GEHL 5635-Series-Ii-Operator-Manual
GEHL 5635-Series-Ii-Operator-Manual
SL5635 907845
English
&
SL6635
Series II
Skid Loaders
OPERATOR’S MANUAL
INTERNATIONAL SYMBOLS
Engine Start Engine Stop Power On Power Off Work Light Hazard Flasher
Horn Volume - Full Volume - Half Full Volume - Empty Battery Charge Fuse
Read Operator’s
Manual
Engine
Hourmeter Diesel Fuel Lift Point Parking Brake
NNeutral
Seatbelt - Lap
Only Tie-Down Fast Slow Bucket - Raise Bucket - Float
IDENTIFICATION INFORMATION
Write your Gehl loader model and serial numbers in the spaces provided below. Refer to
these numbers when inquiring about parts or service from your Gehl dealer.
The model and serial numbers for this loader are on a decal located inside the right
chassis riser, in front of the lift arm pivot.
RISER
RESTRAINT BAR
CONTROL HANDLES
LIFT ARM
OPTIONAL HIGH FLOW SUPPORT
QUICK COUPLERS DEVICE
TILT CYLINDERS
LIFT
CYLINDER
ATTACHMENT
MECHANISM AUXILIARY
COUPLERS
TIRES
ROLLOVER PROTECTIVE
STRUCTURE (ROPS)
HAND HOLDS
ENGINE
COVER
TAILLIGHTS
LIFT ARM
REAR WORK
LIGHTS
REAR GRILLE
Tire Options
Heavy Duty Flotation tires 12 x 16.5 - 10 ply
Extra Wide Heavy Duty tire 33 x 15.50-16.5 - 12 ply
High Clearance Flotation tires 14 x 17.5 - 10 ply
Solid Rubber tires 8 x 16
AirBoss Segmented Industrial tires 8.25 x 15
AirBoss Segmented Flotation tires 12 x 16.5
Ä ACCESSORIES Ã
Ü 3-inch wide Seat Belt - Ü Operator’s Compartment Ü Bucket Bolt-On Cutting Edge
When Required by Law Heater/Defroster Kits
Ü Sliding Side Windows Ü Audible Back-Up Alarm Ü Lift Kit
Ü Deluxe Sound Package Ü Strobe Light Ü Rear Counterweight
Ü Interior Dome Light Ü Dual Flasher Kit Ü Hydraulic Couplers - Kit
Ü Horn Ü Battery Disconnect Switch Ü Centrifugal Pre-Cleaner
Ü Rear View Mirror Ü Engine Auto-Shutdown System Ü Engine Oil Pan Heater
Ü Suspension Seat Ü Gehl-style Quick-Tach™ Ü 2-Speed Transmission
Attachment Mounting
Ü Impact Resistant Front Door with Ü Diesel Engine Exhaust Purifier
Wiper
SAFETY
The above Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED! It stresses an attitude of “Heads Up for
Safety” and can be found throughout this Operator’s WARNING
Manual and on the machine itself. “WARNING” indicates a potentially hazardous
situation which, if not avoided, could result in
Before you operate this equipment, read death or serious injury.
and study the following safety information.
In addition, be sure that every one who
operates or works with this equipment,
whether family member or employee, is
familiar with these safety precautions. CAUTION
The Gehl Company ALWAYS considers the operator’s “CAUTION” indicates a potentially hazardous
situation which, if not avoided, may result in
safety when designing its machinery, and guards
minor or moderate injury. May also alert
exposed moving parts for the operator’s protection. against unsafe practices.
However, some areas cannot be guarded or shielded in
order to assure proper operation. Furthermore, this
Operator’s Manual and the decals on the machine warn
of additional hazards and should be read and observed
closely. Mandatory Safety Shutdown Procedure
Do not modify the ROPS/FOPS unless instructed to do
so in options installations. Modifications such as BEFORE cleaning, adjusting, lubricating, servicing
welding, drilling or cutting can weaken the structure and the unit or leaving it unattended:
reduce the protection it provides. A damaged 1. Move the drive control handle(s) to the “neutral”
ROPS/FOPS cannot be repaired - it must be replaced. position.
Different applications may require optional safety 2. Lower the lift arm and attachment completely.
equipment, such as a back-up alarm, horn, mirror, strobe Also, see Step 4 below.
light or an impact-resistant front door. Be sure you know
3. Move the throttle to the low idle position, shut off
the job site hazards and equip your machine as needed.
the engine and remove the key.
4. If the lift arm MUST be left in the “raised” position,
DANGER BE SURE to properly engage the lift arm support
device instead of performing Step 2.
“ DAN GE R ” i nd ic a te s a n im m in e ntly
ONLY after these precautions can you be sure it is
hazardous situation which, if not avoided, will
result in death or serious injury. safe to proceed. Failure to follow the above
procedure could lead to death or serious injury.
