Gehl All Wheel Steer Loader 680 Operators Manual - PDF DOWNLOAD

®

All-Wheel Steer Loader Beginning Serial Number: 343010001

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

Operator’s Manual

Model 680

Form No. 918121 Revision C August 2007

GEHL COMPANY WARRANTY GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl 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 WARRANTY SERVICE 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. ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL BE DEEMED DELETED FROM THIS WARRANTY; ALL OTHER TERMS WILL CONTINUE TO APPLY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW.

GEHL WARRANTY 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, batteries, trade accessories and engines.

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

5. Repairs or adjustments caused by: improper use; failure to follow 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.

204937/AP0407

Table of contents

Table of contents I

Introduction ....................................................................................................................... 6 General information .................................................................................................... 6 Identification of warnings and hazards ....................................................................... 9 Machine overview ...................................................................................................... 10 Overview.................................................................................................................... 11 Fields of application, attachments ............................................................................. 12 Serial number plate locations ................................................................................... 13 Safety instructions ........................................................................................................... 18 General safety rules .................................................................................................. 20 Additional safety equipment ...................................................................................... 22 Safety reminders ....................................................................................................... 22 Transporting .............................................................................................................. 23 Loading and transporting the machine ..................................................................... 25 Maintenance Safety .................................................................................................. 27 Safety instructions for specific hazards ..................................................................... 30 Operation ........................................................................................................................ 36 Cab: overview ............................................................................................................ 37 Instrument panel, multifunctional lever and drive lever: overview ............................. 39 Indicators and warning lights: overview ................................................................... 41 Getting Started........................................................................................................... 44 Driving the machine ................................................................................................... 53 Working with the machine ......................................................................................... 80 Working with the pallet forks ..................................................................................... 94 Troubleshooting ............................................................................................................ 100 Engine trouble ......................................................................................................... 100 Maintenance ................................................................................................................. 102 Introduction ............................................................................................................. 102 Fuel system ............................................................................................................ 102 Engine lubrication system........................................................................................ 104 Engine and hydraulics cooling system..................................................................... 106 Air filter .................................................................................................................... 108 V-belt ...................................................................................................................... 109 Hydraulic system ..................................................................................................... 111 Lubrication points .................................................................................................... 116 Maintenance of attachments ................................................................................... 117 Maintenance of the brake system............................................................................ 118 Tire care................................................................................................................... 119 Heating .................................................................................................................... 121 Electrical system...................................................................................................... 122 General maintenance work...................................................................................... 124 Fluids and lubricants ............................................................................................... 127 Maintenance schedule Model 680 (overview) ........................................................ 128 Maintenance log ..................................................................................................... 132 Maintenance decal .................................................................................................. 136 Specifications ................................................................................................................ 138 Frame ..................................................................................................................... 138 Engine ..................................................................................................................... 138 Power train............................................................................................................... 139 Axles........................................................................................................................ 140 Brakes ..................................................................................................................... 140 Steering ................................................................................................................... 140 Work hydraulics ...................................................................................................... 141 Pilot control ............................................................................................................. 141 Additional control circuit + high-flow control circuit (option) ..................................... 141

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Table of contents Loader unit .............................................................................................................. 142 Electrical system ...................................................................................................... 142 Tires ....................................................................................................................... 146 Weights .................................................................................................................... 146 Sound levels .......................................................................................................... 146 Vibration ................................................................................................................. 147 Hardware torques .................................................................................................... 147 Dimensions model 680 ........................................................................................... 148

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918121/CP0807

Introduction

Introduction

Introduction General information Your decision to purchase this piece of Gehl equipment was a good one. We are sure that your decision was carefully considered and that you are looking forward to many years of reliable performance from this machine.

Gehl Company has invested much time and effort in developing its lines of equipment. The equipment you have purchased is built with a great deal of pride, and designed to provide long life, efficient operation, durability and dependability.

Modern machinery has become more sophisticated and, with that in mind, Gehl Company asks that you read and COMPLETELY understand the contents of this manual and become familiar with your new machine, BEFORE attempting to operate it.

