfunction.

• Engine is running (engine oil pressure detected).

Throttle Speed Adjust

• Throttle speed analog input value is between 0.425-3.35 VDC.

• • Release Park Brake

• •

166

Throttle speed CAN message is sent to the engine ECU. Throttle • Throttle control malfunction. speed is set to the highest of the two values between the hand • Electrical fault (switch / and foot throttles. components / connections).

NOTE: If the throttle speed

analog input value is out-of• Component malfunction. range, a CAN error code is • CAN communication error. generated.

Parking brake output (release brake) is turned on and the Engine is running (engine oil parking brake indicator light is turned off. Repeated pressing of pressure detected). parking brake button toggles the • Electrical fault (switch / Seat switch CLOSED (seat components / parking brake, and parking brake occupied). connections). indicator light, on/off.

Restraint bar switch CLOSED If the engine is running and the • Component / safety (restraint bar down). interlock system seat switch and/or the restraint malfunction. bar switch is opened for more Parking brake button on the than 0.5 seconds, the parking control keypad is pushed. brake is set and the parking brake indicator light turns on.

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PRINTED IN USA

GEHL V420 / MUSTANG 4200V

ELECTRICAL SYSTEM

Table 7: Controller Area Network (CAN) Functional Detail Function

Inputs/Conditions

Outputs/Actions Turns on the tilt and lift enable solenoids.

Malfunction Indicators

Turns off hydraulic lockout indicator on the road lights control keypad, if so equipped.

If the seat switch is opened and/ or the restraint bar switch is • Electrical fault (switch / turned off for more than 0.5 components / seconds, the enable tilt and lift Seat switch CLOSED (seat connections).

CAN output message turns off occupied).

• Component/safety which turns off the tilt and lift Restraint bar switch CLOSED enable solenoids and turns on interlock system (restraint bar down). malfunction. hydraulic lockout indicator light If equipped with a door, door on the control keypad.

• Hydraulic system proximity switch ON (door malfunction.

NOTE: If the machine is closed). equipped with road lights, pressing the hydraulic lockout button on the road lights control keypad toggles the tilt and lift enable solenoids and the hydraulic lockout indicator light on/off.

Engine is running (engine oil The lock power-a-tach solenoid • Electrical fault (switch / and the lock power-a-tach pressure detected). components / indicator light are on as long as connections).

Seat switch CLOSED (seat the lock power-a-tach button is occupied).

• Component / safety pressed. interlock system Restraint bar switch CLOSED NOTE: If both the lock and malfunction. (restraint bar down). unlock power-a-tach buttons are • Hydraulic system pressed simultaneously, no Lock power-a-tach button is malfunction. action occurs. pressed.

Engine is running (engine oil The unlock power-a-tach • Electrical fault (switch / solenoid and the unlock power-apressure detected). components / tach indicator light are on as long connections).

Seat switch CLOSED (seat as the lock power-a-tach button occupied).

• Component/safety is pressed. interlock system Restraint bar switch CLOSED NOTE: If both the lock and malfunction. (restraint bar down). unlock power-a-tach buttons are • Hydraulic system Unlock power-a-tach button is pressed simultaneously, no malfunction. action occurs. pressed.

• Engine is running (engine oil pressure detected).

• Interlock System Enable Tilt and Lift (Hydraulic Lockout • off) •

• • Lock power-a-tach

• • • •

Unlock power-a-tach

• •

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ELECTRICAL SYSTEM

GEHL V420 / MUSTANG 4200V

Table 7: Controller Area Network (CAN) Functional Detail Function

Activate Beacon/Position/ Work Lights

Inputs/Conditions

• Ignition switch in ON / RUN position.

• Beacon / beacon / position / work lights button is pressed.

Outputs/Actions Pressing beacon / position / work lights button once activates the beacon, the rear red position lights, and turns on the left LED in the button.

Malfunction Indicators

Pressing beacon / position / work • Burned out bulb(s). lights button a second time • Ignition switch activates the beacon, the rear malfunction. red position lights, the front work lights, and turns on the right LED • Electrical fault (switch, components, connections in the button. or battery).

Pressing beacon / position / work lights button a third time activates • Component / safety interlock system the beacon, the rear red position malfunction. lights, the front and rear work lights, and turns on both LEDs in • Hydraulic system the button. malfunction.

Pressing beacon / position / work lights button a fourth time turns off all beacon, position and work lights, and turns off both LEDs in the button.

Self Level Activated when system power is turned on

•

• • Self Level Disable (Cancel)

• •

• Electrical fault (switch, components, connections When the ignition is turned to the or battery).

ON/RUN position, the self-level Ignition switch in ON / RUN • Component / safety bypass solenoid is turned off, position. interlock system activating self-level and turning malfunction. off the self level cancel indicator.

• Hydraulic system malfunction.

Self-level bypass solenoid is turned on (self-level is turned off) and the self-leveling cancel indicator is turned on. Repeated • Electrical fault (switch, Ignition switch in ON / RUN pressing of self-leveling cancel position. components, connections button on the control keypad or battery).

Seat switch CLOSED (seat toggles self-level, and the selfoccupied). level cancel indicator light, on/off. • Component/safety interlock system Restraint bar switch CLOSED Self-leveling is reset to ON when malfunction. (restraint bar down). system power is turned off.

• Hydraulic system Self-leveling cancel button is NOTE: When the self-level malfunction. pressed. cancel indicator light is ON selfleveling is OFF. Resets when engine stopped.

168

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PRINTED IN USA

GEHL V420 / MUSTANG 4200V

ELECTRICAL SYSTEM

Table 7: Controller Area Network (CAN) Functional Detail Function

Inputs/Conditions

Outputs/Actions Attachment float and the float indicator light are turned on.

• Engine is running (engine oil pressure detected).

If the float button is pressed for less than 5 seconds and then released, float is turned on only when the button is held on, and the float indicator flashes.

• Seat switch CLOSED (seat occupied).

Activate Float (pilot control)

Activate Float (mechanical control)

Malfunction Indicators

• Electrical fault (switch / components / connections).

• Restraint bar switch CLOSED If the float button is pressed for (restraint bar down). longer than 5 seconds, float and • Component / safety interlock system • If equipped with a door, door the float indicator are turned malfunction. continuously on. proximity switch ON (door closed).

NOTE: Float function has priority • Hydraulic system malfunction. over hydraglide. If hydraglide is • Float and/or hydraglide on and float is turned on, solenoid(s) detected. hydraglide is turned off and float • Float button is pressed. is turned on; hydraglide then turns back on when float is turned off.

Attachment float is turned on.

Float indicator light is also turned on if ignition is in the ON/RUN or • Mechanical linkage START positions.

• Push right T-bar or left foot malfunction. control forward into the float If the right T-bar control or the left • Hydraulic component / detent. foot control is pushed forward system malfunction. into the float detent, float and the float indicator are turned continuously on.

• Engine is running (engine oil pressure detected).

• •

Activate Hydraglide

•

• •

Hydraglide and float solenoids and the hydraglide indicator light are turned on. Repeated Seat switch CLOSED (seat • Electrical fault (switch / pressing of the hydraglide button occupied). components / toggles hydraglide, and the connections).

Restraint bar switch CLOSED hydraglide indicator light, on/off. (restraint bar down).

• Component / safety NOTE: Float function has priority interlock system If equipped with a door, door over hydraglide. If hydraglide is malfunction. proximity switch ON (door on and float is turned on, closed). hydraglide is turned off while float • Hydraulic component / system malfunction. is turned on; hydraglide then Float and/or hydraglide turns back on when float is solenoid(s) detected. turned off.

Float button is pressed.

• Engine is running (engine oil pressure detected).

Activate Back Up Alarm

• Proximity switches detect both Back-up alarm is turned ON. left and right drives operating in reverse.

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• Electrical fault (components / connections).

169

ELECTRICAL SYSTEM

GEHL V420 / MUSTANG 4200V

Table 7: Controller Area Network (CAN) Functional Detail Function Activate Zero-Speed Alarm

Inputs/Conditions • Engine is running (engine oil pressure detected).

• No movement detected by chaincase proximity switches.

Outputs/Actions Turns on brake lights (via road lights keypad).

Malfunction Indicators • Electrical fault (components / connections).

• Engine is running (engine oil pressure detected).

High- (two-) speed solenoid and the high-speed indicator light are turned on. Repeated pressing of • Restraint bar switch CLOSED the two-speed selection button toggles high-speed and the high(restraint bar down). speed indicator light, on / off.

• If equipped with a door, door NOTE: The high-speed solenoid proximity switch ON (door turns off 0.25 after the two-speed closed). selection button is pressed.

Two-speed selection button is pressed.

Auxiliary hydraulics forward solenoid is turned on, the auxiliary hydraulics reverse Engine is running (engine oil solenoid is turned off, and the auxiliary hydraulics forward flow pressure detected). is activated.

Seat switch CLOSED (seat • Auxiliary hydraulics forward flow occupied). rate is directly proportional to the Restraint bar switch CLOSED analog signal level (how far the (restraint bar down). control toggle switch is moved). •

• Seat switch CLOSED (seat occupied).

• Activate High Gear Select •

•

• • Activate Auxiliary Hydraulics • Forward Flow

• Auxiliary hydraulics control toggle switch is moved to the forward position.