Ü Some photographs in this manual may show doors, Ü ALWAYS wear safety glasses with side shields
guards and shields open or removed for illustrative when striking metal against metal. In addition, it is
purposes ONLY. BE SURE that all doors, guards recommended that a softer (chip resistant material)
and shields are in their proper operating positions be used to cushion the blow. Failure to heed could
BEFORE starting the engine to operate the unit. lead to serious injury to the eyes or other parts of the
body.
Ü To ensure safe operation, replace damaged or
worn-out parts with genuine Gehl service parts, Ü NEVER push the lift/tilt T-Bar control into the
BEFORE operating this equipment. “float” position with the bucket or attachment
loaded or raised, because this will cause the lift arm
Ü Gehl skid loaders are designed and intended to be to lower rapidly.
used ONLY with Gehl Company attachments or
approved referral attachments. The Gehl Company Ü DO NOT drive too close to an excavation or ditch;
cannot be responsible for operator safety if the BE SURE that the surrounding ground has adequate
loader is used with a non-approved attachment. strength to support the weight of the loader and the
load.
Ü The terrain, engine speed, load being carried, and
abrupt control movements can affect machine Ü DO NOT smoke or have any spark producing
stability. IF MlSUSED, ANY OF THE ABOVE equipment in the area while filling the fuel tank or
FACTORS CAN CAUSE THE LOADER TO while working on the fuel or hydraulic systems.
TIP, THROWING YOU FORWARD OR OUT
OF T HE UNIT, CAUS ING DEA TH OR Ü NEVER carry riders. Do not allow others to ride on
SERIOUS INJURY. Therefore, ALWAYS have the machine or attachments, because they could fall
the operator restraint bar lowered and wear the seat or cause an accident.
belt. Operate the controls smoothly and gradually at
an appropriate engine speed that matches the
Ü ALWAYS look to the rear before backing up the
skid loader.
operating conditions.
Ü For additional stability when operating on inclines
Ü Operate the controls only from the operator’s seat.
or ramps, ALWAYS travel with the heavier end of Ü ALWAYS face the loader and use the hand holds
the loader toward the top of the incline. and steps when getting on or off the loader. DO NOT
jump off the loader.
Ü DO NOT raise or drop a loaded bucket or fork
suddenly. Abrupt movements under load can cause Ü Be sure all persons are away from machine and give
serious instability. a warning before starting engine.
Ü NEVER attempt to by-pass the keyswitch to start Ü DO NOT exceed the rated operating load of the
the engine. Use only the jump-starting procedure machine.
detailed in the Service chapter of this manual.
Ü Exhaust fumes can kill. Do not operate this machine
Ü NEVER use your hands to search for hydraulic fluid in an enclosed area unless there is adequate
leaks. Instead, use a piece of paper or cardboard. ventilation.
Escaping fluid under pressure can be invisible and
can penetrate the skin and cause a serious injury. If Ü NEVER use ether or starting fluid in an engine with
any fluid is injected into your skin, see a doctor at glow plugs.
once. Injected fluid MUST be surgically removed
by a doctor or gangrene may result. Ü When you park the machine and before you leave
the seat, check the restraint bar for proper operation.
Ü Remove all trash and debris from the machine each The restraint bar, when raised, applies the parking
day, especially in the engine compartment, to brake and deactivates the lift/tilt controls.
minimize the risk of fire.
122718
129258
129130
114316
091050
093202
093474
091035
093367
L65928 093479
093477
129132
122745
093475
132166
093475
132166
WARNING 1
Read and thoroughly understand ALL safety
decals on the loader BEFORE operating it. DO
NOT o pe ra te th e lo a d e r u n less A LL
factory-installed guards and shields are
properly secured in place.
2
Two-Speed Transmission (Optional)
WARNING WARNING
BE SURE the T-Bar controls are in “neutral” NEVER push the lift/tilt T-Bar control into the
BEFORE starting the engine. Operate the “float” position with the bucket or attachment
T-Bars gradually and smoothly. Excessive loaded or raised, because this will cause the lift
speed and quick T-Bar movements without arm to lower rapidly.
regard for conditions and circumstances is
hazardous and could cause an accident. NOTE: The speed of lift/tilt motion is directly
proportional to the amount of T-Bar movement and
Lift/Tilt Control T-Bar engine RPM.