This manual was developed specifically for the machine you have purchased. The information within is for your assistance in preparing, adjusting, maintaining and servicing your machine. More importantly, this manual provides an operating plan for safe and proper use of your machine. Major points of safe operation are detailed in the SAFETY chapter of this manual – see Safety instructions on page 18. Refer to the Table of Contents for an outline (by chapters) of this manual. Use the Index, located at the back of this manual, for specific chapter and topic/page number references.

If this machine is resold, Gehl Company recommends that this manual be given to the new owner.

If this machine was purchased "used," or if the owner's address has changed, please provide your Gehl dealer or Gehl Company with the owner's name and current address, along with the machine model and serial number. This will allow the registered owner 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.

“Right” and “left” are determined from the position of sitting in the operator’s seat, facing forward.

Gehl Company reserves the right to make changes or improvements in the design or construction of any part without incurring the obligation to install such changes on any unit previously delivered.

Throughout this manual information is provided that is introduced by the word NOTE or IMPORTANT. Be sure to read carefully and comply with the message or directive given.

Following this information will improve your operating or maintenance efficiency, help you to avoid costly breakdowns or unnecessary damage and extend your machine's life.

Operational safety and readiness of the machine depend partially on maintenance and service of the machine. This is why regular maintenance and service work is absolutely necessary. Extensive maintenance and repair work must always be carried out by a qualified technician with appropriate training. Insist on using Gehl original service parts when carrying out maintenance and repair work. This ensures operational safety and readiness of your machine, and maintains its value.

Our wide dealership network stands ready to provide any assistance required, including genuine Gehl service parts. All parts should be obtained from or ordered through your Gehl dealer. Give complete information about the part as well as the model number and serial number of your machine. Record numbers, in the spaces provided, as a handy record for quick reference.

Purchased from: ___________________________________ Date of Purchase: __________________________________ Model No.: _______________________________________ Serial No.: ________________________________________

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Introduction

Serial number The serial number is stamped onto the cab bearing A (on the right as seen in driving direction, behind the cab door lining), and is also located on the type decal.

A

The type decal is located on the frame on the right, next to the loader unit bulkhead (above the front axle).

Type decal information Example: Model 580 Type decal: location

Made in Germany

00 435 12 21

Fig. 1:

Fhzg-Typ Model ModŁle Typ / Ausf.

Version Version Fg.-Nr. Serial no.

No. de sØrie Baujahr Model year AnnØe fabr.

Zul. Achslast vorn Front GAWR [ kg ] PNBE AV Zul. Achslast hinten Rear GAWR [ kg ] PNBE AR Zul. Ges. Gew. GWR [ kg ] PTAC Leistung Output [ kW ] Performance

Type decal

580

Version:

343 00

Serial no.:

343 01 0001

Model year:

2005

Front gross axle weight rating: 9370 lbs. (4250 kg) Rear gross axle weight rating: 9370 lbs. (4250 kg) 30300b0010.eps

Fig. 2:

Machine model:

Gross weight rating:

15,432 lbs. (7000 kg)

Output:

75 hp (56 kW)

Other information – see Specifications on page 138.

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

Fig. 3:

Cab type decal

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918121/CP0807

Introduction Designated uses and exemption from liability • The machine is intended for: • Moving earth, gravel, coarse gravel or ballast and rubble.

• Working with the attachments mentioned – see Fields of application, attachments on page 9.

• Every other use and attachment is not designated for this machine. Gehl will not be liable for damage resulting from any other use or attachment. The user alone will bear the risk.

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

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

• Gehl is not liable for personal injury and/or damage to property caused by failure to properly: • Operate.

• Transport.

• Service and perform maintenance.

• Repair the machine (in accordance with the Operator’s Manual).

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

• The machine may not be used for transport jobs on public roads.

• In applications with lifting gear, only use the machine according to its designated use.

Abbreviations/symbols • This symbol stands for a list.

• Subdivision within lists or an activity. Follow the steps in the recommended sequence.

☞ This symbol requires you to carry out the activity described. ➥ This symbol marks the passages in the text describing the effects or results of an activity.

n. s. = not shown.

“Option” = optional equipment. Stated whenever controls or other components of the machine are installed as an option.

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

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918121/CP0807

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

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

☞ Measures for avoiding the hazard.

