Operator's Manual GEHL - 3640e-3840e-4240e

7/25/2019 Operator's Manual GEHL - 3640e-3840e-4240e

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SL3640E

SL3840E (EU)SL4240E

SL4240E (EU)

Skid-Steer Loaders

Operators

Manual

Form No.

917334/

BP0310

English


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Gehl Company, in cooperationwith the American Society of

Agricultural Engineers and theSociety of Automot ive Engineers, hasadopted this Safety Alert Symbol topinpoint precautions which, if not

properly followed, can create a safetyhazard. When you see this symbol in thismanual or on the machine itself, you arereminded to BE ALERT! Your personalsafety is involved!

Operators must have instructionsbefore running the machine.Untrained operators can cause

injury or death.

Read Operators Manualbefore using machine.

CORRECT

Always fasten seatbeltsnugly. Always keep feet onthe floor/pedals whenoperating loader.

CORRECT

Never use loaderwithout ROPS/FOPS.Never modify theROPS/FOPSstructure.

WRONG

Never use the loaderto lift personnel.

WRONG

Do not use loaderaround explosive dustor gas, or whereexhaust can contactflammable material.

WRONG


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Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Controls and Safety Equipment . . . . . . . . . . . . . . . . . . . 17

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Table of Common Materials and Densities . . . . . . . . . . . 76

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

SL3640E, SL3840E (EU) and SL4240E

Operator s Manual

TABLE OF CONTENTS

All-Tach and Hydraloc are trademarks of Gehl Company.

Gehland Powervieware registered trademarks of Gehl Company.

Loader Model Number

Loader Serial Number

Engine Serial Number
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EC DECLARATION OF CONFORMITY

1. Manufacturer: Gehl Company

2. Address: One Gehl WayWest Bend, WI 53095 U.S.A.FAX: 262-334-6687

3. Technical Construction File Location:Attn.: Quality Manager

915 SW 7th St.Madison, SD 57042 U.S.A.

4. Authorized Representative: Gehl Europe GmbH

5. Address: Burgsteinfurter Damm 89D-48485 Neuenkirchen/RheineGERMANY

6. We hereby declare that the model(s) lis ted belowconforms to EC Directives: 2004/108/EC (EMC),

97/23/EC (Pressure Equipment), 2006/42/EC(Machinery) and 2000/14/EC (Noise Emission),including all current amendments.

7. In accordance with EN/ISO Standards:EN ISO 3450:1996, ISO 6165

8. Category: EARTH-MOVING MACHINERY/LOADERS/COMPACT

9. Model(s): 3840E, 4240E

10. Directive/Conformity Assessment Procedure/Notified Body:

2004/108/EC Type-test Self-certi fication

97/23/EC Self-certi fication ----------

2006/42/EC Self-certi fication ----------

2000/14/EC Annex VIIIFullQuality Assurance

TV Industrie ServiceGmbH TV SD GroupWestendst. 199, D-80686

Mnchen GERMANY


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917334/BP0310 1

CHAPTER 1

INTRODUCTIONThis Operators Manual provides the owner/operator information about main-taining and servicing SL3640E, SL3840E (EU) and SL4240E skid-steer loadermodels. More importantly, this manual provides an operating plan for safe and

proper use of the machine. Major points of safe operation are detailed in theSafetychapter of this manual.

We ask that you read and understand the contents of this manual completely andbecome familiar with your new machine before operating it. See your authorizedGehl dealer if you have any questions concerning information in the manual,require extra manuals or for information concerning the availability of manualsin other languages.

Throughout this manual, information is provided set in italictype and introduced

by the wordNoteorImportant. Read carefully and comply with those messages it will improve your operating and maintenance efficiency, help avoid break-downs and damage, and extend your machines life.

A manual storage box in the operators compartment holds the OperatorsManual and AEM Safety Manual (also available in Spanish). Please return themanuals to this box and keep them with the unit at all times. If this machine isresold, we recommend that these manuals be given to the new owner.

The attachments and equipment available for use with this machine have a wide

variety of potential applications. Read the manual provided with the attachmentto learn how to safely maintain and operate the equipment. Be sure the machineis suitably equipped for the type of work to be performed.

Do not use this machine for any applications or purposes other than thosedescribed in this manual or those applicable for approved attachments. If themachine is to be used with special attachments or equipment other than thoseapproved by Gehl Company, consult your Gehl dealer. Any person using non-approved attachments or making unauthorized modifications is responsible forthe consequences.

The Gehl dealership network stands ready to provide you with any assistance youmay require, including providing genuine Gehl service parts. All service partsshould be obtained from your Gehl dealer. Provide complete information aboutthe part and include the model and serial numbers of your machine. Record thesenumbers in the space provided on the Table of Contents page, as a handy refer-ence.

Gehl Company strives to continuously improve its products and reserves the rightto make changes and improvements in the design and construction of any part

without incurring the obligation to install such changes on any previously deliv-ered unit.

If this machine was purchased used, or if the owners address has changed,please provide your Gehl dealer or Gehl Company Service Department with theowners name and current address, along with the machine model and serialnumber. This will allow the registered owner information to be updated, so thatthe owner can be notified directly in case of an important product issue.


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Loader Identification

1. Upright

2. Lift Cylinder

3. Tires

4. Front Work Lights5. Handholds

6. Lift Arm

7. Auxiliary HydraulicCouplers

8. Tilt Cylinders9. Attachment Bracket

1

2

3

4

5

68

9

7

1. Engine Cover

2. Tail Lights

3. Rear Work Lights

4. Rear Door

5. Roll-Over/Falling ObjectProtective Structure(ROPS/FOPS)

6. Restraint Bar

1

2

3

4

56


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Control/Indicator Symbols

Power Off Power On Engine Start Hazard FlasherWorklight

Worklight w/Flasher Battery Charge Parking Brake Read Operator sManual

Horn

Volume Full Volume Half Full Volume Empty Pre-Heat Diesel Fuel

Lift Point

NNeutral Safety Alert Chaincase Oil Seatbelt Lap Only

Engine Air Filter Engine Oil Engine Oil Filter Engine Oil Pressure Fuel Filter

Engine CoolantTemperature

Hydraulic System Hydraulic OilTemperature

Hydraulic Oil Filter Grease LubricationPoint

Tie-Down Machine Travel Forward

Machine Travel Reverse

Clockwise Rotation CounterclockwiseRotation

Fast Slow Bucket Lower Bucket Raise Bucket Float

Bucket Rollback Bucket Dump


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Notes


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CHAPTER 2

SAFETYThis safety alert symbol means Attention! Become alert! Your safety isinvolved! It stresses an attitude of Heads Up for Safety and can be

found throughout this Operators Manual and on the decals on the machine.

Before operating this machine, read and study the following safety information.For further reference on the safe operation of skid-steer loaders, Gehl Companysuggests that equipment owners obtain the Gehl Skid-Steer Loader Safetyvideo, which is available through Gehl dealers. In addition, be sure that everyonewho operates or works with this machine, whether family member or employee,is familiar with these safety precautions. It is essential to have competent andcareful operators, who are not physically or mentally impaired, and who are thor-oughly trained in the safe operation of the machine and the handling of loads. It is

recommended that the operator be capable of obtaining a valid motor vehicleoperators license.

The use of skid-steer loaders is subject to certain hazards that cannot be eliminatedby mechanical means, but only by exercising intelligence, care and common sense.Such hazards include, but are not limited to, hillside operation, overloading, insta-

bility of the load, poor maintenance and using the equipment for a purpose forwhich it is not intended or designed.

Gehl ALWAYS considers the operators safety when designing its machinery,

and guards exposed moving parts for the operators protection. However, someareas cannot be guarded or shielded in order to assure proper operation. Further-more, this Operators Manual and decals on the machine warn of additional haz-ards and they should be read and observed closely.

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

Different applications may require optional safety equipment, such as a back-upalarm, mirror, strobe light or an impact-resistant front door. Be sure you knowthe job site hazards and equip your machine as needed.

DANGER indicates an imminently haz-ardous situation which, if not avoided, will

result in death or serious injury.

WARNING ind icates a potentially hazardoussituation which, if not avoided, could result in

death or serious injury.

CAUTION ind icates a potent ially hazardoussituation which, if not avoided may result in

minor or moderate injury. May also alert against unsafe practices.