2 7
LEFT T-BAR CONTROL RIGHT T-BAR CONTROL
1 2 3 4
5 6
7 8 9 10
11
FLOAT
RAISE LIFT ARM LOWER LIFT ARM BUCKET ROLLBACK BUCKET DUMP
4 11 10 3
8
2 2
6 7 9 5
LEFT HAND CONTROL LEFT & RIGHT FOOT PEDALS RIGHT HAND CONTROL
1 2 3 4
5 6
7 8 9 10
11
FLOAT
RAISE LIFT ARM LOWER LIFT ARM BUCKET ROLLBACK BUCKET DUMP
4 11 10 3
8
2 2
6 7 9 5
LEFT HAND CONTROL LEFT & RIGHT FOOT PEDALS RIGHT HAND CONTROL
1 2 3 4
5 6
7 8 9 10
FLOAT
RAISE LIFT ARM LOWER LIFT ARM BUCKET ROLLBACK BUCKET DUMP
WARNING
BE SURE the control handles are in “neutral” WARNING
BEFORE starting the engine. Operate controls NEVER push the lift/tilt handle into the “float”
gradually and smoothly. Excessive speed and position with the bucket or attachment loaded
quick handle movements without regard for or raised, because this will cause the lift arm to
conditions and circumstances is hazardous lower rapidly.
and could cause an accident.
8 9
11
2 2
6 5
1 2 3 4
5 6
7 8 9 10
11
FLOAT
RAISE LIFT ARM LOWER LIFT ARM BUCKET ROLLBACK BUCKET DUMP
3
WARNING
NEVER defeat the operator restraint bar or seat 2
switch electrically or mechanically, and
ALWAYS wear your seat belt.
Fig 5-7: Restraint Bar
Seat Positioning (Fig. 5-7) 1. Operator Restraint Bar
2. Seat Forward & Backward Adjustment Lever
The loader seat is mounted on rails for backward or 3. Seat Belt
forward repositioning to accommodate the operator’s
size and comfort. A spring-loaded latch handle activates
the seat adjustment mechanism.
Suspension Seat (Optional): A 3-position back-angle
adjustment bar and a weight adjustment knob are
provided with this seat for operator comfort.
WARNING
NEVER defeat the interlock system by
mechanically or electrically bypassing any
switches, relays or solenoid valves.
The skid loader standard features include an All-Tach Lift Arm Support Device (Figs. 5-14 & 15)
attachment mechanism for mounting a bucket or other
attachment. Two latch levers secure the attachment. The lift arm support device found on the left lift cylinder
Rotate the levers until the handles are horizontal to is used as a cylinder lock to prevent the raised lift arm
engage the lock pins. Rotate the levers until the handles from unexpectedly lowering while servicing the loader.
are vertical to disengage the lock pins. BE SURE to engage the support device when the lift arm
is raised. When the support device is not being used,
store it under the lift arm using the lock pin. The lift arm
support device is a safety device that MUST BE kept in
Disengagement
WARNING
BEFORE leaving the operator’s compartment
to work on the loader with the lift arm raised, WARNING
AL WAY S e n g a g e th e l ift a rm support NEVER leave the operator’s compartment to
device. Turn the keyswitch off, remove the key
and take it with you. disengage the lift arm support device with the
engine running.
To engage the lift arm support device, proceed as
follows:
To return the lift arm support device to its storage
1. Lower the lift arm fully onto the loader frame. position, proceed as follows:
2. Turn the keyswitch to the “OFF” position to stop the 1. Raise the lift arm completely.
engine.
2. Turn the keyswitch to the off position to stop the
3. Leave the operator’s compartment. Press in and engine, remove the key and take it with you.
hold the lock pin button to release its locking
mechanism. Remove the lock pin holding the
support device up against the lift arm. Allow the
support device to come down into contact with the WARNING
lift cylinder. Before testing the machine, ALWAYS clear
4. Return to operator’s compartment and restart the people from the area.
engine.
3. Before leaving the operator’s compartment, check
5. Use the lift control to raise the lift arm until the lift
to make sure that the lift arm is being held in the
arm support device drops over the end of the lift
raised position by the solenoid valve (See NOTE
cylinder and around the cylinder rod. Slowly lower
below).
the lift arm until the free-end of the support device
contacts the top end of the lift cylinder. NOTE: With the keyswitch OFF and the solenoid
valve working, the arm will stay raised when the lift
control is moved forward. If the valve does NOT
hold the arm and it begins to lower, do NOT leave
1
the operator’s compartment. Instead, have
someone store the support device for you. Then,
contact your Gehl dealer to determine the reason
why the lift arm lowers while the keyswitch is in the
OFF position.
2
3 1
Auxiliary Hydraulics
WARNING
CAUTION ALWAYS fasten your seat belt and lower the
BEFORE starting the engine and operating the restraint bar BEFORE starting the engine.
loader, review and comply with ALL safety
recommendations set forth in the SAFETY
The following procedure is recommended for starting
chapter of this manual. Know how to STOP the
loader BEFORE starting it. Also, BE SURE to the loader engine:
fasten and properly adjust the seat belt and 1. Carefully step up onto the back of the bucket or
lower the operator restraint bar. attachment while grasping the ROPS handles to get
into the operator’s compartment.