NOTES:

Electrical fault (components / connections).

Hydraulic component / system malfunction.

Electrical fault (components / connections).

Hydraulic component / system malfunction.

Analog signal level input in the range of 2.55-4.5 VDC. Neutral input dead-band range 48%-52% Max voltage.

170

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GEHL V420 / MUSTANG 4200V

ELECTRICAL SYSTEM

Table 7: Controller Area Network (CAN) Functional Detail Function

Inputs/Conditions

• Engine is running (engine oil pressure detected).

• Seat switch CLOSED (seat occupied).

Outputs/Actions Auxiliary hydraulics reverse solenoid is turned on, the auxiliary hydraulics forward solenoid is turned off, and the auxiliary hydraulics reverse flow is activated.

• Auxiliary hydraulics reverse flow rate is directly proportional to the Activate Auxiliary Hydraulics • Restraint bar switch CLOSED analog signal level (how far the Reverse Flow (restraint bar down). control toggle switch is moved). • • Auxiliary hydraulics control NOTES: toggle switch is moved to the Analog signal level input in the reverse position. range of 0.5-2.45 VDC.

Malfunction Indicators

Electrical fault (components / connections).

Hydraulic component / system malfunction.

Neutral input dead-band range 48%-52% Max voltage.

• Engine is running (engine oil pressure detected).

• • Activate Auxiliary Hydraulics Continuous Flow Latching • (Detent

•

Either the auxiliary hydraulics forward or reverse solenoid is Seat switch CLOSED (seat latched on, and continuous occupied). forward or reverse flow is • Electrical fault Restraint bar switch CLOSED activated. (components / (restraint bar down).

If either the auxiliary hydraulics connections).

Auxiliary hydraulics control control toggle switch and / or the • Hydraulic component / toggle switch is moved to latching trigger are moved, the system malfunction. either the maximum forward or auxiliary hydraulics forward / reverse position. reverse solenoids are turned off and continuous forward / reverse Auxiliary hydraulics flow stops. continuous latching trigger switch ON.

• Ignition switch in ON / RUN position.

Detect Door Closed

Activate Restraint Bar Indicator Light

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• If equipped with a door, door proximity switch ON (door closed) for 2.5 seconds or longer.

• Ignition switch in ON / RUN position.

• Restraint bar switch OPEN (restraint bar up).

Door is detected (door harness plugged into socket) and the door switch is read as ON (door • Electrical fault (switch, closed) by the main control components, connections keypad. or battery).

NOTE: Back of door proximity switch has LED which activates when the switch is ON. Turns on restraint bar indicator light.

• Electrical fault (switch, NOTE: Indicator light turns off when restraint bar switch is CLOSED (restraint bar down).

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components, connections or battery).

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ELECTRICAL SYSTEM

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Table 7: Controller Area Network (CAN) Functional Detail Function

Inputs/Conditions

• Engine is running (engine oil pressure detected).

Activate Air Filter Restriction Alarm • Air filter restriction sender switch ON.

Outputs/Actions Turns on air filter restriction indicator light.

Generates engine error code 107-x.

• Engine is running (engine oil pressure detected).

Activate Hydraulic Filter Restriction Alarm

• Hydraulic oil filter restriction sender switch ON.

Turns on hydraulic oil filter warning indicator light.

• Engine coolant temperature is above 212° F (100° C).

• Engine is running (engine oil pressure detected).

• Hydraulic oil high temperature Turns on hydraulic oil temperature warning indicator sender switch ON. light.

• Engine coolant temperature is above approximately 230° F (110° C).

Turns on coolant temperature • Engine is running (engine oil warning indicator light. pressure detected).

Generates engine error code Activate High Engine Coolant Temperature Alarm • High engine temperature CAN 110-x. message received from NOTE: May cause engine deengine ECU. rating condition.

Turns on engine oil pressure • Engine is running (engine oil warning indicator light. pressure detected).

Generates engine error code Activate Low Engine Oil • Low engine oil pressure CAN 100-x Pressure Alarm message received from NOTE: May cause engine deengine ECU. rating condition.

Turns on associated engine malfunction indicator on • Engine is running (engine oil information center display. pressure detected).

Activate Check Engine Generates various engine error Alarm • Check engine CAN message codes. received from ECU. NOTE: May cause engine derating condition.

Fuel level data sent to, and • Ignition switch in ON / RUN displayed on, information center position. display.

Send Fuel Gauge Data • Fuel level sender resistance: NOTE: Data sent via standard 31.5-34.5 ohms full; 236.5J1939 message.

245.7 ohms empty.

Activate High Hydraulic Temperature Alarm

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Malfunction Indicators • Electrical fault (components / connections).

NOTE: A restricted engine intake air filter requires replacement.

• Electrical fault (components / connections).

NOTE: A restricted hydraulic oil filter requires replacement.

• Electrical fault (components / connections).

NOTE: High hydraulic oil temperature indicates hydraulic system malfunction.

• Electrical fault (components / connections).

NOTE: High engine coolant temperature indicates engine cooling system malfunction.

• Electrical fault (components / connections).

IMPORTANT: Low engine oil pressure indicates a serious engine condition.

• Electrical fault (components / connections).

• Electrical fault (switch, components, connections or battery).

PRINTED IN USA

GEHL V420 / MUSTANG 4200V

ELECTRICAL SYSTEM

Table 7: Controller Area Network (CAN) Functional Detail Function

Inputs/Conditions

Outputs/Actions

Malfunction Indicators

• Ignition switch in ON / RUN position.

• Engine coolant temperature sender resistance: Send Temperature Gauge Data

• 68° F (20° C) - 2.45 (+0.14/-0.13) ohms.

• 176° F (80° C) - 0.318 ± 0.008 ohms.

Engine coolant temperature data sent to, and displayed on, the • Electrical fault (switch, information center display. components, connections or battery).

NOTE: Data sent via standard J1939 message.

• 212° F (100° C) - 0.1836 ohms.

Fuel pump and solenoid are turned on for 10 seconds to prime fuel line.

• • Activate Fuel Sol/Fuel Pump •

•

Enable Electronic (Tier 4 engine) or Mechanical (interim Tier 4 engine) Engine Operation

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Fuel pump and solenoid are turned on when ignition switch is turned to the START position and Seat switch CLOSED (seat remain on with the ignition switch occupied). in the ON/RUN position if any Restraint bar switch CLOSED engine oil pressure is detected, or if the ignition switch is held in • Electrical / mechanical (restraint bar down). the START position (ignition start fault (components, If equipped with a door, door condition). connections or battery). proximity switch on (door NOTE: Fuel pump and solenoid closed). are turned off if the ignition switch Ignition switch in ON/RUN is held in the START position position. (ignition start condition) longer than 15 seconds.

Fuel pump and solenoid are also turned off if a high engine coolant temperature or a low engine oil pressure condition is detected.

If valid engine CAN transmissions are detected, electronic engine functions are • CAN communication performed (Tier 4 engines). errors.

• Monitor CAN transmissions.

If valid engine CAN • Electrical fault transmissions are NOT detected, (components / mechanical engine functions are connections). performed (interim Tier 4 engines).

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Table 7: Controller Area Network (CAN) Functional Detail Function

Inputs/Conditions

• • Activate Fuel Sol/Fuel Pump • (interim Tier 4 engine)

•

Activate Marker/Beacon / Road Lights (optional road lights installed)

Activate High Beam Lights (optional road lights installed)

174

Outputs/Actions Fuel pump and solenoid are turned on for 10 seconds to prime fuel line.

Malfunction Indicators

Fuel pump and solenoid are turned on when ignition switch is turned to the START position and Seat switch CLOSED (seat remain on with the ignition switch occupied). in the ON / RUN position if any Restraint bar switch CLOSED engine oil pressure is detected, or if the ignition switch is held in • Electrical/mechanical fault (restraint bar down). the START position (ignition start (components, connections If equipped with a door, door condition). or battery). proximity switch on (door NOTE: Fuel pump and solenoid closed). are turned off if the ignition switch Ignition switch in ON / RUN or is held in the START position START position. (ignition start condition) longer than 15 seconds.

Fuel pump and solenoid are also turned off if a high engine coolant temperature or a low engine oil pressure condition is detected.

Turns on optional road lights; interacts with main control key pad to control the beacon and position lights. If all lights are off, one press activates the beacon and all position lights; a second • Ignition switch in ON / RUN or press additionally turns on the • Electrical/mechanical fault START position. road lights. (components, connections • Beacon / position / work lights If the work lights are on, pressing or battery). button pressed. the beacon / position / work lights button turns off the work light and turns on the road lights.

If the road lights are on, all lights turn off if the beacon / position / work lights button is pressed.

• Ignition switch in ON / RUN or Turns on high-beam lights and high-beam indicator light; turns START position.

• Electrical/mechanical fault off low-beam lights. Subsequent • Beacon / position / work lights presses of high-beam button (components, connections are on. or battery). toggles high / low-beam lights and indicator.

• High-beam button pressed.