DANGER

WARNING

CAUTION


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Mandatory Safety Shutdown Procedure

Before cleaning, adjusting, lubricating, servicing the unit, or leaving itunattended:

1. Move the drive control handle(s) to the neutral position.

2. Lower the lift arm and attachment completely. If the lift arm mustbe left inthe raised position, BE SURE to properly engage the lift arm support device(page 20).

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

4. Before exiting, move the lift/tilt control(s) to verify that the controls do notcause movement of the lift arm or attachment.

Safety RemindersBefore Starting

Do not modify the ROPS/FOPS unless instructed to do so in installationinstructions. Modifications such as welding, drilling or cutting can weakenthe structure and reduce the protection it provides. A damaged ROPS/FOPScannot be repaired it must be replaced.

To ensure safe operation, replace damaged or worn-out parts with genuineGehl service parts.

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

Remove all trash and debris from the machine each day, especially in theengine compartment, to minimize the risk of fire.

Always face the loader and use the handholds and steps when getting on andoff the loader. Do not jump off the loader.

Never use starting fluid (ether).

Walk around the machine and warn all nearby personnel before starting themachine.

Always perform a daily inspection of the machine before using it. Look fordamage, loose or missing parts, leaks, etc.


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During Operation

Machine stability is affected by: the load being carried, the height of the load,machine speed, abrupt control movements and driving over uneven terrain.DISREGARDING ANY OF THESE FACTORS CAN CAUSE THELOADER TO TIP, THROWING THE OPERATOR OUT OF THESEAT OR LOADER, RESULTING IN DEATH OR SERIOUS INJURY.Therefore: ALWAYS operate with the seatbelt fastened and the restraint barlowered. Do not exceed the machines Rated Operating Load. Carry the loadlow. Move the controls smoothly and gradually, and operate at speeds appro-

priate for the conditions.

When operating on inclines or ramps, always travel with the heavier end ofthe loader toward the top of the incline for additional stability.

Do not raise or drop a loaded bucket or fork suddenly. Abrupt movementsunder load can cause serious instability.

Never activate the float function with the bucket or attachment loaded orraised, because this will cause the arm to lower rapidly.

Do not drive too close to an excavation or ditch; be sure that the surroundingground has adequate strength to support the weight of the loader and the load.

Never carry riders. Do not allow others to ride on the machine or attachments,because they could fall or cause an accident.

Always look to the rear before backing up the skid-steer loader.

Operate the controls only from the operators seat.

Always keep hands and feet inside the operators compartment while oper-ating the machine.

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

Always wear safety goggles, ear and head protection while operating themachine. Operator must wear protective clothing when appropriate.

Exhaust fumes can kill. Do not operate this machine in an enclosed areaunless there is adequate ventilation.

When you park the machine and before you leave the seat, check the restraintbar for proper operation. The restraint bar, when raised, deactivates the lift/tiltcontrols and auxiliary hydraulics, and applies the parking brake.

Maintenance

Never attempt to by-pass the keyswitch to start the engine. Use only the jumpstarting procedure detailed in the Operationchapter of this manual.

Never use your hands to search for hydraulic fluid leaks. Instead, use a pieceof paper or cardboard. Escaping fluid under pressure can be invisible and can

penetrate the skin and cause serious injury. If any fluid is injected into yourskin, see a doctor at once. Injected fluid must be surgically removed by adoctor or gangrene may result.


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Always wear safety glasses with side shields when striking metal againstmetal. In addition, it is recommended that a softer (chip-resistant) material beused to cushion the blow. Failure to heed could lead to serious injury to theeyes or other parts of the body.

Do not smoke or have any spark-producing equipment in the area while fillingthe fuel tank or while working on the fuel or hydraulic systems.

Potential Hazards

A skid-steer loader operator must ALWAYS be conscious of the working envi-ronment. Operator actions, environmental conditions and the job being donerequire the full attention of the operator so that safety precautions can be taken.

ALWAYS maintain a safe distance from electric power lines and avoid contactwith any electrically charged conductor or gas line. Accidental contact or rupture

can result in electrocution or an explosion. Contact the North American One-CallReferral System at: 1-888-258-0808 for the local Digger's Hotline number orthe proper local authorities for utility line locations BEFORE starting to dig!

Exposure to crystalline silica (found in sand, soil and rocks) has been associatedwith silicosis, a debilitating and often fatal lung disease. A Hazard Review(Pub. No. 2002-129) by the U.S. National Institute for Occupational Safety andHealth (NIOSH) indicates a significant risk of chronic silicosis for workersexposed to inhaled crystalline silica over a working lifetime. NIOSH recom-mends an exposure limit of 0.05 mg/m3as a time-weighted average for up to a10-hr workday during a 40-hr workweek. NIOSH also recommends substitutingless hazardous materials when feasible, using respiratory protection and regularmedical examinations for exposed workers.

Safety Decals

The skid-steer loader has decals that provide safety information and precautionsaround the loader. These decals must be kept legible. If missing or illegible, they

must be replaced promptly. Replacements can be obtained from your Gehldealer. New equipment must have all decals specified by the manufactureraffixed in their proper locations.

New Decal Application

Surfaces must be free of dirt, dust, grease and foreign material before applyingthe decal. Remove the smaller portion of the decal backing paper and apply theexposed adhesive to the clean surface, maintaining proper position and align-ment. Peel the rest of the backing paper and apply hand pressure to smooth out

the decal surface. Refer to the following pages for proper decal locations. Textdecals begin onpage 9; no-text decals begin onpage 12.


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Safety Decals inside the ROPS/FOPS

137628 Located on manual box, operator s right

137683 Located onROPS left panel

137647 Located on operator s lower left side

137639 Located onROPS left panel


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Safety Decals on the outside of the Skid Loader

137655 Front of loader

137720 Front of loader

184214 Under ROPS

137637 Lift arm support device, loader left side


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Safety Decals in the Engine Compartment

137657 Right of hydraulic f ilter

137658 On radiator


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ISO-Style (used Internationally)

Safety Decals inside the ROPS/FOPS

A Crush hazard: Keep out from under lift arm unless lift arm is supported.B Crush hazard: Keep hands, feet and body inside cab when operating.C Forward tip hazard: Fasten seat belt. Carry load low. Do not exceed Rated

Operating Load.D Side tip hazard: Avoid steep slopes and high speed turns. Travel up and down

slopes with heavy end uphill.

Safety alert: Read OperatorsManual and all safety signsbefore using machine. Theowner is responsible to ensureall users are instructed on safeuse and maintenance.

137842 Located on manualstorage box

137847 Part of leftinstrument panel

Safety alert: Always followMandatory Safety Shutdown

Procedure in Operators Manual.1 Lower equipment to ground.2 Reduce throttle, stop engine.3 Apply parking brake; remove

key.4 Check safety interlocks.

137849 Part ofleft instrument

panel

Safety alert:A Check machine beforeoperating; Service per OperatorsManual. Contact dealer (ormanufacturer) for information andservice parts.

B Maintain 3-point contact duringentry and exit.C Inspect work area. Avoid allhazards. Look in direction of travel.Keep children and bystanders away.D Start and operate machine onlyfrom seat.E Keep away from power lines;avoid contact.F Wear any needed PersonalProtective Equipment. Do not wear

loose clothing while operating orservicing machine.

A B

C D

E F

137843 Located on operators lower left side

A B C D


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ISO-Style (used Internationally) Safety Decals

on the outside of the Skid-Steer Loader

137844 Located on front o f loader

137852 Located on hitch (manual hitch loaders only)

A Crush hazard: Keep out from under work tool unless lift arm is supported.B Fall hazard: No riders. Never use work tool as work platform.

Crush hazard: Before operating with attachment, check engagement of hitch

locking pin to the attachment:A Incorrect attachment engagement C Lock hitch leverB Correct attachment engagement D Unlock hitch lever

A B

A

BC

D

137853 Located on liftarm support device

Crush hazard: Hoseremoval or componentfailure can cause lift arm todrop. Always use lift armsupport device when

leaving arm raised forservice.


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ISO-Style (used Internationally)

Safety Decals in the Engine Compartment

137845 Located on cross member for frame

A Safety alert: Keep safety devices in place and in working order. Keep guards, screensand windows in place.B Fire hazard: Do not smoke while fueling or servicing machine. Clean debris fromengine compartment daily to avoid fire. Keep fire extinguisher nearby.C Run-over hazard: Jump-start per Operators Manual procedure.D Oil injection hazard: Do not use hands to find hydraulic leaks. Escaping oil underpressure can be invisible and penetrate skin. Use a piece of cardboard to find leaks.E Burn hazard: Allow radiator to cool before removing cap. Loosen cap slowly to avoidburns.F Suffocation hazard: Operate only in a well-ventilated area.

