Gehl AL20DX Articulated Loader Operator’s Manual 908180 - PDF DOWNLOAD

Form No.

908180



AL20DX Articulated Loader

Replaces 908031

OPERATOR’S MANUAL

GEHL CONSTRUCTION WARRANTY GEHL CONSTRUCTION DIVISION of the GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl construction equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months from the Warranty Start Date: GEHL CONSTRUCTION WARRANTY INCLUDES: Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer’s business location.

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

GEHL WARRANTY SERVICE DOES NOT INCLUDE: 1.

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

2.

Used equipment.

3.

Components covered by their own non-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.

TABLE OF CONTENTS Chapter

Description

Page

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Front Cover 1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3

Check Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5

Controls & Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

9

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

11

Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

12

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Standard Hardware Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Back Cover

Printed in U.S.A.

1

908180/AP0601

CHAPTER 1 INTRODUCTION This Operator’s Manual gives the owner/operator information about maintaining and servicing the AL20DX articulated loader. More importantly, this manual provides an operating plan for safe and proper use of the machine. Major points of safe operation are detailed in the Safety chapter of this manual.

MODEL NO.

AL20DX (Fill In)

SERIAL NO. (Fill In)

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

Typical Model & Serial Number Plate

BE SURE the machine is suitable equipped for the type of work to be performed.

DO NOT use this machine for any applications or purposes other that those described in this manual or applicable for approved attachments. If the machine is to be used with special attachments other than those approved by Gehl, consult your Gehl dealer. Any person using non-approved attachments is responsible for the consequences.

Throughout this manual, information is provided which is set in italic type and introduced by the word NOTE or IMPORTANT. BE SURE to read carefully and comply with the message – it will improve your operating and maintenance efficiency, help avoid breakdowns or damage, and extend your machine’s life.

The Gehl dealership network stands ready to provide you with any assistance you may require, including providing genuine Gehl service parts. All service parts should be obtained from your Gehl dealer. Give complete information about the part and include the model and serial numbers of your machine. Record the serial number in the space provided on the pictorial, as a handy record for quick reference.

A manual storage box behind the operator’s seat holds the Operator’s Manual and EMI Safety Manual. Please return the manuals to this box and keep them with the unit at all times. If this machine is resold, we recommend that these manuals be given to the new owner.

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

The model and serial numbers for this unit are on a tag located on a panel behind the right front wheel. ‘‘Right’’ and ‘‘left’’ are determined from a position sitting on the seat and facing forward. From this position, the hand throttle and hydraulic controls are on the ‘‘right’’.

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

The attachments and equipment available for use with this machine have a wide variety of potential applications. Read the manual provided with the attachment to learn how to safely maintain and operate the equipment.

908180/AP0601

2

Printed in U.S.A.

CHAPTER 2 SPECIFICATIONS All Dimensions are in Inches (Millimeters) Unless Otherwise Noted Model & Description . AL20DX Articulated Loader Engine . . . . . . . . . . . 20 hp (14.9 kW) Kubota Diesel Water Cooled Overall Length . . . . . . . . . . . . . . . . . . . 86-3/4 (2206) Overall Width . . . . . . . . . . . . . . . . . . . . 39-3/16 (995) Height . . . . . . . . . . . . . . . . . . . . . . . . . . 49-1/2 (1256) Ground Clearance . . . . . . . . . . . . . . . . . . . . . 8 (203) Axle Width . . . . . . . . . . . . . . . . . . . . . . 42-1/8 (1070) Weight . . . . . . . . . . . . . . . . . . . . . . . 1980 lb (900 kg) Steering Wheel . . . . . . . . . . . . . 4.2 turns stop-to-stop Turning Radius Inside . . . . . . . . . . . . . . . . . . . . . . . . 34-5/8 (880) Outside . . . . . . . . . . . . . . . . . . . . . . 78-3/4 (2000) Lift Height (Std. Boom) . . . . . . . . . . . . . . . 74 (1880) Lift Height (Tele. Boom) . . . . . . . . . . . . . . 86 (2185) Max. Pulling Force . . . . . . . . . . . . 1910 lb (8500 N) Max. Drive Speed . . . . . . . . . . . . . 6 mph (9.8 km/h) Hydraulic Flow and Pressure External Hydraulics . 5.3 or 10.6 gpm @ 2900 psi (20 or 40 L/min @ 20000 kPa) Drive . . . . . . . . . . . . . . . . . 18.1 gpm @ 3990 psi (68 L/min @ 27500 kPa)

Battery – 12 Volt Electric Start 4 Wheel Drive Auxiliary Hydraulics – Flat-faced Couplers Lift Cylinder Mechanical Lock Steering Frame Lock Hydraulic Oil Cooler Quick Attachment System Operator’s Manual Storage Box Optional Features (Customer Selected):

Telescoping Boom Tires: 22.4 x 5.70 – 12, 6 ply . . . . . . . . . Traction Tread 23 x 8.50 – 12, 6 ply . . . . . . . . . . Traction Tread 23 x 8.50 – 12, 6 ply . . . . . . . . . . . . . Grass Tread Buckets General Utility “V” Edge . . . . . . . . . . . 4.25 cu. ft. (0.12 cu. m.), 36 (914) Wide Straight Edge . . . . . . . . 4.25 cu. ft. (0.12 cu. m.), 36 (914) Wide Straight Edge . . . . . . . . . 5.0 cu. ft. (0.14 cu. m.), 41 (1041) Wide With Teeth . . . . . . . . . . . 5.0 cu. ft. (0.14 cu. m.), 41 (1041) Wide Light Material Straight Edge . . . . . . . 8.75 cu ft, 47 (1194) Wide Straight Edge . . . . . . . . 8.5. cu ft, 36 (914) Wide Pallet Forks . . . . . . . . 34 (865) Tines Standard Duty Pallet Forks . . . . . . . . . 42 (1065) Tines Heavy Duty Multi-purpose (4-in-1) Bucket Counterweight – Rear Work Light – Front F.O.P.S.

Volumetric Capacities:

Fuel Tank . . . . . . . . . . . . . . . . . . . . . 3-1/4 gal. (12 L) Hydraulic Reservoir . . . . . . . . . . . . . . . . 8 gal. (30 L) Engine Oil . . . . . . . . . . . . . . . . . . . . . 4 quarts (3.8 L) Standard Features:

Dual Gear Hydraulic Pumps Hourmeter R.O.P.S. Deluxe Seat – Seatbelt, Armrests Controls: Steering Wheel Single Joystick – Boom and Bucket Tilt Manual Accelerator Foot-operated Directional Control

Printed in U.S.A.

See your dealer for other available attachments, accessories and trailer packages.

3

908180/AP0601

Chapter 2 – Specifications

INTENTIONALLY BLANK

908180/AP0601

4

Printed in U.S.A.

CHAPTER 3 CHECKLISTS Remove Dealer’s File Copy at Perforation

PRE-DELIVERY

I acknowledge that pre-delivery procedures were performed on this unit at outlined above.

The following Checklist is an important reminder of valuable information and inspections which MUST be made before delivering the loader to the customer.

Check off each item after prescribed action is taken.

Dealership Name

Check that: has NOT been damaged in shipment. Check for such o Unit things as dents and loose or missing parts; correct or re-

Dealer Representative’s Name

place components as required.

Date Checklist Filled Out

is securely mounted and not cracked. Cable cono Battery nections are tight and the battery disconnect switch is in

Loader Model#

the “ON” position. and tilt cylinders, hoses and fittings are not damaged, o Lift leaking or loosely connected. hoses and fittings are not damaged, leaking or o Radiator loosely connected. o Filters are not damaged, leaking or loosely secured. are properly and securely attached and tires are o Wheels properly inflated. is properly lubricated and no grease fittings are o Loader missing or damaged. system reservoir and engine crankcase are o Hydraulic filled to their proper levels. adjustment are made to comply with settings given in o All the Adjustments chapter of this manual. guards, shields and decals are in place and securely ato All tached. and serial numbers, for this unit, are recorded in o Model space provided on this page and page 2.

Loader Serial#

Engine Serial#

DELIVERY Check that: The following Checklist is an important reminder of valuable information that MUST be passed on to the Customer at the time the unit is delivered. Check off each item as you explain it to the customer.

Review with the customer the contents of this manual; especially: Index at the back, for quickly locating topics; o The The Safety, & Safety Equipment and Operation o chapters, forControls information regarding safe use of the ma-

o o

Start loader engine and test-run the unit while checking that proper operation is exhibited by all controls.

o

Check that:

o

o Drive chains are properly adjusted. control foot pedal and lift/tilt control operate o Directional properly and are not damaged or binding. control foot pedals are properly adjusted for o Directional a correct “neutral” position so that loader does NOT

chine; The Adjustments, Lubrication, Service and Troubleshooting chapters, for information regarding proper maintenance of the machine. Explain that regular lubrication and maintenance are required for continued safe operation and long life.

Give this Operator’s Manual to the customer and instruct the customer to be sure to read and completely understand its contents BEFORE operating the unit.

Explain that the customer MUST consult the Engine Manual (provided) for related specifications, operating adjustments and maintenance instructions.

Completely fill out the Owner’s Registration, including customer’s signature and, return it to the company.

Customer’s Signature

creep.

Date Delivered

(Dealer’s File Copy)

Printed in U.S.A.

5

908180/AP0601

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

908180/AP0601

6

Printed in U.S.A.

CHAPTER 3 CHECKLISTS PRE-DELIVERY

I acknowledge that pre-delivery procedures were performed on this unit at outlined above.