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GEHL V420 / MUSTANG 4200V

ELECTRICAL SYSTEM

Table 7: Controller Area Network (CAN) Functional Detail Function

Inputs/Conditions

Activate Right Turn (Directional) Signal Light (optional road lights installed)

•

Activate Left Turn (Directional) Signal Light (optional road lights installed)

•

Activate Hazard Lights (optional road lights installed)

Hydraulic Lockout (optional road lights installed)

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•

•

•

Outputs/Actions Malfunction Indicators Turns on right directional light and indicator (flashes at 60 Ignition switch in ON / RUN or flashes / min); turns off left • Electrical/mechanical fault START position. directional light and indicator if (components, connections on. Subsequent presses of the Right directional button or battery). right directional button toggles pressed. right directional light and indicator on / off.

Turns on left directional light and indicator (flashes at 60 flashes/ Ignition switch in ON / RUN or min); turns off right directional • Electrical/mechanical fault START position. light and indicator if on. (components, connections Subsequent presses of the left Left directional button or battery). directional button toggles left pressed. directional light and indicator on / off.

Turns on hazard (right and left directional) lights and hazard lights indicator flash (lights flashes at 60 flashes / min).

Subsequent presses of the • Electrical/mechanical fault hazard lights button toggles Hazard lights button pressed (components, connections these hazard lights and indicator or battery). on / off.

• Engine is running (engine oil pressure detected).

• Hydraulics lock-out button pressed.

NOTE: Left / right directional signal lights are disabled when hazard lights are activated.

Disables attachment lift and tilt hydraulics and turns on hydraulics lock-out indicator.

Subsequent presses of the hydraulics lock-out button toggles lift and tilt hydraulic and lock-out indicator on/off.

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• Electrical/mechanical fault (components / connections).

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Table 7: Controller Area Network (CAN) Functional Detail Function

Inputs/Conditions

Outputs/Actions Activates/deactivates windshield wiper:

Malfunction Indicators

• One press turns on the windshield wiper continuously and turns on all three indicator LEDs.

Activate Front Wiper (optional door installed)

Activate Front Washer (optional door installed)

• Ignition switch in ON / RUN or • A second press activates a START position. three second delay; turns on • Windshield wiper button only two indicator LEDs. pressed.

• A third press activates a six second delay; turns on only one indicator LED.

• Electrical/mechanical fault (components, connections or battery).

• A fourth press turns off the windshield wiper and turns off the LEDs. Activates the front windshield washer and wiper continuously • Ignition switch in ON / RUN or while windshield washer button is • Electrical/mechanical fault START position. pressed. (components, connections • Windshield washer button or battery).

When button is released, washer pressed continuously. stops immediately and wiper stops after five seconds.

Activates/deactivates rear wiper: • One press turns on the rear wiper continuously and turns on all three indicator LEDs.

Activate Rear Wiper (optional rear wiper installed)

Activate Rear Washer

176

• Ignition switch in ON / RUN or • A second press activates a three second delay; turns on START position. only two indicator LEDs. • Rear window wiper button • A third press activates a six pressed continuously. second delay; turns on only one indicator LED.

• Electrical/mechanical fault (components, connections or battery).

• A fourth press turns off the rear wiper and turns off the LEDs. Activates the rear windshield washer and wiper continuously • Ignition switch in ON / RUN or while rear window washer button • Electrical/mechanical fault START position. is pressed. (components, connections • Rear window washer button or battery).

When button is released, washer pressed continuously. stops immediately and wiper stops after five seconds.

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PRINTED IN USA

GEHL V420 / MUSTANG 4200V

ELECTRICAL SYSTEM

Table 7: Controller Area Network (CAN) Functional Detail Function

Inputs/Conditions • Front wiper motor present.

Detect Door

• Door electrical harness connected.

• Front wiper motor present.

Detect Door Closed

• Door electrical harness connected.

• Door proximity switch ON (door closed) for 2.5 seconds or longer.

Outputs/Actions Malfunction Indicators If no open-circuit condition is • Electrical/mechanical fault detected on front wiper output, (components, connections the door is assumed to be or battery). attached.

Door is detected as present and the door switch is read as ON (door closed) by the main control • Electrical/mechanical fault keypad. (components, connections or battery).

NOTE: Wired end of door proximity switch has LED which activates when the switch is ON.

• Ignition switch in ON / RUN or START position.

Activate HVAC Blower Fan Low

• HVAC fan deactivated.

Activates fan low speed.

• Electrical/mechanical fault (components, connections or battery).

Activates fan medium speed and deactivates fan low speed.

• Electrical/mechanical fault (components, connections or battery).

• HVAC blower fan button pressed.

• Ignition switch in ON / RUN or START position.

Activate HVAC Blower Fan Med

• Low fan speed activated.

• HVAC blower fan button pressed.

Activate HVAC Blower Fan High

Activate Heat Valve

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• Ignition switch in ON / RUN or Activates fan high speed and START position. deactivates fan medium speed. • Electrical/mechanical fault • Medium fan speed activated. (components, connections NOTE: An additional press will or battery).

• HVAC blower fan button deactivate the HVAC fan. pressed.

Open/closes heat valve and turns on temperature LED • Ignition switch in ON / RUN or associated with heat setting.

Subsequent pressings of heat/ • Electrical/mechanical fault START position. cool (temperature) button opens/ (components, connections • Any HVAC fan speed closes heat valve and turns on/ or battery). activated. off appropriate LEDs. • Heater hose/core leak/ • Cab heat/cool (temperature) With heat valve fully open blockage. button pressed. (warmest setting), pressing heat/ cool (temperature) button closes heat valve (coolest setting).

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Restraint Bar Assembly

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

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HLN INST 3/8 CZY RING/RETAINING HLN INST 1/4 CZY BEARING SPIRALOCK 5/16 SPIRALOCK 3/8-16 PIN/PIVOT NUT/HEX NYLON SWITCH/PROX. MAGNET/SWITCH LN LG FL CTR 1/2 LH/ARMREST TUBE SPRING/EXT. RAIL/ARMREST STOP/TRAVEL BAR PIVOT SPRING/COMP PIVOT ARM SPACER/PIVOT BAR/RESTRAINT PLATE/SLIDER TOP LEVER/ADJUSTER LEVER/ADJUSTER CB 5/16X5/8 C5ZY CS 1/2X1-1/2 C5ZY CS 3/8X1 C5ZY CS 3/8X2 C5ZY CS 3/8X2-1/4 C5ZY RHMS SLT HN MS #1024 CZY CS 5/16X7/8 C5ZY FW 1/4 ANZY CB 1/4X1-1/4 C5ZY FW #4 BRZY FW 1/2 AWZY FW 3/8 ANZY

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ELECTRICAL SYSTEM

Electrical Lights Components

1 2 3 4

LIGHT / WHITE / 55W GROMMET .38ID .188GW 1.0 LIGHT/TAIL LIGHT/WORK

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5 6 7

TIE/CABLE .28X8.00 BLACK HARNESS/TAILLIGHT PANEL/FILLER/HALOGEN

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LED Electrical Lights Components

1 2 3 4 5 6 7

180

TIE/CABLE .19X7.50 BLACK TIE/CABLE .28X8.00 BLACK FIR TREE BRKT/MTG LIGHT WORKLIGHT/LED 2000LM LIGHT/LED PANEL/FILLER BRKT/LIGHT MT

8 9 10 11 12 13 14

HARNESS/JUMPER/LED LIGHT CS 3/8X3/4 C5ZY HN MS #1024 CZY FW #10 AZY PHMS SLT #1024X1/2 CBC CS M10-1.5x25 C8.8 ZY DIN933 FW M10 ZY DIN125

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ELECTRICAL SYSTEM

Electrically-Controlled Standard Auxiliary and High-Flow Hydraulic Flow System Test and Operation

when the high-flow auxiliary hydraulic system is engaged.

The black rocker switch located on the right-hand control handle controls the direction and amount of standard hydraulic flow. The rocker switch sends a signal to the standard flow module, which in turn sends a signal to the control valve. 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.

High-Flow Flow Controls

Standard Flow

High-Flow

Troubleshooting Test - Standard Flow

Standard Flow Control

The high-flow auxiliary switch controls the direction of high-flow hydraulic oil flow. The conrol buttons send a signal to the high-flow module, which in turn sends a signal to the control valve. Push the right button for forward flow or the left button for reverse flow. Pushing the right button will pressurize the high-flow 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

The control module provides 5VDC power to the rocker switch - standard flow.

To verify the functional status of the rocker switch in the control grip, connect the rocker switch to a 5VDC power source 1. Disconnect the eight-pin electrical connector between the control grip/keypad and the chassis electrical harness.

2. Apply 5VDC power to #1 socket terminal in the control grip /keypadelectrical connector.

3. Apply ground to the #3 socket terminal in the control grip/keypad electrical connector.

4. Measure the voltage on the #2 socket terminal in the control grip/keypad electrical connector. When the rocker switch/keypad is in the neutral position, voltage should be 2.5-3.0 VDC; when the switch/ keypad is moved right, voltage should be 4.5VDC; when the switch is moved left, voltage should be 0.5VDC.

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5. Check the hand control fuse in the power distribution panel in the engine compartment.

6. Check the main controller unit (MCU) fuse in the power distribution panel.

7. Verify connections at the control handle/standard auxiliary hydraulics.

8. Ensure that the solenoids on the main control valve are receiving the 12VDC signal to allow hydraulic solenoid operation.