A B C D E F

137845 Located on cross member for frame

A Rotating fan: Keep hands out or stop engine.B Hot surface: Do not touch hot engine or hydraulic

system parts.

A B


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Product and Component Plate Locations

Product and Component Plates

1. Engine plate: with e.g. type designation, product and serial number2. Operator protective system plate: with e.g. model, certification and operator protectionsystem serial number

3. Product plate: with Product Identification Number and e.g. model/type designation4. Seat plate according to ISO 70965. Component plate rear drive axle: with e.g. product and serial number6. Component plate front drive axle: with e.g. product and serial number7. Component plate transmission: with e.g. product and serial number

1

46

5

7

2

3


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Notes


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CHAPTER 3

CONTROLS AND SAFETY EQUIPMENT

Become familiar with and know how to use allsafety devices and controls on the skid-steer

loader before operating i t. Know how to stop loader operation beforestarting it. This Gehl loader is designed and intended to be usedonly with a Gehl attachment or a Gehl-approved referral attachmentor accessory. Gehl cannot be responsible for operator safety if theloader is used with a non-approved attachment.

Guards and Shields

Whenever possible and without affecting loader operation, guards and shields are

provided to protect against potentially hazardous areas. In many places, safetydecals are also provided to warn of potential hazards and/or to display specialoperating procedures.

Read and thoroughly understand all safetydecals on the loader before operating it. Do not

operate the loader unless all factory-installed guards and shieldsare properly secured in place.

Operator Restraint Bar

Lower the restraint bar after entering the operators compartment. The restraint baris securely anchored to the ROPS. The restraint bar switch is wired in series withthe seat switch forming an interlock for the lift arm, tilt, drive and starter circuits(refer to the Safety Interlock Systemtopic onpage 18for more information).

Never defeat the operator restraint bar or seatswitch electrically or mechanically. Always

wear your seatbelt.

CAUTION

WARNING

WARNING


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Operators Seat

The seat is mounted on rails for backwardor forward repositioning. A spring-loadedlatch handle activates the seat adjustmentmechanism.

Suspension seat (optional): A weightadjustment knob is provided with thisseat for operator comfort.

Upper-Torso Restraint

ALWAYS wear the upper-torso restraint whenoperating skid-steer.

The seat belt should always be fastened during operation.

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

Cleaning solvents can cause damage to seatbelt(s).

Safety Interlock System

NEVER defeat the safety interlock system bymechanically or electrically bypassing any

switches, relays or solenoid valves.

An interlock system is used on the loader for operator safety. Together withsolenoid valves, switches and relays, the interlock system:

Prevents the engine from starting unless the operator is sitting on the seat andthe operator restraint bar is down.

Disables the lift arm, attachment tilt and wheel drives when the operatorleaves the seat, turns the keyswitch to OFF or raises the restraint bar.

Disables auxiliary hydraulic system when the restraint bar is raised or thekeyswitch is OFF.

Testing the Safety Interlock System

Before leaving a parked machine, check the safety interlock system for properoperation:

Restraint Bar

1

2

3

Figure 1 Operators Seat1. Restraint Bar

2. Seatbelt

3. Seat Adjustment Level

WARNING

WARNING


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With the engine running, raise the restraint bar. Move each of the controls.There should be not more than a slight movement of the lift arm, attachmentand machine. If there is any significant movement, troubleshoot and correct the

problem immediately. Contact your dealer if necessary.

Seat Switch

With the engine off and the restraint bar lowered, unfasten the seatbelt. Liftyour weight up off the seat. Try to start the engine. If the engine starts, turn offthe engine, and troubleshoot and correct the problem. Contact your dealer ifnecessary.

ROPS/FOPS

The ROPS/FOPS (Roll Over/Falling Object Protective Structure) is designed toprovide protection for the operator from falling objects and in case the loader tipsor rolls over, provided the operator is secured inside the ROPS by the seatbeltand restraint bar.

Never operate the loader with the ROPS/FOPSremoved or locked back.

Parking Brake

This skid-steer loader is equipped with aspring-applied hydraulic-released parking

brake. The parking brake engages whenthe operator lifts the restraint bar, leavesthe operators seat or shuts off the engine.The brake can also be applied manually

by using the switch located on the rightcontrol panel of the ROPS. The red indi-cator on the switch lights when the parking

brake is applied.

WARNING

Figure 2 Parking Brake Switch


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Rear Window Emergency Exit

The ROPS rear window has three func-tions: noise reduction, flying objects bar-rier and emergency exit.

To use the emergency exit, pull on theyellow warning tag at the bottom of thewindow and remove the seal. Push out thewindow and exit.

Lift Arm Support Device

The lift arm support device on the left lift cylinder is used as a cylinder lock toprevent the raised lift arm from unexpectedly lowering. Be sure to engage thesupport device when the lift arm is raised for service. When the support device isnot being used, store it under the lift arm using the lock pin. The support device isa safety device that must be kept in proper operating condition at all times. Thefollowing steps ensure correct usage:

The safest method of engaging the lift arm sup-port device requires two people one person

inside the loader and another person to engage the support device.Note: With the keyswitch OFF and the solenoid valve working, the lift arm willstay raised when the lift control is moved to lower the lift arm. If the valve doesnot hold the lift arm and it begins to lower, do not leave the operators compart-ment. Instead, have someone store the support device for you. Then, contact yourGehl dealer immediately to determine why the lift arm lowers while the keyswitchis OFF.

Figure 3 Rear WindowEmergency Exit

1. Pull Tag

WARNING


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Engagement

Always engage the lift arm support devicebefore leaving the operators compartment to

work on the loader with the lift arm raised.

To engage the lift arm support device:

1. Lower the lift arm fully onto theloader frame.

2. Stop the engine.

3. Leave the operators compartment.Remove the lock pin holding thesupport device up against the lift arm.Allow the support device to drop

down into contact with the lift cylin-der.

4. Return to the operators compartmentand start the engine.

5. Raise the lift arm until the lift armsupport device drops over the end of the lift cylinder and around the cylinderrod. Slowly lower the lift arm until the support device contacts the top end ofthe lift cylinder.

6. Be sure the support device is secure against the cylinder end. Then, stop theengine, remove the key and leave the operators compartment.

WARNING

Figure 4 Lift Arm SupportDevice Engaged


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Disengagement

Never leave the operator s compartment to dis-engage the lift arm support device with the

engine running.

To return the lift arm support device to itsstorage position:

1. Raise the lift arm completely.

2. Stop the engine, remove the key andtake it with you.

Before testing the loader, always clear peoplefrom the area.

3. Before leaving the operators compartment, be sure that the lift arm is beingheld in the raised position by the solenoid valve.

4. To store the support device, raise it up until it contacts the lift arm. Slide the

lock pin through the support device and catch under the lift arm. Once the pinis secure, flip the lock pin loop so that it locks the pin in.

Accessory Outlet

The optional 12-volt accessory outlet is located at the bottom of the left instru-ment panel.

WARNING

Figure 5 Lock Pinin storage Position

WARNING


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Engine Speed Control

A right-hand controlled throttle lever is provided on all models for adjusting theengine speed. Move the control forward to increase the engine speed and rear-ward to decrease the engine speed.

T-Bar Controls Only: A right-footoperated accelerator pedal is provided tocontrol the engine speed. The pedallinkage is spring-loaded to return to theadjusted hand-operated throttle setting.

Figure 6 Throttle Lever

Figure 7 Foot Pedal (T-Bar)


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Instrument Panel

The instrument panel contains the followingswitches and indicators. Symbols on the panelrepresent various functions and conditions, andare visible only when indicator lamps are on.

1. Hourmeter Displays the total operatinghours on the loader.

2. Fuel Level Gauge Displays the amount offuel in the tank.

3. Engine Coolant Temperature Gauge Indicates the engine coolant temperature.

Note: Items 4 through 9 are indicator lamps

which display the following:4. Fasten Seatbelt A momentary visual (and

audible) indicator to remind the operator tofasten the seatbelt.

5. Engine Oil Pressure Lights if the engineoil pressure drops too low, warning theoperator to immediately stop the engine anddetermine the cause for the pressure drop.During normal operation, this indicatorshould be OFF.