The following Checklist is an important reminder of valuable information and inspections which MUST be made before delivering the Loader to the Customer.

Check off each item after prescribed action is taken.

Dealership Name

Check that: has not been damaged in shipment. Check for such o Unit things as dents and loose or missing parts; correct or re-

Dealer Representative’s Name

place components as required.

Date Checklist Filled Out

is securely mounted and not cracked. Cable cono Battery nections are tight and the battery disconnect switch is in

Loader Model#

the “ON” position.

Loader Serial#

Engine Serial#

DELIVERY

and tilt cylinders, hoses and fittings are not damaged, o Lift leaking or loosely connected. hoses and fittings are not damaged, leaking or o Radiator loosely connected. o Filters are not damaged, leaking or loosely secured. are properly and securely attached and tires are o Wheels properly inflated. is properly lubricated and no grease fittings are o Loader missing or damaged. system reservoir and engine crankcase are o Hydraulic filled to their proper levels. adjustment are made to comply with settings given in o All the Adjustments chapter of this manual. guards, shields and decals are in place and securely ato All tached. and serial numbers, for this unit, are recorded in o Model space provided on this page and page 2.

Check that: The following Checklist is an important reminder of valuable information that MUST be passed on to the Customer at the time the unit is delivered. Check off each item as you explain it to the customer.

Review with the Customer the contents of this manual; especially: Index at the back, for quickly locating topics; o The Safety, Controls & Safety Equipment and Operation o The chapters, for information regarding safe use of the ma-

o o

Start loader engine and test-run the unit while checking that proper operation is exhibited by all controls.

o

Check that:

o

o Drive chains are properly adjusted. control foot pedal and lift/tilt control operate o Directional properly and are not damaged or binding. control foot pedals are properly adjusted for o Directional a correct “neutral” position so that loader does not creep.

chine; The Adjustments, Lubrication, Service and Troubleshooting chapters, for information regarding proper maintenance of the machine. Explain that regular lubrication and maintenance are required for continued safe operation and long life.

Give the Operator’s Manual to the customer and instruct the customer to be sure to read and completely understand its contents BEFORE operating the unit.

Explain that the customer MUST consult the Engine Manual (provided) for related specifications, operating adjustments and maintenance instructions.

Completely fill out the Owner’s Registration, including customer’s signature and, return it to the company.

Customer’s Signature

Date Delivered

(Pages 5 and 6 have been removed at perforation)

Printed in U.S.A.

7

908180/AP0601

CHAPTER 4

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 Manual and on decals on the machine.

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

Before you attempt to operate this equipment, read 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. It is essential to have competent and careful operators, who are not physically or mentally impaired, and who are thoroughly trained in the safe operation of the machine and the handling of loads. It is recommended that the operator be capable of obtaining a valid motor vehicle operator’s license.

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

CAUTION

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

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

MANDATORY SAFETY SHUTDOWN PROCEDURE

Gehl Company ALWAYS takes the operator and his/her safety into consideration when designing machinery and guards exposed moving parts. However, some areas can not be guarded or shielded in order to assure proper operation. Furthermore, this Operator’s Manual and decals on the machine warn of additional hazards and should be read and observed closely.

BEFORE leaving the operator’s seat: 1. Move directional control to ‘‘neutral’’ position.

2. Move the throttle to low idle position.

3. Lower lift arm completely and place attachment flat on the ground. However, if the lift arm MUST be left in the “raised” position, BE SURE to properly engage the lift cylinder mechanical lock.

4. Apply the parking brake.

5. Unfasten seat belt, shut off engine, and remove key.

ONLY when you have taken these precautions can you be sure it is safe to proceed. Failure to follow the above procedure, could lead to death or serious bodily injury.

Some photographs used in this manual may show doors, guards and shields open or removed for illustration purposes ONLY. BE SURE that all doors, guards and shields are in their proper operating positions BEFORE starting the engine to operate the unit.

Different applications may require certain optional safety equipment, such as a back-up alarm, horn mirror or strobe light. BE SURE you know the job site hazards and equip your machine as needed.

908180/AP0601

8

Printed in U.S.A.

SAFETY (Continued)

SAFETY REMINDERS

abrupt control movements can affect machine stability. IF MlSUSED, ANY OF THE ABOVE FACTORS CAN CAUSE THE LOADER TO TIP, THROWING YOU FORWARD OR OUT OF THE UNIT, CAUSING DEATH OR SERIOUS BODILY INJURY. Therefore, ALWAYS wear the seat belt. Operate the controls smoothly and gradually at an appropriate engine speed that matches the operating conditions.

Before Starting •

DO NOT modify the ROPS/FOPS unless instructed to in installation instructions. Modifications such as welding, drilling or cutting can weaken the structure and reduce the protection it provides. A damaged ROPS/FOPS cannot be repaired – it must be replaced.

•

To ensure continued safe operation, replace damaged or worn-out parts with genuine Gehl service parts, BEFORE operating this equipment.

•

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

•

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

•

Always face the loader and use the hand holds and steps when getting on and off the loader. Do not jump off the loader.

•

NEVER use starting fluids (ether).

•

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

•

All Always perform a daily inspection of the machine before using it. Look for damage, loose or missing part, leaks, etc. Be sure all fluid levels are at the proper level for operation and all guards and shields are in place.

•

REMEMBER, it is the owner’s responsibility for communicating information on the safe use and proper maintenance to users of this machine.

During Operation •

The terrain, engine speed, load being carried and

Printed in U.S.A.

9

•

Always travel with the heavier end of the loader in the same direction as the top of the incline for additional stability when operating on inclines or ramps.

•

DO NOT raise or drop a loaded bucket or fork suddenly. Abrupt movements under load can cause serious instability.

•

DO NOT drive too close to an excavation or ditch; BE SURE that the surrounding ground has adequate strength to support the weight of the loader and the load.

•

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

•

Always look to the rear before backing up the loader.

•

Operate the controls only from the operator’s seat.

•

Always keep hands and feet inside the operator’s compartment while operating the machine.

•

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

•

Exhaust fumes can kill. Do not operate this machine in an enclose area unless there is adequate ventilation.

•

When you park the machine and before you leave the seat, apply the parking brake.

908180/AP0601

SAFETY (Continued) •

ALWAYS wear eye protection when servicing the unit. Wear a hard hat or other protection as needed.

DO NOT attempt to remove the radiator cap after the engine has reached operating temperature or if it is overheated, because the engine coolant will be extremely HOT and under pressure. ALWAYS wait for the engine to cool BEFORE attempting to relieve pressure and remove the radiator cap. Failure to heed could result in severe burns.

•

ALWAYS “jump” start a unit using the procedure described in the Service chapter of this manual.

•

NEVER charge a frozen battery.

•

Lead acid batteries produce flammable and explosive gases. Keep electrical arcs, sparks, flames and smoking materials away from the battery.

NEVER use your hands to search for hydraulic fluid leaks. Use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and can penetrate the skin and cause serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

•

Battery acid causes severe burns. In case of acid contact, immediately wash with water and seek medical attention.

•

DO NOT smoke while filling the fuel tank or while working on the fuel or hydraulic systems.

•

NEVER by-pass the keyswitch to start the loader engine. Only use the jump-starting procedure detailed in the Service chapter of this manual.

Maintenance •

•

•

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

908180/AP0601

Transporting •

10

If the loader is transported, BE SURE to properly install the steering frame lock as described in the Operation chapter of this manual.

Printed in U.S.A.

SAFETY (Continued)

129132

Telescopic Boom

Standard Boom

Printed in U.S.A.

11

908180/AP0601

SAFETY (Continued)

154118

908180/AP0601

12

Printed in U.S.A.

SAFETY (Continued)

093367

093474

Printed in U.S.A.

13

908180/AP0601

SAFETY (Continued)

093476

122718

L65922

908180/AP0601

14

Printed in U.S.A.

SAFETY (Continued)

156306

Printed in U.S.A.

15

908180/AP0601

CHAPTER 5 CONTROLS & SAFETY EQUIPMENT 1

WARNING Become familiar with ALL safety devices and controls on the loader BEFORE operating it.

Know how to stop loader operation BEFORE starting it. This loader is designed and intended to be used ONLY with mounted Gehl Company attachments, or Gehl Company approved accessory or referral attachments.

The Gehl Company cannot be responsible for operator safety if the loader is used with an unapproved attachment.

2 3

1 – Parking Brake Handle in Disengaged Position 2 – Propulsion Control Pedals 3 – Hand Throttle

GUARDS & SHIELDS

Fig. 1

Whenever possible and without affecting loader operation, guards and shields are used to protect potentially hazardous areas. In many places, decals are also provided to warn of potential hazards and to display operating procedures.

WARNING ALWAYS be sure that all controls are in their “neutral” positions BEFORE starting the engine. Operation of the controls should be smooth. Excessive travel speed and quick control movements are hazardous and could cause an accident.

WARNING Read and understand ALL safety decals on the loader BEFORE operating it. DO NOT operate the loader unless ALL factory-installed guards and shields are properly secured in place.

DIRECTIONAL CONTROL PEDALS (Fig. 1) The directional control pedals are linked to the hydrostatic drives. Depress the right side foot pedal to move the loader forward or depress the left side pedal to move the loader rearward. Turn the steering wheel slowly clockwise to turn right and counterclockwise to turn left.

HAND THROTTLE (Fig. 1) A hand-operated throttle lever is provided to control the engine RPM to match power requirements. The lever is friction-controlled to stay at the selected throttle setting.