Engine Throttle Test and Operation The engine speed is controlled by an electronic rotary throttle. The throttle is located on the right instrument panel. The machines also have a foot throttle located near the operator’s right foot. If there are problems with the throttle, the engine’s ECU will supply an error message to the multi-function display. See the Engine chapter for error code identification.

Hand Throttle

9. Using a volt/ohm multimeter, measure the resistance across the two terminals on each solenoid.

Remove the electrical connector from each solenoid coil and measure the resistance across both exposed solenoid terminals. Resistance should be 4.72 ohms (W).

Troubleshooting Test - High-Flow 1. Verify the right keypad fuses are not blown. They are located in a panel behind the right footwell area.

2. Verify other right keypad functions are working properly.

3. Check the connections between the ROPS/FOPS and the chassis.

4. Check the connections at the high-flow solenoids.

Foot Throttle

Note: Throttle problems generate error messages.

Refer to “Error Codes” on page 229.

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Seat Switch Removal and Installation Removal Procedure

4. Slide the seat switch in its slot until it can be freed from the seat.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: • Shut off the engine.

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

1. Remove the seat from the skid-steer loader per the procedure found in the Mainframe chapter. Turn the seat over.

2. Remove the metal plate covering the seat switch.

WARNING DO NOT attempt to operate the loader without the seat switch installed.

Installation Procedure - Follow all warnings first, then reverse the removal steps*. * Install seat on loader per the procedure in the Mainframe chapter.

Seat Switch

3. Disconnect the electrical connector on the seat switch.

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Restraint Bar Switch Removal and Installation Proximity Switch and Magnet

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: • Shut off the engine.

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

1. Remove the restraint bar assembly per the procedure in the Mainframe chapter.

3. Remove the switches from the bracket assembly.

2. Remove the two washers and hex nuts that secure the magnet and the proximity switch to the pivot assembly bracket.

WARNING DO NOT attempt to operate loader without the restraint bar switch installed.

Installation Procedure - Follow all warnings first, then reverse the removal steps*. * Adjust position of restraint bar switch and actuator switch so they are aligned with each other when restraint bar is down against the rubber stops. * Install the restraint bar according to the procedure in the Mainframe chapter.

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Master Disconnect Switch - Remote Battery Terminal Removal and Installation Gehl V420 and Mustang 4200V model skid-steer loaders have a master electrical disconnect switch located below the left control handle behind a cover inside the ROPS/FOPS.

2. On the switch, find a small screw securing the switch knob to the switch. Remove the screw from the switch and remove the knob.

Disconnect Switch Screw

3. Remove the switch plate jam nut securing the switch plate and the switch into the mounting hole.

Switch Plate Jam Nut

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine.

4. On the back of the disconnect switch, remove two nuts and all cables/wires attached to the disconnect switch. Pull the disconnect switch rearward and out of the skid-steer loader.

• BE SURE the engine electrical disconnect switch is in the OFF position.

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

1. Remove the battery cables from the two batteries.

Reference the “Batteries Removal and Installation” procedure in the Engine chapter.

NOTE: Keep a record of the cable/wire connections for reinstallation.

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

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Front and Rear Work Light Bulb Replacement (Halogen Bulbs) Removal Procedure

IMPORTANT Halogen bulbs SHOULD NOT be touched with bare fingers; they can fail prematurely. Wear clean gloves or use a clean rag if you must handle the halogen bulbs.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: • Shut off the engine.

• Raise engine cover; lock open the rear grille.

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

1. Remove four screws on the lens cover of either a front or rear work light and remove the lens cover and lens.

4. On white lens lights, front and rear, replace the used bulb with a new 55 W H3 bulb. On red lens lights, rear-only, replace the used bulb with a new 35 W H3 bulb.

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

Dome Light Bulb Replacement Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: • Shut off the engine.

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

1. Climb into the cab and find dome light assembly on ceiling of the cab.

2. Detach the electrical connector on the halogen bulb at the rear of the work light housing.

2. Find the notches and pop the dome light lens cover out of the recessed base with a flat-tipped screwdriver.

3. Release the bulb retaining clips and remove the bulb.

3. Replace the used bulb with a new GE168 bulb.

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Troubleshooting

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ENGINE

Introduction

Troubleshooting Guide

This chapter covers troubleshooting, removal, installation, and adjustment procedures for engine components on Gehl V420 and Mustang 4200V model skid-steer loaders. The primary engine system components are shown on following pages.

They are equipped with a Deutz TCD36 turbocharged diesel engine. The four-cylinder engines are 221 cubic inch displacement (3,62 L) engines. The turbo engine compression ratio is 18.0:1. The four-cylinder engines are direct injection four-stroke engines with a firing order of 1, 3, 4, 2.

A “full-flow” oil filter is used in the lubrication system.

As with any engine, clean oil, fuel and air are critical to satisfactory performance and long engine life. If properly maintained, this engine can be expected to provide thousands of hours of trouble-free operation.

When ordering engine parts, always check the Gehl or Mustang Parts Manual to see if a special part has been fitted to the engine. If Gehl or Mustang parts are required, they can be ordered from Gehl Company.

The following troubleshooting guide lists potential engine problems, as well as possible causes and remedies, for Gehl V420 and Mustang 4200V model skid-steer loaders.

When a problem occurs, don’t overlook simple causes.

A malfunction could be caused by something as simple as an empty fuel tank. After a mechanical failure has been corrected, be sure to locate the cause of the problem. For further troubleshooting information, refer to the engine manufacturer’s manual.

IMPORTANT DO NOT attempt to service or repair major components, such as the fuel injector pump, unless authorized to do so by your Gehl or Mustang dealer. Any unauthorized repair will void the warranty.

Troubleshooting

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Troubleshooting

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ENGINE

Engine Components 1 2 3 4 5 6 7 8 9

HLN INST 5/16 CZY HLN INST 1/4 CZY Clamp/Hose .50 x .41 Hole Clamp/Hose #10 Clamp/Hose .69 x .41 Hole Clamp/Tube 1.00 LN FL SPIRALOCK 1/2 CZY Washer ZY Isolator -13 Green-White

28 29 30 31 32 33 34 35

Brkt/Tube Brace/Fill/Oil Brkt/Tubes Wldmt/Mount/Eng Fill/Oil Assy/Mount/Rt Assy/Mount/Left Hose/Drain -10 x13.25

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10 11 12 13 14 15 16 17 18

36 37 38 39 40 41 42 43

LN FL SPIRALOCK 5/8 CZY Isolator -11 Red-White FW 1/2 HT ZY Valve/Drain/M18x1.5 45 HB10-MP08 CS FLH M12-1.75x25 C10.9 ZY SP SHCS M12-1.75x30 C10.9OCG SP CS FL LOCK M8-1.25x16 C8.8 ZY Bracket/Dipstick Retainer

Brkt/Hose Brkt/Hose Coupler/Splined CS M10-1.5x55 C10.9 Z CS 5/16x5/8 C5ZY CS 1/4x1 C5ZY SHCS HS 1/4x1-3/4 C CS 5/8x4 C8ZY

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19 20 21 22 23 24 25 26 27

Washer/Sealing Plate/Coupler/C-080 Plate/Mtg/Pump Wldmt/Mount/Eng Wldmt/Motor/Mnt/Front Plate/Mnt/Fill/Oil Wldmt/Motor/Mnt/Front Lf Eng/090kw/Deutz/Tcd36/T4 Dipstick

CS M10-1.5x30 C10.9 ZY CS M12-1.75x30 C10.9 ZY HN M12-1.75 C10 ZY FW M10.5x20x2.0 ZB Hardened CS M16-2x50 C8.8 ZY CS FL M10-1.50x20 8.8 ZY CS M12-1.75x45 C10.9 ZY

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Air Cleaner and Exhaust Components

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

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CLAMP/HOSE #48 CS FL LOCK 5/16X3/4 CLAMP/MUFFLER 2.50 SEAL/BULB CLAMP/T-BOLT 3.25 LN FL CTR 5/16 CZY COUPLER/CAC CLAMP/EXHAUST CS /LOCK M8-1.25x16 FITTING/HOSE BARB MOUNT/INDICATOR FILTER/SECONDARY FILTER/PRIMARY INDICATOR/FILTER ELBOW ADAPTER/CAC EXTENSION/EXHAUST TUBE/INLET/AIR HOSE/CAC BRKT/TUBE FILTER/AIR/IQ9VERT SPACER WELD/AIR INDICATOR VACUUM HOSE CLAMP/T-BOLT/1.97 CLAMP/T-BOLT/3.09 BRKT/TUBE WLMT/BRKT/TUBE BRKT/TUBE WLMT/SHIELD SHIELD SEAL/BULB WLMT/MTG/TUBE WLMT/MTG/TUBE WLMT/SUPPORT SLEEVE TUBE/INLET/AIR WLMT/BRKT CLAMP/T-BOLT 2.75 CLAMP/T-BOLT 4.75 CLAMP/T-BOLT/2.69-3 CS 1/4X3/4 C5ZY SCREW/HHM #1024X3/4 SHCS M12-1.75x35 HN 1/4 C2ZY HN 5/16 C2ZY FW 5/16 AWZY CS M8-1.25x20 C8.8 ZY CS M8-1.25x55 C8.8 ZY SHCS M8-1.25x20 C12.9 SHCS M10-1.5x25 C12.9 CLAMP/HOSE #44