Before Starting Engine 2. Fasten the seat belt and lower the restraint bar.
Before starting the engine and running the loader, refer 3. Verify the following:
to the Controls & Safety Equipment chapter and
familiarize yourself with the various operating controls, q the lift/tilt and drive control handles are in
their neutral positions
indicators and safety devices on the loader.
q the auxiliary control is in neutral
q the brake is on
1
q the high flow control lever (DX models only)
is in neutral
2
4. Push the throttle forward to half of full speed.
NOTE: When the key is turned to the “ON”
position, a buzzer will sound momentarily
reminding you to check that your seat belt is
fastened.
5. Turn the keyswitch to the “ON” position. Wait for
the glow indicator light to go out, then turn the key
3 to the start position. (Glow is automatically
controlled and is used only if temperature is 32°F
(0°C) or below).
NOTE: Crank the starter until the engine is started.
If the engine fails to start within 15 seconds, return
the key to the “Off” position and repeat Step 5.
Fig. 6-1: Operator’s Compartment Cranking the engine for longer than 15 seconds
1. Operator’s Seat will result in premature failure of the starter.
2. Operator Restraint Bar in “Lowered” Position
3. Seat Belt After the engine starts, allow a sufficient warm-up time
before attempting to operate the controls.
The following procedure should be used when starting a The following procedure is the recommended sequence
skid loader in cold temperatures: Turn the key to the for stopping the loader:
RUN position. If the glow light comes on the instrument 1. Check that drive control handles are in the “neutral”
panel, wait until it goes out before turning the key to the position.
START position.
2. Lower the lift arm and rest the attachment on the
A pan heater is recommended for starting in
ground.
temperatures of 20°F (-7° C) or lower. See your Gehl
dealer for recommended heater options. 3. Pull the throttle lever back to the idle position
(and/or take your foot off the accelerator pedal for
hands only controlled machines).
Loader Movement
4. Turn the keyswitch key to the off position to shut the
The hydrostatic drive of the skid loader controls forward engine off.
and reverse directions and speed. Movement of the
5. Raise the restraint bar, unlatch the seat belt and
wheels is slowed according to how rapidly the drive
grasp the handles while climbing out of the
control handle(s) are moved to the straight “neutral”
operator’s compartment.
position.
NOTE: The skid loader is equipped with a spring-
applied automatic parking brake. The parking
CAUTION brake is engaged when the operator lifts the
restraint bar, leaves the operator’s seat, shuts the
Operate the drive control handles gradually engine off or when the manual switch is on (the top
and smoothly when starting, stopping, turning half of the switch is pushed in).
and reversing loader directions. Excessive
IMPORTANT: High heat and excessive loads may
speed can be hazardous. ALWAYS exercise
caution and good judgment while operating cause the engine to overheat. See t h e
the skid loader. Troubleshooting chapter in this manual for further
instruction.
3 4 5
6
2 3
6
1 4 1 2
WARNING 2
To prevent unexpected attachment release
from the All-Tach attachment, BE SURE to
properly secure the All-Tach mechanism lock
pins by rotating the latch levers to a horizontal Fig. 6-6: All-Tach Attachment (Disengaged)
position. 1. All-Tach Attachment Latch Control Levers
2. All-Tach Attachment Latch Pins
2. Start the loader engine and make sure the lift arm is 2. With the loader engine OFF, leave the operator’s
lowered and in contact with the loader frame. compartment and rotate the latch levers completely
vertical to fully retract the latch pins.
3. Align the loader squarely with the back of the
attachment. 3. Start the loader engine and make sure that the lift
arm is lowered and in contact with the loader frame.
4. Roll the All-Tach attachment mechanism forward
until the top edge of the All-Tach mechanism is 4. Roll the All-Tach attachment mechanism forward
below the flange on the back side of the attachment and slowly back the loader until the attachment is
and centered between the vertical plates. free from the loader.
WARNING 1
To prevent unexpected attachment release 2 2
from the Quick-Tach attachment, BE SURE to
properly secure the Quick-Tach mechanism
lock pins by rotating the latch lever all the way
to the left.
Fig. 6-7: Quick-Tach Attachment (Disengaged)
A field installed Quick-Tach attachment mechanism for 1. Quick-Tach Attachment Latch Lever
mounting a bucket or other attachment is available. A 2. Quick-Tach Attachment Latch Pins
single latch lever secures the attachment.
Attaching
1. Rotate the latch lever completely to the right (as Detaching
viewed from the operator’s compartment) to fully 1. Roll the Quick-Tach mechanism backward until the
retract the latch pins. attachment is off the ground. Exercise the
2. Start the loader engine and make sure the lift arm is MA N D A TOR Y SA FETY SH UTDO WN
lowered and in contact with the loader frame. PROCEDURE (page 10).