Lifting up on the throttle lever increases the engine RPM and lowering the throttle lever decreases the RPM.

WARNING When turning with the loader, BE SURE to maintain adequate side clearance, because the operator’s seat can extend beyond the turning radius of the wheels.

908180/AP0601

16

Printed in U.S.A.

Chapter 5 – Controls & Safety Equipment

PARKING BRAKE (Fig. 1) The loader is furnished with a hand-operated parking brake. The parking brake handle is linked by cable to the brake assembly.

3

IMPORTANT: When parking brake is disengaged, you MUST travel in reverse to fully disengage the parking brake pin from the drive sprocket. It also may be necessary to rock the loader back and forth to release the pin. Failure to do so will damage the pin.

1

4

1 – Lift/Tilt Control 2 – Differential Lock Control 3 – Pump Control Lever 4 – Auxiliary Hydraulics Control Lever 5 – Telescopic Boom Control Lever

WARNING The parking brake MUST BE applied any time the loader is parked on a grade. If the parking brake is NOT applied, the loader can start to roll after the drive motors drain down. Failure to heed could result in death or serious injury.

Fig. 2

TELESCOPIC BOOM CONTROL (Fig. 2) The telescopic boom can be extended when additional boom reach is desirable. Moving the control lever left extends the telescoping boom, and moving the lever to the right retracts it. Extending the boom also reduces the useful load capacity of the loader. Under most operating conditions, the boom should be in the retracted position.

WARNING Function and adjustment of the parking brake should be checked regularly to maintain proper operation at all times. NEVER use the parking brake as a means of checking hydrostatic torque, as this will cause the brake pins to shear and result in parking brake failure.

DIFFERENTIAL LOCK CONTROL (Fig. 2) The differential lock control engages and disengages the differential locks. Additional traction is obtained with the lock engaged. Under most operating conditions, the differential locks should be disengaged.

LIFT/TILT CONTROL (Fig. 2) The lift/tilt control operates the lift arm and tilt cylinders through the loader’s hydraulic control valve. Move the control to the right to tilt the attachment downward; move the control to the left to tilt the attachment up or back. Push the control straight forward to lower the lift arm; pull the control straight back to raise the lift arm.

PUMP CONTROL (Fig. 2) The pump control connects or disconnects one of the two hydraulic pumps, thereby affecting hydraulic speed. One pump is connected when the control is to the right (turtle) and both pumps are connected when the control is to the left (rabbit).

The speed of all movements controlled by the lift/tilt control is directly proportional to the amount of control movement and engine RPM.

Printed in U.S.A.

2

5

17

908180/AP0601

Chapter 5 – Controls & Safety Equipment

2

2

4 1 1 3

1 – Seat Adjustment Lever 2 – Seat Belt Latch 3 – Seat Tilt Adjustment 4 – Lumbar Adjustment

1 – ROPS 2 – Entry/Exit Handhold

Fig. 3

Fig. 5

ROLLOVER PROTECTIVE STRUCTURE (ROPS)(Fig. 5)

2

The rollover protective structure (ROPS) is designed to protect the operator if the loader is accidentally tipped over, provided the operator uses the seat belt. The ROPS is also equipped with a handhold to assist in operator’s compartment entry and exit.

1 3

WARNING

1 – Seat Belt Retractor 2 – Fuel Cap with Fuel Level Gauge 3 – Battery ON/OFF Switch – Electrical Lockout

NEVER operate the loader with the ROPS removed.

Fig. 4

SEAT POSITIONING (See Fig. 3 & 4)

An overhead guard is available as optional equipment for use in applications that have overhead hazards.

The loader seat is mounted on rails to provide forward or rearward repositioning, to adapt to the operator’s size and comfort. A spring-loaded latch handle is provided for activating the seat adjustment mechanism. Also provided are a seat belt, seat tilt and lumbar adjustments.

WARNING

BATTERY SWITCH (See Fig. 4)

DO NOT use this machine in applications with overhead hazards unless an overhead guard is attached to the ROPS.

A battery ON/OFF switch is located on a panel just above the left rear wheel. The key is removable for security.

908180/AP0601

18

Printed in U.S.A.

Chapter 5 – Controls & Safety Equipment

4.

INSTRUMENT & CONTROL PANEL (Fig. 6)

Indicates the hydraulic fluid is too hot. Check the hydraulic reservoir to make sure there is adequate fluid and that the hydraulic oil cooler is clean and in working order.

The instrument and control panel contains the following control switches and indicators. International symbols are provided on the panel to represent various functions, conditions and switch positions.

1.

5.

6.

engine coolant temperature. Under normal operating conditions, this gauge should indicate approximately 185°F (85°C).

6

5

4

3

2

1

7.

Fuse Block – Two SAE 15 ampere blade-type fuses are provided on the instrument panel to protect the loader electrical circuits.

8.

Auxiliary 12 vDC – An auxiliary 12 vDC outlet is provided on the instrument panel.

9.

Ignition Switch – The ignition switch controls the starting and stopping of the engine by rotating the switch to various positions. In a clockwise rotation, these positions are:

9

Off Position - When the key is vertical in the keyswitch, power from the battery is disconnected to the control and instrument panel electrical circuits. This is the only position in which the key can be inserted or removed from the keyswitch.

10

1 – Coolant Temperature Gauge 2 – Oil Pressure Indicator 3 – Charge Indicator 4 – Hydraulic Fluid Overheat Indicator 5 – Glow Plug Indicator 6 – Hourmeter 7 – Fuse Block (two 15 amp Fuses) 8 – Auxiliary Power (12 vDC) 9 – Ignition Switch (Off, On, Glow Plug, Start) 10 – Horn Button

On (or Run) Position - When the key is turned one position clockwise from the vertical (OFF) position, power from the battery is supplied to all control and instrument panel electrical circuits.

NOTE:

All indicators will illuminate as a self-test when the keyswitch is turned to the RUN position with the engine off.

Fig. 6

Glow Plug Position - When the key is turned clockwise until glow plug light comes on, the glow plugs will be energized for starting the engine. When the glow plug light goes out, you may now continue to start the engine.

Engine Oil Pressure – During normal operation, this indicator should be OFF. If the engine oil pressure drops below a preset value, this indicator will light to warn the operator to IMMEDIATELY stop the engine and determine the cause for the low pressure.

3.

Start Position - When the key is turned fully clockwise and held in that position, the electric starter will be energized for starting the engine. Release the key as soon as the engine starts (it will return to the RUN position by itself).

Battery – Indicates the condition of the charging system. During normal operation, this indicator should be OFF. If the charge rate is too low, this indicator will light.

Printed in U.S.A.

Hourmeter – Indicates the total operating hours of the loader. The hourmeter is especially useful for logging time in the “Maintenance Schedule” located at the back of this manual.

8

2.

Glow Plug Indicator – Indicates when the glow plugs are activated during starting.

Coolant Temperature Gauge – Indicates

7

Hydraulic Fluid Overheat Indicator –

10. Horn Button – Pressing the horn button sounds the horn.

19

908180/AP0601

Chapter 5 – Controls & Safety Equipment

FUEL LEVEL GAUGE (Fig. 4) 3

The fuel level gauge is located in the fuel cap, on the left rear fender. It indicates the amount of fuel remaining in the 3.2 gallon (12 liter) fuel tank.

2

ATTACHMENT MOUNTING (Figs. 7 & 8)

1

Levers are provided for operating the attachment mechanism for mounting and releasing a bucket or other attachment. The latch pins are mechanically linked to the levers and are spring-loaded to ensure positive engagement into the attachment. Raise the lever completely and place it in the rest to disengage the lock pins.

Lower the levers to engage the lock pins.

1 – Attachment Lever in “Engaged” Position 2 – Lock Pin Lowered 3 – Lift Cylinder Mechanical Lock Secured with Bolt and Nut

Fig. 8 (Attachment Removed for Clarity)

LIFT CYLINDER MECHANICAL LOCK (Figs. 8 & 9)

WARNING

A mechanical lock is provided for the lift cylinder, and it is to be used as a cylinder block to prevent the raised lift arm from unexpectedly lowering while servicing the loader. BE SURE to engage the lock and secure it with the bolt and nut provided whenever the lift arm is raised for service. When the lock is not being used, secure it to the attachment mount with the bolt and nut provided.

The lift cylinder mechanical lock is a safety device. It must be kept in proper operating condition at all times.

To prevent attachment release from the lift arms, BE SURE the lock pins are properly secured.

2

WARNING When servicing the loader with the lift arm raised, ALWAYS engage the lift cylinder mechanical lock and the parking brake. Also, turn off the keyswitch, remove the key and take it with you.

1 1 – Attachment Lever in “Disengaged” Position 2 – Lock Pin Raised

Fig. 7 (Attachment Removed for Clarity)

Lock Engagement To engage the lift cylinder mechanical lock, proceed as follows: 1. Lower the lift arm into contact with the loader frame.

2. Shut off the engine.

3. Engage the parking brake.

908180/AP0601

20

Printed in U.S.A.

Chapter 5 – Controls & Safety Equipment

4.

Unfasten seat belt, leave the operator’s seat and remove the bolt and nut that secure the lock to the attachment mount. Return to the operator’s seat with the lock.

5.

Restart the engine from the operator’s seat.

6.

Move the lift/tilt control to raise the lift arm until the lift cylinder rod is fully extended. Make sure that the lift arm is being held in the raised position by the action of the lift/tilt control. Without leaving the operator’s seat, install the cylinder lock and secure it with the bolt and nut.

