All-Wheel Steer Loader Operator’s Manualtuffequipco.com/pdfs/Gehl Owners Manuals/Gehl All...Gehl...

All-Wheel Steer LoaderBeginning Serial Number: 342010001

Model 480Form No.918115

Revision CAugust 2007

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Man

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© 2007 Gehl Company • All Rights Reserved. • Printed in USA

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204937/AP0407

GEHL COMPANY

WARRANTY

GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl equipment to theOriginal Retail Purchaser to be free from defects in material and workmanship for aperiod of twelve (12) months from the Warranty Start Date.

GEHL WARRANTY SERVICE INCLUDES:

Genuine Gehl parts and labor costs required to repair or replace equipment at theselling dealer’s business location.

GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND,EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OFMERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT ASEXPRESSLY STATED IN THIS WARRANTY STATEMENT.

ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL BE DEEMEDDELETED FROM THIS WARRANTY; ALL OTHER TERMS WILL CONTINUE TOAPPLY.

SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESEWARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATELAW.

GEHL WARRANTY DOES NOT INCLUDE:

1. Transportation to selling dealer’s business location or, at the option of theOriginal Retail Purchaser, the cost of a service call.

2. Used equipment.

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

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

5. Repairs or adjustments caused by: improper use; failure to follow recommendedmaintenance procedures; use of unauthorized attachments; accident or othercasualty.

6. Liability for incidental or consequential damages of any type, including, but notlimited to lost profits or expenses of acquiring replacement equipment.

No agent, employee or representative of Gehl has any authority to bind Gehl to anywarranty except as specifically set forth herein.

Printed in U.S.A. 1 918115/CP0807

Table of contents

I

Introduction ........................................................................................................................ 4General information ..................................................................................................... 4Identification of warnings and hazards ........................................................................ 7Machine overview ......................................................................................................... 8Overview....................................................................................................................... 9Fields of application, attachments .............................................................................. 10Serial number plate locations .................................................................................... 11

Safety instructions ............................................................................................................ 16General safety rules ................................................................................................... 18Additional safety equipment ....................................................................................... 20Safety reminders ........................................................................................................ 20Transporting ............................................................................................................... 21Maintenance safety .................................................................................................... 25Safety instructions for specific hazards ...................................................................... 28

Operation ......................................................................................................................... 34Description of controls ............................................................................................... 34Cab: overview ............................................................................................................. 35Instrument panel, multifunctional lever and drive lever: overview .............................. 37Getting started ............................................................................................................ 39Indicators and warning lights: overview .................................................................... 42Starting the engine ..................................................................................................... 45Driving the machine .................................................................................................... 56Working with the machine .......................................................................................... 77Working with pallet forks............................................................................................. 91

Troubleshooting ............................................................................................................... 98Engine trouble ........................................................................................................... 98

Maintenance .................................................................................................................. 100Introduction .............................................................................................................. 100Fuel system ............................................................................................................. 100Engine lubrication system......................................................................................... 102Engine and hydraulics cooling system...................................................................... 103Air filter ..................................................................................................................... 105V-belt ........................................................................................................................ 107Hydraulic system ...................................................................................................... 108Lubrication points ..................................................................................................... 112Maintenance of attachments .................................................................................... 113Maintenance of the brake system............................................................................. 114Tire care.................................................................................................................... 115Heating ..................................................................................................................... 117Electrical system....................................................................................................... 118General maintenance work....................................................................................... 121Fluids and lubricants ................................................................................................ 124Maintenance schedule Model 480 (overview) ......................................................... 125Maintenance log ...................................................................................................... 128Maintenance decal ................................................................................................... 131

Specifications ................................................................................................................. 134Frame ...................................................................................................................... 134Engine ...................................................................................................................... 134Power train................................................................................................................ 135Axles ......................................................................................................................... 136Brakes ...................................................................................................................... 136Steering .................................................................................................................... 137

Table of contents


Table of contents

Work hydraulics .......................................................................................................137Pilot control ..............................................................................................................137Loader unit ...............................................................................................................138Electrical system .......................................................................................................139Tires ........................................................................................................................140Weights .....................................................................................................................141Sound levels ...........................................................................................................141Vibration ..................................................................................................................141Hardware torques .....................................................................................................142Dimensions model 480 ............................................................................................143


Introduction

Introduction

General information

Your decision to purchase this piece of Gehl equipment was a good one. We are sure that your decision was carefully considered and that you are looking forward to many years of reliable performance from this machine.Gehl Company has invested much time and effort in developing its lines of equipment. The equipment you have purchased is built with a great deal of pride, and designed to provide long life, efficient operation, durability and dependability.Modern machinery has become more sophisticated and, with that in mind, Gehl Company asks that you read and COMPLETELY understand the contents of this manual and become familiar with your new machine, BEFORE attempting to operate it. This manual was developed specifically for the machine you have purchased. The infor-mation within is for your assistance in preparing, adjusting, maintaining and servicing your machine. More importantly, this manual provides an operating plan for safe and proper use of your machine. Major points of safe operation are detailed in the SAFETY chapter of this manual – see Safety instructions on page 16. Refer to the Table of Contents for an outline (by chapters) of this manual. Use the Index, located at the back of this manual, for specific chapter and topic/page number references.If this machine is resold, Gehl Company recommends that this manual be given to the new owner. If this machine was purchased "used," or if the owner's address has changed, please pro-vide your Gehl dealer or Gehl Company with the owner's name and current address, along with the machine model and serial number. This will allow the registered owner informa-tion to be updated, so that the owner can be notified directly in case of an important prod-uct issue, such as a safety update program.“Right” and “left” are determined from the position of sitting in the operator’s seat, facing forward.Gehl Company reserves the right to make changes or improvements in the design or con-struction of any part without incurring the obligation to install such changes on any unit pre-viously delivered.Throughout this manual information is provided that is introduced by the word NOTE or IMPORTANT. Be sure to read carefully and comply with the message or directive given. Following this information will improve your operating or maintenance efficiency, help you to avoid costly breakdowns or unnecessary damage and extend your machine's life. Operational safety and readiness of the machine depend partially on maintenance and service of the machine. This is why regular maintenance and service work is absolutely necessary. Extensive maintenance and repair work must always be carried out by a quali-fied technician with appropriate training. Insist on using Gehl original service parts when carrying out maintenance and repair work. This ensures operational safety and readiness of your machine, and maintains its value.Our wide dealership network stands ready to provide any assistance required, including genuine Gehl service parts. All parts should be obtained from or ordered through your Gehl dealer. Give complete information about the part as well as the model number and serial number of your machine. Record numbers, in the spaces provided, as a handy record for quick reference.

Purchased from: ___________________________________Date of Purchase: __________________________________Model No.: _______________________________________Serial No.: ________________________________________

Introduction


Introduction

Serial number

The serial number is stamped onto the front axle attachment (on the right in driving direc-tion) A. It is also located on the type decal.

Type decal information

Example: Model 480

Machine model: 342Version: 342 00Serial no.: 342 01 0001Model year: 2005Front gross axle weight rating: 8818 lbs. (4000 kg)Rear gross axle weight rating: 8818 lbs. (4000 kg)Gross weight rating: 14,330 lbs. (6500 kg)Output: 59 hp (44 kW)Other information – see Specifications on page 134.

Cab number

The type decal (arrow) is located in the cab, on the top right frame member.

00 4

35 1

2 21

Mad

e in

Ger

man

y

Fhzg-TypModelModŁleTyp / Ausf.VersionVersionFg.-Nr.Serial no.No. de sØrieBaujahrModel yearAnnØe fabr.

Zul. Achslast vornFront GAWRPNBE AVZul. Achslast hintenRear GAWRPNBE ARZul. Ges. Gew.GWRPTACLeistungOutputPerformance

[ kg ]

[ kg ]

[ kg ]

[ kW ]

30300b0010.eps

Fig. 1: Type decal: location

Fig. 2: Type decal

A

Fig. 3: Cab type decal


Introduction

Designated uses and exemption from liability

• The machine is intended for:• Moving earth, gravel, coarse gravel or ballast and rubble.• Working with the attachments mentioned – see Fields of application, attachments on

page 10.• Every other use and attachment is not designated for this machine. Gehl will not be

liable for damage resulting from any other use or attachment. The user alone will bear the risk.

• Follow the instructions in the Operator’s Manual, Maintenance and Service chapters, accident prevention regulations, safety and occupational regulations, and machine and traffic regulations. Gehl is not liable for damage resulting from the failure to follow these regulations.

• You can damage the machine by modifying it with parts, equipment, attachments and optional equipment that is not checked or released by Gehl. Gehl is not liable for damage resulting from the failure to follow these requirements.

• Gehl is not liable for personal injury and/or damage to property caused by failure to properly: • Operate.• Transport.• Service and perform maintenance.• Repair the machine (in accordance with the Operator’s Manual).

• Read and understand the Operator’s Manual before starting, servicing, or repairing the machine. Follow the safety instructions.

• The machine may not be used for transport jobs on public roads.• In applications with lifting gear, only use the machine according to its designated use.

Abbreviations/symbols

• This symbol stands for a list.• Subdivision within lists or an activity. Follow the steps in the recommended

sequence.☞This symbol requires you to carry out the activity described.

➥This symbol marks the passages in the text describing the effects or results of an activity.

n. s. = not shown. “Option” = optional equipment. Stated whenever controls or other components of the machine are installed as an option.

This symbol shows the driving direction – for better orientation in figures and graphics.


Introduction

Identification of warnings and hazardsThe following signal words are used throughout this manual and on decals on the machine to warn of potentially hazardous conditions.

DANGER!/WARNING!/CAUTION!

Failure to follow the instructions identified by this symbol may result in personal injury or death for the operator or other persons.

☞Measures for avoiding the hazard.

IMPORTANT!

Failure to follow the instructions identified by this symbol may result in damage to the machine.

☞Measures for avoiding damage to the machine.

NOTE:

Contains instructions to help use the machine more efficiently.

Environment!

Failure to follow the instructions identified by this symbol may result in damage to the environment. The environment can be damaged if hazardous material (e.g., waste oil) is not properly used or disposed.


Introduction

Machine overview

Fig. 4: Machine outside views

1 Eye hook1 for cab2 Rearview mirror3 Handle4 Headlight with turn indicator5 Tilt cylinder

6Front eye hook for tieing down the machine

7 Loader unit8 Access9 Door handle

1

2

4

6 7 8 9

13

15 16 17 18

11 12

10

10

3

5

14

10Rear eye hook for tieing down the machine

11 Bracket for working light

12Bracket forrotating beacon (option)

13 Engine cover lock14 Backup warning system15 Reflectors16 Tow away facility17 Brake, rear and turn indicator lights18 Door arrester

1. Eye hooks are for removing the cab only, and may not be used for crane-lifting the machine.


Introduction

Overview

The Model 480 is a versatile and powerful helper for moving earth, gravel and debris on construction sites and elsewhere – see Fields of application, attachments on page 10. Equip the machine with the respective safety devices when using it as a lifting accessory –see Applications with lifting gear on page 19.

The main components of the machine are:• ROPS certified cab, enclosed version (standard).

• or ROPS tested cab, open version (option).

• Oil-cooled Deutz four-cylinder in-line diesel engine, 59 hp (44 kW) at 2400 rpm.

• Exhaust emissions according to EC directive 97/68/EC.

• Sturdy steel frame; rubber-mounted engine.

• Automotive drive, infinitely variable hydrostatic axial-piston gearbox;maximum speed 12 mph (20 km/h) (25 mph [40 km/h] option).

• Hydraulic four-wheel power steering with emergency steering feature. The emergency steering feature, located inside the hydraulic system, allows you to steer the machine if you lose hydraulic or motor power.

• Front and rear planetary axles, rear axle with oscillation.

• Service brake (mechanical and hydrostatic), mechanical disc-type parking brake.

Hydrostatic drive The diesel engine drives a hydraulic pump, whose oil flow is sent to a hydraulic motor flanged onto the rear axle. The force of the hydraulic motor is transmitted to the rear axle via the transfer gearbox. At the same time, the front axle is driven by the cardan shaft, ensuring full-time four-wheel drive.

Work hydraulics and hydrostatic four- wheel steering

The diesel engine also drives the joint gear pump for work hydraulics and hydrostatic four- wheel steering. The oil flow of this pump depends on the diesel engine speed only.When the machine is in operation, the entire diesel engine output can be transmitted to the gear pump for work hydraulics and steering by using the inching valve. This valve responds as soon as the service brake is used, reducing or cutting off power input of the drive. Therefore, full engine output is available for the machine by pressing the accelerator pedal and the brake pedal at the same time.

Cooling system A combined engine/hydraulic oil cooler (for the diesel engine and the hydraulic oil) is located at the rear of the machine. The indicators on the instrument panel of the machine allow you to constantly monitor the engine and hydraulic oil temperatures, and the coolant temperature and level.


Introduction

Fields of application, attachments

The attachments determine how the machine is used.

IMPORTANT!

In order to avoid damage to the machine, only the attachments listed below are certified for attachment to the machine.

☞See Use: attachment.

Use: attachment Possible attachments and material densities.

Description of attachment Model Stock

numberUse

Standard bucket – normal material 342-01 810136 Loosening, picking up, transporting and loading loose or solid material (material density ≤ p=1.35 t/yd³ [≤ p=1.8 t/m³])

Standard bucket – lightweight material 342-01 810134 Picking up, transporting and loading lightweight material(material density ≤ p=0.98 t/yd³ [≤ p=1.3 t/m³])

Standard bucket – ultra lightweight materia 342-01 810137 Picking up, transporting and loading very lightweight material (material density ≤ p=0.65 t/yd³ [≤ p=0.9 t/m³])

Pallet forks1 342-01 810135 Picking up and transporting pallets

1. Only in connection with load diagram.


Introduction

Serial number plate locations

Serial number

The serial number is stamped onto the front axle attachment (on the right in driving direc-tion) A. It is also located on the type decal.

Type decal information

Example: Model 480

Machine model: 342Version: 342 00Serial no.: 342 01 0001Model year: 2005Front gross axle weight rating: 8818 lbs. (4000 kg)Rear gross axle weight rating: 8818 lbs. (4000 kg)Gross weight rating: 14,330 lbs. (6500 kg)Output: 59 hp (44 kW)Other information – see Specifications on page 134.

Cab number

The type decal (arrow) is located in the cab, on the top right frame member.

Engine number

The type decal (arrow) is located on the engine cylinder-head cover.

Example: Deutz F4M2011

00 4

35 1

2 21

Mad

e in

Ger

man

y

Fhzg-TypModelModŁleTyp / Ausf.VersionVersionFg.-Nr.Serial no.No. de sØrieBaujahrModel yearAnnØe fabr.

Zul. Achslast vornFront GAWRPNBE AVZul. Achslast hintenRear GAWRPNBE ARZul. Ges. Gew.GWRPTACLeistungOutputPerformance

[ kg ]

[ kg ]

[ kg ]

[ kW ]

30300b0010.eps

Fig. 5: Type decal: location

Fig. 6: Type decal

A

Fig. 7: Cab type decal

Fig. 8: Diesel engine number


Introduction

Hydraulic pump number

The type decal (arrow) is located on the hydraulic pump housing (next to where the pump is attached to the diesel engine).

Hydraulic motor number

The type decal (arrow) is located above the cardan shaft, on the right of the hydraulic motor.

Rear axle number

The type decal (arrow) is located on the inside of the axle tube, on the left side (arrow).

Front axle number

The type decal (arrow) is located on the inside of the axle tube, on the right side (arrow).

Fig. 9: Hydraulic pump: type decal

Fig. 10: Hydraulic motor: type decal

Fig. 11: Rear axle and gearbox: type decal

Fig. 12: Front axle: type decal


Introduction

Safety decalsThe following section explains signs and symbols that may not be easily understood.

IMPORTANT!

Safety decals must be replaced if they become unreadable.

Meaning

The eye hooks on the cab are for removing the cab only and may not be used for crane-lifting the machine – see Moving the machine with a crane on page 22.LocationCab roof (4x).

Meaning

Points for tieing down the machine.The eye hooks are used for tieing down the machine during loading and transport – see Tieing down the machine on page 24.LocationOn the left and right of the machine frame above the front axle attachment, and on the towing facility at the rear.

Meaning

Sound levels produced by the machine.LWA = sound power level.Other information – see Sound levels on page 141.LocationRear window.

Meaning

General indication of danger.This decal warns persons standing or working near the machine of existing hazards within the area of increased danger around the machine.LocationFront left and right of machine frame, and at rear of machine.

Meaning

The CE mark means that the machine meets the requirements of the Machinery Directive and that the conformity procedure has been carried out. The machine meets all the health and safety requirements of the Machinery Directive.LocationOn the rear window.

Fig. 13: Eye hook decal

Fig. 14: Decal for points used for tieing down the machine

XXFig. 15: Decal: sound levels

Gefahr2.ai

Fig. 16: Danger decal

Fig. 17: CE mark

ce.ai


Introduction

Meaning

DO NOT open engine cover before engine is at a standstill.

DO NOT touch any moving or turning parts.

LocationOn the engine cover of the machine.

Fig. 18: Prohibitory decal


Introduction

Notes:


Safety instructions

Safety instructions

Mandatory safety shutdown procedure

Before operating this equipment, read and study the following safety information. In addi-tion, be sure that every individual who operates or works with this equipment is familiar with these safety precautions.Before leaving the machine:• Lower the working equipment to the ground and support it securely.• Reduce throttle and turn off the engine.• Lock out controls by raising right-hand control console.• Remove the ignition key and take it with you.

Unauthorized modifications Any machine modification made without authorization from Gehl could create a safety haz-ard, for which the machine owner would be responsible.For safety reasons, use only genuine Gehl parts. For example, using incorrect fasteners could lead to a condition in which the safety of critical assemblies is dangerously compro-mised.

Attachment precautions Optional kits are available through your dealer. Because Gehl cannot anticipate, identify and test all of the attachments that owners may wish to install on their machines, please contact Gehl for information on approval of attachments, and their compatibility with optional kits.

Operational safety Control the machine cautiously and gradually until you are fully familiar with all the controls and handling. Avoid high-voltage lines. Serious injury or death can result from contact or proximity to high-voltage electric lines. The bucket or boom does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to keep away from power lines not clearly visible to the operator. Depending upon the voltage in the line and atmospheric conditions, strong current shocks can occur if the boom or bucket is closer than 10’ (3 m) to the power line. Very high voltage and rainy weather can further increase the safe operating distance.Before starting any type of operation near power lines (either above-ground or buried cable-type), always contact the power utility and establish a safety plan with them. Before starting to dig, contact authorities. Contact Diggers Hotline One-Call Information at 1-888-258-0808.Below-ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know what is underneath the work site before starting to dig.Be aware of height obstacles. Any object in the vicinity of the boom could represent a potential hazard, or cause the operator to react suddenly and cause an accident. Use a spotter or signal person when working near bridges, phone lines, work site scaffolds, or other obstructions.Use care on loose ground. Carrying heavy loads over loose, soft ground or uneven, bro-ken terrain can cause dangerous side-load conditions and possible tipover and injury. Traveling with a suspended load or an unbalanced load can also be hazardous.If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen ground. Stay away from ditches, overhangs and other weak support surfaces. Never rely on jacks or other inadequate supports when maintenance work is being done. Use solid support blocking.

Safety instructions


Safety instructions

Overhangs are hazardous. Digging under an overhang is dangerous. Know the height and reach limits of the attachment and plan ahead while working. Avoid creating dangerous sit-uations caused by moving around the work site while working. Move to another digging area before large overhangs are formed. Working around deep pits or along high walls or trenches may require support, especially after heavy rainfalls or during spring thaws. Park the machine away from overhangs.Sloping terrain requires caution. Dig evenly around the work site whenever possible, trying to gradually level any existing slope. If it is not possible to level the area or avoid working on a slope, reduce the cycling rate and size of the load.On sloping surfaces, use caution when positioning the machine prior to starting a work cycle. Stay alert for instability situations. Lifting the bucket too high while the boom is turned uphill can also be hazardous.Stay alert for people moving through the work area. When loading a truck you should always know where the driver is.Avoid loading over the cab of a truck, even if the driver is in a safe spot, because someone else could have gone inside. Slow down the work cycle and use slower travel speeds in congested or populated areas. Use commonly understood signals so that other members of the work crew can warn the operator to slow or halt work in a potentially hazardous situation.Operate ONLY while seated at operator’s station. Never reach in through a window to work a control. Do not try to operate the machine unless you’re in the operator’s position, seated at the controls. Stay alert and focused on your work at all times.Use a signal person if you cannot see the entire work area clearly.Replace damaged safety decals and lost or damaged Operator’s Manuals.Do not let anyone operate the machine unless they have been fully trained in safety and in operation of the machine.DO NOT raise or lower a loaded bucket suddenly. Abrupt movements under load can cause serious instability.

Before starting the engine Do a safety check:• Walk around the machine before getting in the cab. Look for leaking fluids, loose

fasteners, misaligned assemblies and other possible equipment hazards.• The operator’s compartment, steps, and hand grips must be free of oil, dirt, ice and

unsecured objects.• The lighting system must be checked for proper working condition before working in

darkness.• Always keep the windshield and windows clean. Poor visibility can cause accidents.• All equipment covers and safety guards must be in place while the machine is being

operated, to protect against injury.• Look around the work site area for potential hazards, and for people or property that

could be at risk while operation is in progress.• NEVER start the engine if there is any indication that maintenance or service work is in

progress, or if a warning tag is attached to controls in the cab.• Check gauges and displays for normal operation prior to and after starting the engine.

Listen for unusual noises and remain alert for other potentially hazardous conditions.• Never use ether starting aids. Glow plugs are used for cold weather starting. Glow

plugs can cause ether or other starting fluid to detonate, causing injury.• Before starting or moving the machine, warn any personnel in the area.


Safety instructions

General safety rulesOnly trained and authorized personnel, with a full awareness of safe procedures, may be allowed to operate or perform maintenance or service on the machine.All personnel at the work site should be aware of assigned individual responsibilities. Com-munication and hand signals used should be understood by everyone.Terrain and soil conditions at the job site, approaching traffic, weather-related hazards and any above or below ground obstacles and hazards should be observed and monitored by all work crew members.Unless necessary for servicing the engine, the engine hood must not be opened while the engine is running.Engine exhaust gases can cause unconsciousness and fatalities. Ensure adequate venti-lation before starting the engine in an enclosed area.Operators should also be aware of any open windows, doors or ductwork into which exhaust gases may be carried, exposing others to danger.Use a signal person in high traffic areas and whenever the operator’s view is not clear, such as when traveling in reverse. Make sure that no one comes inside the working area of the machine.Anyone standing near the machine is at risk of being caught between moving parts of the machine.Never allow anyone to ride on any part of the machine or attachment, including any part of the boom or operator’s cab.