3. Align the loader squarely with the back of the 2. With the loader engine OFF, leave the operator’s
attachment. compartment and rotate the latch lever completely
to the right (as viewed from the operator’s
4. Roll the Quick-Tach mechanism forward until the compartment) to fully retract the latch pins.
mating parts of the mechanism are in-line with and
slightly below the hooks on the back of the 3. Start the loader engine and make sure that the lift
attachment. arm is lowered and in contact with the loader frame.
5. Slowly drive the loader forward and, at the same 4. Roll the Quick-Tach mechanism forward and
time, roll the Quick-Tach mechanism back to slowly back the loader until the attachment is free
engage the hooks on the attachment. from the loader.
The table at the right lists densities for some common Density
Material
materials which could be carried in a bucket. The (lb/ft3) (kg/m3)
densities listed are average values and intended only as a Ashes 35-50 560-800
guide for bucket selection. For a material that is not in Brick-common 112 1792
the table, obtain its density value before selecting the
Cement 110 1760
appropriate bucket.
Charcoal 23 368
To prevent exceeding the operating load of the loader,
Clay 80-100 1280-1600
use the Table of Common Materials and Densities to
determine the proper size bucket to use based on the type Coal 53-63 848-1008
of material to be carried. Concrete 115 1840
SAE Rated Operating Load Cinders 50 800
Coal-anthracite 94 1504
Model lbs kg
Coke 30 480
SL5635 1900 862 Earth-dry loam 30 480
SL6635 2350 1066 Earth-wet loam 65 1040
To use the table, find the material name and see what its Granite 93-111 1488-1776
maximum density is. Then, divide the operating load of Gravel-dry 66 1056
the loader by the material density to determine the Gravel-wet 90 1440
maximum size bucket to use for a heaped load. Gypsum-crushed 115 1840
NOTE: Where the material density is listed as a Iron Ore 145 2320
range (clay at 80-100 lb/ft3, for example), always Lime 60 960
use the maximum density (100 lb/ft 3 in this
Lime Stone 90 1440
example) for making calculations. Also, see the
following examples. Manure-liquid 65 1040
Manure-solid 45 720
Example 1: If clay (density of 80-100 lb/ft3) is to be
hauled using an SL5635 loader, the maximum bucket Peat-solid 47 752
Phosphate-granular 90 1440
size is (1900 lb ¸ 100 lb/ft3 = 19.0 ft3 ). Therefore, you
could safely use a bucket that has a capacity of 19.0 Potash 68 1088
cubic feet or less. Quartz-granular 110 1760
Example 2: If concrete (density of 1840 kg/m3) is to be Salt-dry 100 1600
hauled using an SL6635 loader, the maximum bucket Salt-Rock-solid 135 2160
size is (1066 kg ¸ 1840 kg/m = 0 .58 m ). Therefore,
3 3 Sand-dry 108 1728
you could safely use a bucket that has a capacity of 0.58 Sand-wet 125 2000
cubic meters or less. Sand-foundry 95 1520
Shale-crushed 90 1440
Slag-crushed 70 1120
CAUTION Snow 15-50 240-800
NEVER exceed the rated operating load of the Taconite 107 1712
loader as shown on the capacity decal. The Specifications chapter lists the buckets available
and their capacities to help you decide what size bucket
to use. You may always use a smaller-capacity bucket,
but NOT a bucket with greater capacity then the
calculated MAXIMUM unless it is only partially filled.
WARNING
ALWAYS maintain a safe distance from
electric power lines and avoid contact with any
electrically charged conductor or gas line!
Accidental contact or rupture can result in
electrocution or an explosion! Contact the
“Digger’s Hotline” or proper local authorities
for utility line locations BEFORE starting to
dig!
Fig. 6-8: Loading the Bucket
To dig with and load a bucket, first lower the lift arm
down into contact with the loader frame and then roll the
bucket’s cutting edge down into contact with the
ground. Move the loader into material and, as the engine
loads, roll the bucket back slowly and, at same time,
gradually pull back the drive control handle(s) to
decrease the travel speed while still maintaining wheel
torque.
When filling the bucket with hard-packed materials, it
may be necessary to raise the lift arm while rolling the
bucket back. Avoid driving onto the material to be
picked-up, if at all possible.
With the bucket filled, back the loader away from the
material and rest the lift arm against the loader frame
before proceeding to the dumping area.
WARNING
Do NOT drive too close to an excavation or
ditch; BE SURE the surrounding ground has
adequate strength to support the weight of the
loader and the load.
To raise the skid loader so all four (4) tires ARE NOT When service or adjustment procedures are complete,
contacting the ground, use the procedure below: the skid loader can be taken down from the “raised”
position. To lower the loader onto its tires:
1. Using a jack or hoist, raise the front of the loader
WARNING until its weight no longer rests on the front blocks.