7.

WARNING BEFORE removing the lift cylinder lock, BE SURE the area BELOW the lift arm and attachment is clear of all personnel and objects.

Shut off the engine again and lower the lift arm until the cylinder lock is engaged.

1 2

3.

Without leaving the operator’s seat, remove the lock

4.

Lower the lift arm.

5.

Turn off the engine.

6.

Return the lock to its storage location on the attachment mount and secure it with the provided bolt and nut.

AUXILIARY HYDRAULICS (Figs. 2 & 10) The loaders are shipped with standard flow auxiliary front hydraulic connections. Three quick-disconnect fittings, conveniently located at the left lift arm, can be used for operating hydraulic attachments. A control next to the lift/tilt control is used to control the oil flow.

A notch in the control slot is provided to lock the control for continuous operation. The rate of flow is controlled by the pump control and engine RPM. The two female connections are for bi-directional pressure flow and the male connection serves as a return line to the reservoir (attachment case drain).

4 3

1 – Lift Arm 2 – Lift Cylinder Mechanical Lock “Installed” 3 – Bolt and Nut for Mechanical Lock 4 – Lift Cylinder

Fig. 9: Lift Arm Raised and Lock “Installed”

Lock Removal

WARNING

1

NEVER attempt to remove the lift cylinder lock by leaving the operator’s seat while the engine is running.

To return the lift cylinder mechanical lock to its “storage” position, proceed as follows: 1.

Start the engine from the operator’s seat and raise the lift arm completely.

2.

Make sure that the lift arm is being held in the raised position by the action of the lift/tilt control.

Printed in U.S.A.

1 – Auxiliary Hydraulics Quick-disconnects

Fig. 10

IMPORTANT: With the auxiliary engaged, the engine will not start.

21

hydraulics

908180/AP0601

CHAPTER 6 OPERATION GENERAL INFORMATION (Fig. 11)

Starting the Engine

WARNING

CAUTION

ALWAYS fasten your seat belt BEFORE starting the loader engine. Leave the parking brake “applied” until the engine is running and you are ready to operate the loader.

BEFORE starting the engine and operating the loader, review ALL safety recommendations in the SAFETY chapter of this manual.

Know how to STOP the loader BEFORE starting it. Also, BE SURE to fasten and properly adjust seat belt BEFORE starting engine.

The following procedure is recommended for starting the loader engine: 1.

Carefully step into the operator’s compartment of the loader while grasping the hand hold.

Before Starting Engine

2.

Sit on the seat and fasten the seat belt.

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

3.

Check that all controls are in their “neutral” positions.

4.

Check that the battery ON-OFF switch is turned on.

5.

Raise the hand throttle to one-fourth of full speed.

2 1

NOTE: When the key is turned to “ON” position, all monitoring lights will come on.

3 4

6.

8

7

5

NOTE:

If the engine runs for a short time and stops or will not start, turn the key to the “OFF” position, wait at least two minutes to allow the starter to cool and then repeat step 6.

6 1 – Steering Wheel 2 – Parking Brake in “Disengaged” Position 3 – Lift/Tilt Control 4 – Pump Control 5 – Auxiliary Hydraulics Control 6 – Hand Throttle 7 – Directional Control Pedals 8 – Lift Arm Float Control Location (Optional)

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

Stopping the Loader The following procedure is the recommended sequence for stopping the loader:

Fig. 11: Operator’s Compartment

908180/AP0601

Turn the keyswitch to “ON” position. Advance the keyswitch to glow plug position. After the glow plugs have heated for a sufficient amount of time, the glowplug light will turn off and the engine can now be started. Turn the key to the “START” position to start the engine. The LOW OIL PRESSURE and BATTERY lights should go off.

22

Printed in U.S.A.

Chapter 6 – Operation

1.

Check that your foot is off the directional control pedals.

2.

Using the lift/tilt control, lower the lift arm and rest the attachment on the ground.

3.

Lower the hand throttle to slowest idle position.

4.

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

5.

Apply the parking brake, unlatch the seat belt and grasp the hand hold while climbing out of the operator’s compartment.

First Time Practice Running

WARNING BE SURE the area being used for test-running is clear of spectators and obstructions. For the first time, operate the loader with an empty bucket.

The most smooth and most efficient loader operation is achieved while running the engine at half-throttle. Be sure the engine is warm and then, using your right hand, slowly and smoothly pull straight back on the lift/tilt control to raise the lift arm. Move the control to the left to tilt the bucket back and to the right to tilt the bucket forward. Attempt all raising and lowering functions, and combinations of the two functions before proceeding to operate the directional control pedals.

WARNING The parking brake MUST BE applied any time the loader is parked on a grade. If the parking brake is not applied, the loader can start to roll because of low resistance in the drive motors due to the oil draining down. Failure to heed could result in death or serious injury.

ALWAYS lower the lift arm and roll the bucket back BEFORE proceeding to operate the directional control pedal.

With your right hand off the lift/tilt control, use your right foot to slowly and smoothly depress the right directional control pedal to travel ahead. Then, slowly and smoothly release the pedal to “neutral” to stop forward movement. To travel rearward, slowly depress the left pedal. Then, slowly release pressure to return the directional control pedal to the “neutral” position to stop reverse movement. Next, turn the steering wheel slowly clockwise to turn right and counterclockwise to turn left. Attempt all forward, reverse and turning movements before proceeding to operate both controls at the same time.

Loader Movement The hydrostatic drive of the loader controls forward and reverse direction and speed. As rapidly as the directional control pedal is moved to the “neutral” position, movement of the wheels is slowed accordingly.

WARNING Operate the directional control pedal gradually and smoothly when starting, stopping, turning and reversing loader directions. Excessive speed can be hazardous. ALWAYS exercise caution and good judgement while operating the loader.

Printed in U.S.A.

Loader operating skills are only obtained through proper coordination of the loader’s forward and reverse movements, with raising and lowering the lift arm and with tilting the bucket forward and back. To gain proficiency, practice all control operations until you are capable of performing the movements without mistake or hesitation.

23

908180/AP0601

Chapter 6 – Operation

CHANGING ATTACHMENTS (Fig. 12)

WARNING When turning with the loader, BE SURE to maintain adequate side clearance because the operator’s seat extends beyond the turning radius of the wheels.

WARNING To prevent unexpected and undesired attachment release from the attachment mount, BE SURE to properly secure the attachment lock pins.

WARNING

The loader features a quick latching and locking mechanism for mounting an attachment to the front of the lift arm. The mechanism uses two locking pins for attaching and detaching the attachment.

BEFORE leaving the operator’s compartment, apply the parking brake and remove the key.

Also, BE SURE to lower the lift arm or engage the lift cylinder mechanical lock, as appropriate.

3

2

PARKING BRAKE (See Fig. 11) 4

1

WARNING Function and adjustment of the parking brake should be checked regularly to maintain proper operation. NEVER use the parking brake as a means of checking hydrostatic torque, because this will result in parking brake failure.

1 – Attachment Lever Locked (1 each side) 2 – Attachment Lock Pin (1 each side) 3 – Front Tie-down Hole Location (1 each side) 4 – Attachment Lever Unlocked Position

Fig. 12

Attaching

NOTE: The parking brake is not designed for or intended to be used as the primary means of stopping forward or reverse movement of the loader.

The propulsion control foot pedals, when they are returned to their “neutral” positions, provide hydrostatic braking and are the primary means for stopping loader movement.

The proper sequence for correct loader operation is to always apply the parking brake before shutting off the loader engine, and to release the brake only after the engine is running and you are ready to move the directional control pedals.

908180/AP0601

24

1.

Raise the lock pins and place their handles in the unlocked position to fully retract the lock pins.

2.

Start the loader engine and make sure the lift arm is lowered and in contact with the loader frame.

3.

Align the loader squarely with the back of the attachment.

4.

Tilt the attachment mechanism forward until the mating parts of the mechanism are in line with and slightly below the hooks on the back of the attachment.

Printed in U.S.A.

Chapter 6 – Operation

5.

6.

7.

Slowly drive the loader forward and, at the same time, roll the attachment mechanism back to engage the hooks on the attachment.

Stop forward travel when the hooks are engaged but, continue to roll the attachment mechanism back to pick the attachment up off the ground.

When the attachment mechanism is rolled back completely, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

With the loader engine OFF, leave the operator’s compartment, and lower the lock pins to secure the attachment.

To use the table, find the material name and see what its maximum density is. Then, divide the operating capacity of the loader (one-half the tipping load) by the material density to determine the maximum size bucket to use for a heaped load.

NOTE:

Where the material density is listed as a range (clay at 80-100 pounds per cubic foot, for example), always use the maximum density (100 lbs/ cu-ft in this example) for making calculations.

(Also, see the following examples.)

EXAMPLE 1: If wet sand (density of 125 lbs/cu. ft.) is to be hauled, the maximum bucket size is (800 lbs divided by 125 lbs/cu. ft. = 6.4 cu. ft.). Therefore, you could safely use a 5 cu. ft. bucket.

Detaching 1.

2.

3.

4.

Roll the attachment mechanism back as far as it will go. Once the mechanism is rolled all the way back, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

With the loader engine OFF, leave the operator’s compartment, and raise the lock pins and place their handles in the unlocked position to fully retract the lock pins.

Start the loader engine and make sure that the lift arm is lowered and in contact with the loader frame.