6. Battery Lights if the charging voltage istoo high or too low. During normal opera-tion, this indicator should be OFF.

7. Preheat Indicator Lamp Lights when thepreheat switch is pressed. During normaloperation, this indicator should be OFF.

8. Engine Coolant Temperature Lights ifthe engine coolant becomes too hot, warningthe operator to stop the engine. Allow theengine to cool, determine the cause for thehigh temperature and correct the problem

before restarting the engine. During normaloperation, this indicator should be OFF.

9. Hydraulic Oil Temperature Lights if thehydraulic oil becomes too hot, warning the

operator to stop engine. Allow the hydraulicsystem to cool and determine the cause ofthe high temperature. During normal opera-tion, this indicator should be OFF.

1

2

3

4

5

6

7

8

Figure 8 Instrument Panel

9

10

11

12

13

14


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T-Bar Controls

The Gehl loader may be equipped withthe T-Bar control option. The left T-Barcontrols the drive and the right T-Bar con-trols the lift/tilt.

Drive Controls

Forward, reverse, speed and turningmaneuvers are controlled by movement ofthe left T-Bar. To go forward, push thecontrol forward; for reverse, pull the con-trol rearward. To turn right, twist the con-trol clockwise; to turn left, twist the con-trol counterclockwise. For gradual turns, twist the T-Bar slightly clockwise orcounterclockwise. For sharp turns, twist the control fully clockwise or counter-clockwise.

Moving the T-Bar farther from neutral increases the speed steadily to the max-imum travel speed. Tractive effort decreases as speed increases. For maximumtractive effort, move the T-Bar only slightly from the neutral position. Theengine will stall if the control is moved too far forward when loading the bucket.

Be sure the controls are in neutral before

starting the engine. Operate the controls grad-ually and smoothly. Excessive speed and quick control movementswithout regard for conditions and circumstances are hazardous andcould cause an accident.

Lift/Tilt Control

Moving the lift arm and tilting the attachment are accomplished by movement ofthe right T-Bar. To raisethe lift arm, pull the control straight rearward; to lowerthe lift arm, push the control straight forward. To tilt the attachment down-

ward, twist the control clockwise; to tilt the attachment up or back, twist thecontrol counterclockwise.

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

To place the lift arm into the detent (float) position, push the right T-Bar all theway forward into the detent. This position allows the lowered lift arm to floatwhile traveling over changing ground conditions.

Never push the lift/tilt T-Bar control into thefloat position with the attachment loaded orraised, because this wil l cause the lift arm to lower rapidly.

Figure 9 T-Bar Controls1. Drive Control

2. Lift/Tilt Control

1 2

WARNING

WARNING


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Hand/Foot Controls

The Gehl loader may be equipped withthe hand/foot control option. The handlescontrol the drive and the foot pedalscontrol the lift/tilt.

Drive Controls

Forward, reverse, speed and turningmaneuvers are controlled by movement ofthe control handles. To go forward, push

both handles forward; for reverse, pullboth handles rearward. For turning, moveone handle farther forward or rearwardthan the other handle. Turn direction is

determined by which handle is moved thefarthest forward; to turn left, move theright handle farther forward than the left handle. For sharp turns, move the handlesin opposite directions.

Moving the handles farther from neutral increases the speed steadily to themaximum travel speed. Tractive effort decreases as speed increases. For maximumtractive effort, move the handles only slightly from the neutral position. The enginewill stall if the controls are moved too far forward when loading the bucket.

Be sure the controls are in neutral beforestarting the engine. Operate the controls grad-

ually and smoothly. Excessive speed and quick control movementswithout regard for conditions and circumstances are hazardous andcould cause an accident.

Lift/Tilt Controls

Moving the lift arm and tilting the attachment are accomplished by movement ofthe foot pedals. The left pedal raises and lowers the lift arm; the right pedal tiltsthe attachment. To raise the lift arm, use your heel to push down on the left

pedal; to lowerthe lift arm, use your toes to push down on the left pedal. To tiltthe attachment downward, use your toes to push down on the right pedal; to tiltthe attachment upor back, use your heel to push down on the right pedal.

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

To place the lift arm in the detent (float) position, use your toes to push the left

pedal all the way down into the detent. This position allows the lowered lift armto float while traveling over changing ground conditions.

Never push the left pedal into the float positionwith the attachment loaded or raised, because

this will cause the lift arm to lower rapidly.

Figure 10 Hand/Foot Controls1. Left Drive Control Handle

2. Right Drive Control Handle

3. Tilt Control Foot Pedal

4. Lift Control Foot Pedal

1

2

3

4

WARNING

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Auxiliary Hydraulic Controls

Auxiliary hydraulics are used with anattachment that has a mechanismrequiring hydraulic power of its own.

Important: Always be sure the auxiliaryhydraulic control is in neutral beforestarting the loader or removing the auxil-iary hydraulic couplers.

Couplers are located on the left lift arm.A port is pressure, B port is returnwhen the auxiliary control is in the detent

position (refer topage 34).

T-Bar Controlled LoadersA foot pedal is used to control the direc-tion of oil flow.

Figure 11 Auxiliary Couplers

AB

Figure 12 T-Bar Auxil iaryControl


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Hand/Foot Controlled Loaders

The right handle controls the direction ofoil flow. A locking pin locks it in the up

position for continuous operation.

Attachment MountingThe Gehl loader is equipped with atwo-pin All-Tach attachment bracketfor mounting a bucket or other attach-ment. Two latch levers secure the attach-ment. Rotate the levers until they are hori-zontal to engage the latch pins. Rotate thelevers until they are vertical to disengage

the latch pins.

To prevent unexpected attachment releasefrom the hitch, be sure to secure the lock pins

by rotating the levers downward into a horizontal posi tion.

Figure 13 Hand/FootAuxi liary Control

Figure 14 All-TachAttaching Mechanism (Hitch)

WARNING


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Notes


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CHAPTER 4

OPERATION

Before starting the engine and operating theloader, review and comply with all safety

recommendations in the Safetychapter of this manual. Know how tostop the loader before starting it. Also, be sure to fasten and prop-erly adjust the seatbelt and lower the operator restraint bar.

Before Starting the Engine

Before starting the engine and running the loader, refer to the Controls and SafetyEquipmentchapter and familiarize yourself with the various operating controls,indicators and safety devices on the loader.

Starting the Engine

The following procedure is recommended for starting the engine:

1. Carefully step up onto the back of the bucket or attachment and grasp theROPS handholds to get into the operators compartment.

2. Fasten the seatbelt and lower the restraint bar.

3. Verify the following:

the lift/tilt, drive and auxiliary controls are in their neutral positions,

the brake is on.

4. Push the throttle forward to half speed.

Note: When the key is turned to the RUN position, an indicator will light on theinstrument panel and a buzzer will sound momentarily to remind you to checkthat your seatbelt is fastened.

5. Turn the keyswitch to the START position.

Important: Do not engage the starter for longer than 15 seconds at a time.Longer use can overheat and damage the starter. Allow the starter to cool for20 seconds between uses.

After the engine starts, allow a sufficient warm-up time before attempting tooperate the controls.

Important:If the warning lights do not go off, stop the engine and investigate thecause.

Cold Starting Procedure

Do not use starting fluid (ether) with preheatsystems. An explosion can result which can

cause engine damage, injury or death.

WARNING

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1. Turn the key to the run position. If the preheat light on the right instrumentpanel comes on, wait until it goes out.

2. Turn the key switch to the start position.

3. Repeat if engine does not start.

Stopping the LoaderThe following procedure is the recommended sequence for stopping the loader:

1. Check that the drive control handle(s) is (are) in neutral position.

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

3. Pull the throttle lever back to the low idle position (and/or take your foot offthe accelerator pedal for hands-only controlled machines).

4. Turn the keyswitch to the OFF position to shut off the engine.

5. Raise the restraint bar, unfasten the seatbelt and grasp the hand holds whileclimbing out of the operators compartment.

Note: The skid-steer loader is equipped with a spring-applied automatic parkingbrake. The parking brake is engaged when the operator lifts the restraint bar,leaves the operators seat, shuts off the engine or when the brake switch isapplied.

Parking the Loader

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

Jump Starting the Engine

If the battery becomes discharged or does not have enough power to start theengine, use jumper cables and the following procedure to jump-start the loaderengine.