BEFORE servicing the machine, exercise the 2. Carefully remove the blocking under the front of the
M ANDAT O RY SAF ET Y SHU TD OWN loader.
PROCEDURE (page 10).
3. Slowly lower the loader until the front tires are
resting on the ground.
3
3 2
8 5
1
8
7 10
6
Fig. 7-2: Adjusting Drive Chain Tension - Left side shown, right side typical
1. Front Adjuster 6. Front Chain Drive
2. 3/4” Flanged Lock Nut 7. Rear Drive Chain
3. 3/4” Adjustment Nut 8. Drain Plugs
4. Lock Nut 9. Oil Level Check Plug
5. Rear Adjuster 10. Oil Fill Plug
Fuseholder with
5 amp AGC
Rocker switch Blade-type fuse
located on
instrument panel
Actuator
Gehl harness
Clockwise = Retract
Controller
Potentiometer
numbers
Engine Oil
Hydraulic System Oil Chaincases All Grease Fittings (Deutz Diesel)
Use a Mobil DTE 15M, Use SAE grade Use Lithium-based µ Below 32°F (0°C)
or Amoco Rykon 46, motor oil Grease Use SAE Grade* 10 or
or equivalent which 10W-30
contains anti-rust,
anti-foam and Capacity (each side): µ Above 32°F (0°C)
anti-oxidation 8 U.S. quarts Use SAE Grade*
additives & conforms (7,6 liters) 15W-40
to
ISO VG46.
*Service Classification:
API - CF-4/CG-4
Capacity:
16 U.S. gallons
Capacity:
(60,5 liters)
10.5 U.S. quarts
(10 liters)
Fill Plug
3
Rear Drain
Plug
Front Drain 3
Plug Check Plug
Fig. 8-1: Chaincase Oil Level Check Fig. 8-2: Tilt Cylinder Grease Points
9
9
11
8
Fig. 8-3: Hydraulic Filter and Level Indicators
100 hours
2 2
3 1
6&9
5 & 11
10
4 7
Electrical System
Problem Possible Cause Remedy
Battery disconnect switch is “Off” Turn battery disconnect switch to “On”.
20 ampere breakers are tripped. Consult wiring diagram, check circuit and
locate trouble (i.e., pinched wires, faulty
connections, etc.) before resetting
breaker.
Entire electrical
system does not Main wiring harness connectors at rear Check main harness connectors.
function. of ROPS not properly plugged in.
Battery terminals or cables are loose or Clean battery terminals and cables and
corroded. retighten them.
Ignition wiring, seat switch, restraint bar Check wiring for poor connections,
switch, etc. loose or disconnected. broken leads; repair wiring or connection.
Faulty light switch or poor ground. Replace light switch. Check ground wire
connections.
Wiring to solenoids disconnected or Consult wiring diagram, spot trouble,
faulty. repair.
Lift/Tilt and/or propel Faulty seat or restraint bar switch. Contact your Gehl dealer for assistance.
lock solenoids do not
work. Faulty solenoid valve coil. Contact your Gehl dealer for assistance.
Faulty hydraulic solenoid relay in Contact your Gehl dealer for assistance.
instrument panel.
High flow or auxiliary valve engaged. Return the control valves to neutral.
Fuel tank empty or faulty fuel gauge Refill fuel tank. Replace fuel gauge
sender. sender.
Engine turns over but Glow module malfunctioning. Check connection and voltage, replace
will not start. as needed.
Fuel shut-off solenoid not energizing. Check electrical connections and voltage
to shut-off solenoid.
Fuel pump not working. Contact your Gehl dealer for assistance.
Crankcase oil level too low or too high. Add or remove oil as required.
Fan air circulation blocked or restricted. With engine OFF, remove blockage or
restriction.
Fan shroud improperly positioned. Contact your Gehl dealer for assistance.
Engine overheats.
Grade of oil improper or excessively dirty. Drain and replace with proper grade new
oil.
Hydraulic oil supply is low. Check for low oil level in reservoir. Add oil.
Traction drive will Control rod linkage disconnected. Check linkage connection at control levers
not operate in either and neutral centering mechanisms.
direction. Reconnect linkage.
Hydrostatic pump(s) relief valves are Contact your Gehl dealer for assistance.
malfunctioning.
Air in the hydraulic system. Cycle lift and tilt cylinders to maximum
stroke and maintain pressure for a short
time to clear air from system. Also check for
low oil level in Reservoir, fill as needed.
Automatic parking brake partially Contact your Gehl dealer for assistance.
Sluggish response engaged.
to acceleration.
Hydraulic oil supply is too low. Check for low oil level in reservoir. Add oil.
Low hydrostatic system charge pressure. Contact your Gehl Dealer for assistance.