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

EXAMPLE 2: If earth-wet loam (density of 65 lbs/cu. ft.) is to be hauled, the maximum bucket size is (800 lbs divided by 65 lbs/cu. ft. = 12.3 cu. ft.). Therefore, you could safely use a 8.5 or 8.75 cu. ft. bucket.

NOTE: Light material buckets are to be used ONLY for moving snow or materials of similar densities.

The Specifications chapter lists the available buckets and their capacities to help you determine which size bucket to use. You can always use a smaller capacity bucket, but not a bucket with greater capacity than the calculated maximum unless it is only partially filled.

MOVING MATERIALS WITH A BUCKET

WARNING

Material Densities

NEVER use the loader to move in excess of one-half of the rated tipping load of the loader as shown on the tipping load charts. Tipping loads decrease if the loader is turning. Tipping loads also decrease if the optional telescoping boom is extended.

The following table lists densities for some common materials that could be carried in a bucket. The densities listed are average values and intended only as a guide for bucket selection. For a material that is NOT in the table, obtain its density value before selecting the appropriate bucket.

NOTE: The rated operating load (SAE) of the loader is one-half of the tipping load. To prevent exceeding the operating capacity of the loader, use the table of common material densities and loader tipping load chart to determine the proper size bucket to use, based on the type of material to be carried.

Printed in U.S.A.

25

908180/AP0601

Chapter 6 – Operation

Table of Common Materials and Densities Material

Density in (lb./ft.3)

Ashes

35-50

Brick-common

112

Cement

110

Charcoal

23

Clay

80-100

Coal

53-63

Concrete

115

Cinders

50

Coal-anthracite

94

Coke

30

Earth-dry loam

30

Earth-wet loam

65

Granite

93-111

Gravel-dry

66

Gravel-wet

90

Gypsum-crushed

115

908180/AP0601

26

Iron Ore

145

Lime

60

Lime Stone

90

Manure-liquid

65

Manure-solid

45

Peat-solid

47

Phosphate-granular

90

Potash

68

Quartz-granular

110

Salt-dry

100

Salt-Rock-solid

135

Sand-dry

108

Sand-wet

125

Sand-foundry

95

Shale-crushed

90

Slag-crushed

70

Snow

15-50

Sulpha

95

Taconite

107

Printed in U.S.A.

Chapter 6 – Operation

Loader Tipping Capacity* Chart Tipping Load, 175 lb (79 kg) operator, w/o counterweight

Tipping Load, 175 lb (79 kg) operator, w/66 lb (30 kg) counterweight 1800lb (816kg)

WARNING

1600lb (726kg)

Rated Operating Load (SAE) is 50% of the Tipping Capacity (SAE).

1400lb (635kg)

1200lb (544kg)

Tipping Capacity is reduced in a full turn.

1000lb (454kg)

800lb (363kg) 63 in 54 in 45 in 36 in 27 in 18 in 9 in (1.60 m) (1.37 m) (1.14 m) (0.91 m) (0.69 m) (0.46 m) (0.23 m)

0

When using forks, Tipping Capacity will be reduced if load center extends beyond load center of bucket.

Load Center to Front Axle With Boom Horizontal, Load Center Extends: 19.0 in

15.75 in

(483 mm)

(400 mm)

Optional Counterweight

CG

Boom Extended * per SAE J732, with 175 lb. (79 kg) operator, frame straight, std. bucket and tires, and full fuel tank.

CG Bucket Load Center to Axle 25.0 in (635 mm)

Boom Retracted or Standard Boom

CG

NOTE:

LOADER OPERATION

The loader’s working ability is increased when ground speed is decreased. To obtain maximum tractive effort while filling the bucket, depress the propulsion control foot pedal only a slight amount from its “neutral” position.

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!

Printed in U.S.A.

27

908180/AP0601

Chapter 6 – Operation

Digging with and Loading a Bucket (Figs. 13 through 16) To dig with and load a bucket, first lower the lift arm into contact with the loader frame and then tilt the bucket’s cutting edge down into contact with the ground. Move the loader into the material and, as engine loads, tilt the bucket back slowly and, at same time, gradually ease pressure on the propulsion foot pedal to decrease travel speed while maintaining tractive effort.

Fig. 15: Digging in Hard-packed Materials

When attempting to fill the bucket while working with most hard-packed materials, it will usually be necessary to raise the lift arm while rolling the bucket back. Also, avoid driving onto the material to be picked up, if at all possible.

WARNING Fig. 13: Digging in Loose Materials

ALWAYS carry loaded bucket or fork with lift arm resting on loader frame. For additional stability when operating on inclines, ALWAYS travel with heavier end of loader toward the top of the incline.

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.

Fig. 14: Loading the Bucket

908180/AP0601

28

Printed in U.S.A.

Chapter 6 – Operation

Carry the loaded bucket (or fork) as low as possible while slowly traveling toward the dumping area. Stop the loader at the position where the bucket extends half-way over the edge of the embankment. Then, tilt the bucket (or fork) forward and raise the lift arm to dump the material. After the material is dumped, back away from the embankment slowly while lowering the lift arm and rolling back the bucket (or fork).

Scraping with a Bucket (Figs. 17 & 18) For scraping, the loader should be operated in the forward direction. First, position the lift arm down against the loader frame. Tip the bucket cutting edge at a slight angle to the surface being scraped. While traveling slowly forward, with the bucket in this position, material can flow over the cutting edge and collect inside the bucket.

Fig. 16: Carrying the Load

Dumping the Load Onto a Pile Carry loaded bucket as low as possible until reaching the pile. Slowly stop forward 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 to dump the material on top of the pile. Empty the bucket and back the loader away while lowering the lift arm and rolling the bucket back.

Dumping the Load Into a Box Carry the loaded bucket (or fork) low and approach the truck, trailer or spreader box squarely with the side of the box. Stop your approach as close to the side of the box as possible while still allowing clearance for raising the lift arm and loaded bucket (or fork). Then, raise the lift arm until the bucket clears the top of the box and slowly move the loader ahead to position the bucket (or fork) over the inside of the box. After the material is dumped, slowly back away from the box and lower the lift arm while rolling back the bucket (or fork).

Fig. 17: Positioning Bucket for Scraping

Dumping the Load Over a Solid Embankment

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.

Printed in U.S.A.

Fig. 18: Scraping with a Bucket

29

908180/AP0601

Chapter 6 – Operation

Leveling with a Bucket (Fig. 19)

WARNING

First drive the loader to the outer edge of the area to be leveled. Then, with the lift arm down against the frame, tilt the bucket forward to place the bucket cutting edge at a 30 to 45 degree angle to the surface being leveled.

Proceed to drive the loader rearward, dragging the dirt and, at the same time, leveling it.

For additional stability when loading the loader on a trailer, ALWAYS travel with heavier end of loader toward the top of the incline.

2

1

1 – Steering Frame Lock 2 – Lock Pin

Fig. 19: Leveling with a Bucket

Fig. 20

Using Pallet Forks

TIE-DOWN LOCATIONS (Figs. 21 and 12)

If possible, plan to load, unload and turn on flat, level ground. Inspect the load to be moved. If it appears to be unstable, do not attempt to move it.

Four tie-down locations are provided near the bottom of the loader to secure the loader while transporting.

Approach the load slowly and squarely with fork tips level. Move slowly forward to engage the load. Position the load equally on both forks. Continue forward until the load touches the fork backrest. Roll the forks back to position the load for travel. Carry the load low. DO NOT make any abrupt movements.

2

BE SURE the landing point can safely support the load.

Move forward slowly into the unloading position.

Lower the load onto the landing point. Tilt the forks forward to be horizontal, and then back away carefully to disengage the forks.

TOWING & HIGHWAY TRAVEL

1

When it becomes necessary to move the loader over long distances, obtain and use a Avantage Tool System Trailer or an Gehl LT8500 Loader Trailer. When transporting the loader, ALWAYS install the steering frame lock, securing it with the provided lock pin.

908180/AP0601

1 – Rear Tie-down Location (1 each side) 2 – Front Tie-down Location (1 each side)

Fig. 21

30

Printed in U.S.A.

CHAPTER 7 ADJUSTMENTS 2

WARNING BEFORE adjusting this unit, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

1

1

ENGINE Loaders are provided with separate engine maintenance manuals which should be consulted for engine-related specifications, adjustments, maintenance and service information.

2

DRIVE CHAINS

1 – Hydraulic Motor Mounting Bolts (four) 2 – Adjustment Bolts and Lock Nuts (two)

Each wheel is driven by a hydraulic motor coupled with a drive chain. To adjust drive chain tension, loosen the four motor mounting bolts and move the motor with the two adjusment bolts and lock nuts. The chains should be adjusted to have 1/4″ (6 mm) or less of slack with 10 lbs (45 N) of force, but should not be adjusted so the chain is tight.

Printed in U.S.A.

Fig. 22

31

908180/AP0601

CHAPTER 8 LUBRICATION GENERAL INFORMATION

hydraulic revervoir. The loader is provided with a dipstick on the hydraulic reservoir cap. Markings on the dipstick represent both full and low (add oil) levels.

The resevoir is accessed by raising the lift arms and removing the front Cover. Use hydraulic oil with anti-wear, anti-foam and anti-oxidation additives that conforms to ISO Viscosity Grade 46, such asMobil DTE 15M, Amoco Rykon 46, or BP Energol HLP-HD 46. Use of synthetic hydraulic fluids is not permitted.

WARNING NEVER lubricate this unit when any part of the machine is in motion. ALWAYS BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE lubricating this equipment.

The hydraulic oil should be changed every 500 hours (or annually).