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ENGINE

Radiator/Cooler Components - Main

2 3 4 5 6 7 11 12 13 14 15 16 17 18 20

CLAMP/HOSE #04 M LN LG FL SERR 3/8 CZ ST MJ12-MORB12 CS FL LOCK 5/16X5/8 C5ZY CS FL LOCK 3/8X3/4 C5ZY CS FL LOCK 5/16X3/4 C5ZY NUT/SPIRALOCK 3/8-16 CS FL LOCK 3/8X5/8 C5ZY CAP/RADIATOR FAN/24/2ZR LN FL SERR 1/4 CZY LN FL SERR 5/16 CZY MOTOR/GEAR/.67 SPACER/FAN 90 HB04-MP04

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21 22 24 25 26 29 30 31 35 36 37 39 40 41 42

SEAL/BULB-24 WLDMT/MTR MOUNT/FAN 90 MJ06-MAORB05 BRKT/MTG/SHROUD WLDMT/BRKT/FAN MTR SEAL/BULB SEAL/BULB SEAL/BULB SENSOR/SPEED/DIRECTION FAN GUARD MOUNT/SENSOR ASSY TARGET/SENSOR WELDMENT MOUNT/SENSOR/ADJUSTMENT TANK/COOLANT WELDMENT/SHROUD

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TUBE/HYD -06 DRAIN HOSE/COOLANT/-04X26 HOSE/COOLANT/-04X4 BRKT/SEAL SIGHT GLASS PAD/RUB WLDMT/MTG/SHROUD HOSE/OVERFLOW CB 3/8X1 C5ZY CS 5/16X1-1/4 C8ZY BHSCS 5/16x1 C8 LW 5/16 RZY FW 3/8 ANZY

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Radiator/Cooler Components -Cooler

1 8 9 10 16 20 23 27 28 32 33 34

200

CLAMP/HOSE #28 LN FL SERR 3/8 CZY DRAIN COCK 90 MP04 BUMPER LN FL SERR 5/16 CZY 90 HB04-MP04 WASHER SENDER/TEMP BRKT/CHRG AIR/TOP EXCHANGER/HEAT WLDMT/COOLER FRAME COOLER/CAC

38 41 43 44 45 46 47 52 53 56 57 60

PLATE/COOLER MNT TANK/COOLANT TUBE/VENT HOSE/UPPER HOSE/RAD/UPPER HOSE/RAD/LOWER HOSE/COOLAT/FILL WLMT/HINGE HINGE/BOTTOM SPRING/COMP .38ID X 3 BUSHING/FLANGE RETAINING RING/HEAVY DUTY

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ROD/LATCH BHSCS 3/8x1 C8 OCG CB 5/16X3/4 C5ZY CS 5/16X7/8 C5ZY FW 5/16 HT ZY HJN 5/16 C2ZY FW 5/16 AWZY FW 3/8 AWZY CP EPSC 1/8x1 Z NUT CLIP RETAINING 3/8-16 CLAMP/HOSE #16

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ENGINE

Fuel Assembly 1 2 3 4 5 6 7

TIE/CABLE .19X7.50 BLACK HLN INST 5/16 CZY FUEL SENDER GASKET CS FL LOCK 3/8X1 C5ZY HLN INST #1024 CZY CLAMP/HOSE .62X.41 HOLE WASHER/SEALING 3/8

8 9 10 11 12 13 14

TIE/CABLE 7.9 SS CLAMP/HOSE .62X.44 FUEL PUMP 90 MJ08-MMA16 ST HB08-FJS08 BRASS SEC FUEL FILTER/DEUTZ WATER SEPARATOR/DEUTZ

15 16 17 18 19 20 21

FITTING/QUICK COUPLER FITTING/QUICK COUPLER WELD/COVER ACCESS GASKET/FUEL COVER WLMT/MOUNT/ENG ST HB08-MP08 SPACER/FILTER

43 44 45 46 47 48 49 50

22 23 24 25 26 27 28

HOSE/PICKUP/FUEL FITTING/FUEL RETURN CLAMP/HOSE 15.8MM CLAMP/HOSE 19MM CONN/QUICK/9.89X.38-90 CONN/QUICK/11.8X.50-90 CONN/QUICK/11.8X.50-ST

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29 30 31 32 33 34 35

WLMT/MOUNT/FILTER BRKT/HOSE BRKT/HOSE ELBOW/.38 HOSE/FUEL/26.5 HOSE/FUEL/2.0 BRKT/HOSE

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PAD/RUB SENDER/FUEL CS 5/16X1 C2Z CS 5/16X3/4 C5ZY SCREW/HHM USL #1024X3/4 SCREW/THM CR #1024X1/2 BHSCS 3/8x1-1/4 C8 OCG CS M10-1.5x50 C8.8 ZY

BRKT/HOSE HOSE/FUEL/.38X64.0 HOSE/FUEL/.50X53 HOSE/FUEL/.50X18 HOSE/FUEL/-08X18.75 GUARD/RAD HOSE/LOWER CLAMP/HOSE 20MM

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Diesel Exhaust Fluid (DEF) Assembly

40 41 42 43 44 45 46

1 2 3 4 5 6 7 8 9 10 11 12 13

202

HLN INST 5/16 CZY HLN INST 1/4 CZY CLAMP/HOSE .69X.41 HOLE CLAMP/HOSE .62X.41 HOLE ST MJ10-MM22 SP CON/J2044/.38 TEE/BARB/10-6-10 BREATHER/DEF NYLON 3/8" HOSE CONNECTOR TEE/HB10-HB06-FJS10 TEE/HB06-HB10-FJS10 BRKT/CLAMP HOSE/DEF/SUPPLY

14 15 16 17 18 19 20 21 22 23 24 25 26

HOSE/DEF/RETURN FILL NECK CLAMP/HOSE .68 TWIN BRKT/HOSE SHIELD/HEAT HOSE/COOLANT HOSE/COOLANT HOSE/HEATER HOSE/HEATER HOSE/COOLANT HOSE/COOLANT HOSE/COOLANT HOSE/COOLANT

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FILTER/DEF CS 5/16X1 C2Z CS 5/16X3-1/2 C5ZY CS 5/16X2 C5ZY CS M6-1x20 C8.8 ZY SHCS M10-1.5x25 C12.9 CLAMP/HOSE #08

J2044/90/.44 WATER HOSE/DEF/SUCTION WLMT/MOUNT/CLAMP BRKT/TANK TANK/DEF BRKT/TANK CLAMP/HOSE 17MM CLAMP/HOSE .96 TWIN CAP/BYPASS/HEATER/.63 SCREEN/FILL WLMT/BRKT/HOSE HOSE/COOLANT/MOLDED CAP/DEF

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ENGINE

Oil Filter Element Removal and Installation The engine oil filter is located on the left side of the engine.

behind the left rear tire and remove the drain plug (refer to operator’s manual for details on changing oil).

Remote Engine Oil Drain

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine and allow to cool.

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

Removal Procedure 1. For additional area, open the left rear engine access panel (not mandatory).

5. 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.

2. On lower left side of the engine, locate the oil filter.

Interior Drain Valve

Engine Oil Filter Location

6. Clean the area around the oil filter element.

7. Turning it counterclockwise, loosen the oil filter with a filter wrench.

8. Turn the filter by hand until it is free of the oil filter mating surface.

Installation Procedure 1. Clean oil filter mating surface of any debris before installing new filter.

3. Place a suitable container beneath the oil filter to catch any leaking oil.

4. If removing old oil, place a suitable container beneath the remote engine oil drain plug located PRINTED IN USA

2. Apply a thin film of oil to seal on filter before installing.

3. Hand-tighten filter, turning it clockwise, until gasket contacts filter mating surface, then turn the filter another 3/4 turn to seat gasket.

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4. If old oil has been removed, fill crankcase with 10. qts. (9,5 L) of oil. (See Lubrication chapter.)

5. Start engine and check for leaks near oil filter. Shut off engine, recheck oil level, and fill as needed.

4. On the inside of the loader, remove four capscrews securing the air cleaner assembly to the chassis ad remove the assembly from the machine.

Air Cleaner Assembly Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: • Shut off the engine and allow to cool.

• BE SURE the engine electrical disconnect switch is in the OFF position.

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

5. Remove the jumpstart terminal cable from the air cleaner housing.

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

1. Open the engine access cover and lock open the rear grille.

2. At the front of the air cleaner assembly, clean the area around the air cleaner hose connection.

3. Loosen the hose clamp securing the air filter hose to the assembly and pull the hose away from the air cleaner. Cover the air cleaner hose opening to help prevent contamination.

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Air Filter Element Removal and Installation

3. Pull the top housing off the air cleaner assembly.

Service the air filter element when the electrical air filter restriction indicator lamp lights, or the standard maintenance interval. The filter restriction indicator lamp indicates a clogged air filter. Replace the primary air filter element. The secondary air filter element should be replaced every third time the primary element is replaced, unless the primary element is damaged or the secondary element is visibly dirty.

Removal Procedure

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

4. Pull the primary air filter element from the air cleaner assembly.

Primary Air Filter

• Shut off the engine and allow to cool.

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

1. Open the engine access cover.

2. Release the four spring clips securing the top filter housing and remove the top housing. Clean out any dirt build-up in the end cap.