Fire hazards The machine has several components that operate at high temperature under normal operating conditions, primarily the engine and exhaust systems. Also, the electrical sys-tem, if not properly maintained or if damaged, can arc or produce sparks. These conditions make it extremely important to avoid circumstances where explosive dust or gases can be ignited by arcs, sparks or heat.The machine must be cleaned on a regular basis to avoid the buildup of flammable debris such as leaves, straw, etc. Accumulated debris, particularly in the engine compartment, poses a fire hazard. Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well ventilated area. The machine must be parked with controls, lights and switches turned off. The engine must be turned off before refueling or service checks are performed.Static electricity can produce dangerous sparks at the fuel-filling nozzle. In very cold, dry weather or other conditions that could produce static discharge, keep the tip of the fuel nozzle in constant contact with the neck of the fuel-filling nozzle, to provide a ground. Make sure that the static line is connected from the machine to the service truck before fueling begins.Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured.

Jump-starting or charging battery Turn off all electrical equipment before connecting leads to the battery, including electrical switches on the battery charger or jump-starting equipment.When jump-starting from another machine, do not allow the machines to touch. Wear safety glasses or goggles while battery connections are made.

DANGER!

Explosion Hazard – Electrical spark can cause battery to explode.

Connect positive cable first when installing jumper cables. The final cable connection, at the metal frame of the machine being charged or jump-started, should be as far away from the batteries as possible.


Safety instructions

Disconnect the negative cable first when removing the jumper cables. For instructions refer – see Battery on page 120.

Travel precautions Loader control lever should not be operated while traveling. Be sure to lock out the control lever during travel.

IMPORTANT!

Do not change selected travel mode (FAST/SLOW) while traveling.

Travel with the bucket or attachment as low as possible [8”-12” (200 mm-300 mm)] to the ground.Never travel over obstacles or slopes that will cause the machine to tilt severely. Travel around any slope or obstacle that would cause a tilt greater than 10º.

Operate carefully on snow and ice and in very cold temperatures.

In cold weather, avoid sudden travel movements and stay away from even very slight slopes. The machine can slide sideways on icy slopes.Snow accumulation can hide potential hazards. Use care while operating and while using the machine to clear snow.

Parking the machine When shutting down the machine for the day, plan ahead so that the machine will be on a firm, level surface away from traffic and away from high walls, cliff edges and any area of potential water accumulation or runoff. If parking on an incline is unavoidable, block the wheels to prevent movement. Lower the bucket to the ground. There should be no possi-bility of unintended or accidental machine movement.After the machine has been parked properly, shut down the engine and cycle all controls to release any remaining hydraulic system pressure. Be sure all switches and operating con-trols are in the OFF position and the right-hand console is raised, locking out the hydraulic functions.

Applications with lifting gear Definition:Applications with lifting gear are used for raising, transporting and lowering loads with the help of load-securing devices (e.g. slings, chains). In doing so, the help of persons is nec-essary for securing and detaching the load. For example, get help from other people when lifting and lowering pipes, culverts or containers.• The machine may only be used with lifting gear if the necessary safety devices are in

place and functional. • The load must be secured to prevent it from falling or slipping.• Persons guiding the load or securing it must stay in visual contact with the operator.• The operator must guide the load to the ground as soon as possible and avoid any

oscillating or swinging movements.• The machine may be moved with a raised load only if the path of the machine is as

level as possible.• Persons attaching or securing loads may only approach the boom from the side, after

the operator has given permission. The operator may only give permission after the machine is at a standstill and the attachment no longer moves.

• Do NOT use any damaged or incorrectly dimensioned lifting attachments (slings, chains).

• Always wear protective gloves when working with lifting attachments.


Safety instructions

Additional safety equipment

WARNING!

Severe operation may require use of additional safety equipment.

Work in mines, tunnels, deep pits or on loose or wet surfaces could produce the hazard of falling rock, roll over or falling objects. Any operator protective system installed on the machine must comply with applicable safety standards and carry appropriate decaling and rating information.Never attempt to alter or modify the protective structure, by drilling holes, welding or re-locating fasteners. Any serious impact or damage to the system requires a complete integ-rity re-evaluation, and the replacement of the system may be necessary.

Install additional safety equipment if conditions require

When working with a hydraulic breaker, a front guard over the windshield may be required.Laminated glass or polycarbonate protection for the front, side or rear windows may also be recommended depending upon particular work conditions.Contact your Gehl dealer for available safety guards and/or recommendations if there is any risk of being hit by objects that could strike the operator’s cab.

Keep a fire extinguisher at hand It is recommended that a 5 lb. (2.27 kg) or larger, multi-purpose “A/B/C” fire extinguisher be mounted in the cab. Check the fire extinguisher periodically and be sure that work site crew members are trained in its use.

Seat belt must be used at all times When the engine is running, the operator must be seated at the control station with the seat belt fastened.

Safety remindersExposure to crystalline silica Exposure to crystalline silica (found in sand, soil and rocks) has been associated with sili-

cosis, a debilitating and often fatal lung disease. A Hazard Review (Pub. No. 2002-129) by the U.S. National Institute for Occupational Safety and Health (NIOSH) indicates a signifi-cant risk (at least 1 in 100) of chronic silicosis for workers exposed to inhaled crystalline silica over a working lifetime. NIOSH recommends an exposure limit of 0.05 mg/m3 as a time-weighted average for up to a 10-hr workday during a 40-hr work week. NIOSH also recommends substituting less hazardous materials when feasible, using respiratory pro-tection, and regular medical examinations for exposed workers.

Maintain safety equipment in good condition

Machinery guards and body panel covers must be in place at all times. Keep clear of rotat-ing parts, such as cooling fan and alternator belts, which could catch hair, jewelry or loose clothing.

Safety-critical parts must be replaced periodically

Replace the following potentially fire-related components as soon as they begin to show signs of deterioration:Fuel system flexible hoses, fuel tank overflow drain hose and the fuel filler cap.Hydraulic system hoses, especially the pump outlet lines.Keep mounting brackets, hose, and cable routing ties tight. Hose routings should have gradual bends.

High pressure hydraulic lines can store energy

Exposed hydraulic hoses on the boom could react with explosive force if struck by a falling rock, overhead obstacle or other job site hazard. Extra safety guards may be required. NEVER allow hoses to be hit, bent or interfered with during operation.

Operator’s cab should be kept clean Cleaning off accumulations of grease and dirt helps extend equipment service life. Clean-ing also provides an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems result.


Safety instructions

Wear eye protection and safety cloth-ing

Full eye protection, a hard hat, safety shoes and gloves may be required at the job site.

Breathing masks, ear protection may be required

Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause permanent inju-ries.

Transporting

Obey state and local over-the-road regulations. Check state and local restrictions regard-ing weight, width and length of a load. The hauling machine, trailer and load must all be in compliance with local regulations.• Only tow, load, and transport the machine in accordance with the Operator’s Manual. • Safely secure the machine to the transport vehicle. Use suitable mounting points and

load-securing devices.

Towing the machine

• The machine may only be towed using a towing bar or a cable and towing facilities (for example, a towing coupling, hooks, and eyes).

• Tow slowly. Make sure no one is near the towing bar.

• Only tow the machine with a cable if the service brakes and steering are fully operational.

WARNING!

Turning the steering wheel requires greater effort if the diesel engine is off. Remember this when towing the machine.

☞Use a tow bar if the diesel engine breaks down.

IMPORTANT!

The hydrostatic drive can be damaged when towing the machine.

☞Turn off the engine.

☞Short-circuit the hydraulic circuit before towing (see next page).

☞Do not tow the machine for more than 328 ft. (100 m), and do not tow it faster than 1 – 2 mph (3 – 4 km/h).

Follow these procedures to tow the machine:

☞Apply the parking brake– see Parking the machine on page 60.


☞Attach an adequately sized tow bar to the towing facilities.


Safety instructions

☞Switch over the HP pressure relief valves A on the hydraulic pump. To do this:

• Loosen hexagon lock nuts B on both HP valves A.

• Screw in hexagon socket head screws C on both HP valves A until they are flush with lock nuts B.

• Secure hexagon socket head screws C on both HP valves A with lock nuts B.

☞Release the parking brake.

☞Run the engine at idling speed when towing the machine.

Follow these procedures before taking the machine back into service:

☞Change over the HP valves.

• Unscrew hexagon socket head screws C.

• Secure them with lock nuts B.

Moving the machine with a crane

Safety instructions • The crane and lifting gear must have sufficient capacity– see Specifications on page 134.

• Crane handling requires lifting gear of four equal lengths.

• Secure the machine against unintentional movement.

Crane handling

WARNING!

Incorrect crane handling of the machine –

Accident risk.

☞Do not allow anyone to stay in the machine.

☞The person giving the instructions to the crane operator must be within sight or sound of the crane operator.

☞Make sure that the lifting capacities of the crane and the lifting gear (cables, chains) are sufficient.

☞Only load the machine if the standard bucket is empty and in the transport position

– see Use: attachment on page 10.☞Avoid suspended loads.

☞Read the safety instructions

– see Safety instructions on page 16.

Fig. 19: Hydraulic pump when towing the machine

A

BC

A B

C


Safety instructions

☞Load the machine as follows:

• Install and lock the standard bucket – see Re-installing attachments on page 81.

• Empty the standard bucket.

• Set the drive to neutral – see Forward-reverse control [71] on page 56.

• Tilt in the standard bucket and lower it into the transport position– see Driving the machine on page -56.

• Turn off the engine.

• Apply the parking brake – see Prevent rolling away on page 58.

• Remove the ignition key.

• Do not allow anyone to stay in the cab.

• Close the doors and engine cover.

• Fasten the loader at the four points provided by using proper lifting gear– see Machine overview on page 8.

WARNING!

Do not use the eye hooks on the cab for loading the machine.

• Carefully raise the machine.

Loading and transporting the machine

Safety instructions • The transport vehicle must support the height and weight of the machine – see Specifi-cations on page 134.

• Remove any dirt, snow, or ice from the tires.

• Secure the machine to prevent unintentional movement.

Loading the machine

DANGER!

The machine must be loaded and transported properly –

Accident risk.

☞– see Safety instructions on page 39.

☞Follow these instructions to load the machine onto the transport vehicle:• Secure the transport vehicle with chocks to prevent it from rolling.

• Place the access ramps at the smallest possible angle.

IMPORTANT!

Do not exceed an angle of 30°.

• Use access ramps with an antiskid surface only.

• Make sure that the loading area is clear and access to it is not obstructed.

• Make sure that the access ramps and the wheels of the machine are free of oil, grease and ice.

• Start the engine of the machine.

• Raise the bucket so that it does not touch the access ramps.

• Carefully drive the loader onto the middle of the transport vehicle.

Fig. 20: Crane handling

34101b330_01.iso

30864brampe.eps

30˚

Fig. 21: Access ramps


Safety instructions

• Set the drive to neutral – see Forward-reverse control [71] on page 56.

• Lower the bucket onto the loading area.


• Apply the parking brake – see Prevent rolling away on page 58.


• DO NOT allow anyone to stay in the cab.

• Close the doors and engine cover.

Tieing down the machine

DANGER!

The machine must be loaded and transported properly –

Accident risk.

☞– see Safety instructions on page 39.

• Be sure that the authorized maximum height is not exceeded – see Specifications on page 134.

• Secure all tires of the wheel loader with chocks in front of and behind each wheel.

• Firmly tie the machine onto the platform by using the eye hooks and belts or chains – see Machine overview on page 8.

• Before transporting the machine through heavy rain, seal the muffler with a cap or adhesive tape.

• Be sure that the operator of the transport vehicle knows the overall height, width, and weight of the vehicle (including the loader) before leaving.

Attachments • Coupling attachments requires special care. • Before fitting attachments to the machine, secure the control lever of the hydraulic

valve.• Attachments and counterweights affect handling, steering, and brake capability of the

machine. • Fit the attachments with the required devices only. • Before uncoupling or coupling hydraulic lines (hydraulic quick couplers):

• Turn off the engine.• Move the control lever(s) of the hydraulic valve back and forth two times to relieve the

hydraulic oil pressure in the hydraulic system.• Secure the attachments against unintentional movement. • Only operate the machine if all brake, light, hydraulic connections, and protective

accessories are installed and functional.• If optional equipment is installed, all required lights, indicators, etc., must be installed

and functional.• Mount the attachments only after stopping the engine.• When driving or working with machines that have a quickhitch facility, make sure that

the attachment is safely locked in the quickhitch facility. The lock pin must be visible on both sides of the holes on the attachment. Check before starting work.

34001b330_02.eps

Fig. 22: Tieing down the loader

34001b330_17.eps


Safety instructions

CAUTION!

When mounting attachments to the machine, there is a risk of personal injury due to crushing and shearing. Make sure nobody is between the machine and attachment, after first securing the machine and attachment against movement.

Maintenance safety ☞Use proper tools

• While working on the machine, never use inadequate tools. They could break or slip, causing injury, or they may not adequately perform intended functions.

☞Battery electrolyte and explosive gases can be lethal

• Flush eyes with water for 10-15 minutes if battery acid is splashed on the face. Anyone who swallows acid must have immediate medical aid. Call the Poison Control Center listing in the telephone directory.

• Sparks can set off explosive battery gas from incidental contact or static discharge. Turn off all switches and the engine when working on batteries. Keep battery terminals tight. Contact between a loose terminal and post can create an explosive spark.

☞Disconnect batteries for electrical service and before electrical welding

• Remove cable to negative terminal first when disconnecting a battery. Connect positive terminal cable first when installing a battery.

☞Use warning tag/control lockout procedures during service• Alert others that service or maintenance is being performed and tag operator’s cab

controls — and other machine areas if required — with a warning notice. ☞Do not run the engine if repairs or work is being performed alone

• You should always have at least two people working together if the engine must be run during service.

☞Always use adequate equipment supports and blocking• Lower bucket to the ground before leaving the operator’s seat. Do not work under any

equipment supported solely by a lift jack.☞Do not work on hot engines, cooling or hydraulic systems

• Wait for the engine to cool after operation. Park the machine on a firm, level surface and lower all equipment before shutting down and switching off controls. When engine lube oil, gearbox lubricant or other fluids require changing, wait for fluid temperatures to decrease to a moderate level before removing drain plugs.

IMPORTANT!

Engine oil will drain more quickly and completely if it is warm. Do not drain hot fluids, e.g., 200° F (95° C), but do not wait for full cool-down either.

☞Cool-down is required prior to radiator or hydraulic reservoir checks• Stop the engine and allow it to cool before performing service on the engine radiator

or hydraulic reservoir. Both assemblies have pressure vents at the filler cap for venting pressure. LOOSEN CAPS SLOWLY. Vent the pressure before removing the filler caps.

• Release hydraulic system pressure by cycling controls and releasing hydraulic reservoir pressure before removing hydraulic reservoir access cover. The hydraulic reservoir is pressurized. Vent the system pressure by rotating the filler cap. LOOSEN CAP SLOWLY prior to removal.


Safety instructions

• Make sure to release stored hydraulic pressure in lines by cycling the operator’s controls in each direction after the engine has been shut down.

☞Pressurized hydraulic oil leaks can be hazardous• Fluid leaks from hydraulic hoses or pressurized components can be difficult to see,

but pressurized oil can have enough force to pierce the skin and cause serious injury.• Always use a piece of wood or cardboard to check for suspected hydraulic leaks.

Never use your hands. Obtain immediate medical attention if pressurized oil pierces the skin. Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

☞Use correct replacement fasteners tightened to proper torque• Refer to the Parts Manual for information on torques and assembly of components.

Always use the correct parts – incorrect fastener connections can dangerously weaken assemblies.

☞Dispose of all petroleum-based oils and fluids properly• Used motor oil may pose a health risk. Wipe oil from your hands promptly and wash

off any residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities. Never drain any petroleum-based product on the ground or dispose of used oil in municipal waste collection containers, or in metropolitan sewer systems or landfills. Check state and local regulations for other requirements.


Safety instructions

Safety instructions for maintenance

• Remove the ignition key before performing any service, maintenance, or repair work. • If you must have the engine running while performing service, maintenance, or repair

work:• Only work in groups of two.• Both persons must maintain visual contact with each other.• Follow the safety instructions in the Operator’s Manual.• Keep a safe distance away from all rotating and moving parts (e.g. fan blades, V-belt

drives, etc.).• Carry out service, maintenance and repair work only if the:

• Machine is positioned on firm and level ground.• Lever for selecting the travel direction is in neutral.• Parking brake is applied.• Hydraulic attachments and working equipment are lowered to the ground.• Machine is secured against unintentional movement.

CAUTION!

Avoid the risk of accidents by securing parts and large assemblies being moved to the lifting tackle. Stay clear of suspended loads.

CAUTION!

Never use machine parts, attachments, or superstructures as a climbing aid.Wear a safety harness when completing maintenance work at greater heights.Keep all handles, steps, handrails, platforms, landings, and ladders free from dirt, snow and ice.

IMPORTANT!

Before cleaning the machine with water, a steam jet (high-pressure cleaning), or detergents, cover or tape up any openings that must be protected against water, steam or detergent penetration. Special care must be taken with the electrical system.

• After cleaning, examine all fuel, lubricant, and hydraulic oil lines for leaks, chafe marks and damage.

• Tighten any loose connections. • Avoid contact with hot parts, such as the engine block or the exhaust system during the

operation of the machine and for some time afterwards – risk of burns. • Retainer pins can fly out or splinter when struck with force – risk of personal injury. • Do not use ether starting aids. This especially applies to those cases in which a heater

(intake-air preheating) is used at the same time – risk of explosions.

Service and maintenance work on ROPS superstructures (ROPS bar)

• DO NOT do any straightening or welding work on ROPS structures. Damaged ROPS structures must be replaced with original Gehl service parts.


Safety instructions

Safety instructions for specific hazards

Electric energy • Only use original fuses with the specified current rating. Turn off the machine immedi-ately if there are any problems with the electrical system.

DANGER!

When working with the machine, maintain a safe distance from overhead electric lines. If work must be carried out close to overhead lines, keep the equipment/attachments as far away from them as possible.

DANGER!

If your machine comes into contact with a live wire:• Do not leave the machine.• Drive the machine out of the area of danger.• Warn others against approaching and touching the machine.• Have the live wire de-energized.• Do not leave the machine until the damaged line has been safely de-

energized.

• Work on the electrical system may only be done by a trained technician.• Inspect and check the electrical equipment of the machine at regular intervals. Defects

such as loose connections or scorched cables must be rectified immediately.• Follow the operating voltage of the machine/attachments. • Always remove the ground strap from the battery when working on the electrical system

or carrying out welding work. • Jump-starting with a battery cable can be hazardous if carried out improperly. Follow

the safety instructions regarding the battery.

Gas, dust, steam, smoke • Only operate the machine in adequately ventilated premises. • Carry out welding, flame-cutting and grinding work on the machine only if this has been

authorized. Before carrying out welding, flame-cutting and grinding work, clean the machine and its surroundings from dust and other flammable substances.

Hydraulic equipment • Check all lines, hoses and connections regularly for leaks and damage. Repair any damage and leaks immediately. Splashed oil may cause injury and fire.

• Depressurize all system and pressure lines (hydraulic system) to be opened before carrying out any repair work.

• Hydraulic lines must be laid and fitted properly. Make sure no connections are inter-changed. Use only genuine Gehl replacement parts to ensure that the fittings, lengths and quality of the hoses comply with the technical requirements.

Noise • Maintain the muffler and exhaust system in good condition.• Wear ear protectors if necessary.

Oil, grease and other chemical sub-stances

• When handling oil, grease and other chemical substances (e.g., battery electrolyte – sulphuric acid), follow the product-related safety requirements (safety data sheet) carefully to prevent burning or scalding yourself or other persons.


Safety instructions

Battery • When handling the battery, follow the specific safety instructions. Batteries contain sulphuric acid and are caustic.

DANGER!

A hydrogen-air mixture, which creates a risk of explosion, is formed in the battery cells during normal operation, and especially during charging. In the case of a frozen battery or of an insufficient electrolyte level, do not try to start the machine with battery jumper cables. The battery can burst or explode.

Tires • Repair work on tires and rims must be carried out only by technical staff or an authorized dealer.

• Damaged tires and/or wrong tire pressure reduce the operational safety of the machine. Therefore, carry out regular checks of the tires for:• Proper tire pressure.• Damage.

DANGER!

DO NOT inflate tires with flammable gas – this creates a risk of explosion.

• Carry out regular checks of the wheel nuts for tightness. After changing tires, check the wheel nuts after 10 service hours.


Safety instructions

Notes:


Pre-Delivery Checklist

The following checklist is an important reminder of valuable infor-mation and inspections that MUST be made before delivering themachine to the customer. Check off each item after the prescribedaction is taken.

CHECK THAT:

Unit has not been damaged in shipment. Check for suchthings as dents and loose or missing parts; correct or replacecomponents as required.Battery is securely mounted and not cracked. Be sure cableconnections are tight.Cylinders, hoses and fittings are not damaged, leaking orloosely connected.Filters are not damaged, leaking or loosely secured.Machine is properly lubricated and no grease fittings aremissing or damaged.Hydraulic system reservoir, engine crankcase and drive axlesare filled to their proper levels.All adjustments are made to comply with settings provided inthe Maintenance chapter of this manual.All guards, shields and decals are in place and secured.Model and serial numbers for this unit are recorded in thespace provided on this page and on page 4.

Start the engine and test run the unit whilechecking that all controls operate properly.

CHECK THAT:

Drive controls and boom/bucket/steering controls operateproperly and are not damaged or binding.Drive controls are properly adjusted for correct neutralposition.The parking brake, along with the lock-out devices, areactivated with the unit stationary (no pilot control pressure). All hydraulic boom functions are NOT operational with thecontrol lever lock in the lock-out position.

I acknowledge the pre-delivery procedures were performed on thisunit as outlined on this page.

_______________________________________________

Dealership Name_______________________________________________

Dealer Representative’s Name_______________________________________________

Date Checklist Filled Out_______________________________________________

Model & Serial Number

Delivery Checklist

The following checklist is an important reminder of valuable infor-mation that MUST be passed on to the customer at the time ofdelivery. Check off each item as you explain it to the customer.