IMPORTANT: BE SURE to install the lift arm lock when accessing the hydraulic reservoir.

It is important to apply sufficient oil and grease to prevent excessive part wear and early failure.

IMPORTANT: Whenever service is performed on hydraulic components (valves, cylinders, hoses, etc.) or transmissions, care must be taken to prevent discharging fluid onto the ground.

Catch and dispose of fluid per local waste disposal regulations.

2 1

ENGINE LUBRICATION All engine maintenance and lubrication requirements are listed in the Engine Operator’s Manual that is supplied with each loader.

DRIVE CHAINS 1 – Hydraulic Reservoir and Cap 2 – Lift Arm Lock

Lubricate all drive chains every eight hours of operation using a good grade of foaming aerosol lubricant such as NAPA Chain and Cable Lubricant. This type of lubricant increases the life of the chain three to four times over those lubricated at eight hour intervals with new motor oil. The recommended method is to spray the entire length of chain on the center of the rollers. It is more effective to oil chains after use, while they are still warm.

Fig. 23

GREASING IMPORTANT: Grease all fittings at intervals of operation listed, after pressure washing, and before and after storing unit. Use a good grade of lithium-base grease.

IMPORTANT: To

minimize wear on the sprockets, the chains should be replaced after they become worn and are 3% longer than their original length, or when the tightener (where provided) has reached the end of its adjustment.

Wipe dirt from the fittings before greasing to prevent dirt from being forced into the bearing or pivot. Replace any missing fittings. Force grease into the fitting until it comes out at the bearing seal or the shaft. To minimize dirt build-up, avoid excessive greasing.

HYDRAULIC RESERVOIR

IMPORTANT: In addition to the grease fittings, repack the wheel bearings at least annually.

The loader is equipped with an 8 gallon (30 L)

908180/AP0601

32

Printed in U.S.A.

Chapter 8 – Lubrication

Grease Fitting Locations Grease Every 10 Hours (or Daily) 1.

Lift Arm Pivots (2 places)

2.

Lift Arm Cylinder Pivots (2 places)

3.

Attachment Mount Pivots (2 places)

4.

Attachment Mount Cylinder Pivots (2 places)

5.

Articulation Joint (2 places)

6.

Articulation Joint Cylinder (2 places)

7.

Optional Telescoping Boom Cylinder Pivots (2 places)

8.

Optional Telescoping Boom Slides (2 places)

Each Side 1 2

7

3

4

8

8

3 7

5 6

Printed in U.S.A.

33

908180/AP0601

CHAPTER 9 SERVICE GENERAL INFORMATION

Valves Internal component service on any of the hydraulic valves should only be performed by (or under the direction of) an authorized GEHL dealer.

CAUTION

Access to the hydraulic valves is gained by unbolting the access covers. After the hydraulic connections and mechanical linkages are carefully marked and removed, remove the valve and take it to your dealer for service or replacement.

BEFORE servicing the loader, unless expressly instructed to the contrary, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8). After service has been performed, BE SURE to restore all guards, shields and covers to their original positions BEFORE resuming loader operation.

Cylinders All hydraulic cylinders used on the loader are appropriately designed with particular strokes, diameters and hose connection provisions unique to the loader application requirements. In addition, internal cylinder component service and replacement requires special knowhow and tools.

IMPORTANT: Whenever service is performed on hydraulic components, (valves, cylinders, hoses, etc.) transmissions or engines care must be taken to prevent discharging fluids onto the ground. Catch and dispose of fluids per local waste disposal regulations.

Any of the hydraulic cylinders can be removed from the loader and taken to the dealer for service or replacement.

To remove a cylinder from the loader, proceed as follows:

This Service chapter details procedures to follow for making routine maintenance checks, adjustments and replacements. For engine related adjustments and servicing procedures, BE SURE to refer to the separate Engine Operator’s Manual provided.

DEALER SERVICES The following areas of internal components service, replacement and operating adjustments should only be performed (or under the direction of) an authorized GEHL dealer.

Hydraulic Components The hydraulic pumps are coupled directly to each other (in tandem) and to the engine crankshaft. All service routines related to the internal components of the pumps are precise and critical to proper operation. The hydraulic drive motors are complex devices that require special know-how and tools for servicing.

Be sure that the lift arm is lowered and in contact with the loader frame.

2.

Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

3.

Relieve ALL pressure in the lines by moving the drive and lift/tilt controls in all directions.

4.

Disconnect the hydraulic hose connections at the desired cylinder.

5.

Remove the rod-end anchor pin first.

6.

Lastly, remove the cylinder-end anchor pin.

Cylinder replacement is in reverse order of removal.

OPERATOR SERVICES Check Engine Air Cleaner (Fig. 24) Loaders require a daily check of the air cleaner outlet hose and clamps and the mounting bracket hardware to ensure they are secure. The air filter should be changed every 100 hours of operation.

NOTE:

If a hydraulic pump or drive motor is suspected of faulty operation, contact your GEHL dealer for further information and directives.

908180/AP0601

1.

34

Printed in U.S.A.

Chapter 9 – Service

Check Hydraulic Oil Level

1

5

4

2

The loader is provided with a dipstick on the hydraulic reservoir cap. Markings on the dipstick represent both full and low (add oil) levels. Refer to the Lubrication chapter for oil recommendations. The hydraulic oil should be changed every 500 hours (or one year). Refer to details in the Lubrication chapter.

3

1

2

1 – Engine Oil Dipstick 2 – Engine Oil Fill Cap 3 – Air Cleaner Outlet Hose & Clamps 4 – Battery 5 – Fuel Cap and Gauge

Fig. 24

Check Radiator Coolant Level (Fig. 25)

3

Access to the radiator is obtained by unlatching and removing the engine access cover. Refer to the engine manual for anti-freeze recommendations.

1 – Radiator Cap 2 – Hydraulic Oil Cooler 3 – Wheel Lug Nuts (4 each Wheel)

A loader’s engine coolant level is checked and filled by removing the radiator cap. Fluid level should be just below the neck of the filler hole. ALWAYS check the fluid level when the engine is cool.

Fig. 25

Lubrication Perform lubrication procedures as detailed in the Lubrication chapter.

WARNING

Check Alternator/Fan Belt Tension & Condition

DO NOT remove the radiator cap when the engine is HOT or overheated. Coolant is extremely HOT and under pressure and it can burn your skin. Wait for the engine to cool BEFORE relieving the pressure and removing the radiator cap.

Refer to the separate engine manual for setting proper belt tension. If the belt is worn, cracked or otherwise deteriorated, replace the belt following the procedure in the separate engine manual.

Check Engine Oil Level (Fig. 24)

Check Battery Electrolyte Level

Unlatch and remove the engine access cover. Pull out the dipstick, located on the left side of engine, and check the oil level. Markings on the dipstick represent both full and low (add oil) levels. Refer to the separate Engine Operator’s Manual for the proper location and procedures for adding/changing engine oil. Also, refer to the separate Engine Operator’s Manual for oil requirements information. A hole in the loader bellyplate gives access to the engine oil drain.

The battery furnished on the loader is a 12 volt, wet-cell battery. The top of the battery MUST always be kept clean. Clean the battery with a brush dipped in an alkaline solution (ammonia or baking soda and water).

After the foaming has stopped, flush the top of the battery with clean water. If the terminals and cable connection clamps are corroded or have a build-up, disconnect the cables and clean the terminals and clamps with the same alkaline solution.

Printed in U.S.A.

35

908180/AP0601

Chapter 9 – Service

Handling Battery Safely

WARNING WARNING

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

Explosive gas is produced while a battery is in use or being charged. Keep flames or sparks away from the battery area. Make sure battery is charged in a well-ventilated area.

NEVER lay a metal object on top of a Battery as a short circuit can result.

Battery acid is harmful on contact with skin or fabrics. If acid spills, follow these first aid tips: 1.

IMMEDIATELY remove any clothing on which acid spills.

2.

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

3.

4.

DO NOT attempt to jump-start the loader battery if it is frozen, because this may cause it to rupture or explode.

If acid contacts the eyes, flood the eyes with running water for 10 or 15 minutes.

See a doctor at once. NEVER use any medication or eye drops unless prescribed by the doctor.

NOTE:

BE SURE that the jumper battery is also a 12 volt D.C. battery.

To neutralize acid spilled on the floor, use one of the following mixtures: a. b.

5.

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

1 Pound (0.5 kg) of baking soda in 1 U.S. Gallon (4 liters) of water

1.

Turn the keyswitches of both vehicles to OFF and make sure that both vehicles are in “Neutral” and NOT touching each other.

2.

Connect one end of the positive (+) jumper cable to the positive (+) battery terminal on the disabled loader first. DO NOT allow the jumper’s positive cable clamps to touch any metal other than the positive (+) battery terminals. Connect the other end of the positive jumper cable to the jumper battery positive (+) terminal.

3.

Connect one end of the negative (-) jumper cable to the jumper battery negative (-) terminal.

4.

Make the final negative (-) jumper cable connection to the disabled loader’s engine block or loader frame (ground) -- NOT to the disabled battery’s negative post. If making the connection to the engine, keep the jumper clamp away from the battery, fuel lines or moving parts.

1 Pint (0.4 liters) of household ammonia in 1 U.S. Gallon (4 liters) of water

Acid from the battery can damage the paint and metal surfaces of the machine.

Avoid overfilling the battery cells.

Whenever battery is removed from the unit, BE SURE to disconnect the negative (-) battery terminal connection cable first.