Secondary Air Filter

5. Replace both air filter elements, if needed. (See Service chapter of the Operator's Manual.)

6. Check the condition of the dust ejector.Vacuum out the inside of the housing, if needed.

Installation Procedure - Follow all warnings first, then reverse the removal steps.* * Clean the radial seal surfaces of the mating plastic body.

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Batteries Removal and Installation Gehl V420 and Mustang 4200V model skid-steer loaders utilize two 12 V batteries to power the electrical system. To remove or replace one or both batteries, they must both be disconnected, freed of their holddown brackets and slid off to either side.

Removal Procedure

A

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

Fig. 1 – Battery Master Disconnect Switch

• Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device • Shut off the engine.

• Tilt back ROPS/FOPS until lock engages.

3. Disconnect the negative battery cables (B, Fig. 2) from both batteries.

4

• BE SURE the engine electrical disconnect switch is in the OFF position.

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

WARNING

B

Review the following safety considerations before working on or around the battery: • Keep sparks and flames away from battery.

Gas given off by the battery’s electrolyte solution is extremely explosive.

Fig. 2 – Negative Battery Cables

• Avoid contact with battery electrolyte; wash off any electrolyte immediately.

4. Disconnect the positive battery cables (C, Fig. 3) from both batteries.

• Wear safety glasses when working near battery.

• Do not tip battery more than 45° to avoid spilling electrolyte solution. ˘ To avoid injury from spark or short circuit, disconnect negative (-) battery cable before servicing electrical system.

1. Remove the battery access cover per the procedure in the Mainframe chapter.

2. Turn the battery master disconnect switch (A, Fig. 1) to the OFF position.

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C

Diesel Exhaust Fluid (DEF) Level

Fig. 5 DEF Level Indicator

Fig. 3 – Positive Battery Cables

5. Remove the two capscrews on each battery hold-down bracket (D, Fig. 4) and remove the hold-downs.

The DEF level (F, Fig. 5) is shown on the multi-function display.

The DEF symbol will appear on the multi-function display when the DEF tank level reaches 15%. The symbol will begin flashing when the DEF level falls below 10%. If the level falls below 5%, a 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.

D

The DEF fluid reservoir filler is located behind a latched cover at the rear right side of the chassis.

Fig. 4 – Battery Hold-Downs

6. Slide the right side battery out of the tray toward the chain case to gain clearance for left battery removal.

7. Remove the left battery first, then the right battery.

8. Remove the batteries through the crossmember and floorplate.

9. For the master disconnect switch, refer to its removal procedure in the Electrical System chapter of this manual.

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

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Fig. 6 DEF Reservoir

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DEF Dosing Unit Filter Replacement

the system to complete the purge cycle before disconnecting the DEF line.

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.

Fig. 7 DEF Dosing Unit filter cap

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.

The DEF dosing unit (Fig. 7) 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.

WARNING 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.

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.

6. Remove the aftertreatment DEF filter equalizing element (O, Fig. 8) and discard.

WARNING

Fig. 8 DEF Dosing Unit Filter Removal

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

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7. Remove the old aftertreatment DEF dosing unit filter element (P, Fig. 8).

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 the appropriate end of the tool, depending on the color of the

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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.

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

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

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.

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. 9) appears on the multi-function display.

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

Stay clear of the engine compartment during regeneration.

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. 10) 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.

Fig. 9 Standstill Regeneration Request Screen Fig. 10 Regeneration Inhibit Button

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.

PRINTED IN USA

Important: Perform standstill regeneration as soon as possible when the standstill regeneration request screen displays. Postponing standstill regeneration will result in CAN errors, engine derating, and declining engine power and performance.

To proceed with standstill regeneration:

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1. Park the machine in a safe, will-ventilated location away from flammable materials.

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

2. Lift the restraint bar/armrests to apply the parking brake. A check mark is displayed next to the parking brake symbol (A, Fig. 11).

Note: Standstill regeneration takes approximately 35-50 minutes.

CAUTION It is not necessary to stay in the machine during standstill regeneration. Keep the machine under observation while regeneration is in progress in case of malfunction. Keep bystanders away from the machine while regeneration is in progress.

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

Fig. 11 Standstill Regeneration

3. When the engine coolant has reached operating temperature (above 149° F (65° C), a check mark is displayed next to the coolant temperature symbol (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.

5. When all three check marks (A, B, C) are displayed on the standstill regeneration screen, press and hold the button (Z, Fig. 12) until the standstill regeneration in-progress screen displays (Fig. 12).

Fig. 12 Standstill Regeneration In-Progress Screen

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 if it is interrupted.

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Starter Removal and Installation For wiring connections to the starter and solenoid, refer to the Electrical System chapter of this manual.

3. Remove two black covered wires from the solenoid too and cut a black wire tie securing them to the starter solenoid.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

• Raise lift arm; engage lift arm support device.

• Shut off the engine and allow to cool.

• BE SURE the engine electrical disconnect switch is in the OFF position. ˘ (For detailed instructions, refer to the Safety chapter of this manual.)

4. Remove the two screws securing the starter to the engine and remove the starter.

1. Unlatch and remove the left side engine access cover.

2. On the starter solenoid, remove the nuts that secures the positive ( + ) battery cables and remove the cables.

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

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Exhaust Assembly Removal and Installation

C

Removal Procedure

B

WARNING

D

BEFORE beginning this service procedure, perform the following SAFETY procedures: • Remove attachment from lift arm.

E

• Raise lift arm; engage lift arm support device.

• Shut off the engine and allow to cool.

Fig. 14 – Exhaust Tip

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

1. Open the engine access cover and lock open the rear grille.

6. Remove the two capscrews (F, Fig. 15) that secure the aftertreatment component bracket (G) to the fixed engine cover.

2. Remove the engine access cover per the procedure found in the Mainframe chapter.

3. Remove the right and left engine compartment side covers (A, Fig. 13).

F G

Fig. 15 – Aftertreatment Component Bracket

A

7. Remove the four capscrews (H, Fig. 16) that secure the coolant remote tank (I) to the fixed engine cover (J).

Fig. 13 – Engine Compartment Side Covers

4. Remove the four capscrews (B, Fig. 14) that secure the exhaust tip (C) to the fixed engine cover (D).

Remove the exhaust tip from the machine.

5. Remove the two capscrews and nuts (E, Fig. 14) that secure the left side of the fixed engine cover to the machine.

J

H I

Fig. 16 – Remote Tank Capscrews

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8. Remove the capscrew and nut (K, Fig. 17) that secure the hydraulic fluid dipstick P-clip (L) to the fixed engine cover.

10. Disconnect the washer fluid hose (N, Fig. 19) and remove it from the fixed engine cover.

K N

L

Fig. 17 – Hydraulic Fluid Dipstick

Fig. 19 – Washer Fluid Hose

9. Remove the five capscrews (M, Fig. 18) that secure the left side of the fixed engine cover to the machine. Note the location of the P-clip on the bottom side of the fixed engine cover.

11. Remove the fixed engine cover from the machine.

12. Remove the exhaust outlet by removing a clamp and two bolts on the exhaust support bracket.

M M

Fig. 18 – Right Side Fixed Engine Cover

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

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Alternator Belt Adjustment

Radiator/Cooler Removal and Installation

Adjustment Procedure

The radiator/cooler is mounted on a swing-out support bracket located just behind the engine.

Removal Procedure

WARNING

WARNING

BEFORE beginning this service procedure, perform the following SAFETY procedures: • Shut off the engine and allow to cool.

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

BEFORE beginning this service procedure, perform the following SAFETY procedure: • Remove attachment from lift arm.

1. Open the engine access cover and lock open the rear grille.

• Raise lift arm; engage lift arm support device.

2. Test the fan belt tension by pushing on the belt midway between the alternator and the engine crankshaft pulley. The belt should deflect about 1/ 2” (13 mm) under a load of 20 lbs. (90 N). If adjustment is needed, follow the step below.

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

3. Loosen two bolts on the alternator, one at the low pivot area and one on top of the slide bracket.

2. If necessary, drain the engine coolant from the radiator per the procedure in the Lubrication chapter.

• Shut off the engine and allow to cool.

1. If necessary, drain the oil from the hydraulic reservoir per the procedure in the Lubrication chapter.

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

3. Open the engine access cover and lock open the rear grille.

4. Lift the radiator latch (B, Fig. 20) to allow the radiator/hydraulic oil cooler (C) to open.

4. Rotate the alternator in a clockwise direction (viewed from the engine end) until the correct belt tension is achieved.

B

5. Retighten the bolts.

C

Fig. 20 – Radiator Latch

5. Drain the cooling system.

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6. Apply a vacuum or drain the hydraulic system.

7. Loosen the hose clamp (D, Fig. 21) that secures the upper radiator hose (E) to the radiator. Remove the upper radiator hose from the radiator. Close all openings.

9. Remove the upper hydraulic cooler hose quick connect clip, or remove the entire fitting (I, Fig. 23). Disconnect the hydraulic hose (J). Close all openings using caps and plugs.

E

D I

J Fig. 23 – Upper Hydraulic Cooler Hose Fig. 21 – Upper Radiator Hose

8. Loosen the hose clamp (F, Fig. 22) that secures the lower radiator hose (G) to the radiator (H). Remove the upper radiator hose from the radiator. Close all openings.