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

☞ Measures for avoiding damage to the machine.

NOTE: Contains instructions to help use the machine more efficiently.

Environment!

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

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918121/CP0807

Introduction Machine overview

1

Eye hook1 for cab

1

2

Rearview mirror

2

3

Handle

4

Headlight with turn indicator

3

5

Tilt cylinder

4

6

Front eye hook for tieing down the machine

5

7

Loader unit

8

Access

9

Door handle

6

7

10

8

10

9

Rear eye hook for tieing down the machine

11 Bracket for working light 12 11

12

Bracket for rotating beacon (option)

13 Engine cover lock 14 Backup warning system 15 Reflectors 16 Tow away facility 17 Hydraulic connections (option)

13

18 Brake, rear and turn indicator lights 19 Door arrester

14 1.

15

Fig. 4:

16

17

10

18

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

19

Machine outside views

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918121/CP0807

Introduction Overview The Model 680 is a versatile and powerful helper for moving earth, gravel and debris on construction sites and elsewhere – see Fields of application, attachments on page 12.

Equip the machine with the respective safety devices when using it as a lifting accessory – see Applications with lifting gear on page 21.

The main components of the machine are:

• ROPS certified cab, enclosed version (standard).

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

• Oil-cooled Deutz four-cylinder in-line diesel engine, 75 hp (56 kW) at 2300 rpm.

• Exhaust emissions according to EC directive 97/68/EC. • Sturdy steel sheet frame; rubber-mounted engine.

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

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

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

• Service brake (hydraulic multi-disc brake), mechanical disc-type parking brake.

Hydrostatic drive

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

Work hydraulics and hydrostatic fourwheel steering

The diesel engine also drives the joint gear pump for work hydraulics and hydrostatic fourwheel steering. The oil flow of this pump depends on the diesel engine speeds only.

When the machine is in operation, the entire diesel engine output can be transmitted to the gear pump for work hydraulics and steering by using the inching valve. This valve responds as soon as the service brake is used, reducing or cutting off power input of the drive. Therefore, full engine output is available for the loader unit by pressing the accelerator pedal and the brake pedal at the same time.

Cooling system

A combined engine/hydraulic oil cooler (for the diesel engine and the hydraulic oil) is located at the rear of the machine.

The indicators on the instrument panel of the machine allow you to constantly monitor the engine and hydraulic oil temperatures, and the coolant temperature and level.

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918121/CP0807

Introduction Fields of application, attachments The attachments determine how the machine is used.

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

☞ See Use: attachment.

Use: attachment

Possible attachment and material densities.

Description of attachment

Model

Stock number

Use

Standard bucket – normal material

680

810139

Loosening, picking up, transporting and loading loose or solid material (material density ≤ p=1.35 t/yd.³ [≤ p=1.8 t/m.³])

Standard bucket – lightweight material1

680

810137

Picking up, transporting and loading lightweight material (material density ≤ p=0.98 t/yd.³ [≤ p=1.3 t/m.³])

Pallet forks

680

810140

Picking up and transporting pallets

1.

Only in connection with additional lights when driving on public roads

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918121/CP0807

Introduction Serial number plate locations Serial number The serial number is stamped in the cab bearing A (on the right as seen in driving direction, behind the cab door lining). It is also located on the type decal.

A

The type decal is located on the machine frame on the right, next to the loader unit bulkhead (on the right above the front axle).

Type decal information Example: Model 580 Type decal: location

Made in Germany

00 435 12 21

Fig. 5:

Fhzg-Typ Model ModŁle Typ / Ausf.

Version Version Fg.-Nr. Serial no.

No. de sØrie Baujahr Model year AnnØe fabr.

Zul. Achslast vorn Front GAWR [ kg ] PNBE AV Zul. Achslast hinten Rear GAWR [ kg ] PNBE AR Zul. Ges. Gew. GWR [ kg ] PTAC Leistung Output [ kW ] Performance

Type decal

580

Version:

343 00

Serial no.:

343 01 0001

Model year:

2005

Front gross axle weight rating: 9370 lbs. (4250 kg) Rear gross axle weight rating: 9370 lbs. (4250 kg) 30300b0010.eps

Fig. 6:

Machine model:

Gross weight rating:

15,432 lbs. (7000 kg)

Output:

75 hp (56 kW)

Other information – see Specifications on page 138.