Drive motor(s) or hydrostatic pump(s) Contact your Gehl Dealer for assistance.
have internal damage or leakage.
Drive system overloaded continuously. Improve efficiency of operation.
Oil cooler fins are plugged with debris. Clean oil cooler fins.
Loader being operated in a high Reduce duty cycle; improve air circulation.
temperature area with no air circulation.
Drive motor(s) or hydrostatic pump(s) Contact your Gehl dealer for assistance.
have internal damage or leakage.
Rear hydrostatic pump arm control shaft Contact your Gehl dealer for assistance.
key missing.
Right side doesn’t
drive in either Relief valves on rear hydrostatic pump Contact your Gehl dealer for assistance.
direction. Left side malfunctioning.
operates normally.
Control rod linkage to rear hydrostatic Attach control rod linkage.
pump disconnected.
Right side doesn’t Left hand relief valve on rear hydrostatic Contact your Gehl dealer for assistance.
drive in forward pump is malfunctioning.
direction.
Rear hydrostatic pump malfunctioning. Contact your Gehl dealer for assistance.
Right side doesn’t Right hand relief valve on rear hydrostatic Contact your Gehl dealer for assistance.
drive in reverse pump is malfunctioning.
direction.
Rear hydrostatic pump malfunctioning. Contact your Gehl dealer for assistance.
Key missing on front hydrostatic pump Contact your Gehl dealer for assistance.
arm control shaft.
Left side doesn’t drive
in either direction. Relief valves on front hydrostatic pump Contact your Gehl dealer for assistance.
Right side operates malfunctioning.
normally.
Control rod linkage to front hydrostatic Attach control rod linkage.
pump disconnected.
Relief valve on front hydrostatic pump is Contact your Gehl dealer for assistance.
Left side doesn’t drive malfunctioning.
in one direction.
Front hydrostatic pump malfunctioning. Contact your Gehl dealer for assistance.
Hydraulic oil level is low. Check oil level in reservoir. If oil is low,
Lift/Tilt controls check for an external leak. Repair and add
fail to respond. oil.
Hydraulic oil viscosity is too heavy. Allow longer warm-up or replace existing
oil with proper viscosity oil.
Hydraulic oil leaking past cylinder Contact your Gehl dealer for assistance.
Hydraulic cylinder piston seals.
action is slow for lift
and/or tilt functions. Worn gear pump. Contact your Gehl dealer for assistance.
Relief valve in control valve not functioning Contact your Gehl dealer for assistance.
correctly. Squealing noise should be
evident while operating.
Seat or restraint bar switch malfunction. Check electrical connections to the
switches. Replace as needed.
Jerky lift arm and Air in the hydraulic system. Cycle lift and tilt cylinders to maximum
bucket action. stroke and maintain pressure for short time
to clear air from system.
Oil in hydraulic reservoir is low. Check and add oil to reservoir as needed.
Bucket does not Self-leveling valve misadjusted or Contact your Gehl dealer for assistance.
level on the lift malfunctioning.
cycle.
Oil leaking past tilt cylinder seals Contact your Gehl dealer for assistance.
(internal or external).
Bucket drifts
downward with tilt Self-leveling valve is malfunctioning. Contact your Gehl dealer for assistance.
control in neutral.
Leaking hydraulic hoses, tubes, or fittings Inspect hoses and tubes, tighten fittings.
between control valve and cylinders. Replace hoses or tubes as needed.
Control valve in “Float” position. Take control out of “Float” position.
No down pressure Tilt cylinders are malfunctioning. Contact your Gehl dealer for assistance.
on the bucket.
Relief valve in control valve not functioning Contact your Gehl dealer for assistance.
properly. Squealing noise should be
evident while operating.
Tilt spool in control valve not actuated or Check valve control linkage and/or tube
leaking. connections to valve.
Pilot control lines have air in them. Bleed the pilot control line from the main
Slow or no response control valve.
for bucket tilt, lift
works properly Low charge pressure. Contact your Gehl dealer for assistance.
(Hand & Foot units
only). Linkage misadjusted between right foot Readjust for full travel without restriction.
pedal and pilot valve.
Lift solenoid valve malfunctioning. Check electrical connections to lift
solenoid and repair connections as
Lift arm does not needed. If lift solenoid valve is still not
raise, bucket tilt functioning properly, contact your Gehl
works properly. dealer for assistance.
Lift spool in control valve not actuated or Contact your Gehl dealer for assistance.
leaking.
Oil leaking past lift cylinder seals (internal Contact your Gehl dealer for assistance.
or external).
Lift arm doesn’t Oil leaking past lift spool in control valve. Contact your Gehl dealer for assistance.
maintain raised
position with lift Self-leveling valve malfunctioning. Contact your Gehl dealer for assistance.
control in NEUTRAL.