The ONLY safe method for jump starting witha discharged battery is for TWO PEOPLE to

perform the following procedure. The second person removes thejumper cables so that the operator does not have to leave theoperators compartment with the engine running. NEVER make

jumper cable connections directly to the starter solenoid of eitherengine. DO NOT start the engine from any position other than onthe operators seat and then ONLY after being sure ALL controls

are in neutral .Closely follow the procedure, in order, to avoid personal injury. Inaddition, wear safety glasses to protect your eyes and avoidleaning over the batteries while jump-starting.

DO NOT jump-start the battery if it is frozen, because it may rupture or explode.

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

1. Turn the keyswitches of both vehicles to OFF, be sure the vehicles are inneutral and NOT touching each other.

2. Connect the positive (+) jumper cable to the positive (+) battery terminal on thedisabled loader first. DO NOT allow the positive clamps to touch any metal

other than the positive (+) battery terminals.3. Connect the other end of the positive jumper cable to the jumper vehicles bat-

tery positive (+) terminal.

4. Connect the negative (-) jumper cable to the jumper vehicles battery negative(-) terminal.

5. Make the final negative (-) jumper cable connection to the disabled loadersengine block or loader frame (ground) NOT to the disabled batterys negative

post. If connected to the engine, keep the jumper clamp away from the battery,

fuel lines and moving parts.6. Start the loader. If it does not start at once, start the jumper vehicle engine to

avoid excessive drain on the booster battery.

7. After the disabled loader is started and running smoothly, have the secondperson remove the jumper cables (negative (-) jumper cable first) from thejumper vehicles battery and then from the disabled loader while being sureNOT to short the two cables together.

Allow sufficient time for the skid-steer loader alternator to build-up a charge inthe battery before attempting to operate the loader or shut the engine off.


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Changing Attachments

To prevent unexpected attachment releasefrom the attachment bracket, be sure to prop-

erly secure the latch pins by rotating the latch levers to a horizontal

position.The skid-steer loader features a All-Tach attaching mechanism for mounting a

bucket or other attachment. Two latch levers secure the attachment.

Connecting an Attachment

1. Rotate the latch levers to a verticalposition to fully retract the latch pins.

2. Start the loader engine and make sure

the lift arm is lowered and in contactwith the loader frame.

3. Align the loader squarely with theback of the attachment.

4. Tilt the attachment bracket forwarduntil the top edge of the bracket is

below the flange on the back side ofthe attachment and centered betweenthe vertical plates.

5. Slowly drive the loader forward and, at the same time, tilt the attachmentbracket back to engage the flange on the back side of the attachment.

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

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

8. With the loader engine OFF, leave the operators compartment and rotate the

latch levers to a horizontal position to fully engage the latch pins.Important: To check that the attachment is properly installed, apply down pres-sure to the attachment prior to operating.

Connecting Auxiliary Hydraulic Couplings

Note: With the engine OFF, key in the ON position and the restraint bar down,the auxiliary hydraulic control can be moved to relieve any pressure in thehydraulic system.

The hydraulic couplers are located on the left lift arm. A port is pressure, Bport is return when the auxiliary control is in the detent position.

WARNING

Figure 15 Hitch disengaged1. Latch Levers

2. Latch Pins

1 1

2 2


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Removing Attachments

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

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

3. Relieve any hydraulic pressure in the auxiliary and attachment lines.

a. Turn the key switch, but do not start the engine.

b. With the restraint bar down, move the auxiliary hydraulic control back andforth. This will relieve the pressure in the hydraulic system.

4. With the engine OFF, leave the operators compartment, disconnect the auxil-iary hydraulic hoses and rotate the latch levers completely vertical to fullyretract the latch pins.

5. Start the engine and be sure that the lift arm is fully lowered and in contactwith the loader frame.

6. Tilt forward and slowly back the loader until the attachment is free from theloader.

Self-Leveling (optional)

The feature is designed to keep the attachment level while the lift arm is beingraised.

Using a Bucket

Always maintain a safe distance from electr icpower lines and avoid contact with any electri-

cally charged conductor or gas line. Accidental contact or rupturecan result in electrocution or an explos ion. Contact the DiggersHotline or proper local authorities for utili ty line locations beforestarting to dig.

Driving over Rough Terrain

When traveling over rough terrain, drive slowly with the bucket lowered.

Driving on an Incline

When traveling up or down on an incline, travel with the heavy end pointinguphill. Try to avoid traveling on an incline, but always travel with the bucket as

possible to maintain stability.

WARNING


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Loading a Bucket

Approach the pile with the lift arm fullylowered and the bucket tilted slightly for-ward until the edge contacts the ground.Drive forward, lifting the lift arm andtilting back the bucket to fill it. Backaway from the pile.

Always carry the loaded bucket with the li ft armresting on the loader frame. For additional sta-

bili ty when operating on inclines, always travel with the heavier end

of the loader toward the top of the incline.

Digging with a Bucket

Approach the digging site with the liftarm slightly raised and the bucket tiltedforward until the edge contacts theground. Break the ground by driving for-ward and gradually lowering the lift arm.

With the bucket filled, tilt the bucketback, and back the loader away from thematerial. Rest the lift arm against theloader frame before proceeding to thedumping area.

Dumping the Load onto a Pile

Carry a loaded bucket as low as possible until reaching the pile. Gradually stopforward motion and raise the lift arm high enough so that the bucket clears the

top of the pile. Then slowly move the loader ahead, to position the bucket todump the material on top of the pile. Empty the bucket and back the loader awaywhile tilting the bucket back and lowering the lift arm.

Never push the controls into the float positionwith the bucket or attachment loaded or raised,

because this will cause the lift arm to lower rapidly.

Figure 16 Loading

WARNING

Figure 17 Digging

WARNING


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Dumping the Load Into a Box

Carry the loaded bucket low and approachthe vehicle or bin. Stop your approach asclose to the side of the box as possiblewhile allowing for clearance to raise thelift arm and loaded bucket. Next, raise thelift arm until the bucket clears the top ofthe box and move the loader ahead, to

position the bucket over the inside of thebox, slowly dump the bucket. After thematerial is dumped, back away from the

box while tilting the bucket back and low-ering the lift arm.

Dumping the Load Over an Embankment

Do not drive too close to an excavation orditch. Be sure the surrounding ground has ade-

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

Carry the loaded bucket as low as possible while traveling to the dumping area.Stop the loader where the bucket extends half-way over the edge of the embank-ment. Tilt the bucket forward and raise the lift arm to dump the material. Afterthe material is dumped, back away from the embankment while tilting the bucket

back and lowering the lift arm.

Scraping with a Bucket

For scraping, the loader should be operatedin the forward direction. Position the liftarm down against the loader frame. Tilt the

bucket cutting edge forward at a slightangle to the surface to be scraped. Whiletraveling slowly forward with the bucket in

this position, material can flow over thecutting edge and collect inside the bucket.

Leveling the Ground

Drive the loader to the far edge of the areato be leveled. Tilt the bucket forward to

place the bucket cutting edge at a 30 to45 degree angle to the surface to beleveled. Then place the lift arm into thefloat position and drive the loader rear-ward dragging the dirt and, at the sametime, leveling it.

Figure 18 Dumping Into a Box

WARNING

Figure 19 Scraping

Figure 20 Leveling the Ground


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Note: The float (detent) position for T-Bar controlled loaders is reached bypushing the right handle all the way forward. For hand/foot controlled loaders,use your toes to push the front of the left pedal all the way down.

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

travel.

Highway Travel

If it becomes necessary to move the loader a long distance, obtain and use aproperly rated trailer. For short distance highway travel, attach an SMV (SlowMoving Vehicle) emblem (purchased locally) to the back of the loader. Forhighway operation, obtain and install dual amber flashers or a strobe light. Checkstate and local laws and regulations.

Lifting the Loader

The loader can be lifted using a single-point or four-point lift kit, which is avail-able from your Gehl dealer.

Before lifting, check the lift kit for proper installation.

Never allow riders in the operators compartment while theloader is lifted.

Keep everyone a safe distance away from the loader while it is

lifted.

Loader may only be lifted with an empty bucket or empty pallet

forks, or with no attachment. Never lift the loader with attach-

ments other than those stated.

Lift equipment used and its installation is the responsibility of the party con-ducting the lift. All rigging MUST comply with applicable regulations andguidelines.

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

Important:As needed, use a spreader bar to prevent the slings or chains fromrubbing the sides of the ROPS/FOPS. (Four-point lift only)

Note: The loader my be slightly off level (10 degrees max.) when lifted,

depending on loader model and attachment (single-point lift only.)