Jump-starting If the loader battery becomes discharged or does not have enough power to start the engine, use jumper cables and the following procedure to jump-start the loader engine.

908180/AP0601

NOTE: Twist jumper cable clamps on the battery terminals and ground connection to ensure a good electrical path for conducting current.

36

Printed in U.S.A.

Chapter 9 – Service

5.

Proceed to start the loader. If it does not start immediately, start the jumper vehicle engine to avoid excessive drain on the booster battery.

•

Use a clip-on tire chuck with a remote hose and gauge, which allows you to stand clear of the tire while inflating it.

6.

After loader is started and running smoothly, have second person remove the jumper cables (negative (-) jumper cable first) from jumper vehicle battery and then from disabled loader, while making sure not to short the two cables together.

•

DO NOT place your fingers on the tire bead or rim during inflation.

•

Wheel lug nut torque should be checked after every 50 hours of operation. Tighten the lug nuts, which secure the wheels to the loader axles, to a torque of 70 ft-lbs (95 Nm).

NEVER inflate beyond 35 PSI (240 kPa) to seat the beads. If the beads have not seated by the time the pressure reaches 35 PSI, deflate the assembly, reposition the tire on the rim, relubricate both parts and re-inflate it. Inflation pressures beyond 35 PSI with unseated beads may break the bead or rim with explosive force sufficient to cause death or serious injury.

•

After seating the beads, adjust the inflation pressure to the recommended operating pressure listed.

Check Tire Pressures

•

DO NOT weld, braze, or otherwise attempt to repair or use a damaged rim.

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

Tighten Wheel Lug Nuts (Fig. 25)

Check the tire pressures after every 50 hours of operation. Tires should be inflated according to the following chart.

Tire Inflation Pressures Tire Size & Description

CAUTION Tire mounting, repairing and replacing should ONLY be performed by a qualified tire manufacturer’s representative, or by properly trained personnel following the tire manufacturer’s instructions. If you do not have such instructions, contact your tire dealer or our Company.

•

Lubricate both the tire beads and rim flanges with a soap solution. DO NOT use oil or grease.

Printed in U.S.A.

kPa

22.4 x 5.70 x 12 6-ply traction tread

36

250

23 x 8.50 x 12 6-ply traction tread

36

250

23 x 8.50 x 12 6-ply grass tread

36

250

When installing tires on the loader, BE SURE that the tires are of the same size and style on the same side of the loader. ALWAYS replace tires with the same size furnished as original equipment; replacement tires MUST be purchased locally.

Check Radiator Hoses & Clamps

Inflating or servicing tires can be dangerous.

Whenever possible, trained personnel should be called to service and mount tires. To avoid possible death or serious injury, follow the safety precautions below: BE SURE the rim is clean and free of rust.

PSIG

Proper tire pressure should be maintained equally for all four tires to enhance operating stability and extend tire life. Refer to the chart for the proper inflation pressure.

WARNING

•

Inflation Pressure

Check for coolant leaks and/or deteriorated hoses.

Oil & Tighten All LinkageBall Joints Ball joint style pivoting connectors may used for coupling some controls. The metal to metal type ball joints should be lubricated with a couple of drops of oil to help maintain freedom of movement. At the same time the ball joints are lubricated, all linkage locking nuts should be tightened.

37

908180/AP0601

Chapter 9 – Service

Notes

908180/AP0601

38

Printed in U.S.A.

CHAPTER 10 TROUBLESHOOTING NOTE: This Troubleshooting guide presents problems, causes and suggested remedies beyond the extent of loose, worn or missing parts. It was developed with the understanding that the machine is in otherwise good operating condition. Refer to the Index at the back of this manual for chapter and topic page references. For additional assistance, contact your GEHL dealer.

ELECTRICAL SYSTEM PROBLEM Starter will not crank.

CAUSE

REMEDY

Main fuse is blown.

Replace fuse. If it blows again, contact dealer for assistance.

Battery connections are loose or corroded or starter solenoid is defective.

Clean battery terminals and cables and retighten them or replace solenoid.

Check wiring connections.

Electrolyte level is low.

Add distilled water to replenish electrolyte.

Terminals or cables are loose or corroded, battery is defective or alternator (or regulator) is defective.

Clean battery terminals and cables and retighten them. If required, have battery tested and/or contact your dealer for testing alternator output, if necessary.

Entire electrical system does not function.

Main fuse is blown.

Replace fuse. If it blows again, contact dealer for assistance.

Indicator lights do not work.

15 ampere fuse is blown.

Replace fuse. If it blows again, contact dealer for assistance.

Battery will not recharge.

ENGINE (See also separate Engine Manual) Engine will not turn over.

Engine turns over but will not start.

Printed in U.S.A.

Battery terminals or cables are loose or corroded.

Clean battery terminals and cables and tightly secure them.

Battery is discharged or defective.

Recharge battery (refer to battery topic in Service chapter) or replace it.

Starter or pinion is faulty.

Contact dealer for directives.

Keyswitch wire connections are loose, broken or disconnected.

Inspect wiring for poor connections or broken leads and repair wiring or connections, as necessary.

Battery is weak or drained.

Check battery charge; if battery does not hold a charge, replace it.

Engine cranking speed is too slow.

Battery requires recharging or, in cold temperatures, pre-warm engine and hydraulic oils.

Fuel tank is empty.

Refill fuel tank; check for faulty fuel gauge.

Fuel shutoff solenoid is not energizing pump.

Check electrical connections to and voltage at fuel shutoff solenoid.

Fuel pump is not working.

Refer to Engine Manual or contact your nearest Engine Service center.

39

908180/AP0601

Chapter 10 – Troubleshooting

ENGINE (Continued) PROBLEM Engine overheats.

CAUSE

REMEDY

Crankcase oil is low or too full.

Add or remove oil, as required.

Engine is overloaded.

Operate at half to full throttle.

Coolant level is too low.

Add coolant, as necessary.

Fan air circulation is restricted by a plugged radiator.

With engine off, safely remove restriction.

Exhaust is restricted.

Allow exhaust system to cool and then remove restriction.

Engine oil is of the improper grade or is excessively dirty.

Drain and replace oil with proper grade.

Air cleaner filter is restricted.

Replace filter.

HYDROSTATIC DRIVE PROBLEM

CAUSE

REMEDY

Traction system overloaded.

Improve efficiency of operation.

Lift and tilt system overloaded.

Improve efficiency of operation.

Internal pump or motor leakage.

Repair or replace pump or motors; contact dealer for assistance.

Unit being operated in high temperature area with little or no air circulation.

Reduce duty cycle and improve air circulation.

Hydraulic oil is too heavy.

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

Oil supply is too low.

Check for low oil level in reservoir. Add oil, as necessary.

Reservoir strainer is plugged.

Remove reservoir cover and clean strainer. Also, inspect reservoir for any debris plugging the system.

Wheels turn with servo in neutral.

Neutral centering spring mechanism needs adjustment.

Contact dealer for assistance.

Traction drive will not operate in either direction.

Hand brake on.

Disengage hand brake.

Oil supply is too low.

Check for low oil level in reservoir. Add oil, as necessary.

Control linkage disconnected.

Check linkage connection. Reconnect linkage, if necessary. Contact dealer for adjustment assistance.

Low or no drive pump charge pressure.

Contact dealer for assistance.

Gear pump not pumping oil.

Contact dealer for assistance.

Hydrostatic drive overheating.

NO response from either the Drive or Lift/Tilt systems.

908180/AP0601

40

Printed in U.S.A.

Chapter 10 – Troubleshooting

HYDROSTATIC DRIVE (continued) PROBLEM Hydrostatic (drive) system is noisy.

CAUSE

REMEDY

Oil is too heavy.

Allow longer warm-up. Replace existing oil with proper weight oil.

Air in system.

Check for low oil level in reservoir.

Loose connection to charge inlet.

Contact dealer for assistance.

Internal pump or motor damage.

Contact dealer for assistance.

Neutral is difficult to maintain.

Control linkage out of adjustment.

Contact dealer for assistance.

Sluggish response to acceleration.

Air in system.

Check for low oil in reservoir. Add oil, as necessary

Internal motor or pump damage.

Contact dealer for assistance.

Engine not responding to load.

Troubleshoot/adjust engine per Engine Manual; contact dealer for assistance.

HYDRAULIC CYLINDERS & CONTROLS NO response to lift arm or bucket.

Gear pump is damaged.

Contact dealer for assistance.

Oil flow to pump blocked.

Inspect suction hose and reservoir.

Lift arm does not raise but bucket operates properly.

Valve not actuated or is leaking.

Check connection to valve. Contact dealer for assistance as necessary.

Hydraulic cylinder action is slow.

System pump is worn and pressure is low.

Check pressure and oil flow. Contact dealer for assistance as necessary.

Tilt cylinder leaks down.

Oil is leaking past the cylinder packing or the system valve spool is leaking.

Contact dealer for assistance.

Printed in U.S.A.

41

908180/AP0601

CHAPTER 11 DECAL LOCATIONS GENERAL INFORMATION

CAUTION

Decal location information is provided to assist in the proper selection and application of new decals, in the event the original decals become damaged or the machine is repainted. Refer to the listing for the illustration reference number, part number, description and quantity of each decal provided in the kit. Refer to the appropriate illustrations for replacement locations.

ALWAYS follow safety precautions on decals.

Replace the decals if they are damaged, or if the unit is repainted. If repainting, BE SURE all applicable decals are affixed to your unit.