Leaking hydraulic hoses, tubes or fitting Inspect hoses and tubes, tighten fittings
between control valve and cylinders. as needed. Replace hoses or tubes when
needed.
Lift arm support device engaged. Raise lift arm and disengage support
device.
Seat or restraint bar switch malfunction. Check electrical connections to the switch.
Replace switch as needed.
Attachment Relief valve on high flow manifold valve is Replace relief valve.
connected to high malfunctioning.
flow hydraulics stalls
or has low-power Relief valve in lift/tilt control valve Replace relief valve.
(DX units only). malfunctioning.
2 4
Service Every 10 Hours or Daily
Check Engine Oil Level (Fig. 10-2)
1
NOTE: For new units, the first oil change should be
after the first 50 hours. 5
Open the engine access cover. Pull out the dipstick and
check the oil level. Markings on the dipstick represent
both full and low (add oil) levels. Refer to the “Change
Engine Oil & Filter” subtopic under the “Service Every Fig. 10-1: Servicing the Loader
500 Hours” topic in this chapter for the correct location
1. Rear Grille Latch and Release Handle
and procedure for adding engine oil. Refer to the 2. Fuel Fill Cap
Lubrication chapter and/or the separate engine manual 3. Engine Access Cover
for oil viscosity and requirements information. 4. Muffler
5. Rear Grille
6. Gas-Charged Spring Cylinder
Check Hydraulic Oil Level (Fig. 10-2)
w For new units, the first oil change should be after the first 50 hours. Refer to the engine manual for additional
information.
NOTE: Continue to repeat the service procedures at every specified time interval.
H
C
Hand & Foot Controls, Electric
Chaincase Oil . . . . . . . . . . . . . . . . . . . . . . . . . 67
Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . 22
CHECKLISTS. . . . . . . . . . . . . . . . . . . . . . . . . 7,9
Drive Control Handles . . . . . . . . . . . . . . . . . 22
Cold Starting Procedure. . . . . . . . . . . . . . . . . . 36
Lift/Tilt Foot Pedals . . . . . . . . . . . . . . . . . . . 22
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hand & Foot Controls, Mechanical
CONTROLS & SAFETY EQUIPMENT. . . . . . . 19
Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . 24
Drive Control Handles . . . . . . . . . . . . . . . . . 24
D Lift/Tilt Foot Pedals . . . . . . . . . . . . . . . . . . . 24
Dealer Services. . . . . . . . . . . . . . . . . . . . . . . . 59 Highway Travel . . . . . . . . . . . . . . . . . . . . . . . . 44
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . 63
Electrical Components . . . . . . . . . . . . . . . . 59 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Hydraulic System Gear Pump . . . . . . . . . . . 59
Hydrostatic Components . . . . . . . . . . . . . . 59 I
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . 30
Drive Chains . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Interlock System . . . . . . . . . . . . . . . . . . . . . . . 32
Adjust Chain Tension . . . . . . . . . . . . . . . . . 47
International Symbols . . . . . . . . inside front cover
Dual Hand Controls
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . 2
Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . 26
Drive Control Handles . . . . . . . . . . . . . . . . . 26
Lift/Tilt Control Handles . . . . . . . . . . . . . . . . 26 J
Jump-Starting . . . . . . . . . . . . . . . . . . . . . . . . . 65
METRIC
GRADE 8.8 GRADE 10.9 GRADE 12.9
COARSE
THREAD DRY LUBED DRY LUBED DRY LUBED
M6-1 8 6 11 8 13.5 10
M8-1.25 19 14 27 20 32.5 24
M10-1.5 37.5 28 53 39 64 47
M12-1.75 65 48 91.5 67.5 111.5 82
M14-2 103.5 76.5 145.5 108 176.5 131
M16-2 158.5 117.5 223.5 165.5 271 200
*All Torque Values are in ft-lbs except those marked with an * which are in in-lbs.
For metric torque value (N·m) multiply ft-lbs value by 1.355 or the in-lbs value by 0.113.
WARRANTY
Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer’s
business location.
1. Transportation to selling dealer’s business location or, at the option of the Original Retail
Purchaser, the cost of a service call.
2. Used equipment.
3. Components covered by their own non-Gehl warranties, such as tires, trade accessories and
engines.
4. Normal maintenance service and expendable, high wear items.
5. Repairs or adjustments caused by: improper use; failure to follow recommended maintenance
procedures; use of unauthorized attachments; accident or other casualty.
6. Liability for incidental or consequential damages of any type, including, but not limited to lost
profits or expenses of acquiring replacement equipment.
No agent, employee or representative of Gehl has any authority to bind Gehl to any warranty except
as specifically set forth herein. Any of these limitations excluded by local law shall be deemed
deleted from this warranty; all other terms will continue to apply.
®
Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 U.S.A.