2. Center the hoist over the ROPS/FOPS. To prevent shock loading of the equip-ment and excessive swinging, slowly lift the loader off the ground. Perform allmovements slowly and gradually. As needed, use a tag line to help position theloader.

WARNING

WARNING


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Storing the Loader

If your skid-steer loader is to be stored for a long period of time, the followingprocedure is suggested:

1. Fully inflate the tires.

2. Lubricate all grease zerks.3. Check all fluid levels and replenish as necessary.

4. Add stabilizer to the fuel per the fuel suppliers recommendations.

5. Remove the battery, charge fully and store in a cool, dry location.

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

Transporting the Loader

Park the truck or trailer on a level surface. Besure the vehicle and its ramps have the weight

capacity to support the loader. Make sure the vehicle surface and itsramps are clear of debris and s lippery material that may reduce trac-tion. Move the loader on and off the vehicle ramp slowly and care-fully. Failure to follow these instructions could result in an overturnaccident.

Observe all local regulations governingthe loading and transporting of equip-ment. Ensure that the hauling vehiclemeets all safety requirements beforeloading the skid-steer loader.

1. Place blocks at the front and rear ofthe hauling vehicles tires.

2. If the loader has an attachment, lift it

slightly off the ground.

3. Back the loader slowly and carefullyup the ramp onto the vehicle.

4. Lower the loader attachment to thevehicle deck, turn off the engine andremove the key.

5. Fasten the loader to the hauling vehi-cle at the points indicated by the tie-

down decals.6. Measure the clearance height of the

loader and hauling vehicle. Post theclearance height in the cab of the vehi-cle.

WARNING

Figure 21 Front Tie

Down/Retrieval point

Figure 22 Rear Tie Down/Retrieval point


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Notes


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CHAPTER 5

SERVICE

Before servicing the machine, unless expresslyinstructed to the contrary, exercise the MAN-

DATORY SAFETY SHUTDOWN PROCEDURE(page 6).After service has been performed, be sure to restore all guards,shields and covers to their original positions before resumingloader operation.

This Service chapter details procedures for performing routine maintenancechecks, adjustments and replacements. Most procedures are referred to in theTroubleshooting and Maintenance Schedule Schedule chapters of this manual.Refer to the separate engine manual provided for engine-related adjustments,

lubrication and servicing procedures.

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

Important: More frequent service than the recommended intervals may berequired under severe operating conditions. You must decide if your operationrequires more service.

Important: Always dispose of waste lubricating oils and hydraulic fluidsaccording to local regulations or take to a recycling center for disposal. Do notpour onto the ground or down the drain.

Dealer Services

The following areas of component service, replacement and adjustments requirespecial tools and knowledge for proper servicing and should be performed only

by your authorized Gehl skid-steer loader dealer: hydrostatic components,hydraulic system gear pump, valves, cylinders, electrical components (other than

the battery, circuit breakers).

WARNING

Figure 23 Engine Compartment1. Air Cleaner

2. Muffler

3. Radiator/Cooler

4. Coolant Recovery Tank

5. Hydraulic Oil Filter

6. Engine Oil Dipstick

7. Engine Oil Fill Cap

8. Engine Oil Filter

9. Fuel Filter

10. Fuel Pump

11. Water Trap

1 5

2

3

76

9

104

118


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Tilting Back the ROPS/FOPS

For service, unbolt the two anchor bolts atthe front of the ROPS/FOPS and tilt it

back slowly, moving the control handlesout of the way. A gas-charged spring

helps tilt it back. A self-actuating lockmechanism engages to lock theROPS/FOPS in a rolled-back position. Tolower the ROPS/FOPS, apply upwardforce on it while pulling the lock mecha-nism handle toward the front of theloader. Lower the ROPS slowly onto thechassis, moving the control handles out ofthe way. Reinstall the anchor bolts,

washers and locknuts.

Never operate the loader with the ROPS/FOPSremoved or locked back. Be sure the lock is

securely engaged when the ROPS/FOPS is ti lted back. Properly sup-port the ROPS/FOPS when unlatching the lock mechanism and low-ering the ROPS/FOPS. Be sure to reinstall the anchor bol ts, washersand locknuts before resuming loader operation.

Loader Raising ProcedureTo raise the skid-steer loader so all four tires are off the ground, use the

procedure below:

Do not rely on a jack or hoist to maintain theraised position without additional blocking

and supports. Serious personal injury could result from improperlyraising or blocking the skid-steer loader.

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

2. Stack wooden blocks under the flat part of the loader chassis. They shouldrun parallel with, but not touch, the rear tires (Figure 25).

3. Slowly lower the loader until its weight rests on the blocks. If the tires stilltouch the ground, raise the loader again, add more blocks and lower again.

4. Repeat Steps 1 through 3 for the front end. When the procedure is finished, all

four tires will be off the ground so they can be removed.

Loader Lowering Procedure

When service or adjustment procedures are complete, the skid-steer loader can betaken down from the raised position. To lower the loader onto its tires:

Figure 24 ROPS LockMechanism

WARNING

WARNING


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1. Using a jack or hoist, raise the front of the loader until its weight no longerrests on the front blocks.

2. Carefully remove the blocking underthe front of the loader.

3. Slowly lower the loader until the fronttires are resting on the ground.

4. Repeat Steps 1 through 3 for the rearof the loader. When the procedure isfinished, all four tires will be on theground and the blocks removed fromunder the loader.

Replacement Parts

Note: Part numbers may change. Your Gehl dealer will always have the latestpart numbers.

Adjustments

Control Handles

The control handles do not require routine adjustment. Refer to the ServiceManualfor the initial setup procedure.

Fuel Sender

The fuel sender, located in the fuel tank, sends a signal to the fuel gauge indi-cating the amount of fuel left in the fuel tank.

Check the fuel sender periodically to ensure that the mounting screws are tightand that there is no fuel seepage around the gasket. If replacement is required,apply an RTV or gasket sealant around the gasket when restoring the fuel sender.

Part Description Gehl Part No.

Air Cleaner Element, Primary 188814

Air Cleaner Element, Secondary 188817

Hydraulic Oil Filter Element 074830

Engine Oil Filter Element 137500

Fuel Filter Cartridge 182130

Figure 25 Blocked Loader


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Engine Speed Control

The throttle cable does not require routine adjustment. Refer to the ServiceManualfor the initial setup procedure.

Besides throttle cable adjustment, the throttle lever friction pad pressure can bereadjusted if the throttle lever does not hold its position. Belleville washers and a

lock nut on the throttle lever are used for making this adjustment.

Drive Chains

The drive chains do not require routine adjustment. Refer to the Service Manualfor the initial setup procedure.

Lubrication

Listed below are the locations, temperature ranges and types of recommendedlubricants to be used when servicing this machine. Refer to the separate enginemanual for more information regarding recommended engine lubricants, quanti-ties required and grades.

Refer to the following figure for grease fitting locations. Wipe dirt from the fit-tings before greasing them to prevent contamination. Replace any missing ordamaged fittings. To minimize dirt build-up, avoid excessive greasing.

Hydraulic System

Use Mobil DTE 15M or equivalent that contains anti-rust,

anti-foam and anti-oxidation additives, and conforms to ISO VG46.

Capacity:8 U.S. gallons (30,0 liters)

Chaincases

Use SAE15W-40 motor oil.

Capacity(each side):

8 U.S. quarts (7,6 liters)

Grease Fittings Use lithium based grease

Engine

Below 32F (0C) Use SAE Grade* 10 or 10W-30

Above 32F (0C) Use SAE Grade* 15W-40

*Service Classification: API - CH-4/CI-4

Capacity:3-cylinder: 7.6 U.S. quarts (7,2 liters)

4-cylinder: 9.0 U.S. quarts (8,6 liters)


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Engine Air Cleaner

Important: Failure to followproper filter servicing instructionscould result in catastrophic enginedamage.

The air cleaner consists of an outer(primary) filter element and aninner (secondary) filter element. Anair filter restriction indicator formonitoring the condition of the ele-ments is located on the right side ofthe front of the air cleaner. If the airfilter becomes restricted, this indi-cator will turn red to warn the

operator that the element(s) requireservice. Push the reset buttonlocated on the end of the indicatorafter fitting a clean element. Forreplacement elements, refer to theReplacement Parts topic (page 43).