EXPLAIN:

The Safety Instructions and Operation chapters of thismanual, regarding the safe operation of this machine.The Maintenance and Troubleshooting chapters forinformation regarding the proper maintenance of this machine.Explain that regular lubrication and maintenance is requiredfor continued safe operation and long machine life.Give the Operator’s Manual to the customer and instruct thecustomer to read and completely understand the contentsbefore operating the unit.Completely fill out the Owner’s Registration, includingcustomer’s signature and return it to the Gehl Company.

_______________________________________________

Customer’s Signature

_______________________________________________

Date Delivered

RETAIN FOR CUSTOMER’S RECORDS

CHECKLISTS


Pre-Delivery Checklist

The following checklist is an important reminder of valuable infor-mation and inspections that MUST be made before delivering themachine to the customer. Check off each item after the prescribedaction is taken.

CHECK THAT:

Unit has not been damaged in shipment. Check for suchthings as dents and loose or missing parts; correct or replacecomponents as required.Battery is securely mounted and not cracked. Be sure cableconnections are tight.Cylinders, hoses and fittings are not damaged, leaking orloosely connected.Filters are not damaged, leaking or loosely secured.Machine is properly lubricated and no grease fittings aremissing or damaged.Hydraulic system reservoir, engine crankcase and drive axlesare filled to their proper levels.All adjustments are made to comply with settings provided inthe Maintenance chapter of this manual.All guards, shields and decals are in place and secured.Model and serial numbers for this unit are recorded in thespace provided on this page and on page 4.

Start the engine and test run the unit whilechecking that all controls operate properly.

CHECK THAT:

Drive controls and boom/bucket/steering controls operateproperly and are not damaged or binding.Drive controls are properly adjusted for correct neutralposition.The parking brake, along with the lock-out devices, areactivated with the unit stationary (no pilot control pressure). All hydraulic boom functions are NOT operational with thecontrol lever lock in the lock-out position.

I acknowledge the pre-delivery procedures were performed on thisunit as outlined on this page.________________________________________________

Dealership Name________________________________________________

Dealer Representative’s Name________________________________________________

Date Checklist Filled Out________________________________________________

Model & Serial Number

Delivery Checklist

The following checklist is an important reminder of valuableinformation that MUST be passed on to the customer at thetime of delivery. Check off each item as you explain it to thecustomer.

EXPLAIN:

The Safety Instructions and Operation chapters of thismanual, regarding the safe operation of this machine.The Maintenance and Troubleshooting chapters forinformation regarding the proper maintenance of this machine.Explain that regular lubrication and maintenance is requiredfor continued safe operation and long machine life.Give the Operator’s Manual to the customer and instruct thecustomer to read and completely understand the contentsbefore operating the unit.Completely fill out the Owner’s Registration, includingcustomer’s signature and return it to the Gehl Company.

________________________________________________

Customer’s Signature

________________________________________________

Date Delivered

RETAIN FOR DEALER’S RECORDS

CHECKLISTS

Rem

ove

dea

ler’

s fi

le c

op

y at

per

fora

tio

n.


INTENTIONALLY BLANK(To be removed as dealer’s file copy)

Operation


Operation

Description of controlsThis chapter describes the indicators and controls in the cab.The pages listed in the table refer to the description of the controls.Number/letter combinations describe the controls, for example 40/18 or 40/A, means: fig. no. 40/control no. 18 or position A in fig. no. 40.You can unfold pages (35 and/or 37) for a better overview.

The following symbols are used:• This symbol stands for a list.

• Subdivision within lists or an activity. Follow the steps in the recommended sequence.☞This symbol requires you to complete the activity described.

➥This symbol marks the passages in the text describing the effects or results of an activity.n. s. = not shown.“Option” = optional equipment. Stated whenever controls or other components of the machine are installed as an option.

Operation

Cab overview: see overleaf

Operation


km/h

0

34200b00_00.iso

I

0

Fig. 23: Cab: overview

Cab: overview

Pos. Description For more information see page

Roof console

1 Interior light.................................................................................................................................................................................................622 Sun visor

Operator compartment

3 Instrument panel

4 Steering electronics (25 mph [40 km/h] option)..........................................................................................................................................545 Air vent – front window

6 Fuse box (right) ........................................................................................................................................................................................1397 Air vent – side window

8 Accelerator pedal .......................................................................................................................................................................................579 Door locks ..................................................................................................................................................................................................72

10 Control lever – loader unit ..........................................................................................................................................................................7811 Arrester lock – cab door .............................................................................................................................................................................7212 Control lever base

13 Parking brake lever ....................................................................................................................................................................................58

14 Preheating/start switch ...............................................................................................................................................................................43

15 Switch panel in control lever base

16 Control lever lock 10 for road travel ...........................................................................................................................................................7817 Air vent – rear window

18 Bracket – cab door arrester........................................................................................................................................................................7219 Storage pocket for operator’s manual

20 Tank – washer system ...............................................................................................................................................................................5821 Side console

22 Prepared installation for radio (option)

23 Lever – weight adjustment .........................................................................................................................................................................6824 Seat belt .....................................................................................................................................................................................................7025 Lever – horizontal adjustment ....................................................................................................................................................................6926 Fixture – first-aid kit

27 Operator's seat ...........................................................................................................................................................................................6828 Air vent – leg room

29 Lever – backrest adjustment ......................................................................................................................................................................6930 Hydrostatic steering....................................................................................................................................................................................5431 Service brake pedal (hydrostatic)/inching ..................................................................................................................................................4832 Brake fluid tank.........................................................................................................................................................................................11433 Multifunctional lever....................................................................................................................................................................................5934 Fuse box (left) ..........................................................................................................................................................................................139

19

1 32

5 34

5

6

10

11

13

15

16

8

9

7

14

12

17

1818

33

32

7

30

21

22

23

24

26

11

9

25

31

27

4

20

17

28

29

Operation


Instrument panel overview: see overleaf Instrument panel overview: see overleaf

km/h

00

Operation


Fig. 24: Instrument panel: overview

56 65 66

69

Fig. 25: Multifunctional lever

Instrument panel, multifunctional lever and drive lever: overview


Instrument panel

35 Not Assigned

36 Rocker switch – rotating beacon (option)................................................................................................................................................... 6337 Rocker switch – front working light (option) ............................................................................................................................................... 6238 Indicator (green) – right/left turn indicator for rear attachments .................................................................................................................4239 Indicator (red) – steering synchronization (25 mph [40 km/h] high speed option) ..................................................................................... 5440 Switch – hazard warning system

41 Pressure indicator – hydraulic oil filter ....................................................................................................................................................... 4342 Temperature indicator – hydraulic oil ......................................................................................................................................................... 4243 Indicator (red) – alternator charge function ................................................................................................................................................ 4244 Indicator (red) – parking brake ................................................................................................................................................................... 4245 Indicator (red) – engine oil pressure .......................................................................................................................................................... 4246 Indicator (red) – diesel engine temperature ............................................................................................................................................... 4247 Socket/cigarette lighter

48 Indicator (green) – front axle steering (25 mph [40 km/h] high speed option)............................................................................................ 4349 Indicator (green) – four wheel steering (25 mph [40 km/h] high speed option).......................................................................................... 4350 Indicator (green) – forward driving direction............................................................................................................................................... 4351 Rocker switch – front socket for electrically operated attachments (option) .............................................................................................8252 Tip switch – steering synchronization (25 mph [40 km/h] high speed option)............................................................................................ 5453 Rocker switch with lock – four wheel/front axle steering (25 mph [40 km/h] high speed option) ............................................................... 5454 Rocker switch with lock – 3rd control circuit............................................................................................................................................... 8255 Rocker switch – lights ................................................................................................................................................................................ 6156 Rocker switch – rear working light ............................................................................................................................................................. 62

57 Not assigned58 Indicator (green) – right/left turn indicator .................................................................................................................................................. 4259 Indicator (yellow) – cold starter .................................................................................................................................................................. 4260 Indicator (blue) – high beam ...................................................................................................................................................................... 4261 Fuel level indicator

62 Indicator (red) – 3rd control circuit, continuous operation ..........................................................................................................................8263 Speedometer – high speed (25 mph [40 km/h] high speed option)

64 Indicator (green) – reverse driving direction............................................................................................................................................... 5665 Rocker switch – load stabilizer (option)...................................................................................................................................................... 5266 Rocker switch – rear wiper with tip switch for wiper water ......................................................................................................................... 6667 Rocker switch – drive range selection (25 mph [40 km/h] high speed option) ...........................................................................................54

Fig. 26: Switch panel for heating

Fig. 27: Control lever base

67

68 70 737271

74

75

76

14

77

78

79

80

16

84

85

8683

82

81

6460 63

36 37 40 41 47 48 4935 4438 50 51 52464542 43 5339

59 6158 625554

71 87

72

73

76

New Control Lever (Joystick)


Operation


Multifunctional lever

68 Tip switch – horn ...................................................................................................................................................................................... 5969 Rotary switch and tip switch – front wiper, washer pump .......................................................................................................................... 5970 Lever – turn indicator, high beam, horn ..................................................................................................................................................... 59

Control lever

71 Toggle switch – drive range selection 1 ..................................................................................................................................................... 5772 Tip switch – unlock 3rd control circuit (electrical operation)....................................................................................................................... 7973 Tip switch – lock 3rd control circuit (electrical operation)........................................................................................................................... 7974 Tip switch – unlock 3rd/high-flow control circuit (electrical operation, option)75 Tip switch – lock 3rd/high-flow control circuit (electrical operation, option)

76 Tip switch – neutral drive range 2............................................................................................................................................................... 57

Control lever console

77 Rocker switch – air conditioning system (option)78 Rocker switch – additional control circuit (option)

79 Rocker switch – 3rd control circuit, continuous operation (option)............................................................................................................. 7980 Lock– tilt cylinder (option)

81 Not assigned82 Not assigned

83 Rotary switch – auxiliary heating (option) .................................................................................................................................................. 65

Left side console

84 Rotary switch – heater fan ......................................................................................................................................................................... 6485 Rotary switch – heater fan temperature regulation .................................................................................................................................... 6486 Rotary switch – fresh air/recirculated air .................................................................................................................................................... 6487 Not Assigned

1. Joystick can also be equipped with switch for selection of driving direction.2. Tip switch not fitted if joystick is equipped with switch (neutral position in switch) for selection of driving direction.

Operation


Operation

Getting started

Safety instructions

• Never use the controls or cables as handles.

• Never climb onto or jump off a moving machine.

• Refer to the load diagrams for the loader unit pallet forks – see Load diagram on page 95.

Important information • The machine may only be used in good operating condition in accordance with its designated use and the instructions in the Operator’s Manual, and only by persons who are properly trained and fully aware of the risks involved in operating the machine – see Checklists on page 40.

Running-in period The performance and service life of the machine is heavily dependent on using the machine carefully during its first 100 operating hours.

• Do not overload the machine.

• Do not run the engine at a high speed for extended periods of time.

• Increase the load gradually while varying the engine speed.

• Follow the maintenance schedule – see Maintenance schedule Model 342-01 (overview) on page 125.


Operation

Checklists

Use the checklists in this section to help you check and monitor the machine before, during and after operation.

Start-up checklist Complete the checklist below before starting the engine or putting the machine into service:

No. Question ✔

1 Sufficient fuel in the tank? (➠ 100)

2 Engine oil level OK? (➠ 102)

3 Oil level in hydraulic tank OK? (➠ 108)

4 Water level in washer tank OK? (➠ 66)

5 V-belt condition and tension checked? (➠ 107)

6 Loader unit lubricated? (➠ 113)

7 Brake system (including parking brake) OK? (➠ 49)

8 Tire condition and inflation pressure OK? (➠ 115)

9 Wheel nuts securely tightened (especially after a wheel change)?(➠ 116, 142)

10 Lights, signals, indicators, warning lights and indicators OK? (➠ 61, 62, 42)

11 Windows, mirrors, lights and steps clean?

12 Is the attachment on the loader unit correctly locked? (➠ 81)

13 Is the engine cover firmly locked? (➠ 73)

14 Especially after cleaning, maintenance or repair work:Rags, tools and other loose objects removed?

15 Seat position and rearview mirror correctly adjusted? (➠ 45)

16 Seat belt fastened? (➠ 70)


Operation

Operation checklist Complete the checklist below after starting the engine, during operation, and when driving on public roads:

Parking checklist Complete the checklist below when parking the machine:

No. Question ✔

After starting and during operation:

1 Indicators for engine oil pressure and alternator went out? (➠ 42)

2 Braking effect sufficient? (➠ 49)

3 Temperature indicator for engine coolant in normal range? (➠ 42)

4 Steering working properly? (➠ 48)

5 Is anyone hazardously close to the machine? (➠ 18, 48)

When driving on public roads:

6 Bucket and attachments in the transport position? (➠ 48)

7 Control lever for lift and tilt hydraulics of the loader unit locked with the lock? (➠ 48)

No. Question ✔

When parking:

1 Attachments on the loader unit lowered to the ground? (➠ 60, 78)

2 Parking brake applied? (➠ 58)

3 Machine cab locked (especially if the machine cannot be supervised)? (➠ 72)

When parking on public roads:

4 Machine adequately secured? (➠ 60)

When parking on uphill and downhill gradients:

5 Machine additionally secured with chocks under the wheels to prevent it from rolling away? (➠ 60)


Operation

Indicators and warning lights: overview

Unfold page 35 for a better overview.

46 Indicator (red) – engine oil pressure

Comes on if the engine oil pressure is too low. If the oil pressure is to low:

☞Stop the machine.

☞Turn off the engine immediately and check the oil level (➠ page 102).

Comes on after the ignition is turned and goes out after the engine runs.

45 Temperature indicator – engine and cooling oil

Indicates the engine oil temperature.

IMPORTANT!

The engine oil temperature must range from 176 – 248 °F (80 – 120 °C). The max-imum permissible engine oil temperature is 266 °F (130 °C) (red section).

43 Indicator (red) – alternator charge function

Comes on after the ignition is turned and goes out after the engine runs.

Comes on while the engine is running if:

• The V-belt or charging circuit for the alternator is faulty.

• The battery is not charged any more (➠ page 107).

38 Indicator (green) – right/left turn indicator on rear attachment

Flashes repeatedly:

• When turn indicator 18/33 is used.

• If there is an electrical connection to a front or rear attachment.

60 Indicator (blue) – high beam

Comes on if high beam is turned on or during headlight flashing.

46 Indicator (yellow) – cold starter

Comes on when the key in preheating start switch 18/14 is in position 2 (a glow plug pre-heats the air in the combustion chamber of the engine when the key is in position 2).

43 Indicator (red) – parking brake

Comes on when parking brake lever 19/13 is applied.

42 Hydraulic oil temperature indicator

Comes on if the hydraulic oil temperature exceeds 203°F (95°C).

46

45

43

38

60

46

P43

42


Operation

IMPORTANT!

Risk of hydraulic damage as soon as temperature indicator 47 comes on.

☞Relieve work and driving hydraulics. To do this:

• Stop the machine.

• Move control lever 18/10 to neutral.

• Select neutral by using tip switch 22/76.

• Run the engine at increased speeds until temperature indicator 47 goes out.

41 Indicator (red) – hydraulic oil filter

Indicates too high of pressure in the hydraulic reflux line to the tank. In this case:

☞Have the hydraulic oil filter checked and, if necessary, replaced by an authorized dealer.

58 Indicator (green) – right/left turn indicator

Flashes repeatedly while turn indicator 18/33 is used.

57 Indicator (yellow) – hose burst valve (option)

Indicates that the hose burst valve is turned on (the hose burst valve prevents lowering or dumping out the loader unit without any resistance).

39 Indicator (red) – steering synchronization

Indicates that the wheels on both axles are aligned.

➥– see Synchronizing the steering system (with 25 mph [40 km/h] high speed option) on page 55.

49 Indicator (green) – four-wheel steering

Indicates that four wheel steering is turned on.

➥– see Steering system on page 54.

48 Indicator (green) – front-axle steering (option)

Indicates that front axle steering is turned on.

➥– see Steering system on page 54.

50 and 64 Indicators (green) – driving direction

Indicates forward/reverse driving direction.

➥– see Selecting the drive range on page 50.

41

58

57

39

49

48

64 50


OperationOperation

Notes:


Operation

Starting the engine

Before starting the engine 0☞Complete the Start-up checklist

– see Start-up checklist on page 40.

☞Adjust seat position and rearview mirror.

CAUTION!

All controls must be within easy reach. The operator must be able to fully move the brake and accelerator pedals.

☞Fasten the seat belt.

☞Make sure that the:

• Parking brake (fig. 18/13) is applied.

• Control lever (fig. /) for the loader unit is in neutral.

General

IMPORTANT!

You MUST apply parking brake (fig. 18/13) to start the engine. Do NOT run the starter for more than 10 seconds.

If the engine does not start, wait for about one minute to let the battery recover before trying again.

NOTE:

You cannot start the engine by towing the machine, because there is no driving connection between the engine and gearbox when the engine is off.

• You cannot actuate the starter if the engine is already running (start repeat interlock).

Starting the engine

After completing the instructions – see Before starting the engine on page 45:

☞ Insert the ignition key in preheating/start switch 28/14.

☞Turn the ignition key to position “1”.

☞Check whether the following indicators come on:• 29/46 for the engine oil pressure.• 29/43 for the alternator charge function.• 29/59 for the cold starter.• 29/44 if the parking brake is applied.

IMPORTANT!

If any of the above indicators do NOT come on, they may have failed and should be replaced immediately.

☞Turn the ignition key to position “2,” and hold it in this position for about 5 seconds.

➥The intake air is preheated.

➥ Indicator 46 turns off.

☞Press accelerator pedal 18/8 to about 25% of its maximum power.

☞Turn the ignition key to position “3” and hold it in this position until the engine starts.

☞Release the ignition key.

10 2

3

Fig. 28: Preheating/start switch

14

Fig. 29: Indicators

44

46

43

45


Operation

Starting at low temperatures

☞Turn the ignition key to position “2” hold it in this position for about 15 seconds.

☞Press accelerator pedal 18/8 all the way down.

☞Turn the ignition key to position “3” and hold it in this position until the engine starts.

☞Release the ignition key.

When the engine runs smoothly (increased engine speed):

☞Release accelerator pedal 18/8.

IMPORTANT!

In general, a battery delivers less energy in cold conditions. Therefore, make sure the battery is always well charged.

After the engine has started

☞Check that the following indicators have gone out:

• 29/43

• 29/46

☞Let the engine warm up.

In cold (winter-type) weather

☞ Increase the engine speeds slowly.

☞Do NOT run the engine at full load until it has reached its operating temperature.


Operation

Jump-starting the engine Safety instructions

DANGER!

Never jump-start the engine if the battery of the machine is frozen, because there is a risk of explosion. The Model 480 must not touch the jump-starting machine because when both machines are connected by jump leads, there is a risk of sparking.

• The external power source must deliver 12-V; higher supply voltages will damage the electrical systems of both machines.

• Only use authorized jumper cables that are in good condition.

IMPORTANT!

The jumper cable connected to the positive (+) terminal of the starting battery must never touch electrically conductive machine parts, because there is a risk of short circuit.

• Route the jumper cables so that they cannot catch on rotating components in the engine.

Procedure

☞Start the engine of the jump-starting machine.

☞Connect one end of the red jump lead (+) to the + terminal of the dead battery, then connect the other end to the + terminal of the starting battery.

☞Connect one end of the black jump lead (–) to the – terminal of the starting battery.

☞Clip the other end of the black jump lead (–) onto the engine block.

DANGER!

DO NOT connect the other end of the jump lead to the negative terminal of the dead battery, because gas emerging from the battery may ignite if sparks are formed.

☞Start the engine of the machine with the dead battery.

After the engine has started:

☞While the engine is running, disconnect both jump leads in exactly the reverse order (first remove the – terminal, then the + terminal) – this prevents sparking near the battery).

12 V

12 V

34001b710_05.epsFig. 30: Starting aid with jump leads

Dead battery

Starting battery


Operation

Before driving the machine

Special instructions for public roads • Follow these instructions – see Use: attachment on page 10.

☞Carry out a functional check of:• Brakes.• Steering.• Lights.

☞Empty the bucket

– see Hand lever of the machine on page 78.

☞Tilt back the bucket 31/B.

☞Raise the wheel loader so that both red marks D on the lift frame and the bulkhead are aligned.

IMPORTANT!

Ground clearance for transport 31/C is about 8” (200 mm) (with the standard bucket, standard tires, and both marks D aligned).

Securing the control lever (joystick)

☞Secure control lever 10 against unintentional operation. To do this:

• Lock stop cock 16 (see arrow).

➥The stop cock is located to the right of the control lever base console,next to the preheating start switch.

☞High speed (option): Press rocker switch 24/65 for the load stabilizer.

➥– see Load stabilizer (option) on page 52.

Inspection and adjustment of important functional units

Steering

☞Functional check: Move the steering wheel to the left and right.

The power steering system is only operational when the engine is running. But if the diesel engine or hydraulic steering fails (e.g., failure of the pump drive), the machine can still be steered.

Fig. 31: Driving on public roads

B

C

A

Fig. 32: Marks for the transport position

D

Fig. 33: Lock for control levers

10

16


Operation

WARNING!

If the power steering fails, turning the steering wheel requires greater effort. Take this into account especially when towing the machine.

☞Adapt towing speed to the steering.

☞Use a tow bar.

Wheel synchronization position

NOTE:

The machine has self-synchronizing axles. If you notice that the wheels on both axles do NOT run in the same track – see Synchronizing the steering system (with 25 mph [40 km/h] high speed option) on page 55.

Service brake/inching pedal

WARNING!

The rear brake lights do not come on when you:

• Brake by applying the parking brake.

• Brake hydrostatically with the drive.

☞Only pressing brake/inching pedal 23/31 causes the brake lights to come on.

Dirt accumulation in the area of the brake pedal can result in brake malfunctions –

Accident risk.

☞Always keep brake/inching pedal 23/31 clean.

☞Before driving the machine, press brake/inching pedal 23/31 down and check:

• For resistance after pressing the pedal down to about 50% of its maximum thrust.

• If the brake lights come on after you press the brake pedal down.

☞For resistance after pressing the pedal down at a low speed.

WARNING!

Pressing brake/inching pedal 23/31 down slightly causes the inching valve to respond; the inching valve does NOT effectively brake the machine –

Accident risk.

☞Press brake/inching pedal 23/31 down to its maximum power.


Operation

Driving

IMPORTANT!

You can only move the machine after releasing parking brake 23/31.

After starting the engine:

☞Release parking brake 23/13.

☞Select the driving direction by using toggle switch 27/71 on the control lever.

➥ Indicator 24/50 comes on.

☞Gradually press down accelerator pedal 23/8.

➥Machine is now moving.