To insure proper selection of the correct replacement decals, compare all of the various closeup location drawings to your machine before starting to refinish the unit. Then circle each shown decal (applicable to your machine) while checking off its part number in the listing. After you have verified all the decals needed for replacement, place any extra unnecessary decals aside for disposal.

PAINT NOTICE Use this list to order paint for refinishing: 906213 One Gal. Construction Yellow 906323 One Qt. Charcoal Grey 906317 One Gal. Charcoal Grey 906214 6 (12 oz. Spray Cans) Yellow 906318 6 (12 oz. Spray Cans) Grey

NOTE: Refer to the SAFETY Chapter of the Operator’s Manual for the specific information provided on all of the various safety decals furnished in the decal kit(s).

The decal kit part number for the AL20DX Loader is 155752. Individual decals are listed below: Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

NEW DECAL APPLICATION Surfaces MUST be free from dirt, dust, grease and other foreign material before applying the new Decal. To apply, remove the smaller portion of the decal backing paper and apply this part of the exposed adhesive backing to the clean surface while maintaining proper position and alignment. Peel the other portion of the backing paper off slowly while applying hand pressure to smooth out the decal surface.

908180/AP0601

42

Part No. L65922 093367 093474 093476 114316 122718 129132 132139 145216 154118 155724 155729 155733 156306 156139

Description & Quantity IMPORTANT – Operator’s Manual WARNING - Owner’s Responsibility WARNING - General Safety Precautions WARNING - Fasten Seat Belt IMPORTANT – Starting WARNING – Attachment Lock Pin DANGER – Lift Arm Lock Tiedown Location (4 Places) Red Reflector (2 Places) DANGER – Pinch Point (2 Places) GEHL (4 Places) AVANTAGE (2 Places) AL20DX (2 Places) WARNING – Injury Hazard Control Panel

Printed in U.S.A.

Chapter 11 – Decals

4

6

5

1

11 8

9 2

14 15

13

3

10

11 11

7

12

11 8 13

10

Printed in U.S.A.

43

908180/AP0601

CHAPTER 12 MAINTENANCE LOG SERVICE EVERY 10 HOURS COMPONENT and SERVICE REQUIRED

PROCEDURE and/or CHAPTER TOPIC REFERENCE (Check Page No. in Index)

Check engine oil and radiator coolant level.

Refer to Service chapter.

Lubricate grease fittings.

Refer to Lubrication chapter.

Check air cleaner and hydraulic fluid level.

Refer to Service chapter.

SERVICE EVERY 50 HOURS Check drive chains.

Refer to Adjustments chapter.

Check tire pressure and wheel nut torque.

Refer to Service chapter.

Date of Service

908180/AP0601

44

Printed in U.S.A.

Chapter 12 – Maintenance Log

SERVICE EVERY 100 HOURS COMPONENT and SERVICE REQUIRED

PROCEDURE and/or CHAPTER TOPIC REFERENCE (Check Page No. in Index)

Change engine oil and filter.

Refer to Engine Operator’s manual.

Check alternator belt tension.

Refer to Engine Operator’s manual.

Clean air filter.

Refer to Engine Operator’s manual.

Change fuel filter and clean sediment bowl.

Refer to Engine Operator’s manual.

Date of Service

SERVICE EVERY 500 HOURS Change engine coolant.

Refer to Engine Owner’s manual.

Change hydraulic fluid.

Refer to Service chapter.

Date of Service

Printed in U.S.A.

45

908180/AP0601

Index A

F Fan Belt. See Alternator Belt Fuse Block, 19

Adjustments, 31 Air Cleaner, service check, 34 Alternator Belt, service, 35 Attachment Mountings, 20 Attachments, changing, 24 Auxiliary 12 vDC outlet, 19 Auxiliary Hydraulics, 21

G Glow Plug, Indicator, 19 Keyswitch, 19 Grease Fitting locations, 33 Greasing, 32 Guards, 16

B Battery Indicator, 19 servicing, 35–38 Battery Switch, 18 Buckets, operating techniques, 28–30

H Hand Brake. See Parking Brake Highway Travel, 30 Horn Button, 19 Hourmeter, 19 Hydraulic Fluid Overheat, Indicator, 19 Hydraulic Oil, check level, 35 Hydraulic Pump, servicing, 34 Hydraulic Resevoir, 32 Hydraulic Valves, servicing, 34 Hydrostatic Drive, troubleshooting, 40–43

C Capacities, 3 Checklists, delivery, 5–7 Controls & Safety Equipment, 16–21 Cylinder Lock. See Cylinders Cylinders Lift Cylinder Lock, 20 servicing, 34 troubleshooting, 41

I Identification numbers, 2, 5 Ignition Switch. See Keyswitch Indicator Lights, 19 Instrument & Control Panel, contents, 19 Introduction, 2

D Dealer, Services, 34 Decal Locations, 42–43 Differential Lock, operation, 17 Directional Control Pedal, operation, 16 Drive Chains lubrication, 32 Dumping, with a Bucket, 29

J Jump–starting battery, 36

L Leveling, with a Bucket, 30 Lift/Tilt, operation, 17 Linkage Ball Joints, tighten, 37 Loader moving, 23 operation, 27 practice running the, 23 starting operation, 22 stopping, 22 Loader tipping load chart, 27 Lubrication, 32–33

E Electrical System, troubleshooting, 39 Engine adjustments, 31 Oil Pressure Indicator, 19 starting, 22 troubleshooting, 39–41 Engine lubrication, 32 Engine Oil, check level, 35 Engine temperature gauge, 19

908180/AP0601

46

Printed in U.S.A.

Index (Cont.)

M

S Safety, 8 Scraping, with a Bucket, 29 Seat, Operator’s, positioning, 18 Service, 34–38 Shields, 16 Specifications, 3 Starter Switch. See Keyswitch

Maintenance, 44–45 MANDATORY SAFETY SHUTDOWN PROCEDURE, 8 Material Density, 25 Moving materials with a bucket, 25

O

T

Operation, 22–30 Operator, required services, 34–38 Operator’s Manual, storing, 2

Tables Material Densities, 26 Tire Inflation Presures, 37 Telescopic Boom Control, operation, 17 Throttle, operation, 16 Tie-downs, for transporting Loader, 30 Tires, servicing, 37 Torque Specification Chart, Inside Rear Cover Transporting Loader, 30 Troubleshooting, 39–41

P Pallet forks, 30 Parking Brake, operation, 17, 24 Pump Control, operation, 17

R Radiator, check coolant, 35 Radiator Hoses & Clamps, check, 37 Rollover protective structure, 18 ROPS. See Overhead Guard

Printed in U.S.A.

W Warranty, Inside Front Cover Wheel Lug Bolts, tighten, 37

47

908180/AP0601

Notes

908180/AP0601

48

Printed in U.S.A.

TORQUE SPECIFICATIONS NOTE:

Use these torque values when tightening GEHL hardware (excluding: Locknuts and Self-tapping, Thread Forming and Sheet Metal Screws) unless specified otherwise.

All torque values are in Lb-Ft except those marked with an * which are Lb-In (For metric torque value Nm, multiply Lb-Ft value by 1.355 or Lb-In value by 0.113)

Unified National Thread

Grade 2

Grade 5

Dry

Lubed

Dry

Lubed

Dry

Lubed

8-32 8-36

19* 20*

14* 15*

30* 31*

22* 23*

41* 43*

31* 32*

10-24 10-32

27* 31*

21* 23*

43* 49*

32* 36*

60* 68*

45* 51*

1/4-20 1/4-28

66* 76*

50* 56*

9 10

75* 86*

12 14

9 10

5/16-18 5/16-24

11 12

9

17 19

13 14

25

18 20

3/8-16 3/8-24

20 23

15 17

30 35

23 25

45 50

35

7/16-14 7/16-20

32 36

24 27

50 55

35 40

70 80

55 60

1/2-13 1/2-20

50 55

35 40

75 90

55 65

110 120

80 90

9/16-12 9/16-18

70 80

55 60

110 120

80 90

150 170

110 130

5/8-11 5/8-18

100 110

75 85

150 180

110 130

220 240

170 180

3/4-10 3/4-16

175 200

130 150

260 300

200 220

380 420

280 320

7/8-9 7/8-14

170 180

125 140

430 470

320 360

600 660

460 500

1-8 1-14

250 270

190 210

640 710

480 530

900 1000

680 740

Metric Course Thread

Grade 8.8

8.8

Grade 10.9

Grade 8

10.9

Grade 12.9

12.9

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

WARNING THIS OPERATOR’S MANUAL IS PROVIDED FOR OPERATOR USE DO NOT REMOVE FROM THIS MACHINE DO NOT START, OPERATE OR WORK ON THIS MACHINE UNTIL YOU HAVE CAREFULLY READ AND THOROUGHLY UNDERSTOOD THE CONTENTS OF THE OPERATOR’S MANUAL. FAILURE TO FOLLOW SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY TO THE OPERATOR OR BYSTANDERS, POOR OPERATION, AND COSTLY BREAKDOWN. IF YOU HAVE ANY QUESTIONS ON PROPER OPERATION, ADJUSTMENT OR MAINTENANCE OF THIS MACHINE, CONTACT YOUR DEALER OR THE GEHL COMPANY SERVICE DEPARTMENT BEFORE STARTING OR CONTINUING OPERATION. California Proposition 65 Warnings: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer and birth defects and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects and other reproductive harm. Wash hands after handling battery.



Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179, U.S.A.

908180/AP0601

2001 GEHL Company. All rights reserved.

Printed in U.S.A.