Figure 26 Grease Every 10 Hours (or daily)1. Lift arm pivots (2)

2. Lift cylinder pivots (4)

3. Tilt cylinder pivots (2)

4. Attachment Bracket pivots (2)

1

2

4

3

Figure 27 Dual-Element AirCleaner

1. Restriction Indicator

2. Element Housing3. Inner Filter Element

4. Outer Filter Element

5. Element Cover

1

2

34

5


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Note: Before replacing the filter element(s), push the reset button on the indi-cator. Start the engine and adjust the throttle to full speed. If the indicator doesnot turn red, donotreplace the element(s).

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

Along with a daily check of the restriction indicator, check the air cleaner intakehose and clamps, and the mounting bracket hardware to be sure they are properlytightened.

Access

1. Open the rear door and engine access cover.

2. Unlatch the clamps on the air cleaner and remove the cover. Clean out any

dirt built up in the cover assembly.

Outer Element

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

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

3. Replace the outer element.

Note: Gehl does not recommend cleaning the outer element.

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

Inner Element

Note:Replace the inner element only if it is dirty or if the outer element has beenreplaced three times.

1. Before removing the inner element from the housing, clean out any dirt builtup in the housing. Leave the inner element installed during this step to pre-vent debris from entering the engine intake manifold.

2. Remove the inner element.


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Reinstallation

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

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

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

4. Secure the cover to the housing with clamps.

5. Check the hose connections and be sure they are all clamped and tightenedproperly.

6. Reset the restriction indicator by pressing the reset button.

Engine Service

Check Engine Mounting HardwareAll bolts that secure the engine mounting brackets to the engine and the loaderframe should be checked and re-tightened as necessary.

Allow hot engine and hydraulic system compo-nents to cool before servicing.

Checking Engine Oil Level

Important: For new units, the initial oilchange should be after the first 50 hours.

Open the rear door and engine accesscover. Pull out the dipstick and check theoil level. Markings on the dipstick repre-sent FULL and LOW (add oil) levels.

Refer to the Maintenance Interval Chart(page 67) for the service interval for

replacing the engine oil and filter.

WARNING

Figure 28 Oil Dipstick

and Fill Cap1. Oil Dipstick

2. Oil Fill Cap

12


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Changing Engine Oil and Filter

1. Run the engine until it is at operatingtemperature. Stop the engine. Removethe rear belly pan.

2. Remove the drain plug.

3. From the engine compartment,remove the oil filter. Clean the filtersealing surface.

4. Put clean oil on the new oil filtergasket. Install the filter and tighten 3/4of a turn past the point where the gas-ket contacts the filter head.

5. Reinstall and tighten the drain plug.

6. Remove the oil cap and add the recommended oil. Refer to the Lubricationtopic in this chapter for oil specifications and capacities.

7. Start the engine and let it run for several minutes at low idle. Stop the engine.Check for leaks at the oil filter, drain plug and remote oil drain hose. Checkthe oil level. Add oil if it is not at the top mark on the dipstick.

For a replacement element, refer to the Replacement Parts topic (page 43).

Changing Fuel Filter

The engine has a fuel filter located on the left side of the engine. To change it:1. Shut off the fuel supply by turning the fuel shutoff valve on top of the water

trap.

2. Shut off return line by turning valve on the fuel tank.

3. Remove the fuel filter element.

4. Lubricate new fuel filter element gasket with diesel fuel.

5. Install and tighten the filter element one-half turn past point the where thegasket contacts the filter head.

6. Turn shutoff valve on water separator to ON.

7. Turn on the fuel supply at fuel tank.

The engine is self-priming. To remove air before starting, turn the ignition key tothe ON position for 30 seconds.

For a replacement element, refer to the Replacement Parts topic (page 43).

Figure 29 Rear Belly Pan


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Servicing Water Separator

Periodically check for water in water separator by checking level of float in waterseparator bowl. If water is present:

1. Shut off the fuel supply by turning the fuel shutoff valve on top of the waterseparator.

2. Turn nut to release the bowl from the valve head. Dispose remaining fuel andwater.

3. Clean bowl and filter element with warm water until all foreign material isremoved. Replace fuel filter if damaged. Refer to Parts Manual for part num-

ber.

4. Place element onto valve head. Lubricate o-ring on bowl with diesel fuel andplace on valve head. Turn nut to tighten.

5. Turn on fuel supply.

Releasing Water from Separator

1. Check red float located in the water separator bowl. If red float is raised, openvalve on the bottom of the bowl to drain water.

2. Close valve quickly after float reaches the bottom of the bowl.

Spark Arrestor Muffler

Important: The loader is factory-equipped with a spark arrestor type muffler.Muffler maintenance is required to keep it in working condition. Refer to locallaws and regulations for spark arrestor requirements.

1. Stop the engine, open the rear door and engine cover.

2. Remove the plug from the bottom of the muffler.

3. Block the outlet of the muffler with a non-combustible material.

4. Start the engine and run it for 10-15 seconds.

5. Stop the engine and remove the blockage.6. Put anti-seize coating on the plug.

7. Reinstall and tighten the plug.

Alternator/Fan Belt

Refer to the separate engine manual for setting proper belt tension. If the belt isworn, cracked or otherwise deteriorated, replace the belt by following the proce-

dure in the separate engine manual.


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Hydraulic System

Checking Hydraulic Oil Level

The loader has a dipstick located in theengine compartment. Check the fluidlevel with the lift arm lowered and theattachment on the ground.

When hydraulic fluid is required, allowthe system to cool. Slowly remove the oilfill cap, allowing the pressure to dispel

before removing the cap completely.

Add hydraulic fluid as required. Refer tothe Lubrication topic (page 44) for oilrecommendations. Replace the cap.

Changing Hydraulic Oil Filter

Before servicing the hydraulic filter, be surethe lift arm is lowered.

1. Open the rear door and engine coverto access the filter. Unscrew the filter.

2. Clean the surface of the filter housingwhere the element seal contacts thehousing. Put clean oil on the rubbergasket of the new filter element.

3. Install and tighten the filter element3/4 of a turn past the point where thegasket contacts the filter head.

4. For a replacement element, refer to the

Replacement Partstopic (page 43).

Changing Hydraulic Oil

The hydraulic oil must be replaced if it becomes contaminated, after majorrepairs, and after 1000 hours or one year of use.

1. Remove the oil filler cap.

2. Install a catch pan of sufficient capacity under the oil reservoir (8 gallons[30 liters])

3. Remove the drain plug located on the bottom left of the oil reservoir.4. Remove and replace the hydraulic oil filter.

5. Reinstall the drain plug.

6. Refill the reservoir until the oil is between the two lines on the dipstick gauge.

7. Start the engine and operate the hydraulic controls.

Figure 30 Hydraulic Oil Service

WARNING

Figure 31 Drain Plug


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8. Stop the engine and check for leaks at the filter and reservoir drain plug.

9. Check the fluid level and add fluid if needed.

Cooling Systems

Important: Check the cooling system every day to prevent overheating, loss ofperformance or engine damage.

Checking Coolant Level

1. Open the rear door. Check the coolantlevel in the coolant recovery tank onthe inside of the rear door. The coolantrecovery tank must be 1/3 to 1/2 fullwith a cold engine and 2/3 to 3/4 full

with a hot engine.

2. Allow the coolant to cool. Do notremove the cap when the coolant ishot. Serious burns may occur.

3. Add premixed coolant, 50% water and50% ethylene glycol, to the recoverytank if the coolant level is low.

Cleaning Cooling System1. Park the loader on a level surface,

lower the lift arm and stop the engine.Allow the engine to cool.

2. Open the rear door. Lift the engine cover.

3. Clean the radiator and oil cooler by blowing through the fins with high pres-sure water or air.

Note: The radiator can be tipped out for cleaning by loosening and rotating the

over-center links on each side. This will also help in cleaning the oil cooler.

Draining/Flushing Cooling System

1. Open the rear door. Lift the engine cover.

2. Slowly remove the radiator cap, allowing pressure to dispel before removingcompletely.

Liquid cooling systems build up pressure as the

engine becomes hot. Before removing the radi-ator cap, stop the engine and let the system cool. Remove the radiatorcap only after the coolant has cooled. Remove the cap slowly orsevere burns may result.

3. Remove the drain plug and drain the coolant into a suitable container.

4. Replace the drain plug.

Figure 32 Cooling System

1. Recovery Tank2. Radiator/Cooler

3. Drain Plug

1

2

3

WARNING


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Note: Protect the cooling system by adding premixed 50% water and 50% ethy-lene glycol to the system. This mixture will protect the cooling system to -34F(-36C).