Drive range selection

Selecting the drive range

The machine has two drive ranges. To select a drive range:

☞Set the driving direction to neutral by using tip switch 76 on the joystick.

☞Select the required drive range by using rocker switch 67. To do this:

• Press rocker switch 67/B.

➥2nd drive range selected.

• Press rocker switch 67/A.

➥1st drive range selected.

Drive speed without high speed

Drive speed with high speed (option)

Fig. 34: Rocker switch for drive range selection

76

A

B67

Symbol Meaning Recommended

Drive range A = 0 – 3.2 mph(0 – 5.1 km/h).

Use for work involving short loading cycles (i.e., a rapid succession of loading and unloading operations, e.g. onto a truck) and for work requiring precise speed adjustment (e.g., rotary broom applications).

Drive range B = 0 – 12 mph(0 – 20 km/h).

Use for long-haul travel.

Symbol Meaning Recommended

Drive range A = 0 – 3.2 mph(0 – 5.1 km/h).

Use for work involving short loading cycles and for work requiring precise speed adjust-ment, allowing for speeds above 3 mph (5 km/h).

Drive range B = 0 – 25 mph(0 – 40 km/h).

Use for long-haul travel.


Operation

Selecting drive range, high speed (option)

Switching on high speed (option)

IMPORTANT!

Front axle steering is automatically selected when you shift to high speed.

☞Press lock A of rocker switch 53 in the direction of the arrow and at the same time press rocker switch 53 down.

➥ Indicator 48 on the instrument panel comes on.

☞Select the required drive range by using rocker switch 67.

☞Select the required driving direction by using toggle switch 71 (located on the joystick).

Shifting from high speed (option)

CAUTION!

Changing front-axle to four-wheel steering at high travelling and engine speeds is hazardous –

Accident risk.

☞Slow the machine down to 12 mph (20 km/h) before changing front axle to four-wheel steering.

☞Press rocker switch 53.


☞Select the required drive range with rocker switch 67.

☞Select the required driving direction with tip switch 71 on the joystick.

Changing direction

CAUTION!

Changing direction at high speed and full throttle causes the machine to brake immediately.

Accident risk.

☞Slow the machine to walking pace before changing direction.

☞Reduce engine speed by removing your foot from accelerator pedal 23/8.

☞Slow the machine to a walking pace.

☞Select a new driving direction by using toggle switch 71 as follows:

Fig. 35: Rocker switch for high speed (option)

7671

53

67

48 49

A

Fig. 36: Lever for selection of driving direction

F

R

71

76

50 64 Function Operation Effect

• Forward ☞Press toggle switch 71 forward F.

➥ Indicator 50 comes on.

• Reverse ☞Press toggle switch 71 rearward R.


• Neutral ☞Press tip switch 76 down. ➥ Indicators 50/64 turn off.


Operation

Load stabilizer (option)

The load stabilizer protects the machine against unstable oscillating movements.

DANGER!

When driving on public roads, the machine may become unstable if the load stabilizer is NOT turned on –

Accident risk.

☞Always turn on the load stabilizer when driving on public roads.

☞Follow these instructions

– see Before driving the machine on page 48.

IMPORTANT!

Do NOT use the load stabilizer while performing heavy duty work.

Refer to the following table to determine when to use the load stabilizer:

Turning on

☞Press bottom of rocker switch 65, below A.

➥ Indicator in rocker switch comes on.

Turning off

☞Press top of rocker switch 65, above B.

➥ Indicator in rocker switch turns off.

Before working with the loader unit:

☞Turn off the load stabilizer.

IMPORTANT!

The loader unit yields easily with the load stabilizer turned on, making it difficult to carry out any precise lifting movements. The lifting capacity of the loader unit is only about 60% of the rated capacity.

Load stabilizer

Turned off Turned on May be turned on• In general for heavy-duty

work, e.g., picking up excavated material.

• For driving on public roads.

• For lighter work with the loader unit.

• For light off-road transport.

Fig. 37: Rocker switch for load stabilizer (option)

B

A

65


Operation

Backup warning system The backup warning system consists of backup alarm A, fitted onto the inside of the towing device cover, and a switch and wiring. The backup alarm generates an acoustic signal when you shift into reverse. The acoustic level is about 103 dB(A) at a distance of 3’ (1 m) and at a frequency of 2800 Hz.

WARNING!

When backing up with the machine –

Accident risk.

☞Make sure nobody is within the work area of danger of the machine.

☞Do not rely exclusively on the backup alarm to alert others.

Differential lock

IMPORTANT!

A differential lock distributes traction evenly to the front and rear wheels.Both the front and rear axles of the machine are fitted with self-locking differentials. The lock value is 45% for each axle. The differential is locked automatically and cannot be turned on or off by the operator.

Fig. 38: Backup warning system

A


Operation

Steering system

Synchronizing the steering system

WARNING!

DO NOT synchronize the steering system as you drive on public roads –

Accident risk.

☞Synchronize the steering system as described below before driving on public roads.

If the wheels on both axles are not running in the same track:

☞Drive at a slow speed, turn the steering wheel slowly to the left and right maximum positions twice.

☞Quickly turn the steering wheel back to the straight-ahead position.

☞Contact your Gehl dealer if this does not synchronize the wheels.

Synchronizing the steering system(with 25 mph [40 km/h] high speed option)

After starting the machine, synchronize by turning the steering wheel to the left and right. Indicator 40/39 comes on as you turn the wheel. When both steering rams have passed through the straight-ahead position from both directions, synchronization is complete and Indicator 40/39 turns off.

Only the first drive range is active during synchronization. Use rocker switch 40/67 to select the second range, the machine shifts after it finishes synchronizing.

IMPORTANT!

You must synchronize if the wheels no longer follow the same track when driving straight-ahead on level ground.

☞Proceed as follows:

• Machines with high speed (option): make sure high speed is turned off.

IMPORTANT!

The machine must be at a standstill.

• Select low drive range 67/A – see Forward-reverse control [71] on page 56.

• Drive at walking pace on level ground and press tip switch 52/B.

• Steer to the left and right while driving until indicator 39 turns off.

• Complete a functional check of the steering system.

Fig. 39: Tip switch for steering synchronization

67AB

SO

52

AB

39


Operation

Changing steering mode (with high-speed option)

Front-wheel steering

The machine actuates front-wheel steering when you shift to high speed (option).

➥– see Drive range selection on page 50.

➥The machine shifts only after the rear axle is set to straight-ahead. Indicator 48 flashes as the machine shifts.

➥ Indicator 48 for front-wheel steering comes on.

Four-wheel steering

The machine actuates four-wheel steering when you disengage high speed (option).

➥– see Drive range selection on page 50.

➥The machine shifts after the front axle is set to straight-ahead. Indicator 49 flashes as the machine shifts.

➥ Indicator 49 for four-wheel steering comes on.

AB

Fig. 40: Steering mode selection (with high speed)

4849

53SO


Operation

Driving the machine

Controls

Preheating/start switch [14]

The engine will NOT start unless the parking brake is applied and the indicator is on.

Forward-reverse control [71]

Function

• Select the driving direction by using toggle switch 71 on the joystick.

• Select the neutral position by using tip switch 76 on the joystick.

• Select the driving direction by using indicators 50 and 64 on the instrument panel.

☞– see Driving on page 50.

Neutral position is activated after you start the engine, apply the parking brake, or switch off the engine. You can only select the driving direction if the parking brake is released.

10 2

3

Fig. 41: Preheating/start switch

14 Position Function Power consumer

0 Inserting or removing the ignition key.

None.

1 ON/drive position. ➥All functions are operational.

➥ Indicator comes on if the parking brake is applied.

2 Preheating the engine(10 – 15 seconds).

➥– see Starting the engine on page 45.

3 Starts the engine. ➥– see Starting the engine on page 45.

Fig. 42: Lever for selection of driving direction

F

R

71

76

50 64

Function Operation Effect

• Forward ☞Press toggle switch 71 forward F.


• Reverse ☞Press toggle switch 71 rear-ward R.


• Neutral ☞Press tip switch 76 down (if equipped with switch 71 move to neutral).

➥ Indicators 50 and 64 go out.


Operation

Drive range selector

• Select the drive range by using rocker switch 67 located on the instrument panel on the right.

☞– see Drive range selection on page 50.

Accelerator pedal [8] Accelerator pedal 23/8 controls the drive speed as follows:

Speed depends on the drive range selected with rocker switch 44/67.

Brake/inching pedal [31] Function

• To brake the machine regardless of the setting of the drive lever 36/71 and accelerator pedal 23/8.

• When you inch the brake pedal (pedal pressed in slightly), the pedal can be used like a car’s clutch. The drive system is no longer supplied with hydraulic oil, which means the entire engine output is available to the work hydraulics. This allows you to raise the loader unit rapidly.

Braking

☞Press brake/inching pedal 23/31 down with force.

Inching

☞Press brake/inching pedal 23/31 down slightly.

Fig. 43: Drive range selector

67AB

Rocker switch 67 Drive speeds

Position To do this... StandardHigh speed

option

A☞Press rocker switch 67 down. 1st = 0 – 3.2 mph

(0 – 5.1 km\h).1st = 0 – 3.2 mph

(0 – 5.1 km\h).

B☞Press on the symbol on rocker

switch 67.2nd = 0 – 12 mph

(0 – 20 km\h)2nd = 0 – 25 mph

(0 – 40 km\h).

• Press accelerator pedal 23/8 down. ➥Drive speed is increased.

• Release accelerator pedal 23/8 slowly.

➥Drive speed is reduced.

• Release accelerator pedal 23/8 fully. ➥Hydrostatic braking.


Operation

Parking brake [13]

IMPORTANT!

You cannot start or drive the machine unless parking brake 46/13 is released.

Function

• Prevents the machine from rolling away (use on sloped surfaces only).

• Emergency brake (only use if the service brake fails).

DANGER!

Only use parking brake 13 instead of the service brake if the service brake fails. When you use parking brake 13, the brake lights do not light up, and the machine brakes abruptly –

Accident risk.

Prevent rolling away

☞Pull lever 13 up into the top notch.

➥ Indicator 24/45 comes on.

➥Neutral is activated.

Release the parking brake

☞Pull up lever 13 slightly.

☞Press button A.

☞Move lever 13 all the way down.

13

Fig. 44: Parking brake

13

Fig. 45: Applying and releasing the parking brake

A


Operation

Multifunctional lever [33] Function

• Use lever 70 to actuate the multifunctional lever (turn indicators).

• Use lever 70 to switch the high beam on and off.

• Use lever 70 to flash the headlight flasher.

• Use rotary switch 69 to start the washer pump for the front window.

• Use tip switch 68 to sound the horn.

Actuate high beam and headlight flasher

Actuate the turn indicators

Actuate the wiper with the rotary switch for the washer pump

Actuate the horn

34200b0312.eps

69 70

33


68

34200b0312.eps

70Fig. 47: Actuating high beam and headlight

O

2

1

Position Lever Effect

• 0 ☞ In idle position (center position).

➥High beam and headlight flasher OFF.

• 1 ☞Pull up to position 1 and release.

➥ If low beam is turned on by using switch 24/55, high beam ON.

• 2 ☞Pull up to position 2 and hold.

➥Headlight flasher ON, indicator 24/60 comes on.

34200b0313.eps

Fig. 48: Turn indicator

L

R

0

Position Lever Effect

• L ☞Push forward. ➥Left turn indicators come on.

• 0 ☞ In center position. ➥None.

• R ☞Push downward. ➥Right turn indicators come on.

34200b0313.eps

Fig. 49: Horn and washer pump

692

Position Effect

• J ➥Not assigned.

• 0 Turn to position 0. ➥OFF.

• 1 Turn to the right to position 1. ➥Slow wipe.

• 2 Turn to the right to position 2. ➥Fast wipe.

• 69/2Slide the rotary switch to the right. ➥Washer pump ON.

34200b0313.eps

Fig. 50: Horn and washer pump

68

Tip switch Effect

☞Press outer tip switch 68. ➥Horn ON.


Operation

Stopping the machine

☞To stop the machine, proceed as follows:

• Reduce engine speeds by removing your foot from accelerator pedal 23/8.

• Stop the machine by pressing service brakes 23/31.

• Set the driving direction to neutral by using tip switch 27/76 on the joystick.

• Apply the parking brake by pulling the lever up to the last notch– see Parking brake [13] on page 58.

➥Indicator 24/45 comes on.

Parking the machine

WARNING!

Machines parked on slopes may roll away. If you park on a slope:

☞Apply the parking brake

– see Parking brake [13] on page 58.

☞Place chocks under the downhill sides of the tires.

☞Stop the machine

– see Stopping the machine on page 60.

☞Set the driving direction to neutral by pressing tip switch 27/76 on the joystick.

☞Use the parking brake


☞Lower the machine. To do this:

• Push control lever 23/10 forward out of neutral.

• Place the bucket on the ground so that the edge is flush with the ground. To do this: Push control lever 23/10 to the left or right.

➥– see Hand lever of the machine on page 78.

After operation at full power

☞Allow the engine to run until the temperature stabilizes.

☞Turn off the engine. To do this:

• Turn the ignition key to position “0.”


➥– see Preheating/start switch [14] on page 56.


Operation

Light system

The switch panel for the light system is located on the left side of the instrument panel.

IMPORTANT!

The parking light stays lit if the ignition is turned off. Turn off the parking light by turning the key in the preheating/start switch 23/14 to position 0.

Fig. 51: Light system switches

B

A

55

60

Parking lights

ON ☞Press rocker switch 55/B into the 1st position.


OFF ☞Press rocker switch 55/A down. ➥ Indicator in rocker switch turns off.

Low beam

ON ☞Press rocker switch 55/B into the 2nd position.


OFF ☞Press rocker switch 55/A down. ➥ Indicator in rocker switch turns off.

34200b0312.eps

70


O

2

1

High beam

ON ☞With low beam turned on, pull lever 70 to position 1 towards the steering wheel and release.

➥High beam and indicator 52/60 come on.

OFF ☞ Push lever 70 to position O towards the steering wheel and release.

➥High beam and indicator 52/60 turn off.

Headlight flasher

ON ☞Pull lever 70 up to position 2 and hold.

➥High beam and indicator 52/60 come on.


Operation

Working light

WARNING!

The working light may momentarily blind motorists on public roads.

☞DO NOT turn on the working light when driving on public roads.

Interior light

Fig. 53: Switch for working light

56

B

A

37

Front and/or rear working light (option)

ON ☞Press rocker switches 37/B front and 56/B rear down.


OFF ☞Press rocker switches 37/A front and 56/A rear down.

➥ Indicator in rocker switch turns off.

Fig. 54: Switch for interior light

1

Interior light 3

ON ☞Press switch 1 to the left or right.

OFF ☞Move switch 1 to center position.


Operation

Signaling system

CAUTION!

If indicator 56/58 flashes about twice as fast as normally:

☞Check the front and rear indicators immediately.

➥Have the turn indicator system repaired if necessary.

Rotating beacon (option)

km/h

Fig. 55: Switch for hazard warning system

58 40 Hazard warning system

ON ☞Press switch for hazard warning system 40.

➥The indicator in the switch and indicator 58 come on.

OFF ☞Press switch for hazard warning system 40.

➥The indicator in the switch and indicator 58 turn off.

34200b0313.eps

Fig. 56: Turn indicator

70

R

L

Turn indicator

LEFT ☞Pull lever 70 to the rear L. ➥ Indicator 56/58 flashes.

RIGHT ☞Push lever 70 to the front R. ➥ Indicator 56/58 flashes.

B

A

36

Fig. 57: Switch for rotating beacon

Rotating beacon (option)

ON ☞Press rocker switch 36/B. ➥ Indicator in rocker switch comes on.

OFF ☞Press rocker switch 36/A. ➥ Indicator in rocker switch turns off.


Operation

Cab heating and ventilation

IMPORTANT!

The machine heater can be set to any of the following four modes:

• Ventilation, fresh air.

• Heating, fresh air.

• Heating, mixed mode.

• Heating, recirculated air.

The air flow is directed to the front window via the two defroster vents 23/5, to the two leg room vents 23/7, and to the rear window via the two defroster vents 23/17.

Each nozzle can be closed and directed separately.

The side console with the rotary switches for the heating system is located on the left side, next to the operator's seat.

0

84

Fig. 58: Heating adjustment

C

85

86

C

W

BA

E

D

Ventilation, fresh air

1st speed☞Switch 87 in position A.

☞Switch 86 in position D.

Heating, fresh air

2nd – 3rd speed

☞Switch 84 in position B and/or C.

☞Set the required temperature by using switch 85.

➥C = cold / W = warm

☞Switch 86 in position D.

Heating, mixed mode

2nd – 3rd speed


☞Set the required temperature by using rotary switch 85.


☞Switch 86 between position D and E.

Heating, recirculated air mode

2nd – 3rd speed


☞Set the required temperature by using switch 85.


☞Switch 86 in position E.


Operation

Auxiliary heating (option)

DANGER!

Turn off the heater immediately if you are working near a gas station and/or are in any other work environment where flammable vapors or dust may arise (e.g. fuel, coal, wood dust, cereal storage, etc.) –

Risk of explosion.

☞Turn off heater first.

☞Always switch off heater before refueling.

Exhaust gases contain toxic matter –

Risk of poisoning and suffocation.

☞Turn off the heater before entering closed rooms.

☞Turning cab heating on and off; setting the temperature.

IMPORTANT!

There is a delay between when you turn rotary switch 83 to when the changes take effect. After switching off the auxiliary heating, it will run until it has cooled off.

Correcting malfunctions Proceed as follows:

☞Turn heater off and on again, a maximum of two times.

☞Check the fuse.

➥Have repair work carried out by an authorized dealer only.

If the heater overheats

WARNING!

Indicator A flashes repeatedly if the heater overheats.

☞Clean blocked heater ducts and hoses.

☞Turn off and on again.

Fig. 59: Dial for auxiliary heating

83

A

Rotary switch for auxiliary heating (option)

ON☞Continuously turn rotary

switch 83 to the right (MAX).➥ Indicator A in the switch comes on, green

or red, when the machine lights are on.

OFF☞Turn rotary switch 83 to the

left (OFF).➥ Indicator A in switch goes out.


Operation

Windshield washer system

Tank for washer system

The tank filler inlet 20 is located in the engine compartment below the battery.

IMPORTANT!

Fill with clean tap water only. Add a cleaning agent if required. In winter, add anti-freeze to the water. For further information on concentrations – see Fluids and lubricants on page 124.

34200b0313.eps

Fig. 60: Switch for front and rear wipers

69 70

Front window wiper

I ☞ Intermittent wipe. ➥Not assigned.

0 ☞Turn to position 0. ➥OFF.

1 ☞Turn to the right to position 1. ➥Slow wipe.

2 ☞Turn to the right to position 2. ➥Fast wipe.

34200b0313.eps

Fig. 61: Washer pump

A

69 70

Front window washer pump

ON ☞Press tip switch 69 on lever 70 to the right A and hold.

OFF ☞Release tip switch 69.

Fig. 62: Washer pump

66

B

A

Rear window wiper

ON ☞Press rocker switch 66/B down. ➥Rear wiper is on.

OFF ☞Press rocker switch 66/A down. ➥Rear wiper is off.

Rear window washer pump

OFF ☞Press rocker switch 66/B fully down (tip switch function).

20

Fig. 63: Tank for washer system


Operation

Notes:


Operation

Operator's seat

WARNING!

Never change the seat position when driving or working –

Accident risk.

☞Adjust the seat before moving the machine.

☞Make sure the levers for seat adjustment are safely engaged.

Weight setting You can adjust the seat suspension to your weight in 9 levels, 110 – 287 lbs. (50 – 130 kg), with lever 22.

☞Sit down on the operator’s seat.

For a higher weight:

☞Press lever 23 down 22 lbs. (10 kg) per notch.

For a lower weight:

☞Press lever 23 down to the lowest position.

➥Weight setting automatically returns to the upper 110 lbs. (50 kg) position.

☞Press lever 23 down to the required position.

307b0370.ai

307b0380.ai

Fig. 64: Seat adjustment

21

24

22

26

307b0360.ai

Fig. 65: Weight setting

23


Operation

Horizontal adjustment


☞Pull lever 25 up A and at the same time move the operator's seat forward or rearward B.

Backrest adjustment


☞Pull handle 29 up C, and at the same time move the seat forward or rearward D. The backrest reclines as follows E:

307b0330.ai

Fig. 66: Horizontal seat adjustment

25

B

A

307b0350.ai

Fig. 67: Backrest adjustment

29

C

E

D • Seat moved forward. ➥Flatter backrest inclination.• Seat moved rearward. ➥Steeper backrest inclination.


Operation

Seat belt

WARNING!

Do not drive or work with the seat belt unbuckled –

Risk of personal injury.

☞Buckle up before moving or working with the machine.

• Seat belt must not be twisted.

• Seat belt must run over the hips, not over the stomach, and must always be applied tightly.

• Do not place seat belt over hard-edged, or fragile items (tools, metal ruler, glasses, pen) carried inside your clothes.

• Never buckle up two persons by using one seat belt.

• Check seat belts regularly. Have damaged parts immediately replaced by an authorized dealer.

• Always keep seat belt clean.

After an accident, the seat belt strap is stretched and is no longer serviceable. In another accident the same strap –

Will not provide adequate protection.

☞Replace the seat belt strap after an accident.

☞Have fastening points and seat fixture checked for bearing capacity.

Seat belt 24 is designed for the operator's safety during work on construction sites and road travel.

Fastening the seat belt

☞Fasten seat belt 24 as follows before moving the machine:

• Hold the belt at buckle latch A and run it slowly and steadily over the hips to buckle B.

• Insert buckle latch A into buckle B until it engages audibly (pull test).

• Tighten seat belt by pulling at its end.

➥The seat belt must always be tightly in place over the hips.

0763b0007.eps

Fig. 68: Fasten your seat belt

24

B

A


Operation

Unfastening the seat belt

☞Unfasten seat belt 24 as follows:

• Hold the seat belt.

• Press red button C on buckle B.

➥Latch A is released from buckle B by spring action.

• Slowly return the seat belt to the retractor.

Lengthen/shorten seat belt setting

☞Lengthen the seat belt as follows:

• Hold buckle latch A at a right angle to the seat belt and pull the seat belt to the required length.

☞Shorten the seat belt by pulling the free end D of the belt.

IMPORTANT!

When pulled slowly, the automatic seat belt allows full freedom of movement. However, it locks during abrupt braking and may also lock when driving over potholes or uneven terrain.