10. Remove the lower hydraulic cooler hose quick connect clip, or remove the entire fitting (K, Fig. 24). Tag and disconnect the hydraulic hose (L).

Close all openings using caps and plugs.

L

H

K K G F

Fig. 22 – Lower Radiator Hose

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L Fig. 24 – Lower Hydraulic Cooler Hose

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11. Support the radiator/hydraulic oil cooler and remove the four capscrews (M, Fig. 25) that secure the cooler tabs to the machine.

NOTE: The radiator/hydraulic oil cooler weighs approximately 150 lb. (68 kg).

Charge Air Cooler Removal and Installation The charge air cooler, next to the radiator/cooler, functions as an air cooler for the air intake system, cooling the air prior to entering the engine.

Removal Procedure

WARNING

M

BEFORE beginning this service procedure, perform the following SAFETY procedure: • Remove attachment from lift arm.

M

• Raise lift arm; engage lift arm support device.

• Shut off the engine and allow to cool.

Fig. 25 – Cooler Tab Capscrews

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

12. Remove the radiator/hydraulic oil cooler from the machine.

1. Open the engine access cover and lock open the rear grille.

2. Pull up on the oil cooler/radiator lock pin and put it in its placeholder, then swing the oil cooler/radiator out.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

3. Loosen the hose clamp (B, Fig. 26) that secures the upper charge air hose (C) to the charge air cooler (D). Disconnect the upper charge air hose from the charge air cooler. Close all openings.

B

D

WARNING

C

ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

Fig. 26 – Upper Charge Air Hose

13. ALWAYS check for hydraulic/coolant fluid leaks after reassembling components of the hydraulic system.

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4. Lift the radiator latch (E, Fig. 27) to allow the radiator (F) to open.

7. Remove the two nuts and washers (L, Fig. 29) that secure the lower charge air cooler bracket to the machine.

E J

K

F

L Fig. 29 – Lower Charge Air Cooler Bracket Fig. 27 – Radiator Latch

5. Loosen the hose clamp (G, Fig. 28) that secures the lower charge air pipe (H) to the charge air cooler (I). Disconnect the lower charge air pipe from the charge air cooler. Close all openings.

8. Remove the two capscrews (M, Fig. 30) and nuts that secure the upper charge air cooler bracket (N) to the machine.

9. Disconnect the charge air cooler temperature sensor electrical connector (O, Fig. 30).

M

H G

I

Fig. 28 – Lower Charge Air Pipe

O

6. Remove the two capscrews and washers (J, Fig. 29) that secure the lower charge air cooler bracket (K) to the charge air cooler.

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N

Fig. 30 – Upper Charge Air Cooler Bracket

10. Remove the charge air cooler from the machine.

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

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Fan Shroud Removal and Installation Removal Procedure

4. Remove the capscrew and nut (A, Fig. 31) that secure the hydraulic oil fill tube P-clip to the left side rear cover.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: • Remove attachment from lift arm.

A

• Raise lift arm; engage lift arm support device.

• Shut off the engine and allow to cool.

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

Fig. 31 – Hydraulic Fill Tube Capscrew and Nut

WARNING DO NOT attempt to service any part of radiator/oil cooler system until engine has been allowed to cool. Serious injury may result from high temperature oil or water coolant or high pressure.

5. Remove the two capscrews (B, Fig. 32) that secure the window washer fluid pumps to the right side rear cover.

6. Remove the left and right side rear cover capscrews (C, Fig. 32) and remove the left and right rear covers (right side shown).

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

1. Remove the radiator/cooler per the procedure in this chapter.

C B

2. Remove the fan and fan motor per the procedure in the Hydraulic Chapter.

3. If necessary, remove the charge air cooler per the procedure in this chapter.

Fig. 32 – Right Side Rear Panel

7. Remove the three capscrews (D, Fig. 33) that secure the diesel exhaust fluid (DEF) dosing module to the fan shroud.

8. Disconnect all DEF fluid lines.

9. Disconnect the DEF electrical connector to the chassis harness.

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10. Remove the DEF module.

13. Open the clips that secure the harness to the fan shroud and remove the harness (G, Fig. 35).

11. Disconnect the fan speed sensor electrical connector (E, Fig. 33).

G D E

Fig. 35 – Fan Electrical Harness Clips Fig. 33 – DEF Dosing Module

12. Remove the reversing fan coil electrical connector (F, Fig. 34).

14. Disconnect the fan motor hydraulic lines (H, Fig. 36) from the fittings on the fan shroud. Close all openings.

H

F

Fig. 36 – Fan Motor Hydraulic Lines Fig. 34 – Fan Coil Electrical Connector

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15. Remove the eight capscrews (I, Fig. 37) from the left and right fan shroud brackets (left side shown) and remove the fan shroud.

Fan Adjustment The hydraulically-driven fan on the fan shroud can be adjusted left or right, up or down, fore or aft, to center the fan in the shroud opening.

Adjustment Procedure

I

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

• Shut off the engine and allow to cool.

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

Fig. 37 – Fan Shroud Capscrews

Installation Procedure - Follow all warnings first, then reverse the removal steps.* * BE SURE and uncap/unplug the hydraulic oil lines prior to reconnecting them to the fan shroud.

1. Open the engine access cover and lock open the rear grille.

2. Pull up on the oil cooler/radiator lock pin and put it in its placeholder, then swing the oil cooler/radiator out.

3. If necessary, remove the charge air cooler per the procedure in this chapter.

4. At the front lower right of the fan shroud, loosen the three hydraulic fittings in the shroud.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

ALWAYS check for hydraulic fluid leaks after installing any components of the hydraulic system.

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5. The fan motor bracket bolts can be loosened to center the fan left or right in the shroud.

Engine Removal and Installation The following procedure allows removal of the diesel engine. Some hydraulic hoses/oil lines need to be disconnected in this procedure, and if they cannot be capped/plugged to prevent fluid loss, the hydraulic reservoir should be drained BEFORE disconnecting any hydraulic hoses/oil lines.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: 6. The fan motor mount bolts can be loosened to move the fan up or down, forward or backward in the shroud.

• Remove attachment from lift arm.

• Shut off the engine.

• BE SURE the engine electrical disconnect switch is in the OFF position.

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

1. Remove the lift arm and timing link per the procedure in the Mainframe chapter.

2. Remove the right and left engine compartment side covers (A, Fig. 38).

7. How the the fan is centered in the shroud opening.

8. The fan should be concentric with the shroud with a tip clearance of 0.25” ± 0.06 (6,35 mm ± 1,5).

9. The face of the fan base should be 0.5” ± 0.06 (12,7 mm ± 1,5) out from the shroud.

10. Torque the fan mounting bolts to 6.60 ft-lbs. (8,9 N•m) with Loctite® 242 (or equivalent).

11. Tighten the locking capscrews on the fan shroud supports to secure the height and/or depth adjustment(s), as well as, the three hydraulic fittings loosened in step 3.

A Fig. 38 – Engine Compartment Side Covers

3. Drain the hydraulic oil reservoir and the engine oil.

4. Remove the engine access covers per the procedure in the Mainframe chapter.

5. Remove the rear grille per the procedure in the Mainframe chapter.

6. Remove the ROPS/FOPS per the procedure found in the Mainframe chapter.

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7. Remove the air cleaner assembly per the procedure in this chapter.

WARNING DO NOT PROCEED with the following steps unless engine has completely cooled and is safe to touch.

8. Remove the exhaust assembly per the procedure in this chapter.

17. Remove the rear crossmember.

18. Disconnect the fuel lines from the electrical fuel pump. Disconnect its electrical connector too.

19. Remove the left and right side covers from the fuel fill and DEF fill.

20. Cut the wire ties on the vertical upright located on the rear of the machine.

21. Remove the washer reservoir and its bracket.

22. Remove the vertical uprights.

23. Disconnect the main engine harness connector (R, Fig. 40) at the engine.

9. Remove the radiator/cooler per the procedure in this chapter.

10. Remove the remote tank per the procedure in this chapter.

11. Remove the charge air cooler per the procedure in this chapter.

12. Remove the fan motor and fan shroud per the procedures in this chapter.

13. Remove the rear crossmember per the procedure in this chapter.

IMPORTANT Plastic ties on electrical lines may have to be removed to free lines from the engine.

R

Fig. 40 – Main Engine Harness Connector

14. Remove the four capscrews (E, Fig. 39) that secure the rear cross member (right side shown) to the machine.

E

Fig. 39 – Rear Cross Member

15. Cut the wire ties securing the electrical harness to the rear crossmember.

16. Remove the rear door latch linkage from the rear crossmember.

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24. Remove the nut and lock washer (S, Fig. 41) that secure the two cables (T) to the positive post on the back of the starter (U). Remove the two cables from the starter. Remove the ground cable from the engine.

26. Disconnect the three temperature sensors.

T

S U Fig. 43 – One of three sensor to remove.

Fig. 41 – Starter

25. Cut the steel ties on the sensor mounting.

Fig. 44 – Two of three sensors to remove.

Fig. 42 – Ties on Sensor Mounting Plate

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GEHL V420 / MUSTANG 4200V 28. Disconnect the ECU.

Fig. 45 – Three of three sensors to remove.