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

Fig. 7:

Cab type decal

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

Example:

Fig. 8:

Deutz BF4M2011

Diesel engine number

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

Fig. 9:

Hydraulic pump: type decal

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

Fig. 10: Hydraulic motor: type decal

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

Fig. 11: Rear axle and gearbox: type decal

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

Fig. 12: Front axle: type decal

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918121/CP0807

Introduction Notes:

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918121/CP0807

Introduction Safety decals The following section explains signs and symbols that may not be easily understood.

IMPORTANT! Safety decals must be replaced if they become unreadable.

Meaning The eye hooks on the cab are for removing the cab only and may not be used for cranelifting the machine – see Moving the machine with a crane on page 24.

Location Cab roof (4x).

Fig. 13: Eye hook decal

Meaning Points for tieing down the machine.

The eye hooks are used for tieing down the machine during loading and transport – see Tieing down the machine on page 26.

Location Fig. 14:

On the left and right of the machine frame above the front axle attachment, and on the towing facility at the rear.

Decal for points used for tieing down the machine

Meaning Sound levels produced by the machine.

LWA = sound power level.

XX

Other information – see Sound levels on page 146.

Location

Fig. 15: Decal: sound levels

Rear window.

Meaning General indication of danger.

This decal warns persons standing or working near the machine of existing hazards within the area of increased danger around the machine.

Gefahr2.ai

Location Front left and right of machine frame, and at rear of machine.

Fig. 16: Danger decal

Meaning The CE mark means that the machine meets the requirements of the Machinery Directive and that the conformity procedure has been carried out. The machine meets all the health and safety requirements of the Machinery Directive. ce.ai Fig. 17: CE mark

Printed in U.S.A.

Location On the rear window.

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918121/CP0807

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

DO NOT touch any moving or turning parts.

Location On the engine cover of the machine.

Fig. 18: Prohibitory decal

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918121/CP0807

Safety instructions

Safety instructions

Safety instructions Mandatory safety shutdown procedure

Before operating this equipment, read and study the following safety information. In addition, be sure that every individual who operates or works with this equipment is familiar with these safety precautions.

Before leaving the machine:

• Lower the working equipment to the ground and support it securely.

• Reduce throttle and turn off the engine.

• Lock out controls by raising right-hand control console.

• Remove the ignition key and take it with you.

Unauthorized modifications

Any machine modification made without authorization from Gehl could create a safety hazard, for which the machine owner would be responsible.

For safety reasons, use only genuine Gehl parts. For example, using incorrect fasteners could lead to a condition in which the safety of critical assemblies is dangerously compromised.

Attachment precautions

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

Operational safety

Control the machine cautiously and gradually until you are fully familiar with all the controls and handling.

Avoid high-voltage lines. Serious injury or death can result from contact or proximity to high-voltage electric lines. The bucket or boom does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to keep away from power lines not clearly visible to the operator.

Depending upon the voltage in the line and atmospheric conditions, strong current shocks can occur if the boom or bucket is closer than 10’ (3 m) to the power line. Very high voltage and rainy weather can further increase the safe operating distance.

Before starting any type of operation near power lines (either above-ground or buried cable-type), always contact the power utility and establish a safety plan with them.

Before starting to dig, contact authorities. Contact Diggers Hotline One-Call Information at 1-888-258-0808.

Below-ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know what is underneath the work site before starting to dig.

Be aware of height obstacles. Any object in the vicinity of the boom could represent a potential hazard, or cause the operator to react suddenly and cause an accident. Use a spotter or signal person when working near bridges, phone lines, work site scaffolds, or other obstructions.

Use care on loose ground. Carrying heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side-load conditions and possible tipover and injury.

Traveling with a suspended load or an unbalanced load can also be hazardous.

If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen ground. Stay away from ditches, overhangs and other weak support surfaces.

Never rely on jacks or other inadequate supports when maintenance work is being done.

Use solid support blocking.