30763b0006.eps

Fig. 69: Unfastening the seat belt

24

B

A

C

30763b0005.epsFig. 70: Lengthen/shorten seat belt setting

A

D


Operation

Doors

WARNING!

Close the doors when driving and working with the machine –

Accident risk.

☞Close the doors before moving the machine.

Opening the door from the outside

☞Pull door handle A to the outside.

Opening the door from the inside

☞Pull lever B.

NOTE:

Normally, enter and exit the cab by using the left door. If you leave the cab on the right side, secure the control lever (joystick) and fold back the control lever base.– see Exit on right side of cab on page 74.

Securing an open door

☞Press the door against the bracket of arrester 18 until it audibly locks.

IMPORTANT!

Lubricate latch 11 weekly.

Locking the door

☞Press button B of latch 11.

➥The door is released from the lock.

☞Close the door.

A

Fig. 71: Outside door opener and lock

B

Fig. 72: Inside door opener left/right

Fig. 73: Securing an open door

11 18

Fig. 74: Unlocking the door arrester

B


Operation

Opening the cab door to a gap

The door can be opened to a gap and secured with the arrester to improve cab ventilation.

☞Safely engage lever C in door lock D.

Engine cover

Opening

☞Press lock A.

☞Pull the engine cover upwards.

Closing

☞Firmly press down the engine cover until lock A audibly locks.

Locking and unlocking

Lock the engine cover with the ignition key of the ignition switch.

Fig. 75: Door arrester

C

D

Fig. 76: Engine cover lock

A

RL


Operation

Other controls

Exit on right side of cab

The cab door on the right can be used as an entry and exit.

☞Do the following before entering or exiting the cab:

• Stop and secure the machine – see Parking the machine on page 60.

• Lower the loader unit.

• Apply the parking brake.



• Move control lever 10 (joystick) back and forth several times– see Lowering the loader unit with the engine turned off on page 80.

• Secure control lever 10 (joystick)– see Control lever lock (joystick) on page 78.

☞Raise control lever base 12 with handle D to position A.

➥The gas strut keeps the control lever base in the top position.

CAUTION!

DO NOT use handle D on the control lever base as a support for your entrance or exit:

☞Use the entrance handles in the cab.

☞Fold control lever base 12 downwards to position B after you are in the cab.

➥The gas strut keeps the control lever base in the lower position.

NOTE:

The control lever base height can be set with stop bolt C.Fig. 77: Control lever base

A

10

12

B

C

D

12


Operation

Removing the cab for low clearance heights

Machine height without cab – see Dimensions model 480 on page 143.

WARNING!

Incorrectly removing the cab with a crane –

Accident risk.

☞Have loads fastened.

☞Make sure the lifting capacities of the crane and the lifting gear (cables, chains) are sufficient.

☞Avoid suspended loads.

☞Always read the safety instructions

– see Safety instructions on page 16.

☞Remove the cab as follows:

• Drive the machine onto level ground.



• Lower the loader unit without pressure– see Lowering the loader unit with the engine turned off on page 80.

• Remove electrical connection A (behind the operator's seat, on the left).• Remove the rear left and right mudguards.

• Remove the left and right hexagon head screws B used for securing the cab.

• Carefully raise the cab at the four eye hooks C by using a crane.

• Place the cab onto level ground.

Mounting the cab ☞Mount the cab in the reverse order of removal.

Tightening torque for cab attachment: 144 lb.-ft. (195 Nm).

34001b330_01.eps

Fig. 78: Cab removal

C

B

A


Operation

Notes:


Operation

Working with the machine

General safety instructions

• Never drive up to the edge of a pit from the outside – risk of cave-in.

• Never undermine the foundations of walls – risk of collapse.

• When excavating, look out for high-voltage and underground cables, and gas and water pipes.

• When using lifting accessories such as pallet forks, comply with the load diagrams– see Load diagram on page 95.

• The hydraulic system of the machine is still pressurized even when the engine is not running. Depressurize the sections of the system and hydraulic lines that you want to open before starting setup or repair work (e.g., fitting/removing an attachment with hydraulic functions) – see Depressurizing the quick couplers on the loader unit on page 80.

• If your machine is equipped with a load stabilizer (option):

IMPORTANT!

Turn off the load stabilizer before working with the loader unit. If you leave the load stabilizer on, the lifting capacity of the machine is only about 60% of the rated force.

Operation


Operation

Hand lever of the machineControl lever for lift and tilt cylinder hydraulics

WARNING!

Unintentional operation of control lever 10 when driving on public roads:

Accident risk.

☞Lock the lock lever 80/16

– see Control lever lock (joystick) on page 78.

NOTE:

The control valve is equipped with a float position. This helps you when working with a rotary broom, snowplow, and grading in reverse.

Complete the following procedures to turn on the float position:

☞ Push control lever 10 fully forward to final position E.

Control lever lock (joystick)

The lock lever for locking the control lever is located on the control lever base console.

Locking the lock lever

☞Push lock lever 16 lever forward A.

➥The control valve is cut off from the hydraulic oil circuit.

➥Follow these instructions

– see Before driving the machine on page 48.

Opening the lock lever

☞Push stop cock 16 lever rearward B.

➥The control valve is connected to the hydraulic oil circuit.

Fig. 79: Control lever for loader unit

C

D

A B

E

10

Position Lever 10 Function

• A ☞Left ➥Tilts in attachment• B ☞Right ➥Dumps out attachment• C ☞Forward ➥Lowers boom• D ☞Rearward ➥Raises boom• E ☞Fully forward ➥Lowers boom to float position

Fig. 80: Lock for driving on public roads

A 16

B


Operation

Operation of 3rd control circuit

WARNING!

When working with attachments without a hydraulic function, press tip switch 72 on control lever 10 to unlock the quickhitch facility –


☞Turn on rocker switch 54/A

– see Locking 3rd control circuit on page 79.

☞Use rocker switch 60 to lock the 3rd control circuit as follows:

☞The 3rd control circuit is actuated by using tip switches 72 and 73 on control lever 10, with rocker switch 54/A turned off


B

A

Fig. 81: Locking 3rd control circuit

10

C

54

73

h0000000

62

72

10

73

Locking 3rd control circuit Function

ON ☞Press rocker switch 54 down to position A.

➥ Indicator 62 on the instrument panel turns off.

➥Rocker switch 54 is locked.

➥Tip switches 72 and 73 do not function.

OFF ☞Press lock C down.

☞At the same time press rocker switch 54 down to position B.


➥Tip switches 72 and 73 are functional.

Fig. 82: Operation of 3rd control circuit

7372

79

10

73

Operation of 3rd control circuit

Function

Unlocking:

☞Press tip switch 72.

➥With the quickhitch facility connected:

• Unlocks the quickhitch facility.

➥With an attachment connected:

• Pressurizes right hydraulic line.

Locking:

☞Press tip switch 73.

➥With the quickhitch facility connected:

• Locks the quickhitch facility.

➥With an attachment connected:

• Pressurizes left hydraulic line.

Continuous setting:

☞Press rocker switch 79 down to position B.

➥With an attachment fitted.

➥Continuous hydraulic movements/procedures.

➥Operation of hydraulic motors (e.g., rotary broom).

➥Operation of hydraulic equipment with a control valve adjusted to maximum oil flow, and an unpressurized reflux.

• Indicator in rocker switch 79 comes on.

• Indicator 62 on the instrument panel comes on.


Operation

Lowering the loader unit with the engine turned off

Lower the loader unit as follows:

☞Make sure no one is near the machine.

☞Push and hold control lever 10 forward C.

➥Until the loader unit is completely lowered.

☞Return control lever 10 to neutral.

Depressurizing the quick couplers on the loader unit

IMPORTANT!

The hydraulic system of the machine is still pressurized even when the engine is not running. The hydraulic quick couplers can be released, but they cannot be re-attached because the hydraulic lines are pressurized. Therefore:

☞ Depressurize the sections of the system and hydraulic lines that you want to open before starting setup or repair work (e.g., fitting/removing an attachment).

Depressurize as follows:

☞Apply the parking brake



➥Do not turn off the ignition.

☞Press and hold tip switches 72 and 73 on the control lever for about 5 – 8 seconds.

➥Hydraulic lines are depressurized.

☞Turn off the ignition and remove the ignition key.

Fig. 83: Lowering the loader unit with the engine turned off

C

10

Fig. 84: Depressurizing hydraulic lines

7372


Operation

Re-installing attachments

Re-installing attachments is described below for the standard bucket. If you are fitting orremoving attachments with their own hydraulic functions, you must follow the informationprovided in the Operator’s Manual of the attachment.

Fitting attachments onto the quickhitch facility WARNING!

The attachment must always be locked onto the quickhitch facility –

Accident risk.

☞Before working, be sure that the attachment is locked onto the quickhitch by using the lock cylinder. Be sure that you can see the lock pins on both sides of the mounting holes on the attachment.

Re-install as follows:

☞Drive the machine up to the attachment.☞Lower loader unit E by pressing control lever 10 forward C.

☞Tilt the quickhitch facility forward by pushing control lever 10 to the right B.

☞Adjust the height of pin shanks G of the quickhitch facility so that they are under catch hooks F of the attachment.

☞Drive the machine forward until pin shanks G of the quickhitch facility are directly beneath the catch hooks of attachment F.

☞Raise loader unit E until pin shanks G engage in pin shanks Fof the attachment. To do this: Pull control lever 10 rearward D.

☞Fully tilt in the quickhitch facility. To do this:Push control lever 10 to the left A.

Fig. 85: Driving up to the attachment

10

B

C

D

GF

E

Fig. 86: Raising the attachment

E

H

C

D

A

10


Operation

Locking: attachments without hydraulic function

Secure the attachment with lock pins H of the quickhitch facility. To do this:

☞Press tip switch 87/73 on the control lever.

➥Lock pin H engages in the mounting holes of the attachment.

➥Make sure the attachment is safely locked with lock pins H.

☞Lock the 3rd control circuit with the rocker switch (fig. 24/54):

➥– see Locking 3rd control circuit on page 79.

WARNING!

You must be able to see lock pins H on the left and right of the mounting holes on the attachment. The attachment is not safely locked unless you can see the lock pins.

Locking: attachments with hydraulic function



☞Apply the parking brake.

☞Unlock the 3rd control circuit with the rocker switch (fig. 25/54)

➥– see Locking 3rd control circuit on page 79.

☞Depressurize the 3rd control circuit

➥– see Depressurizing the quick couplers on the loader unit on page 80.

☞Attach the hydraulic and electrical connections (if used) for the attachment by following its Operator’s Manual.

Fig. 87: Locking the attachment

H73


Operation

Removing an attachment from the quickhitch facility

WARNING!

The attachment must be placed on the ground so that it will not fall over when removed –


☞Position the attachment so that after unlocking it will not tip over.

Take the attachment off the quickhitch facility as follows:

☞Be sure that the attachment is empty and up.

☞Tilt in the quickhitch facility by pushing control lever 10 to the left A.

☞Lower the loader unit until the attachment is about 2–4 in. (5–10 cm) above the ground by pushing control lever 10 forward C.

☞Unlock the 3rd control circuit by using the rocker switch (fig. 24/54):


For attachments with hydraulic function




☞Unlock the 3rd control circuit with the rocker switch (fig. 24/54)


☞Depressurize the quick couplers

– see Depressurizing the quick couplers on the loader unit on page 80.

☞Change over the quick couplers on the lock cylinder:

• Connect flexible line A onto the right plug D of the quickhitch facility.

• Connect flexible line B onto the left plug C of the quickhitch facility.

• Remove electrical connections (if necessary).

☞Start the engine.

☞Open the lock on the quickhitch facility. To do this:

➥Press tip switch 72 on control lever 10.

☞Slightly tilt the quickhitch facility forward. To do this:Push control lever 10 to the right B.

☞Lower the loader unit. To do this:

➥Push control lever 10 forward C.

As soon as the pin shanks of quickhitch facility F are beneath the catch hooks of attachment E:

☞Release the parking brake.

☞Reverse the machine away from the attachment.

Fig. 88: Lowering and tilting in the attachment

H

C

D

A

10

C D

A

B

C

B

74

10

F

E

Fig. 89: Changing over hydraulic connections – setting down an attachment


Operation

Working with the standard bucket

This section describes work operations for the machine equipped with the standard bucket.

The standard bucket is mainly used for digging, loosening, lifting, transporting and loading loose or solid materials.

Checking the tilt position of the bucket

IMPORTANT!

Angle of mark A = angle of blade B.

Checking the transport position of the bucket

IMPORTANT!

The bucket is in the transport position if:

• Bucket is tilted back completely A.

• Marks on the loader unit and the machine frame are lined up C.

The distance of the bucket (with standard tires) to the ground B is about 8” (20 cm).

B

Fig. 90: Tilt position of the bucket

A

Fig. 91: The transport position of the bucket

A

B

C

Fig. 92: Marks on loader unit and machine frame


Operation

Transporting with a full bucket

WARNING!

Transporting full buckets in the raised position is an –

Accident risk.

Pay attention to this when cornering or driving on slopes. The lower the bucket and center of gravity, the less risk there is of tipping over. To avoid accidents:

☞Tilt the bucket fully back.

☞Raise the bucket to the transport position – see fig. 93.

☞Tilt the bucket all the way back A.

☞Raise the bucket to the transport position:

➥B and C.

Fig. 93: The transport position of the bucket

A

B

C

Fig. 94: Marks on loader unit and machine frame


Operation

Loading loose material

☞Align the blade flush with the ground A

– see Checking the tilt position of the bucket on page 84.

☞Lower the bucket to the ground B. To do this:Push control lever 10 forward C.

☞Drive forward into the material A.

When the engine speeds decreases due to too much material:

☞Slightly raise the bucket B. To do this:Pull control lever 10 rearward D.

Loading if the material is hard to penetrate

☞Proceed as for loading loose material.

☞Tilt the bucket in and out slightly by moving control lever 10 to the left and right A and B.

Ending loading

☞Tilt back the bucket C by pushing control lever 10 to the left A.

☞Reduce engine speed.

A

Fig. 95: Lowering the loader unit

C

B

10

Fig. 96: Driving into the material

BA

D

10

Fig. 97: Loading, if the material is hard to penetrate

B

10

A

Fig. 98: Tilting back the bucket

C

10

A


Operation

☞Reverse out of the material A.

☞Raise the bucket to the transport position B.

Removing material/digging in soft soil

WARNING!

If foundations or walls are undermined – risk of collapse.

Accident risk.

☞Never undermine foundations or walls.

☞Place the bucket horizontally on the ground B by pushing control lever 10 forward C.

☞Set the digging angle α 1 by pushing control lever 10 to the right B.

☞Drive the machine forward 1.

After the bucket has penetrated the soil:

☞Set the digging angle α (slightly flatter) 2 by pushing control lever 10 to the left A, so that the:

• Layer being removed is as even as possible.

• Wheel spin is reduced.

☞Proceed as for loading loose material.

Fig. 99: Reversing out of the material

B

A

Fig. 100: Lowering the bucket horizontal to the ground

C

B

10

α

1Fig. 101: Setting the digging angle

B

1

10

10

Fig. 102: Removing an even layer

2

1

A


Operation

Removing material/digging in hard soil

☞Lower the bucket horizontally to the ground 1 by pushing control lever 10 forward C.

☞Set the digging angle α (flatter) 2 by pushing control lever 10 to the left A.

☞Drive the machine forward 3.

☞Press the bucket rearward slightly by pushing control lever 10 forward C.

After the bucket has penetrated the soil:

☞Set the digging angle α (slightly flatter) 1 by pushing control lever 10 to the left A, so that the:

• Layer being removed is as even as possible.

• Wheel spin is reduced.

☞Push control lever 10 to the left A, or move it alternately to the left and right A and B to loosen the material.

☞Proceed as for loading material hard to penetrate.

Fig. 103: Removing hard soil

2

1

C

3

A10

Fig. 104: Setting the digging angle flatter

1

A B10


Operation

Loading heaped material (non-compacted material)

WARNING!

Digging under heaped material can cause it to collapse –

Accident risk.

☞Never undermine heaped material.

☞Set the blade parallel to the ground by pushing control lever 10 to the left or right A and B.

☞Lower the bucket horizontally to the ground by pushing control lever 10 forward C.

☞Drive forward.

After penetrating the heaped material:

☞Smoothly raise the boom.

☞Keep the bucket level.

When the boom cannot be raised further:

☞Tilt in the bucket 1.

☞Raise the boom 2.

☞Reverse out of the material 3.

☞Lower the attachment into the transport position.

Loading heaped material (compacted material)

☞Proceed as for non-compacted material.☞When raising the loader unit through the heaped material: tilt the bucket slightly in and

out 1.

☞To do this: move control lever 10 alternately to the left and right (A and B).

➥Material is loosened.

Grading

After having finished removing/loading the material:

☞Lower the bucket horizontally to the ground 1.

☞Reverse across the surface to be graded 2.

Fig. 105: Penetrating heaped material

BC

10

A

Fig. 106: Reversing away from heaped material

13

2

Fig. 107: Heaped compacted material

1

A B

10

Fig. 108: Grading

12


Operation

Digging tips

When completing digging work, we recommend the following:

• Exit the pit, as level as possible, from outside the digging line.

• Dig by removing adjacent strips.

• Drive in forward when transporting a full bucket out of the digging area.

• Drive in reverse when transporting a full bucket down a steep slope.

Loading trucks

When loading trucks, we recommend the following:

• The truck and loader working direction should form an angle of 45°.

• Only raise a full bucket to the dump height when you are driving in a straight line towards the truck.

• Dump with the wind behind you to keep the dust away from your eyes, air filters, and fans.

Freeing the wheel loader

If your machine gets stuck in the soft ground:

☞Dump out the bucket until the blade is vertical above the ground.

☞Completely lower the boom.

☞Gradually tilt back the bucket

➥The machine is pushed rearward.

☞Reverse slowly.

☞Repeat this procedure until the wheels reach firm ground.

☞Reverse the machine away.

Fig. 109: Loading machines


Operation

Working with pallet forks

• Maintain a minimum distance of 20’ (6 m) between loader unit/load and overhead lines.

• Before working, be sure that the fork arms on the fork frame are safely locked.

• Always approach the material with the machine wheels in straight-ahead position.

• Always tilt the forks slightly back (toward the machine) for transport.

• Always transport the load close to the ground.

• Only set loads onto designated areas, with a stable base, that have load-bearing capacity.

• Only load on firm and level ground with sufficient load-bearing capacity (for a fully loaded machine).

• Only stack loads up to the authorized maximum pallet height.

• Only place loads in designated areas within the construction site.• Move the fork arms all the way under the pallets so that the load is picked up as closely

as possible to the fork frame.

• Move under the load with the straight fork arms as far apart as possible and at an equal distance to the left and right side of the load (figure b).

• Lock the adjustable fork arms with the locking lever before moving the machine (with loaded or unloaded pallet forks).

• Lower the forks as near as possible to the ground for transport. Follow minimum ground clearance.

• Drive slowly with a raised load, especially in off-road applications, to avoid swinging movements of the load.

• When driving or working across a slope, the load must be on the uphill side of the machine/attachment.

• On sloping terrain, drive the machine rearward to prevent the load from falling off and the machine from tilting forward when braking.

• When transporting large bulk loads, drive the machine rearward for improved visibility.

• Learn the load bearing capacity of bridges, basement ceilings, vaults, and similar struc-tures before moving the machine onto them.

• Learn the clearances of underpasses, tunnels, gates, and similar structures before driving through or under them.

• Follow the load bearing capacity of the set-down area (e.g., truck platforms, storage areas in high-bay warehouses).

• Position and distribute the load evenly on the front tires.

• Never raise a load with only one fork arm.

• Never operate the machine and loaded attachment at high speeds.

• Never leave the machine with the load raised.

• Never work or stand under raised or suspended loads (figure a).

• Never use the controls, movable lines, or cables as handles.

• Never use bent, cracked, or damaged fork arms/pallet forks.

• DO NOT stack or set down loads that are not properly packaged, have shifted in higher places, or have damaged pallets/stacking containers.

• DO NOT overload the attachment or the machine - follow the load diagram.

• DO NOT set down loads too near slopes, construction pits, fire escape routes, equipment that you need to access, etc.

a

126801d0.ai

b


Operation

Overview of fork arms

These instructions are based on the “Guidelines for testing and repairing fork arms” (© by VETTER Umformtechnik GmbH):

• Only use fork arms according to their designated use.

• Only the manufacturer is authorized to complete repair work on the fork arms.

• Always keep fork arms clean.

• Load both fork arms evenly.

• Tie down loads to avoid losing them.

• Follow the limits of application for the fork lift, and its Operator’s Manual.

• Complete frequent visual checks.

• Complete regular checks according to the Operator’s Manual.

• DO NOT exceed the load center and lifting capacity.

• DO NOT use standard fork arms as reverse forks.

• DO NOT push, pull or shove the fork arms, or move them in at a slanting angle (risk of damaging them due to lateral forces).

• DO NOT pull off loads, or allow them to fall onto the fork arms.

• DO NOT raise by using the tilt cylinder (tilt device).

• DO NOT modify the fork arms, or attach any additional device.

• DO NOT transport people on the fork arms.

• DO NOT transport molten material.

• DO NOT perform any cable-laying work.

• The operator must regularly check:

• Lock: Functional check.

• Hooks: Visual check for cracks and deformations.

• Bend: Visual check for indents, nicks and cracks.

• Bend and blade: Do not use any longer if worn over 10%.

• Blade and tip: Check for deformations.

• Wear on fork arms:See service manual or manufacturer.• In case of damage:

Stop using the fork arms.


Operation

Fitting the attachment onto the quickhitch facility

☞Pick up the attachment

➥– see Locking: attachments without hydraulic function on page 82.

WARNING!

The attachment must always be safely locked onto the quickhitch facility –

Accident risk.

☞Before working, make sure that the attachment is safely locked onto the quickhitch facility by using the lock cylinder.

➥You must be able to see the lock pins on both sides of the mounting holes on the attachment.

Removing the pallet forks from the quickhitch facility

WARNING!

The attachment must be placed on the ground so that it will not fall over when removed –


☞Position the attachment so that after unlocking it will stand safely and not tip over.

Checking the lock pins


Operation

Adjusting the fork arms

WARNING!

If the fork arms are not secured to avoid lateral sliding or slipping –

Accident risk.

☞Before using the pallet forks, be sure that both locking levers on the fork arms are folded down. This locks the safety pins of the fork arms in the notches on the fork frame, and prevents the fork arms from slipping or slid-ing.

When you position the fork arms under the load, make sure that they have the greatest possible space between them.

Always evenly align the fork arms to the fork frame.