5. Fill the radiator fully and the recoverytank half full with the premixedcoolant.

6. Reinstall the radiator cap.

7. Run the engine until it is at operatingtemperature. Stop the engine and let itcool. Check the coolant level. Addmore coolant if required.

Chaincases

The chaincase contains the drivesprockets and drive chains. There are two

plugs in each chaincase. One is to drainthe fluid and the other is to check the fluidlevel. Refer to theMaintenance Schedulechapter (page 67) for change intervals.Refer to the Lubrication topic (page 44)for information on oil type and quantity.

Checking and Adding Oil1. Park the loader on a level surface.

Stop the engine.

2. Remove the check plug from eachchaincase housing. If the oil can be reached with the tip of your finger, the oillevel is adequate.

3. If the level is low, add fluid through the check plug until the oil level reachesthe edge of the hole. Reinstall the check plug.

Draining Oil

1. Raise the rear of the machine to aid in draining the chaincases.

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

3. Reinstall and tighten the drain plugs.

4. Refill the chaincases at the check plugs.

Seat and Restraint Bar Switches

Electrical switches in the seat and restraint bar must be closed (operator sitting inthe seat and restraint bar lowered) to complete the circuit and start the engine.

Figure 33 Check Plug

Figure 34 Drain Plugs


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Bucket Cutting Edge

The bucket cutting edge should be replaced when it is worn to within 1 in. (25 mm)of the bucket body.

Wheel Nuts

Wheel nut torque must be checked before initial operation and every two hoursthereafter until the wheel mounting hardware torque stabilizes at therecommended setting of 120-130 ft-lbs (161-175 Nm). When tires are removedand replaced, this procedure must be repeated.

Tires

Rear tires usually wear faster than the front ones. To keep tire wear even, rotatethe tires from front to rear and rear to front.

It is important to keep the same size tire on each side of the loader to preventexcessive wear on tires or other damage. If different sizes are used, each tire will

be turning at different speeds, causing excessive wear.

The tread bar of all tires must face the same direction.

Mounting Tires

Inflating or servicing tires can be dangerous.When possible, trained personnel shouldservice and mount tires. To avoid possible death or serious injury,follow the safety precautions below.

1. Be sure the rim is clean and free of rust.

2. Lubricate the tire beads and rim flanges with a soap solution. Do not use oilor grease.

3. Use a clip-on tire chuck with remote hose and gauge, allowing you to stand

clear while inflating the tire. Do not place your fingers on the tire bead or rimduring inflation.

4. Never inflate beyond 35 psi (240 kPa) to seat the beads. If the beads have notseated by the time the pressure reaches 35 psi (240 kPa), deflate the assembly,reposition the tire on the rim, lubricate both parts and re-inflate. Inflation

pressure beyond 35 psi (240 kPa) with unseated beads may break the bead orrim with explosive force sufficient to cause death or serious injury.

5. After seating the beads, adjust the inflation pressure to the recommendedoperating pressure.

6. Do not weld, braze or otherwise attempt to repair and use a damaged rim.

WARNING


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Checking Tire Pressure

Correct tire pressure should be maintained for all tires to enhance operatingstability and extend tire life. Refer to the above chart for the proper inflation

pressure.When installing tires, be sure they are the same size and style on each side of theloader. Always replace tires with the same size as the original equipment.

Electrical System

Circuit Breakers

The circuit breakers for the loader are located on the right instrument panel.There is also a 35-amp main circuit breaker located on the right side of the enginecompartment, directly behind the ROPS/FOPS.

Tire SizeInflation Pressure

psi kPa

10 x 16.5 8-ply Heavy-Duty Flotation 60 414

27 x 8.5 15 8-ply Heavy-Duty 60 414

27 x 10.5 15 8-ply Heavy-Duty 60 414

6.5 x 16 5.50 Solid Rubber - -

7.00-15 SS Chevron Narrow 8-ply 60 414


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Battery

Before servicing the battery or electricalsystem, be sure the battery disconnect switch

(if equipped) is in the OFF position. If not equipped with a discon-nect switch, disconnect the ground (-) terminal from battery.

The battery on the loader is a 12-volt, wet-cell battery. To access the battery,open the rear door and lift the engine cover.

The battery top must be kept clean. Clean it with an alkaline solution (ammoniaor baking soda and water). After foaming has stopped, flush the battery top withclean water. If the terminals and cable connection clamps are corroded or have a

build-up, disconnect the cables and clean the terminals and clamps with the samealkaline solution.

Explosive gas is produced whi le a battery is inuse or being charged. Keep flames or sparksaway from the battery area. ALWAYS charge the battery in a well-ventilated area.

Never lay a metal object on top of a battery, because a short circuitcan result.

Battery acid is harmful on contact with skin or fabrics. If acid spills,follow these first-aid tips:

1. Immediately remove any clothing on which acid spills.

2. If acid contacts the skin, rinse the affected area with runningwater for 10 to 15 minutes.

3. If acid contacts the eyes, flood the eyes with running water for 10to 15 minutes. See a doctor at once. Never use any medication oreye drops unless prescribed by the doctor.

4. To neutralize acid spilled on the floor, use one of the followingmixtures:

a. 1 pound (0.5 kg) of baking soda in 1 gallon (4 L) of water

b. 1 pint (0.5 L) of household ammonia in 1 gallon (4 L) of water

Whenever the battery is removed, be sure to disconnect the nega-tive (-) battery terminal connection first .

WARNING

WARNING


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Notes


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CHAPTER 6

TROUBLESHOOTING

Electrical System

Problem Possible Cause Remedy

Entire electrical

system does not

function.

Battery disconnect switch is

OFF.

Turn battery disconnect

switch to ON.

15-ampere breakers tripped. Check circuit and locate

trouble before resetting

breaker.

Main wiring harness

connectors at rear of ROPS

not properly plugged in.

Check main harness

connectors.

Battery terminals or cables

are loose or corroded.

Clean battery terminals and

cables and retighten them.

Battery is faulty. Test battery and replace as

needed.

No instrument panel

lamps with keyswitch

turned to ON.

25 ampere breakers are

tripped.

Check circuit and locate

trouble before resetting

breaker.


are loose or corroded.

Clean battery terminals and

cables and retighten them.

Seatbelt buzzer not

sounding when key

turned to ON,

indicator lamps work

properly.

Buzzer is disconnected. Reconnect wires to buzzer.

Faulty buzzer. Replace buzzer.

Fuel gauge does not

work.

Faulty fuel gauge sender. Replace fuel gauge sender.

Faulty fuel gauge. Replace fuel gauge.

Loose wiring/terminalconnections. Verify wiring connections.

Engine temperature

gauge does not work.

Faulty temperature sender. Replace temperature sender.

Faulty temperature gauge. Replace temperature gauge.

Loose wiring/terminal

connections.

Verify wiring connections.

Hourmeter does not

work.

Loose wiring/terminal

connections.

Verify wiring connections.

Faulty alternator. Repair the alternator.Faulty hour meter. Replace hour meter.


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Starter will not

engage when key is

turned to START.

Seat or restraint bar switch

malfunctioning or not

activated.

Replace switches as needed.

If engine still doesnt start,

contact your dealer.

Poor connections to starter

relay in instrument panel.

Verify relay connections.


loose or corroded.

Clean terminals, cables and

retighten.

Faulty starter relay in

instrument panel.

Contact your dealer.

Battery discharged or

defective.

Recharge or replace battery.

Starter solenoid not

functioning.

Troubleshoot circuit. Replace

the starter solenoid.

Ignition wiring, seat switch,

restraint bar switch, etc.

loose or disconnected.

Check wiring for poor

connections, broken leads;

repair wiring or connection.

Starter or pinion faulty. Remove starter;

repair/replace as needed.

Work lights not

functioning properly.

Single light doesnt work:

Light bulb burned out, faultywiring.

Check and replace light bulb

as needed. Check wiringconnection to light.

No lights at all; 25-ampere

breaker tripped.

Check circuit and locate

trouble before replacing fuse.

Faulty light switch or poor

ground.

Replace light switch. Check

ground wire connections.

Lift/Tilt

Operator's Manual GEHL - 3640e-3840e-4240e

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Transcript of Operator's Manual GEHL - 3640e-3840e-4240e