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918121/CP0807

Safety instructions Overhangs are hazardous. Digging under an overhang is dangerous. Know the height and reach limits of the attachment and plan ahead while working. Avoid creating dangerous situations caused by moving around the work site while working. Move to another digging area before large overhangs are formed. Working around deep pits or along high walls or trenches may require support, especially after heavy rainfalls or during spring thaws. Park the machine away from overhangs.

Sloping terrain requires caution. Dig evenly around the work site whenever possible, trying to gradually level any existing slope. If it is not possible to level the area or avoid working on a slope, reduce the cycling rate and size of the load.

On sloping surfaces, use caution when positioning the machine prior to starting a work cycle. Stay alert for instability situations. Lifting the bucket too high while the boom is turned uphill can also be hazardous.

Stay alert for people moving through the work area. When loading a truck you should always know where the driver is.

Avoid loading over the cab of a truck, even if the driver is in a safe spot, because someone else could have gone inside.

Slow down the work cycle and use slower travel speeds in congested or populated areas.

Use commonly understood signals so that other members of the work crew can warn the operator to slow or halt work in a potentially hazardous situation.

Operate ONLY while seated at operator’s station. Never reach in through a window to work a control. Do not try to operate the machine unless you’re in the operator’s position, seated at the controls. Stay alert and focused on your work at all times.

Use a signal person if you cannot see the entire work area clearly.

Replace damaged safety decals and lost or damaged Operator’s Manuals.

Do not let anyone operate the machine unless they have been fully trained in safety and in operation of the machine.

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

Before starting the engine

Do a safety check:

• Walk around the machine before getting in the cab. Look for leaking fluids, loose fasteners, misaligned assemblies and other possible equipment hazards.

• The operator’s compartment, steps, and hand grips must be free of oil, dirt, ice and unsecured objects.

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

• Always keep the windshield and windows clean. Poor visibility can cause accidents.

• All equipment covers and safety guards must be in place while the machine is being operated, to protect against injury.

• Look around the work site area for potential hazards, and for people or property that could be at risk while operation is in progress.

• NEVER start the engine if there is any indication that maintenance or service work is in progress, or if a warning tag is attached to controls in the cab.

• Check gauges and displays for normal operation prior to and after starting the engine.

Listen for unusual sounds and remain alert for other potentially hazardous conditions.

• Never use ether starting aids. Glow plugs are used for cold weather starting. Glow plugs can cause ether or other starting fluid to detonate, causing injury.

• Before starting or moving the machine, warn any personnel in the area.

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918121/CP0807

Safety instructions General safety rules Only trained and authorized personnel, with a full awareness of safe procedures, may be allowed to operate or perform maintenance or service on the machine.

All personnel at the work site should be aware of assigned individual responsibilities. Communication and hand signals used should be understood by everyone.

Terrain and soil conditions at the job site, approaching traffic, weather-related hazards and any above or below ground obstacles and hazards should be observed and monitored by all work crew members.

Unless necessary for servicing the engine, the engine hood must not be opened while the engine is running.

Engine exhaust gases can cause unconsciousness and fatalities. Ensure adequate ventilation before starting the engine in an enclosed area.

Operators should also be aware of any open windows, doors or ductwork into which exhaust gases may be carried, exposing others to danger.

Use a signal person in high traffic areas and whenever the operator’s view is not clear, such as when traveling in reverse.

Make sure that no one comes inside the working area of the machine.

Anyone standing near the machine is at risk of being caught between moving parts of the machine.

Never allow anyone to ride on any part of the machine or attachment, including any part of the boom or operator’s cab.

Fire hazards

The machine has several components that operate at high temperature under normal operating conditions, primarily the engine and exhaust systems. Also, the electrical system, if not properly maintained or if damaged, can arc or produce sparks. These conditions make it extremely important to avoid circumstances where explosive dust or gases can be ignited by arcs, sparks or heat.

The machine must be cleaned on a regular basis to avoid the buildup of flammable debris such as leaves, straw, etc. Accumulated debris, particularly in the engine compartment, poses a fire hazard.

Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well ventilated area.

The machine must be parked with controls, lights and switches turned off. The engine must be turned off before refueling or service checks are performed.