If necessary, adjust the spacing of the fork arms as follows:

☞Set the locking lever to vertical position a.

➥The fork arms can be moved on the fork frame.

☞Slide the fork arms to the required distance until the safety pin engages in a slot on the fork frame.

☞Fold down the locking lever again, to position b.

➥The upper edge of the locking lever must be flush with edge c.

IMPORTANT!

The locking mechanism must be replaced immediately if it is damaged.

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b

a

c


Operation

Load diagramThe load diagram is located in the cab (front window) of the machine, values are calcu-lated for the respective machine model – see Use: attachment on page 10.

WARNING!

If you exceed the maximum loads stated, the machine may become unstable.

24” (610 mm) load center:

Rated operating load, standard bucket (SAE) - lbs. (kg.)

Rated operating load, pallet forks (SAE) - lbs. (kg.)

3748 (1700) 3031 (1375)


Operation

Picking up loads with the pallet forks☞Move the wheel loader up to the load so that the forks are at a right angle to the load.

➥The fork arms must be the farthest possible distance apart, and at an equal distance from the left and right side of the load.

☞Drive the wheel loader forward and position the fork arms as far as possible underneath the pallet.

➥The load must fit closely to the fork frame.

☞Carefully raise the load.

WARNING!

Do not exceed the loader's output limit, otherwise the machine may become unstable.

☞Follow the load diagram

– see Load diagram on page 95.

☞Tilt in the load slightly rearward.

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Operation

Transporting loads with the pallet forks

DANGER!

When transporting loads with the pallet forks raised, the load can fall down or the machine can tilt –

Accident risk.

When turning or driving on slopes, the center of gravity must always be in the lowest possible position.

☞To avoid accidents:

• Tilt the pallet forks slightly rearward.

• Lower the pallet forks to the transport position, and only raise them (if necessary) just before setting down the load.

• Never raise the load over persons.

• Never park the machine with the load raised.

• Avoid any operation that might endanger machine stability.

☞Only move the load after it is placed on the fork arms.

☞Only move the machine after you have sufficient visibility.

☞Lower/raise loads to the transport position before moving and transporting them. If nec-essary, increase ground clearance for off-road applications.

(ground clearance – see Checking the transport position of the bucket on page 84).

☞Always tilt the pallet forks slightly back (towards the machine) for transport.

☞Always drive slowly (especially in off-road applications) to avoid strong swinging move-ments.

☞When driving or working across a slope, the load must be on the uphill side of the machine/attachment.

☞Drive the machine rearward on sloping terrain to prevent the load from falling off and the machine from tilting forward when braking.

☞Drive the machine rearward when transporting large bulk loads for improved visibility.

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Troubleshooting

Troubleshooting

Use this section to determine malfunctions and repair solutions.

Engine trouble

Problem Possible causesSeepage

Engine does not start or is not easy to start

Parking brake is not applied 58

Steering-column control lever is not in neutral

Engine starting temperature is too low

Wrong SAE grade of engine lubrication oil 124

Fuel quality does not comply with specifications 124

Battery defective or dead 120

Loose or oxidized cable connections in starter circuit

Starter defective, or pinion does not engage

Wrong valve clearance

Fuel injector defective

Engine starts, but does not run smoothly or faultless



Injection line leaks


Engine overheats. Temperature warning system responds

Oil level is too low 102

Oil level is too high 102

Air filter not working 105

Air filter maintenance switch or gauge defective

Oil cooler fins not working

Fan defective, V-belt torn or loose 107

Cooling air heats up

Resistance in cooling system too high, flow capacity too low


Insufficient engine output

Oil level too high 102





Injection line leaks


Engine does not run on all cylindersInjection line leaks


Insufficient or no engine oil pressure

Oil level is too low 102

Engine inclination is too high

Wrong SAE grade of engine lubrication oil 124

Engine oil consumption too highOil level is too high 102


Troubleshooting


Troubleshooting

Engine smoke

BlueOil level is too high 102


White

Engine starting temperature is too low




Black





Problem Possible causesSeepage


Maintenance

Maintenance

Introduction

Operational readiness and the service life of the machine can be increased through proper maintenance.

Before carrying out service and maintenance work, always read, understand and follow the instructions given in:

• – see Safety instructions on page 16.

• The Operator’s Manuals of the attachments.

Daily service and maintenance work, and maintenance according to maintenance plan “A” must be completed – see Maintenance schedule Model 480 (overview) on page 125.

Fuel system

Safety instructions

DANGER!

• When handling fuel, there is a high risk of fire.

• Never work on the fuel system around open flames or sparks.

• DO NOT smoke when working on the fuel system or refueling.

• Before refueling, turn off the engine and remove the ignition key.

• Do not refuel in closed rooms.

• Wipe up fuel spills immediately.

• Keep the machine clean to reduce the risk of fire.

Maintenance


Maintenance

Refueling

Filler inlet A of the fuel tank is located on the right side, in the front section of the cab.

DANGER!

All work involving fuel carries an increased

Risk of fire and poisoning.

☞Do not refuel in closed rooms.

☞Never work on the fuel system in the vicinity of naked flames or sparks.

Environment!Collect and dispose of the fuel in a manner that is consistent with environ-mental laws.

Stationary fuel pumps General

IMPORTANT!

Only refuel from stationary fuel pumps. Fuel from barrels or canisters is usually contaminated.

Even the smallest particles of dirt can cause:

• Increased engine wear.

• Malfunctions in the fuel system.

• Reduced effectiveness of the fuel filters.

Diesel fuel specification Only use high-grade fuels.

Bleeding the fuel system

IMPORTANT!

The fuel system of the machine is bled automatically.

Fig. 110: Fuel filler inlet

A

GradeCetane number

Use

• No. 2-D according to DIN 51601.

Min. 45

For normal outside temperatures.

• No. 1-D according to DIN 51601. For outside temperatures below 39°F (4°C) or for operation above 4’9” (1500 m) altitude.


Maintenance

Engine lubrication system

IMPORTANT!

If the engine oil level is too low or if an oil change is overdue, this may cause:Engine damage or loss of output.

☞Have the oil changed by an authorized dealer

– see Maintenance schedule Model 480 (overview) on page 125.

Checking the oil level

IMPORTANT!

Check the oil level before starting the engine and after every 10 service hours or daily (if you use the machine less than 10 service hours in one day). After turning off a warm engine, wait at least 5 minutes before checking the oil level.

Checking the oil level

Proceed as follows:

☞Park the machine on level ground.

☞Turn off the engine

– see Parking the machine on page 60.

☞Remove the key.


☞Open the engine cover.

☞Pull out oil dipstick A.

• Wipe it with a lint-free cloth.

• Push it back in as far as possible.

• Pull it out and read the oil level.

☞You must fill the oil tank when the oil level reads at the MIN mark on the oil dipstick A

– see Adding engine oil on page 103.

Fig. 111: Checking the oil level

maxmin

A


Maintenance

Adding engine oil

IMPORTANT!

Excessive or incorrect engine oil may result in engine damage. For this reason:

☞Do NOT add engine oil above the MAX mark of oil dipstick 111/A.

☞Only use the engine oil specified

– see Fluids and lubricants on page 124.

Environment!Use a container to collect the engine oil as it drains and dispose of it in a manner consistent with environmental laws.

Filling up the engine oil


• Clean the area around oil filler cap B by using a lint-free cloth.• Open filler cap B.

• Raise oil dipstick A slightly to allow any trapped air to escape.

• Add engine oil.

• Wait a moment until all of the oil has run into the oil sump.

• Check the oil level – see Checking the oil level on page 102.

• Add oil if necessary and check the level again.

• Close filler cap B.

• Push oil dipstick A back in as far as possible.

• Completely clean any oil spilt on the engine.

Engine and hydraulics cooling system

The combined engine/hydraulic oil cooler is located in the engine compartment, on the right side, next to the engine. It cools the diesel engine, hydraulic oil of the drive and the work hydraulics.

Specific safety instructions

• Dirt on the cooling fins reduces the cooler’s heat dissipation capacity. To avoid this:

☞Clean the outside of the cooler at regular intervals – see Maintenance schedule Model 480 (overview) on page 125.

☞ In dusty or dirty work conditions, clean more frequently than the maintenance sched-ule states.

• An insufficient coolant level (engine/hydraulic oil) reduces the heat dissipation capacity and can lead to engine damage.

☞Check the oil level at regular intervals – see Maintenance schedule Model 480 (over-view) on page 125.

☞ If coolant must be added frequently, check the cooling system for leaking and/or con-tact your dealer.

Fig. 112: Oil dipstick and oil filler cap

A

B

OIL


Maintenance

Cleaning the oil cooler

DANGER!

You may come into contact with the engine at hot temperatures when cleaning the oil cooler –

Risk of burns.

☞Wait at least 10 minutes after turning off the engine.

☞Wear protective goggles, gloves, and clothing.


• Park the machine on level ground.

• Lower the loader unit.



• Let the engine cool down.

• Remove the key.

• Open the engine cover.

• Clean the cooling fins by blowing compressed air from side A of the cooler.Fig. 113: Cleaning the oil cooler

A


Maintenance

Air filter

IMPORTANT!

The filter cartridge will be damaged if it is washed or brushed out.To avoid premature engine wear:

☞DO NOT clean the filter cartridge.

☞Replace the filter cartridge when the indicator comes on.

☞Never reuse a damaged filter cartridge.

☞Ensure cleanliness when replacing the filter cartridge.

Weekly air filter contamination check Air filter restriction indicator display B on the filter housing monitors the filter cartridge.

☞Filter cartridge D must be replaced:

• If you can see red mark C in the display maintenance window.

• After 1500 service hours (or yearly if you use the machine for less than 1500 service hours during one year).

– see Replacing the filter cartridge on page 106.

IMPORTANT!

For dusty environments, the air filter is fitted with an extra safety cartridge F. DO NOT clean the safety cartridge. Replace the safety cartridge every third time maintenance work is performed.

IMPORTANT!

Filter cartridges degrade prematurely when you use the machine in acidic air for long periods of time. Acidic air is present, for example, in acid production facilities, steel and aluminium mills, chemical plants, and other nonferrous-metal plants.

☞Replace filter cartridge D and safety cartridge F after 500 service hours

– see Replacing the filter cartridge on page 106.

Weekly dust valve functional check


• Squeeze the discharge slot of dust valve E.

• Remove hardened dust by compressing the upper area of the valve.

☞Clean the discharge slot if necessary.

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Fig. 114: Air filter with maintenance display

B

A

D

FE

C

Fig. 115: Air filter – dust valveE

Maintenance


Maintenance

Replacing the filter cartridge

☞Replace filter cartridge D as follows:


• Prevent the machine from rolling away and remove the ignition key – see Parking the machine on page 60.


• Fold bow hooks G on lower housing section H to the outside.

• Remove lower housing section H.

• Carefully remove filter cartridge D by using slight turning movements.

• Every third time you replace the filter, carefully remove safety cartridge 114/F by using slight turning movements.

• Make sure all contamination (such as dust) inside the upper and lower housing sections is removed.

• Carefully insert new safety cartridge 114/F into the upper housing section.

• Carefully insert new filter cartridge D into the upper housing section.

• Position lower housing section H (make sure it is properly seated).• Close both bow hooks G.

☞After replacing the filter:

• Press button A to reset red mark C (visible in the display maintenance window of indicator B).

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Fig. 116: Removing the lower housing section

G

H

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D

Fig. 117: Removing the filter element

Fig. 118: Air filter with maintenance display

B

A

C


Maintenance

V-belt

DANGER!

Only check, re-tension, or replace the V-belt after the engine is turned off –


☞Turn off the engine before working on or around the engine.

IMPORTANT!

Cracked and stretched V-belts cause engine damage.

☞Have the V-belt replaced by an authorized dealer.

Check the V-belt after 50 service hours (or weekly if you use the machine for less than 50 service hours in one day). Re-tension the V-belt if necessary.

Re-tension new V-belts after about 15 minutes of running time.

Checking V-belt tension

☞Check the V-belt tension as follows:




• Carefully inspect V-belt 1 for damage.

• If the V-belt is damaged:

• Have the V-belt replaced by authorized staff.

• Press with your thumb to be sure that the V-belt cannot be deflected between the pulleys by more than about 0.39” (10 mm).

• Re-tension the V-belt if necessary. See below.

Re-tensioning the V-belt

☞Re-tension the V-belt as follows:




• Slacken attachment screws 3 of alternator 4.

• Use a suitable tool to push the alternator in the direction of arrow A until the correct V-belt tension is obtained (fig. 119).

• Keep the alternator in this position, and at the same time tighten attachment screws 3.

• Check the V-belt tension (fig. 119) again.

Fig. 119: Checking V-belt tension

1approx. 0.39” (10 mm)

Fig. 120: Re-tensioning the V-belt

3

4

A


Maintenance

Hydraulic system

Safety instructions

• You must depressurize all lines carrying hydraulic oil before performing any mainte-nance or repair work. To do this:

• Lower all hydraulically controlled attachments to the ground.

• Actuate all control levers of the hydraulic control valves several times.

• Apply the parking brake to prevent the machine from rolling away before you perform service and maintenance work.

DANGER!

Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries. Always consult a doctor immediately, even if the wound appears insignificant, to be sure that serious infections do not set in.

IMPORTANT!

If the hydraulic oil in the level glass is cloudy, this indicates that water or air has penetrated the hydraulic system. This may damage the hydraulic pump.

☞Contact your Gehl dealer immediately.

IMPORTANT!

Insufficient, incorrect, or contaminated hydraulic oil –

Risk of severe damage to the hydraulic system.

☞Always add hydraulic oil by using the filling screen.

☞Only use the same type of authorized oils


☞Always add the hydraulic oil before the level gets too low.

☞ If the hydraulic system is filled with biodegradable oil, only use the same type of biodegradable oil, following the label on the hydraulic oil tank.

☞Contact your Gehl dealer if the hydraulic system filter is contaminated with metal chippings. Otherwise, damage may result.

Environment!Collect hydraulic oil, including biodegradable oil, with a container. Dispose of drained oil and used filters in accordance with environmental laws. Always contact the authorities or establishments in charge of oil disposal before disposing of biodegradable oil.


Maintenance

Checking the hydraulic oil level



• Retract all hydraulic cylinders.




• Check the hydraulic oil level in sight glass A.

If the oil level is lower than it is in fig. 121/A:

• Fill up the hydraulic oil.

Adding hydraulic oil

IMPORTANT!

Only add hydraulic oil to the hydraulic oil tank if the engine is turned off.

☞Add oil as follows:


• Retract all hydraulic cylinders.




• Clean the area around the filler and breather filter B by using a cloth.

• Open breather filter B.

With the filter insert in place:

• Add hydraulic oil until the tank is full.

• Check the hydraulic oil level by using the oil level sight glass (121/A).

• Fill up if necessary and check again.

• Firmly close breather filter B.

Monitoring the hydraulic oil reflux filter

Refer to the instrument panel, red indicator 41 monitors reflux pressure and filter, indicator 42 monitors oil temperature.

The filter must be replaced by an authorized dealer:

• The hydraulic oil reflux pressure in the filter is too high and indicator 42 comes on.

• The hydraulic oil operating temperature is too high and indicator 41 comes on.

• After 1500 service hours (or yearly if you use the machine less than 1500 service hours per year).

In cold weather, indicator 41 may come on when you start the engine because of increased oil viscosity. In this case:

☞Set the engine speed so that indicator 41 turns off.

– see Starting the engine on page 45.

Fig. 121: Oil level sight glass on the hydraulic oil tank

A

Fig. 122: Hydraulic oil tank

B

Fig. 123: Indicator for reflux filter

42

41


Maintenance

Important information about the use of biodegradable oil

• Only use biodegradable hydraulic fluids that have been approved by Gehl – see Fluids and lubricants on page 124. Always contact your Gehl dealer for the use of other products that have not been recommended. In addition, ask the oil supplier for a written guarantee. This guarantee is applicable to damage occurring on the hydraulic compo-nents, which can be proved to be due to the hydraulic fluid.

• Only use the same type of biodegradable oil when filling up. A decal stating the oil used is located on the hydraulic oil tank (next to the filler inlet).

IMPORTANT!

Replace missing decals.

• Using two different biodegradable oils at the same time can affect the quality of one of the oils. When changing biodegradable oil, be sure that the remaining amount of initial hydraulic fluid in the hydraulic system does not exceed 8% (manufacturer indications).

• If hydraulic attachments are mounted or operated, use the same type of biodegradable oil for these attachments to avoid mixtures in the hydraulic system.

• If you are running the machine with biodegradable oil, the same oil and filter replacement intervals used for mineral oil are valid – see Maintenance schedule Model 480 (overview) on page 125.

• Do NOT top off with mineral oil – the content of mineral oil should not exceed 2%.

• Have an authorized dealer drain the condensation water in the hydraulic oil tank after every 500 service hours (or before the cold season if you have not yet used your machine for 500 service hours). The water content must NOT exceed 0.1% by weight.

• All environmental instructions stated in this manual are valid for the use of biode-gradable oil.

IMPORTANT!

A change from mineral to biodegradable oil must be carried out by an authorized dealer.


Maintenance

Checking hydraulic pressure lines

Safety instructions

DANGER!

Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries.


☞Always consult a doctor immediately, even if the wound appears insignifi-cant, to be sure that serious infections do not set in.

☞Always follow these instructions:

• Only tighten leaking screwed fittings and hose connections after you have released the pressure.

• Only use paper or wood to check for minor leaks, never use an unpro-tected light or open flame.

• Only authorized dealers should replace damaged flexible lines.

• Never weld faulty or leaking pressure lines and connections, always replace damaged parts with new ones.

• Never search for leaks with your bare hands, always wear protective gloves.

• An authorized dealer or after-sales staff should immediately repair or replace any leaking or damaged pressure lines.

• Replace hydraulic hoses every six years from the date of manufacture, even if they do not appear to be damaged.

The date of manufacture (month or quarter and year) is stated on the flexible line.

Example:

The indication “1 Q/05” means manufactured in the 1st quarter of 2005.

1 Q/05


Maintenance

Lubrication points

Lubricate all points listed below with lithium-based brand-name grease – see Fluids and lubricants on page 124.

Lubricating the rear axle oscillation-type bearing

IMPORTANT!

The machine has an oscillation-type rear axle. The bearing must be greased after every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week).

The grease nipple is located above the axle tube, on the left side.

☞Lubricate grease nipples A of the oscillation-type bearing.

Lubricating the planetary drive bearing

☞Lubricate grease nipples B on each planetary drive bearing every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week).

Fig. 124: Grease nipples for oscillation-type bearing

A

Fig. 125: Grease nipples on planetary drive bearings

B

Maintenance


Maintenance

Lubricating the loader unit

Lubricate the following points on the loader unit

☞Lubricate grease nipple C on the tilt cylinder bearing on the frame with grease every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞Lubricate grease nipple D on the loader unit bearing every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubri-cate daily during heavy-duty operation.

☞Lubricate grease nipple E on the lift cylinder bearing on the frame every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞Lubricate grease nipple F on the tilt rod bearing every 10 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞Lubricate grease nipple G on the tilt cylinder bearing every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubri-cate daily during heavy-duty operation.

☞Lubricate grease nipple H on the lift cylinder bearing every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubri-cate daily during heavy-duty operation.

☞Lubricate grease nipple I on the tilt lever bearing every 10 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞Lubricate grease nipples K on the quickhitch bearing every 10 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubri-cate daily during heavy-duty operation.

☞Lubricate grease nipples L on the tilt lever bearing every 10 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

Maintenance of attachments

IMPORTANT!

Correct maintenance and service improves operation and increases the service life of attachments. Follow the lubrication and maintenance instructions in the attachments' Operator’s Manuals.

Fig. 126: Lubrication points on frame

C

D

E

Fig. 127: Lubrication points for lift and tilt ram bearings

F

G

HIK

L


Maintenance

Maintenance of the brake system

Environment!Use a container to collect brake fluid as it drains and dispose of it in accordance with environmental laws.

Safety instructions WARNING!

Brakes are necessary for safety. Incorrect maintenance or repair may cause brake failure.

• All maintenance and repair work on the brakes must be completed by trained staff.

• The machine operator must complete a daily check of the brake fluid level in the tank.

• An authorized dealer must immediately replace damaged brake lines or hoses – risk of accidents.

Checking/filling up the brake fluid level

The brake fluid tank is located at the front, left side in the cab (next to the brake/inching pedal).

DANGER!

An incorrect brake fluid grade or an insufficient brake fluid level may impair the safety of the brake system –

Accident risk.

☞Check the brake fluid in the tank regularly.

☞Fill the brake fluid up to the upper edge of the sight glass.

☞The brake fluid must comply with the SAE specification


☞Replace brake fluid every two years.

If the level is below the upper edge of the sight glass:

• Open tank cover A.

☞Fill the brake fluid up to the upper edge of the sight glass.

Fig. 128: Checking the brake fluid level in the tank

A

MAX

MIN


Maintenance

Tire care

WARNING!

Improper tire repairs are an:

Accident risk.

☞All repair work on tires and rims may only be completed by authorized specialist dealers.

IMPORTANT!

Regular inspection of the tires:

• Improves operating safety.

• Increases the service life.

• Can reduce machine downtime

– see Specifications on page 134 for the authorized tire types and the correct tire pressures. Machines are also delivered with a tire table decal on the front window or the loader unit bulkhead.

Tire check

Daily check

☞Complete the following maintenance work daily:

• Check tire pressure.

• Check the inside and outside of tires and rims for damage (cracks, aging, etc.).

• Remove objects from the tire tread.

• Remove oil and grease.

Weekly check

☞Complete the following maintenance work weekly:

• Check tires for wear and measure tread depth.


Maintenance

Wheel change

DANGER!

Using the wrong tires or wheels –

Accident risk.

☞Only use authorized wheels and tires

– see Tires on page 140.

☞Check the wheel nuts for tightness after every wheel or tire change.

IMPORTANT!

The wheels are heavy and can damage the wheel stud threads if not handled correctly.

☞Use the correct assembly tools, such as covering sleeves for the studs, a jack, etc.

Removing the wheels ☞Proceed as follows:

• Park the machine on level and firm ground, prevent it from rolling away– see Parking the machine on page 60.

• Slightly loosen the wheel nuts of the tire you want to remove.

• Place a jack under the axle beam; and make sure that it is secure.

• Be sure that the jack is firmly positioned.

• Raise the side of the axle from which you want to remove the wheel.

• Be sure that the machine is firmly positioned.

• Remove the wheel nuts.

• Remove the wheel.

Fitting the wheels ☞Proceed as follows:

• Place the wheel onto the wheel studs.