27. Disconnect the DEF injection electrical wire at the mixing pipe.

Fig. 46 – DEF injection wire to remove.

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Fig. 47 – ECU connection to remove.

29. Disconnect the NOX outlet sensor and two fasteneres from the ECU and leave with the engine.

Fig. 48 – NOX outlet sensor connection.

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30. Disconnect the pressure sensor and remove the electrical wire from the ECU bracket.

W

X

V Fig. 51 – Fuel Line Tie Band

33. Disconnect the two A/C lines (Y, Fig. 52) at the compressor (Z). Close all openings using caps and plugs.

Fig. 49 – Pressure sensor to remove.

31. Remove electrical wires from the rear of the ECU bracket and remove the ECU. Z

Y

Fig. 52 – A/C Lines at Compressor Fig. 50 – Remove electrical wires from ECU bracket.

34. Tag and disconnect the A/C compressor electrical connector (A).

32. Remove the tie band (V, Fig. 51) that secures the fuel line (W) to the A/C compressor bracket (X).

A

Fig. 53 – A/C Compressor Electrical Connector

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35. Remove the nut that secures the alternator wire (B, Fig. 54) to the alternator (C). Remove all tie bands that secure the alternator wire to the engine.

36. Route the alternator wire through the A/C compressor bracket.

40. Remove the three upper capscrews (G, Fig. 56) that secure the A/C compressor bracket (H) to the engine.

H

C

G B

Fig. 56 – Upper A/C Compressor Bracket Capscrews

Fig. 54 – Alternator Wire

37. Loosen the two capscrews (D, Fig. 55) allowing the A/C belt tensioner (E) to pivot and release the A/C belt (F) tension.

38. Remove the A/C belt from the machine.

39. Remove the two capscrews that secure the A/C belt tensioner tothe machine and remove theA/C belt tensioner from the machine.

41. Remove the two lower capscrews (I, Fig. 57) that secure the A/C compressor bracket to the motor mount.

F I

E

Fig. 57 – Lower A/C Compressor Bracket Capscrews D Fig. 55 – A/C Belt

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42. Remove the A/C compressor and bracket from the machine.

43. Remove the capscrew that secures the ground cable (J, Fig. 58) to the engine block located behind the fuel filter (K) on the left side of the engine.

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44. Loosen the hose clamp that secures the engine oil drain hose (L, Fig. 58) to the engine. Remove the engine oil drain hose from the engine.

46. Disconnect the two heater hoses (N, Fig. 60) at the splices located at the bottom of the engine. Close all openings.

K L J N

Fig. 58 – Engine Ground

45. Remove the capscrew that secures the ground wires to the ground lug (M, Fig. 59).

Fig. 60 – Heater Hoses

47. Remove the hose clamp (G, Fig. 61) that secures the air intake pipe (H) to the bracket (I).

M

G I

H Fig. 59 – Ground Lug

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Fig. 61 – Air Intake Pipe Bracket

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48. Remove the hose clamp (K) that secures the air intake pipe to the turbocharger (L). Remove the air intake pipe from the machine.

50. Remove the two nuts (R, Fig. 64) that secure the lower charge air pipe U-bolt (S) clamp to the bracket (T).

T R K

S

L Fig. 62 – Air Intake Pipe at Turbocharger

Fig. 64 – Lower Charge Air Pipe U-bolt Clamp

49. Tag and disconnect the fuel line (P, Fig. 63) at the back of the engine. Remove the P-clip (Q) that secures the fuel line to the engine.

51. Remove the two capscrews and nuts (U, Fig. 65) that secure the lower charge air pipe bracket (V) to the engine.

V

P U

Q

Fig. 63 – Fuel Line at Back of Engine

228

Fig. 65 – Lower Charge Air Pipe Bracket

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52. Loosen the hose clamp (W, Fig. 66) that secures the lower charge air pipe (X) to the turbocharger (Y).

I X

Y W

Fig. 68 – Engine Mount Capcrews

Fig. 66 – Lower Charge Air Pipe at Turbocharger

53. Disconnect the A/C line (Z, Fig. 67) at the bracket (A) located at the rear of the engine. Close all openings.

56. With the aid of an assistant, remove the engine from the machine.

Engine Diagnostic Chart 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.

A

Z Fig. 69 Data Ports for the Engine and Machine. Left and right are determined by sitting in the operator’s seat and facing forward.

Fig. 67 – A/C Line at Back of Engine

54. Disconnect the hydraulic hoses from the hydrostatic pump as described in the Hydrostatic chapter.

55. Attach an appropriate lifting device to the engine and remove the four engine mount capscrews (I, Fig. 68) (front two shown).

NOTE: The engine weighs approximately 1100 lb. (500 kg).

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.

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.

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Engine Diagnostic Fault Codes

DTC

230

SPN

FMI

Trouble Code Type

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

0 5.6 5.6 5.6 5.6 5.6 5.6 5 5 5.6 5 5.6 5.6

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

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240

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INDEX

I ND E X A Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air Cleaner and Exhaust Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Air Cleaner Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Air Duct Louver Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Air Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 All-Tach® and Power-A-Tach® Hitch Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 All-Tach® Hitch Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Alternator Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Auxiliary (Fan) Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Axle and Wheel Bearing Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Axle Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Axle Housing Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Axle Housing Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

B Batteries Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Brake/Two-Speed and Safety Lock Solenoid Valves - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

C Cab Heater Assembly - ROPS/FOPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Charge Air Cooler Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Charge Pressure Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Chassis Electrical - Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Chassis Electrical - Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Control Console Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Control Cover Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Control Handle Removal and Installation - Electrical Auxiliary Grip / Left Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Control Handle Tracking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Control Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Control Valve Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Control Valve Solenoid Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Controller Area Network (CAN) Functional Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Cooling System Drain Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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D Diesel Exhaust Fluid (DEF) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Diesel Exhaust Fluid (DEF) Service (If So Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Dome Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Drive Chain Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Drive Motor Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

E Electrical Foot Throttle Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Electrical Foot Throttle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Electrical Lights Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Electrically-Controlled Standard Auxiliary and High-Flow Hydraulic Flow System Test and Operation. . . . . . . . . . . . . . . 181 Engine Access Cover - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Engine Diagnostic Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Engine Diagnostic Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Engine Throttle Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Exhaust Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

F Fan Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Fan Control Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Fan Guard and Fan Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Fan Shroud Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Floor Plate, Battery Access Cover and Kickplate Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Front and Rear Work Light Bulb Replacement (Halogen Bulbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Fuel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Fuel Sensor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

G Grease Fitting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

H HVAC Assembly - Compressor - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 HVAC Assembly - Front - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 HVAC Assembly - Rear - ROPS/FOPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 HVAC Assembly - Routing - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic Oil Reservoir Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Hydraulics - High-Flow Auxiliary Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Hydraulics - High-Flow Auxiliary Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Hydraulics - High-Flow Chassis Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Hydraulics - Hydraglide™ Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Hydraulics - Standard Auxiliary Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Hydraulics - Standard Auxiliary Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Hydraulics - Standard Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Hydrostatic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Hydrostatic Pump Drive Coupling Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Hydrostatic Pump Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Hydrostatic Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Hydrostatic/Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

I Inlet Relief Valve and Drain Orifice Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

J J1939 Data Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Joystick Drive Supply, All-Tach/Fan and Hydraglide™ Ride Control Solenoid Valves - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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L LED Electrical Lights Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Lift and Tilt Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Lift Arm Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Lift Arm Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Arm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lift Arm Support Device Engagement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Arm, Rear Link, Hose Pivot and Timing Link Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Lift Circuit Spool Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Lift Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Lift Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Lift/Tilt Cylinder Disassembly / Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Lift/Tilt, Joystick Drive Supply, Brake/Two-Speed, All-Tach/Fan and Hydraglide™ Ride Control Solenoid Valves - Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Load-Sense Axial Piston Pump Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

M Machines Equipped with Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Main Control Unit LEDs/Pins Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Main Control Valve Components - High-Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Mainframe - Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Mainframe - Engine Cover Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Mainframe - Rear Grille Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Mandatory Safety Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Master Disconnect Switch - Remote Battery Terminal Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

N Neutral Centering Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

O Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

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P Potential Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Power Distribution Panel Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Power-A-Tach® Components - Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Power-A-Tach® Components - Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Pressure and Load-Sense Check, Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

R Radiator/Cooler Components - Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Radiator/Cooler Components -Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Radiator/Cooler Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Rear Grille Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Rear Link Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Relieving Hydraulic Pressure - Joystic Controls - Lift/Tilt/Auxiliary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Restraint Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Restraint Bar Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Restraint Bar Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Restraint Bar Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ROPS/FOPS – Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ROPS/FOPS – Raising. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ROPS/FOPS Electrical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 ROPS/FOPS Rear Window Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ROPS/FOPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

S Seat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Seat Slide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Seat Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Selective Catalytic Reduction (SCR) Standstill Regeneration (If So Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 Self-Leveling Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Self-Leveling Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Self-Leveling Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Side Console Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Solenoid Valve Test - Joystick Drive Supply, All-Tach/Fan, Brake/Two-Speed, Safety Locks and Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

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T Tilt Circuit Spool Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Tilt Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Tilt Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Tilt Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Timing Link Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

W Wheel Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Wheel Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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T h i s P ag e I nte nt i on a l ly L e f t Bl an k

Manitou Group One Gehl Way West Bend, WI 53095-0179 U.S.A. www.gehl.com For support and service, contact your dealer. www.gehl.com/dealer-locator

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© 2018 MANITOU GROUP All Rights Reserved.

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