Static electricity can produce dangerous sparks at the fuel-filling nozzle. In very cold, dry weather or other conditions that could produce static discharge, keep the tip of the fuel nozzle in constant contact with the neck of the fuel-filling nozzle, to provide a ground.

Make sure that the static line is connected from the machine to the service truck before fueling begins.

Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured.

Jump-starting or charging battery

Turn off all electrical equipment before connecting leads to the battery, including electrical switches on the battery charger or jump-starting equipment.

When jump-starting from another machine, do not allow the machines to touch. Wear safety glasses or goggles while battery connections are made.

DANGER! Explosion Hazard – Electrical spark can cause battery to explode.

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

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918121/CP0807

Safety instructions Disconnect the negative cable first when removing the jumper cables. For instructions – see Battery on page 117.

Travel precautions

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

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

Travel with the bucket or attachment as low as possible [8”-12” (200 mm-300 mm)] to the ground.

Never travel over obstacles or slopes that cause the machine to tilt severely. Travel around any slope or obstacle that would cause a tilt greater than 10º.

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

In cold weather, avoid sudden travel movements and stay away from even very slight slopes. The machine can slide sideways on icy slopes.

Snow accumulation can hide potential hazards. Use care while operating and while using the machine to clear snow.

Parking the machine

When shutting down the machine for the day, plan ahead so that the machine will be on a firm, level surface away from traffic and away from high walls, cliff edges and any area of potential water accumulation or runoff. If parking on an incline is unavoidable, block the wheels to prevent movement. Lower the bucket to the ground. There should be no possibility of unintended or accidental machine movement.

After the machine has been parked properly, shut down the engine and cycle all controls to release any remaining hydraulic system pressure. Be sure all switches and operating controls are in the OFF position and the right-hand console is raised, locking out the hydraulic functions.

Applications with lifting gear

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

• The machine may only be used with lifting gear if the necessary safety devices are in place and functional.

• The load must be secured to prevent it from falling or slipping.

• Persons guiding the load or securing it must stay in visual contact with the operator.

• The operator must guide the load to the ground as soon as possible and avoid any oscillating or swinging movements.

• The machine may be moved with a raised load only if the path of the machine is as level as possible.

• Persons attaching or securing loads may only approach the boom from the side, after the operator has given permission. The operator may only give permission after the machine is at a standstill and the attachment no longer moves.

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

• Always wear protective gloves when working with lifting attachments.

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918121/CP0807

Safety instructions Additional safety equipment WARNING! Severe operation may require use of additional safety equipment.

Work in mines, tunnels, deep pits or on loose or wet surfaces could produce the hazard of falling rock, roll over or falling objects.

Any operator protective system installed on the machine must comply with applicable safety standards and carry appropriate decaling and rating information.

Never attempt to alter or modify the protective structure, by drilling holes, welding or relocating fasteners. Any serious impact or damage to the system requires a complete integrity re-evaluation, and the replacement of the system may be necessary.

Install additional safety equipment if conditions require

When working with a hydraulic breaker, a front guard over the windshield may be required.

Laminated glass or polycarbonate protection for the front, side or rear windows may also be recommended depending upon particular work conditions.

Contact your Gehl dealer for available safety guards and/or recommendations if there is any risk of being hit by objects that could strike the operator’s cab.

Keep a fire extinguisher at hand

It is recommended that a 5 lb. (2.27 kg) or larger, multi-purpose “A/B/C” fire extinguisher be mounted in the cab. Check the fire extinguisher periodically and be sure that work site crew members are trained in its use – see Fire extinguisher (option) on page 13.

Seat belt must be used at all times

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

Safety reminders Exposure to crystalline silica

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

Maintain safety equipment in good condition

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

Safety-critical parts must be replaced periodically

Replace the following potentially fire-related components as soon as they begin to show signs of deterioration: Fuel system flexible hoses, fuel tank overflow drain hose and the fuel filler cap.

Hydraulic system hoses, especially the pump outlet lines.

Keep mounting brackets, hose, and cable routing ties tight. Hose routings should have gradual bends.

High pressure hydraulic lines can store energy

Exposed hydraulic hoses on the boom could react with explosive force if struck by a falling rock, overhead obstacle or other job site hazard. Extra safety guards may be required.