• Partially tighten all wheel nuts.

• Lower the raised axle.

• Tighten the wheel nuts to the correct tightening torque – see Hardware torques on page 142.


Maintenance

Heating

The machine’s heating system is equipped with a dust filter that must be cleaned regularly and replaced yearly.

The filter is located in the cab behind the operator's seat.

Cleaning the dust filter of the heating systemA dust filter cleans the air taken in by the heater. Clean the filter with compressed air as required, but at least yearly. The air that flows from the vents decreases as dust on the fil-ter increases.

☞Clean the filter as follows:

• Remove cover A at the left beside the operator's seat. To do this:

☞ Remove screws B.

• Remove dust filter C. To do this:

☞ Remove the screws.

• Clean dust filter C, replace it if necessary.

• Install cover A.

Fig. 129: Replacing the dust filter of the heating system

A

C

B


Maintenance

Electrical system

Safety instructions

The battery contains sulphuric acid. Sulphuric acid must not come into contact with skin, eyes, clothing, or the machine.

DANGER!

Battery acid is highly caustic.

Risk of acid burn.When recharging and/or working near the battery:☞Always wear goggles and protective clothing with long sleeves.If acid is spilt:☞Thoroughly rinse all affected surfaces immediately with plenty of water.☞Thoroughly wash any body part touched by the acid immediately with

plenty of water and seek medical attention at once.During charging and normal battery operation, an oxygen-hydrogen mixture is formed in the battery cells – risk of explosion.☞Avoid open flame and sparks in the vicinity of the battery and do not smoke.☞Never jump-start the machine if the battery is frozen or if the acid level is

low. The battery may rupture or explode.

IMPORTANT!

Always disconnect the negative pole (–) from the battery before starting repair work on the electrical system.

Only use 12-V power sources, higher voltages damage the electrical compo-nents.

When connecting the battery leads, make sure that the poles +/– are not reversed, reversing the poles damages sensitive electrical components.

Never interrupt voltage-carrying circuits at the battery terminals, the inter-ruption creates a risk of sparking.

Never place tools or other conductive articles on the battery, there is a risk of short circuit.

Service and maintenance work at regular intervals

Before driving the machine

☞Check every time before using the machine:

• Light system.

• Signaling and warning system.

Weekly

☞Check weekly:

• Electrical fuses – see Fuse box on left and right of steering column on page 139.

• Battery terminal, battery cable, cable and ground connections.

• Charge condition of battery – see Battery on page 120.


Maintenance

Instructions for cables, fuses, bulbs, alternator

Cables, bulbs and fuses Follow these instructions:

• Failed electrical system components must always be replaced by an authorized technician. The operator or other persons may change bulbs and fuses.

• Ensure good contact in leads and fuses.

• Blown fuses indicate overloading or short circuits. Check the electrical system before installing the new fuse.

• Only use fuses with the specified amperage – see Fuse box on left and right of steering column on page 139.

Alternator Follow these instructions:

• Only test the engine with the battery connected.

• When connecting the battery, make sure that the poles (+/–) are not reversed.

• Always disconnect the battery before completing welding work or connecting a quick battery charger.

• Replace failed charge indicators immediately– see 37 Rocker switch – front working light (option) 62 on page 37.


Maintenance

Battery

DANGER!

Battery acid is highly caustic.

Risk of acid burn.

When recharging and/or working near the battery:

☞Always wear goggles and protective clothing with long sleeves.

If acid is spilt:

☞Thoroughly rinse all affected surfaces immediately with plenty of water.

☞Thoroughly wash any part of the body touched by the acid immediately with plenty of water and seek medical attention.

During charging and normal battery operation, an oxygen-hydrogen mixture is formed in the battery cells –

Risk of explosion.

☞Avoid open flame and sparks in the vicinity of the battery, and do not smoke.

☞Do not jump-start the machine if the battery is frozen or if the acid level is low.The battery may rupture or explode.

☞Always disconnect the negative pole (–) from the battery before starting repair work on the electrical system.

Battery A is located on the left side of the engine compartment. The original equipment manufacturer battery does not need any fluid to be refilled under normal operating condi-tions. However, have the battery checked at regular intervals.

Always follow the safety instructions for the battery.-

A+

Fig. 130: Battery


Maintenance

General maintenance work

Cleaning

Cleaning the machine consists of three separate cleaning areas:

• Machine interior.

• Machine exterior.

• Engine compartment.

The wrong cleaning equipment and agents can affect machine safety and undermine the health of the persons cleaning the machine.

Follow these instructions:

General instructions for all areas of the machine

When using washing solvents

• Ensure adequate room ventilation.

• Wear suitable protective clothing.

• DO NOT use flammable liquids, such as gasoline or diesel fuel.

When using compressed air

• Wear goggles and protective clothing.

• DO NOT aim the compressed air at the skin or at other people.

• DO NOT use compressed air for cleaning your clothing.

When using a high-pressure or steam jet cleaner

• Cover electrical components and damping materials.

• Cover the vent filter on the hydraulic oil tank, the filler caps for fuel, hydraulic oil, etc.

• Protect the following components from moisture:

• Engine.

• Electrical components (such as the alternator, etc.).

• Control devices and seals.

• Air intake filters, etc.

When using volatile and flammable anticorrosion agents and sprays

• Ensure adequate room ventilation.

• DO NOT use unprotected lights or open flames.

• DO NOT smoke.


Maintenance

Cleaning inside the cab

CAUTION!

Never use high-pressure cleaners, steam jets, or high-pressure water to clean the inside of the cab. Water under high-pressure may:• Penetrate into the electrical systems and cause short circuits.• Damage the seals and disable controls.

Use any of the following to clean the cab:

• Broom

• Vacuum cleaner

• Damp cloth

• Bristle brush

• Water with mild soap solution

Cleaning the seat belt • Only clean the seat belt (DO NOT disconnect the seat belt from the machine) by using a mild soap solution; DO NOT use chemical agents because they may destroy the fabric.

WARNING!

Debris or water on automatic seat belts (option) may affect winding –


☞Only rewind the seat belt if it is both clean and dry.

Exterior of the machine Use either or both of the following to clean the outside of the cab:

• High-pressure cleaner

• Steam jet

Engine compartment

WARNING!

Only clean the engine after it is turned off and stopped –


☞Turn off the engine before cleaning.

CAUTION!

When cleaning the engine with a steam or water jet:

☞The engine must be cold.

☞DO NOT point the jet directly at electrical sensors, such as the oil pressure sender.

Any humidity penetrating these sensors causes them to fail and leads to engine damage.


Maintenance

Checking bolted connections

IMPORTANT!

All bolted connections must be checked regularly, even if they are not listed in the maintenance schedules. Tighten loose connections immediately – see Specifications on page 134 for the tightening torques.

Checking pivots and hinges IMPORTANT!

All mechanical pivot points on the machine (e.g., door hinges, joints) and fittings (e.g., door arresters) should be lubricated regularly, even if they are not listed in the lubrication plan.


Maintenance

Fluids and lubricants

Component/application

FluidSAE gradeSpecification

Season/temperature

Capacities1

1. The capacities indicated are approximate values; only the oil level check is accurate for the correct oil level.

Diesel engine Engine oil2 with filter

2. MIL-L-2104C; API CD/CE/CF4; CCMC-D4.

SAE 10W; EO103

3. Abbreviation for lubricants.

Below 23 °F (-5 °C)

2.8 gal. (10.5 L)

SAE 20W20; EO203 14 ° to 50 °F(-10 ° to 10 °C)

SAE 30; EO303 41 °F to 86 °F(5 °C to 30 °C)

HD-C 10W/40; EO1040B3

Year-roundHD-C 15W/40; EO1540B3

12 mph (20 km/h) gearbox

Gearbox oil4

4. MIL-L-2105B; API-GL5.

80W/90 API GL5 orSAE 90 LS (hypoid gear oil)

Year-round

0.3 gal. (1.25 L)

25 mph (40 km/h) gearbox (option)

1.0 gal. (4.0 L)

Planetary drives – left and right,front axle

0.4 gal. (1.5 L) each

Planetary drives – left and right,rear axle

0.2 gal. (0.7 L) each

Differential – front and rear axle 1.2 gal. (4.5 L) each

Hydraulic oil tank

Engine oil2

SAE 5W/30 Up to -13° F (-25°C)

About 17 gal.(65 L)

SAE 5W/40; EO 0540B3

SAE 10W/40; EO 0540B3 Up to 5°F (-15°C)

SAE 15W/40; EO 1540B3 Up to 14°F (-10°C)

Hydraulic oil5

5. DIN 51 521 T3.

HVLPD 46 (HYD05303) (ATF 46)Year-round

Biodegradable oilAVILUB Syntofluid 46 (bio-oil)PANOLIN HLP Synth 46 (bio-oil)

Grease nipples,telescopic unit pad tracks

Multipurpose greaseLithium-based brand-name grease MPG-A3 Year-round As required

Battery terminals Acid-proof grease SP-B3 Year-round As required

Mounting of pins, shafts, etc. Special greaseOptimoly paste “TA”6 White paste

6. 250 gr tube.

Year-round As required

Fuel tank Diesel fuel7

7. DIN 51 601, min 45 Cetane.

Grade no. 2-D Over 39 °F (4 °C)About 21 gal. (80 L)

Grade no. 1-DBelow 39 °F

(4 °C)

Brake system Brake fluid8

8. Standard: B 71 2710.

Agip LHM Super / Shell LHM Year-roundAbout 0.1 gal.

(0.5 L)

Washer system Cleaning agent Water + antifreeze Year-roundAbout 0.4 gal.

(1.5 L)

Printed in U.S.A.125

918115/CP0807

Maintenance

Maintenance schedule Model 342-01 (overview)

Work description

For service and maintenance work on the attachment, also refer to the operation and maintenance manual of the attachment manufacturer.

Maintenance schedule/service hours

Regular maintenance

(daily)

Deliveryinspection

“A”

every 50 hours(w

eekly)

1st Inspection1

at 100 hours

“B”

every 500hours 2

2nd Inspection

“C”

every 1500service hours

(yearly)

Oil and filter changes ( ):

Carry out the following oil and filter changes (check oil levels after test run):• Engine oil ● ● ●

• Engine oil filter ● ● ●

• Fuel filter ● ● ●

• Air filter3, 4 replace safety cartridge every third time the air filter is replaced ● ●

• Gearbox oil in front and rear axle differentials and in rear axle gearbox ● ●

• Gearbox oil in front and rear axle planetary drives, left and right ● ●

• Gearbox oil in 25 mph (40 km/h) gearbox (option) ● ●

• Hydraulic oil5 ●

• Hydraulic oil filter ● ●

• Breather filter – hydraulic oil tank 4 ●

Inspection work ( ):

Check the following material. Refill if necessary:• Engine oil ● ● ●

• Hydraulic oil ● ● ● ● ● ●

• Gearbox oil in front and rear axle differentials and in rear axle gearbox ● ● ●

• Gearbox oil in front and rear axle planetary drives, left and right side ● ● ●

• Brake fluid6 ● ● ● ● ● ●

Check cooler for engine and hydraulic oil for contamination. Clean if necessary7 ● ● ● ●

When using biodegradable oil: Drain the condensation water in the hydraulic oil tank 5 ● ●

Clean dust valve on air filter housing 3 ● ● ● ● ● ●

V-belt: Check condition and pre-tension. Tighten or replace if necessary8 ● ● ● ● ●

Check the fuel/water separator. Drain water if necessary ● ● ● ●

Clean filter insert on fuel pump, replace if necessary ● ● ● ●


918115/CP0807

Maintenance

Check valve tip clearance (engine timing): Set if necessary ● ●

Battery: Check charge condition ● ●

Other inspection work ( ):

Heating: Clean dust filter, replace every 1500 service hours if necessary9 ●

Check and set service and parking brake pads. Replace if necessary ● ● ●

Tire check (damage, air pressure, tread depth) ● ● ● ● ● ●

Check screws and nuts or screw connections for tightness on the following assemblies/components. Tighten if necessary• Engine and engine bearing ● ● ●

• Steering system ● ● ●

• Hydraulic system ● ● ●

• Loader unit (pin locking) ● ● ●

• Axle mounting, axle suspension ● ● ●

• Counterweight (attachment) ● ● ●

• Attachment cap screws of propshafts ● ● ●

• Attachment cap screws of cab ● ● ●

• Wheel nuts ● ● ● ●

Electric system: Check electrical and ground connections, chafing on wiring harness, battery terminals ● ● ● ●

Lubrication service ( ):10

Lubricate the following assemblies/components:• Rear axle oscillating bearing ● ● ● ● ●

• Front and rear axle planetary drive bearings, left and right ● ● ● ● ●

• Loader unit– see section Lubricating the loader unit on page 113• Lift frame bearing ● ● ● ● ●

• Tilt rod bearing ● ● ● ● ●

• Tilt lever bearing ● ● ● ● ●

• Lift cylinder bearing ● ● ● ● ●


Work description



Regular maintenance

(daily)

Deliveryinspection

“A”every 50 hours

(weekly)

1st Inspection1

at 100 hours

“B”

every 500hours 2

2nd Inspection

“C”

every 1500service hours

(yearly)


918115/CP0807

Maintenance

• Tilt cylinder bearing ● ● ● ● ●

• Quickhitch facility: Bearing on lift frame ● ● ● ● ●

• Hinges, joints and fittings (e.g., door arrester) ● ● ● ●

Functional check ( ):

Check the function of the following assemblies/components. Rectify if necessary:• Service and parking brake ● ● ● ● ● ●

• Steering system ● ● ● ● ● ●

• Lights and electrical system ● ● ● ● ● ●

Leakage check ( ):

Check for tightness, leakage and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Correct if necessary:• Air intake line (air filter – engine) ● ● ● ● ● ●

• Engine lubrication (engine – filter) ● ● ● ● ● ●

• Fuel lines11 ● ● ● ● ● ●

• Cooling system (engine – hydraulic oil) ● ● ● ● ● ●

• Steering system (flexible lines and rams) ● ● ● ● ● ●

• Hydraulic system/loader unit (flexible lines and rams) 12 ● ● ● ● ● ●

• Brake system (flexible lines and rams) ● ● ● ● ● ●

1. Work to be carried out once after the first 100 service hours. This work must be carried out by an authorized dealer for warranty claims to be acknowledged.2. Work after the first 500 service hours (2nd Inspection) must be carried out by an authorized dealer for warranty claims to be acknowledged.3. Replace filter as indicated by the indicator on the instrument panel, however at least every 12 months or 1500 service hours.4. When working in an acidic environment, replace the filter every 300 service hours.5. When using biodegradable oil: Drain the condensation water in the hydraulic oil tank every 500 service hours, and in any case before the cold season.6. Replace every two years.7. Depending on operation and dust conditions, it may necessary to clean the cooler more frequently.8. Replace the toothed belt every 3000 service hours or after 5 years at the latest (toothed belt must be replaced by authorized staff).9. Depending on operation and dust conditions, it may be necessary to replace the dust filter more frequently.10. Lubricate attachment according to manufacturer's instructions.11. Replace flexible fuel leak oil lines every twoyears.12. Replace flexible lines every six years (UVV, DIN 20066 part 5).


Work description



Regular maintenance

(daily)

Deliveryinspection

“A”every 50 hours

(weekly)

1st Inspection1

at 100 hours

“B”every 500

hours 2

2nd Inspection

“C”every 1500

service hours(yearly)


Maintenance

Maintenance log

Use the following table to record the maintenance and service work that you complete after a certain amount of service hours – see Maintenance schedule Model 342-01 (over-view) on page 125.

Check off the columns in the boxes below after the work is completed.

The 1st and 2nd Inspections must be completed by an authorized dealer for warranty claims to be acknowledged. For information on maintenance material, consumables, and lubricants – see Fluids and lubricants on page 124.

Maintenance log

Afte

r ser

vice

ho

urs

Mai

nten

ance

sc

hedu

le

Date

Serv

ice

hour

s

Com

pany

/si

gnat

ure

Delivery

50 A

100 1st Inspection

150 A

200 A

250 A

300 A

350 A

400 A

450 A

500B 2nd

Inspection

550 A

600 A

650 A

700 A

750 A

800 A

850 A

900 A

950 A

1000 B

1050 A

1100 A

1150 A

1200 A

1250 A

Maintenance log

Afte

r ser

vice

ho

urs

Mai

nten

ance

sc

hedu

le

Date

Serv

ice

hour

s

Com

pany

/si

gnat

ure

Maintenance


Maintenance

1300 A

1350 A

1400 A

1450 A

1500 C yearly

1550 A

1600 A

1650 A

1700 A

1750 A

1800 C

1850 A

1900 A

1950 A

2000 B

2050 A

2100 A

Maintenance log

Afte

r ser

vice

ho

urs

Mai

nten

ance

sc

hedu

le

Date

Serv

ice

hour

s

Com

pany

/si

gnat

ure

2150 A

2200 A

2250 A

2300 A

2350 A

2400 A

2450 A

2500 B

2550 A

2600 A

2650 A

2700 A

2750 A

2800 A

2850 A

2900 A

2950 A

Maintenance log

Afte

r ser

vice

ho

urs

Mai

nten

ance

sc

hedu

le

Date

Serv

ice

hour

s

Com

pany

/si

gnat

ure


Maintenance

3000 C

3050 A

3100 A

3150 A

3200 A

3250 A

3300 A

3350 A

3400 A

3450 A

3500 B

3550 A

3600 A

3650 A

3700 A

3750 A

3800 A

Maintenance logAf

ter s

ervi

ce

hour

s

Mai

nten

ance

sc

hedu

le

Date

Serv

ice

hour

s

Com

pany

/si

gnat

ure

3850 A

3900 A

3950 A

4000 B

4050 A

4100 A

4150 A

4200 A

4250 A

4300 A

4350 A

4400 A

4450 A

4500 B

4550 A

4600 A

4650 A

Maintenance log

Afte

r ser

vice

ho

urs

Mai

nten

ance

sc

hedu

le

Date

Serv

ice

hour

s

Com

pany

/si

gnat

ure


Maintenance

Maintenance decal

Location

Inside the cab on the rear window.

Explanation of symbols on maintenance decals

Symbol Explanation

Before starting maintenance work, read the safety instructions in the Operator’s Manual.

Before starting maintenance work, read the “Maintenance” section in the Operator’s Manual.

Check that the light system functions correctly.

Check tires for damage, pressure and tread depth.

Complete a functional check and synchronize the steering system.

Complete a functional check of the brake system.

Check hydraulic oil level. Fill up if necessary.

Check engine oil level. Fill up if necessary.

Check coolant level. Fill up if necessary.

Compress the dust valve.

Check cooler for engine coolant and hydraulic oil for contamination. Clean if necessary.

Check condition and initial tension of V-belt. Tighten or replace if necessary.

Leakage check:Check for tightness, leakage and chafing: Pipes, flexible lines and screw connections. Correct if necessary.

Leakage check:Check the fuel/water separator. Drain water if necessary.

Lubrication service:Lubricate the assemblies.


Maintenance

100

010

40 1

4

10 h T�glichDailyTous les jours

50 hI=> 342 01 0001


Maintenance

Notes:


Specifications

Specifications

Frame

Sturdy steel frame, rubber-mounted engine.

Engine

Engine

Product Deutz diesel engine

Model F4M 2011

Type In-line

No. of cylinders 4

Displacement 190 in.³ (3109 cm³)

Bore and stroke 3.7 x 4.4” (94 x 112 mm)

Compression ratio 19:1

Output (as per ISO 9249) 44 kW/59 DIN hpat 2400 rpm

Max. torque 144 lb.-ft. (195 Nm) at 1700 rpm

Specific minimum fuel consumption 298 g/hph (222 g/kWh)

Fuel injection system Direct fuel injection

Firing order 1 – 3 – 4 – 2

Starting aid Glow plug

Max. inclined position (engine no longer supplied with oil):

Max. lateral left/right inclination: 30/57%Max. uphill/downhill inclination: 30/57%

Follow tilting limit of the machine.

Oil pressure 44 – 65 psi (3.0 – 4.5 bar) at 2300 rpm

Valve clearance (engine at cold temperature)

Intake valve 0.01” (0.3 mm)Exhaust valve 0.02” (0.5 mm)

Specifications


Specifications

Power train

Variable displacement pump

Type Automotive, infinitelyvariable hydrostaticaxial-piston gearbox

Displacement 0 – 2.7 in. ³/rev (0 – 45 cm³/rev)

Max. operating pressure Δp 4931 psi (340 bar)

Starting RPMs 1250 – 1300 rpm at 725 psi (50 bar) HP

Droop 2100 ±150 rpm, 5802 psi (400 bar) high pressure

Boost pump:

Type Internal gear pump

Displacement 0.7 in.³/rev (11.6 cm³/rev)

Charging/boost pressure 435 psi (30 bar) at 1500 rpm

Control Speed-sensitive, hydraulic displacement adjustment with

pressure cut-off

Driving direction Electro-hydraulic control

Inching Inching valve

Variable displacement motor

Type Axial piston motor(swash plate design)

Displacement

Standard 1.3 to 4.9 in. ³/rev(20.6 to 80.7 cm³/rev)

High speed option 2.2 to 14.2 in.³/rev(36.1 to 233 cm³/rev)

Drive speed

Standard 1st drive range: 0 – 3.2 mph (0 – 5.1 km/h), forward and

reverse2nd drive range: 0 – 12.4 mph

(0 – 20 km/h), forward and reverse

High speed option

1st drive range: 0 – 3.2 mph (0 – 5.1 km/h), forward and

reverse2nd drive range: 0 – 25.0 mph

(0 – 40 km/h), forward and reverse

Tractive effort 8093 lbf (36.0 kN)


Specifications

Axles

Brakes

Front axle (with 45 % self-locking differential)

Type Planetary drive steering axle, rigid screw connection with frame

King-pin inclination 7°

Camber 1.5°

Steering angle 40°

Toe-in 0” (0 mm)

Tread width 53.3” (1355 mm)

Rear axle (with 45 % self-locking differential)

Type Oscillating planetary drive steering axle

King-pin inclination 7°

Camber 1.5°

Oscillation angle +/- 9°

Steering angle 40°

Toe-in 0” (0 mm)

Tread width 53.3” (1355 mm)

Service brake

Type Foot-operated, hydraulic multi-disc brake + hydrostatic

Location Front axle, drive (rear axle)

Effect On both axles via cardan shaft

Brake fluid Special hydraulic fluid based on basic mineral oil – see Fluids and lubricants on page 124

Parking brake

Type Manual, mechanical disc brake

Location Front axle input


Specifications

Steering

Work hydraulics

Pilot control

Steering

Type Hydrostatic four-wheel steeringwith emergency steering feature

Steering mode Four-wheel steering

Steering mode(25 mph [40 km/h] high speed option)

1st four-wheel steering2nd front-axle steering

High-speed version: 2nd speed allows for front-axle steering only.

Assemblies Hydraulic pump, steering unit with flanged priority valve, steering cylinder, self-synchronizing in left and

right final position (25 mph [40 km/h] high speed option: electric)

Max. pressure of hydraulic lines 2538 – 2611 psi (175 – 180 bar)

Hydraulic pump (gear pump)

Displacement1.4 in.³/rev

(22.5 cm³/rev)

Displacement2.0 in. ³/rev

(32.0 cm³/rev)

Maximum steering angle ±40°

Hydraulic pump Gear pump

Displacement 1.4 in. ³/rev (22.5 cm³/rev) 2.0 in.³/rev (32.0 cm³/rev)14 gal./min (52 L/min) at

2400 rpm20 gal./min (74 L/min) at

2400 rpm

Control valve 3-fold pilot control

Max. service pressure 3046 psi (210 bar)

Secondary pressure limiting Tilt cylinder Rod side 3481 psi (240 bar)Bottom side 1740 psi (120 bar)

Lift cylinder Bottom side 4351 psi (300 bar)

Filter Suction reflux filter

Pilot control pump = boost pump of hydraulic pump

Displacement 0.7 in .³/rev (11.6 cm ³/rev)

Charging/boost pressure 435 psi (30 bar) at 2300 rpm

Pilot control unit

Joystick Four-way lever – control of lift and tilt cylindersElectrical control of lock cylinder or attachments via

tip switches

Locked via lock lever with four-way lever and rocker switch (electrical system)

Lock against unintentional operation (for long-haul travel and transport)


Specifications

Loader unit

Loader unit with bucket 1, 2

1. With tires 12.5-202. With standard bucket

Bucket capacity 30 ft.³ (0.85 m.³) according to ISO

Tipping capacity (SAE J732) 7496 lbs. (3400 kg.)

Rated operating load (SAE J818) 3373 lbs. (1530 kg.)

Pin height 128” (3252 mm)

Dump reach 27.6” (700 mm)

Digging depth below ground 2.4” (60 mm)

Tilt-back angle 50°

Dump angle 45°

Breakout force (lift cylinder) 8992 lbf (40 kN)

Breakout force (tilt cylinder) 7868 lbf (35 kN)

Fork arms (payloads stated for 24” [610 mm] load distance

Payload, safety factor 2.00: 2890 lbs. (1311 kg.)

Lifting height 118” (3000 mm)

Movable payload in the transport position (safety factor 2.00):

3498 lbs. (1587 kg.)


Specifications

Electrical system

Fuse box on left and right of steering column

Electrical system

Alternator 12-V, 95 A

Starter 12-V, 3.0 hp (2.3 kW)

Battery 12-V, 72 Ah

Socket (e.g. for cigarette lighter) 15 A

Fig. 131: Fuse box

F1 F2 F3 F4 F5 F6 F7

F10 F11 F12 F13 F14 F15 F16

F8

F9

F17 F18 F19 F20 F21 F22 F23 F24No.

Rated current

Protected circuit

F1 25 Heating, air conditioning system (option)

F2 10 Forward/reverse solenoid valve, driving direction, 1st/2nd speed, front wiper motor, washer pump

F4 5 Rear wiper motor, washer pump

F5 10 Air-suspension seat (option)

F6 3 Cutoff solenoid

F7 5 Turn indicator unit

F8 3

Alternator charge function, hydraulic oil temperature, hydraulic oil filter, engine oil pressure, 3rd control circuit, coolant tempera-ture, parking brake, preheating, high beam, hour meter, fuel gauge, drive lever, forward/reverse relay

F9 7.5 Unlock/lock solenoid valve, front socket solenoid valve

F10 5 Brake lights

F11 10 Load stabilizer solenoid valve, load stabilizer relay,hose burst valve solenoid valve (option)

F12 7.5 Extend/retract telescopic unit relay, extend/retract solenoid valve, indicator, quickhitch lock

F13 7.5Steering electronics, 4 wheel steering solenoid valve, front axle steering, high speed, synchronicity indicator, 4 wheel steering, front axle steering

F14 5 Steering sensor, radio

F15 15 Cigarette lighter, rotating beacon (option)

F16 10 Interior light, terminal 15 relay, preheating relay, starting relay

F17 25 Rear lights, parking lights, low beam, high beam, horn, relay: high, low beam

F19 7.5 High beam (right)

F20 7.5 High beam (left)

F21 7.5 Low beam (right)

F22 7.5 Low beam (left)

F23 7.5 Front right parking light, rear right light, front socket, instrument lights, switch lights, cigarette lighter

F24 7.5 Front left parking light, rear left light, front socket


Specifications

Main fuse box with relays

The main fuse box is located in the engine compartment, on the left side.

Relays

The relays are installed on the left and right side next to the fuse box.

Tires

Fig. 132: Main fuse box in the engine compartment

F26

F25

K20 K21

Fuse no. Rated current (A) Protected circuit

F25 80 A – Main fuse

F26 40 A – Preheating/start fuse (starter)

Relay no. Protected circuit

K 20 – Preheating

K 21 – Start

Fig. 133: Relays

K4

K6

K3

K10

K7

K11 K1K15

Switching relay no.

Protected circuit

K1 High current relay

K3 Switching relay reverse driving

K4 Switching relay front socket (option)

K6 Turn indicator relay

K7 Wiper switching relay

K10 Switching relay (lock)

K11 Switching relay (unlock)

K15 Switching relay load stabilizer (option)

Tire sizeTire pressure Wheel rims

Front Rear Wheel rim Wheel offset

12.5-20 MPT 10 PR 132 E 2.5 bar (36 psi)

2.0 bar (29 psi)

11 x 20 0” (0 mm)335/80 R20 132 B


Specifications

Weights

Sound levels

NOTE:

Measurement of sound power level according to EC Directive 2000/14/EC. Sound level in the cab measured according to EC Directives 84/532/EEC, 89/514/EEC and 95/27/EEC. Measurements carried out on an asphalt surface.

Vibration

Weight

Operating weight1

1. With standard bucket, operator and full fuel tank

9921 lbs. (4500 kg)

Gross weight rating 14,330 lbs. (6500 kg)

Front axle weight rating8818 lbs. (4000 kg)

Rear axle weight rating

Max. authorized load for towing facility None

Sound power level

Measured value 102 dB (A)

Guaranteed value 104 dB (A)

Sound level in the cab 78 dB (A)

Vibration

Effective acceleration value for the upper extremities of the body

< 2.5

Effective acceleration value for the body

< 0.5

m

s2------

m

s2------


Specifications

Hardware torques

General torques

Specific torques

Cap screw dimensionsTorques in lb.-ft. (Nm)1

1. These values are valid for cap screws with untreated, non-lubricated surfaces

Grade 7 (8.8) Grade 8 (10.9) Grade 10 (12.9)

M4 2 (3) 3 (4) 4 (5)M5 4 (5.5) 6 (8) 7 (10)M6 7 (10) 10 (14) 12 (16)M8 17 (23) 25 (34) 30 (40)

M10 34 (46) 49 (67) 58 (79)M12 58 (79) 85 (115) 100 (135)M14 92 (125) 136 (185) 162 (220)M16 144 (195) 214 (290) 251 (340)M18 207 (280) 295 (400) 347 (470)M20 291 (395) 413 (560) 487 (660)M22 398 (540) 561 (760) 656 (890)M24 502 (680) 715 (970) 848 (1150)M27 738 (1000) 1069 (1450) 1254 (1700)M30 996 (1350) 1438 (1950) 1696 (2300)

Description Torque

Wheel nut 295 ±15 lb.-ft. (400 ±20 Nm)

Track-rod end (steering cylinder) 148 lb.-ft. (200 Nm)

Piston rod (steering cylinder/track rod)

184 lb.-ft. (250 Nm)


Specifications

Dimensions model 480

Fig. 134: Machine dimensions

128”

(325

2)

122”

(310

0)

98”

(250

0)

71” (1800) 76” (1920)

200” (5080)

107”

(271

0)

8” (2

00)

73” (1850)

67” (1700)54” (1360)

99”

(251

0)

26”(660)

Dimensions

Overall length1 200” (5080 mm)

Overall height 2, 3 99” (2510 mm)

Overall height2 with rotating beacon 107” (2710 mm)

Overall height 2, 4 without cab 83” (2100 mm)

Overall width without bucket5 67” (1700 mm)

Overall width1 73” (1850 mm)

Ground clearance in the transport position of loader unit 8” (200 mm)

Ground clearance2 below rear axle gearbox 13” (330 mm)

Tread width, front/rear 53” (1355 mm)

Wheelbase 76” (1920 mm)

Turning radius6 100” (2550 mm)

1. With standard bucket.2. With tires 12.5-20.3. Overall height with protective screen (option) 103” (2610 mm).4. Measured at top edge of seat backrest.5. With outside mirrors folded in.6. Measured at outer edge of tires.


Index

AAbbreviations ...........................................................................................6Accelerator pedal ...................................................................................57Air filter .................................................................................................105Applications with lifting gear ...................................................................19BBiodegradable oil .................................................................................110Brake system ........................................................................................114

Brake fluid .....................................................................................114Safety instructions .........................................................................114

Brake/inching pedal ................................................................................57CCab

Cab removal ....................................................................................75Removal clearance height ...............................................................75

Checklists ........................................................................................31, 40Pre-delivery and Delivery ................................................................32

Clearance heightCab removal ....................................................................................75

Controls ..................................................................................................56DDesignated use and exemption from liability ............................................6Differential lock .......................................................................................53Drive lever ..............................................................................................56Driving on public roads ...........................................................................48Driving the machine ................................................................................56Dust filter ..............................................................................................117FFluids and lubricants ............................................................................124Fork arms

Adjusting distance ...........................................................................94Overview .........................................................................................92

Functional checkDust valve ......................................................................................105

GGeneral information ..................................................................................4HHazard warning system ..........................................................................63Heating ...................................................................................................64

Heating, fresh air .............................................................................64Heating, mixed mode ......................................................................64Heating, recirculated air ..................................................................64

IIndicators ................................................................................................42Interior light ............................................................................................62JJump-starting the engine ........................................................................47LLight system ...........................................................................................61Load diagram .........................................................................................95Load stabilizer (option) ...........................................................................52Loader unit

Checking the tilt position of the bucket ............................................84Checking the transport position of the bucket .................................84Depressurizing quick couplers ........................................................80Lowering with the engine turned off ................................................80Lubrication .....................................................................................113Re-installing .....................................................................................81

Lock cylinder ..........................................................................................93Locking lever ..........................................................................................94Lowering the loader unit with the engine turned off ................................80MMachine

Fields of application .........................................................................10Loading and transporting .................................................................23Overview ......................................................................................8, 9

MaintenanceAdding hydraulic oil .......................................................................109Air filter cartridge ...........................................................................106Biodegradable oil ...........................................................................110Brake system .................................................................................114Checking the engine oil level .........................................................102

Checking the hydraulic oil level .................................................... 109Cleaning ........................................................................................ 121Cleaning the oil cooler .................................................................. 104Electrical system ........................................................................... 118Engine and hydraulics cooling system .......................................... 103Engine lubrication system ............................................................. 102Filling up the engine oil ................................................................. 103Fluids and lubricants ..................................................................... 124Fuel system .................................................................................. 100General maintenance work ........................................................... 121Heating ......................................................................................... 117Hydraulic pressure lines ............................................................... 111Hydraulic system .......................................................................... 108Instructions for cables, fuses, bulbs, alternator ............................. 119Maintenance log ........................................................................... 128Maintenance of attachments ......................................................... 113Maintenance plan ......................................................................... 125Pivots and hinges ......................................................................... 123Screw connections ........................................................................ 123Service and maintenance work at regular intervals ...................... 118Tire care ........................................................................................ 115V-belt ............................................................................................ 107Wheel change ............................................................................... 116

Multifunctional lever ............................................................................... 59OOperation ............................................................................................... 34

Cab (overview) ................................................................................ 35Driving ............................................................................................. 50Driving the machine ........................................................................ 48Gearbox operation .......................................................................... 50Instrument panel, multifunctional lever and drive lever (overview) . 37Parking the machine ....................................................................... 60Seat belt height setting ................................................................... 70Selecting the drive range ................................................................ 50Starting the engine .......................................................................... 45Stopping the machine ..................................................................... 60

Operational safety .................................................................................. 16PParking brake ......................................................................................... 58Preheating start switch .......................................................................... 56QQuickhitch facility ................................................................................... 93

Fitting an attachment ...................................................................... 93Removing an attachment ................................................................ 93

RRefueling .............................................................................................. 101Rotating beacon ..................................................................................... 63Running-in period .................................................................................. 39SSafety Decals ......................................................................................... 13Safety instructions ................................................................................. 16

Applications with lifting gear ........................................................... 19Attachments .................................................................................... 24Maintenance ................................................................................... 27Specific hazards ............................................................................. 28

Seat adjustment ..................................................................................... 68Backrest adjustment ....................................................................... 69Horizontal adjustment ..................................................................... 69Weight adjustment .......................................................................... 68

Seat belt ................................................................................................. 70Seat belt height setting .......................................................................... 70Service brake ......................................................................................... 49Signalling system ................................................................................... 63Sound levels ................................................................................. 13, 141Specifications ....................................................................................... 134

Axles ............................................................................................. 136Brakes ........................................................................................... 136Electrical system ........................................................................... 139Engine ........................................................................................... 134Frame ........................................................................................... 134Hardware torques ......................................................................... 142Loader unit .................................................................................... 138Pilot control ................................................................................... 137Power train .................................................................................... 135

IndexI


Index

Sound levels ..................................................................................141Steering .........................................................................................137Vibration ........................................................................................141Weights .........................................................................................141Work hydraulics .............................................................................137

Stability ...................................................................................................93TTaking into service .................................................................................39

Checklists ........................................................................................40Overview of controls ........................................................................56Safety instructions ...........................................................................39

Tire care ...............................................................................................115Towing and transporting the machine ....................................................21Transport ................................................................................................85Transporting loads ..................................................................................97Turn indicator .........................................................................................63UUnlocking ................................................................................................93VVentilation ...............................................................................................64

Ventilation, fresh air .........................................................................64WWheel change ......................................................................................116Wheel synchronization position ..............................................................49Windshield washer pump

Front window ...................................................................................66Rear window ....................................................................................66

Windshield washer system .....................................................................66Wiper

Front window ...................................................................................66Rear wiper .......................................................................................66

WorkingFreeing the machine ........................................................................90Grading ............................................................................................89Loading heaped material .................................................................89Loading loose material ....................................................................86Removing material/digging in hard soil ...........................................88Removing material/digging in soft soil .............................................87With the pallet forks .........................................................................91

Working light ...........................................................................................62

TORQUE SPECIFICATIONSNote: Use these torque values when tightening Gehl hardware (excluding: locknuts and self-tapping, thread forming andsheet metal screws) unless specified otherwise.

Hydraulic fittings with various seals (light application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

ThreadStraight pipe fitting with thread and screwed plug (GE) Non-return valve

with elastic sealIdentification aid outside ØSealing washer Elastic seal O-ring

M10X1.0 7 (9) 13 (18) 11 (15) 13 (18) 0.4 in. (10 mm)M12X1.5 15 (20) 18 (25) 18 (25) 18 (25) 0.5 in. (12 mm)M14X1.5 26 (35) 33 (45) 26 (35) 26 (35) 0.6 in. (14 mm)M16X1.5 33 (45) 41 (55) 30 (40) 37 (50) 0.6 in. (16 mm)M18X1.5 41 (55) 52 (70) 33 (45) 52 (70) 0.7 in. (18 mm)M22X1.5 48 (65) 92 (125) 44 (60) 92 (125) 0.9 in. (22 mm)M27X2.0 66 (90) 133 (180) 74 (100) 107 (145) 1.0 in. (27 mm)M33X2.0 111 (150) 229 (310) 118 (160) 155 (210) 1.3 in. (33 mm)M42X2.0 177 (240) 332 (450) 155 (210) 266 (360) 1.7 in. (42 mm)M48X2.0 214 (290) 398 (540) 192 (260) 398 (540) 1.9 in. (48 mm)G1/8A 7 (9) 13 (18) 11 (15) 13 (18) 0.4 in. (9.73 mm)G1/4A 26 (35) 26 (35) 22 (30) 26 (35) 0.5 in. (13.16 mm)G3/8A 33 (45) 52 (70) 33 (45) 37 (50) 0.7 in. (16.66 mm)G1/2A 48 (65) 66 (90) 41 (55) 48 (65) 0.8 in. (20.96 mm)G3/4A 66 (90) 133 (180) 74 (100) 103 (140) 1.0 in. (26.44 mm)G1A 111 (150) 229 (310) 118 (160) 140 (190) 1.3 in. (33.25 mm)G1 1/4A 177 (240) 332 (450) 155 (210) 266 (360) 1.7 in. (41.91 mm)G1 1/2A 214 (290) 398 (540) 192 (260) 398 (540) 1.9 in. (47.80 mm)

Hydraulic fittings with various seals (heavy application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

ThreadStraight pipe fitting with thread and screwed plug (GE) Non-return valve

with elastic sealIdentification aid outside ØSealing washer Elastic seal O-ring

M12X1.5 15 (20) 26 (35) 26 (35) 26 (35) 0.5 in. (12 mm)M14X1.5 26 (35) 41 (55) 33 (45) 33 (45) 0.6 in. (14 mm)M16X1.5 33 (45) 52 (70) 41 (55) 41 (55) 0.6 in. (16 mm)M18X1.5 41 (55) 66 (90) 52 (70) 52 (70) 0.7 in. (18 mm)M20X1.5 41 (55) 92 (125) 59 (80) 74 (100) 0.8 in. (20 mm)M22X1.5 48 (65) 100 (135) 74 (100) 92 (125) 0.9 in. (22 mm)M27X2.0 66 (90) 133 (180) 125 (170) 100 (135) 1.0 in. (27 mm)M33X2.0 111 (150) 229 (310) 229 (310) 155 (210) 1.3 in. (33 mm)M42X2.0 177 (240) 332 (450) 243 (330) 266 (360) 1.7 in. (42 mm)M48X2.0 214 (290) 398 (540) 310 (420) 398 (540) 1.9 in. (48 mm)G1/8A 26 (35) 41 (55) 33 (45) 33 (45) 0.5 in. (13.16 mm)G1/4A 33 (45) 59 (80) 44 (60) 44 (60) 0.7 in. (16.66 mm)G3/8A 48 (65) 85 (115) 55 (75) 74 (100) 0.8 in. (20.96 mm)G1/2A 66 (90) 133 (180) 125 (170) 107 (145) 1.0 in. (26.44 mm)G3/4A 111 (150) 229 (310) 229 (310) 192 (260) 1.3 in. (33.25 mm)G1A 177 (240) 332 (450) 243 (330) 266 (360) 1.7 in. (41.91 mm)G1 1/4A 214 (290) 398 (540) 310 (420) 398 (540) 1.9 in. (47.80 mm)

With coarse-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

ThreadThreads according to DIN 912, DIN 931, DIN 933, etc. Threads according to DIN 7984

8.8 10.9 12.9 8.8 10.9M5 4.1 (5.5) 6 (8) 7 (10) 4 (5) 5 (7)M6 7 (10) 10 (14) 13 (17) 6.3 (8.5) 9 (12)M8 18 (25) 26 (35) 31 (42) 15 (20) 22 (30)M10 33 (45) 48 (65) 59 (80) 30 (40) 44 (59)M12 64 (87) 81 (110) 108 (147) 51 (69) 74 (100)M14 100 (135) 133 (180) 170 (230) 81 (110) 118 (160)M16 155 (210) 203 (275) 258 (350) 125 (170) 184 (250)M18 207 (280) 302 (410) 354 (480) 181 (245) 254 (345)M20 302 (410) 420 (570) 509 (690) 251 (340) 361 (490)M22 406 (550) 575 (780) 686 (930) 339 (460) 487 (660)M24 524 (710) 738 (1000) 878 (1190) 435 (590) 620 (840)M27 767 (1040) 1092 (1480) 1305 (1770) 642 (870) 922 (1250)M30 1047 (1420) 1482 (2010) 1770 (2400) 885 (1200) 1254 (1700)

With fine-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

ThreadThreads according to DIN 912, DIN 931, DIN 933, etc. Threads according to DIN 7984

8.8 10.9 12.9 8.8 10.9M8X1.0 18 (25) 27 (37) 32 (43) 16 (22) 24 (32)M10X1.0 37 (50) 55 (75) 65 (88) 32 (43) 48 (65)M10X1.25 36 (49) 52 (71) 61 (83) 31 (42) 46 (62)M12X1.25 64 (87) 96 (130) 111 (150) 55 (75) 81 (110)M12X1.5 61 (83) 92 (125) 107 (145) 53 (72) 77 (105)M14X1.5 100 (135) 148 (200) 173 (235) 89 (120) 129 (175)M16X1.5 155 (210) 229 (310) 266 (360) 133 (180) 195 (265)M18X1.5 232 (315) 332 (450) 391 (530) 199 (270) 284 (385)M20X1.5 325 (440) 465 (630) 538 (730) 277 (375) 391 (530)M22X1.5 435 (590) 620 (840) 723 (980) 369 (500) 524 (710)M24X2.0 546 (740) 789 (1070) 922 (1250) 465 (630) 664 (900)M27X2.0 811 (1100) 1143 (1550) 1328 (1800) 679 (920) 959 (1300)M30X2.0 1106 (1500) 1586 (2150) 1844 (2500) 959 (1300) 1364 (1850)

Notes:

918115/CP0807 © 2007 GEHL Company. All rights reserved. Printed in U.S.A.

THIS OPERATOR'S MANUAL ISPROVIDED FOR OPERATOR USE

DO NOT REMOVEFROM THIS MACHINE

Do not start, operate or work on the machine until you carefully readand thoroughly understand the contents of this Operator’s Manual.

Failure to follow safety, operating and maintenance instructions canresult in serious injury to the operator or bystanders, poor operation,and costly breakdowns.

If you have any questions on proper operation, adjustment or mainte-nance of the machine, contact your dealer or the Gehl CompanyService Department before starting or continuing operation.

California Proposition 65 Warnings:

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer and birth defects and other reproductive harm.Battery post, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects and other reproductive harm. Wash hands after handling battery.

Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 U.S.A.www.gehl.com

WARNING

®

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