NEVER allow hoses to be hit, bent or interfered with during operation.

Operator’s cab should be kept clean

Cleaning off accumulations of grease and dirt helps extend equipment service life. Cleaning also provides an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems result.

Printed in U.S.A.

22

918121/CP0807

Safety instructions Wear eye protection and safety clothing

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

Breathing masks, ear protection may be required

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

Transporting Obey state and local over-the-road regulations. Check state and local restrictions regarding weight, width and length of a load. The hauling machine, trailer and load must all be in compliance with local regulations.

• Only tow, load, and transport the machine in accordance with the Operator’s Manual.

• Safely secure the machine to the transport vehicle. Use suitable mounting points and load-securing devices.

Towing the machine

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

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

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

WARNING! Turning the steering wheel requires greater effort if the diesel engine is off.

Remember this when towing the machine.

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

IMPORTANT! The hydrostatic power train can be damaged when towing the machine.

☞ Turn off the engine. ☞ Short-circuit the hydraulic circuit before towing (see below). ☞ Do not tow the machine for more than 328’ (100 m) and do not tow it faster than 2 – 3 mph (3 – 4 km/h).

Follow these procedures to tow the machine:

D

A C

B

☞ Apply the parking brake – see Parking the machine on page 21.

☞ Turn off the engine. ☞ Attach an adequately sized tow bar to the towing facilities. ☞ Switch over pressure relief valves B on the hydraulic pump A. To do this: • Loosen hexagon locknuts C on both pressure relief valves B. • Screw in hexagon socket screws D on both pressure relief valves B until they are flush with hexagon locknuts C.

Fig. 19: Hydraulic pump when towing the machine

• Secure hexagon socket screws D on both pressure relief valves B with locknuts C.

☞ Release the parking brake. ☞ Run the engine at idling speed when towing the machine.

Follow these procedures before taking the machine back into service:

☞ Reverse the changeover of the pressure relief valves.

• Unscrew hexagon socket screws D on both pressure relief valves B to the limit.

• Secure hexagon locknuts C on both pressure relief valves B. Printed in U.S.A.

23

918121/CP0807

Safety instructions Moving the machine with a crane Safety instructions

• The crane and the lifting gear must have sufficient capacity – see Specifications on page 138.

• Crane handling requires lifting gear of four equal lengths.

• Secure the machine against unintentional movement.

Crane handling WARNING! Incorrect crane handling of the machine –

Accident risk.

34101b330_01.iso

☞ Do not allow anyone to stay in the machine. ☞ The person giving the instructions to the crane operator must be within sight or sound of the crane operator.

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

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

– see Use: attachment on page 12.

Fig. 20: Crane handling

☞ Avoid suspended loads. ☞ Read the safety instructions

– see Safety instructions on page 44.

☞ Load the machine as follows: • Install and safely lock the standard bucket – see Re-installing attachments on page 84.

• Empty the standard bucket.

• Set the drive to neutral – see Forward-reverse control [76] on page 53.

• Tilt in the standard bucket and lower it to the transport position – see Special instructions for public roads on page 50.

• Turn off the engine.

• Apply the parking brake – see Preventing the machine from rolling away on page 55.

• Remove the ignition key.

• Do not allow anyone to stay in the cab.

• Close the doors and the engine cover.

• Fasten the loader at the four points provided by using proper lifting gear – see Machine overview on page 10.

WARNING! Do not use the cab eye hooks for loading the machine.

• Carefully raise the machine.

Printed in U.S.A.

24

918121/CP0807

Safety instructions Loading and transporting the machine • The transport vehicle must support the height and weight of the machine

Safety instructions

– see Specifications on page 138.

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

• Secure the machine to prevent unintentional movement.

Loading the machine DANGER! The machine must be loaded and transported properly –

Accident risk. ☞ – see Safety instructions on page 18. ☞ Follow these instructions to load the machine onto the transport vehicle: • Secure the transport vehicle with chocks to prevent it from rolling.

30˚

• Place the access ramps at the smallest possible angle.

30864brampe.eps

Fig. 21: Access ramps

IMPORTANT! Do not exceed an angle of 30°.

• Use access ramps with an antiskid surface only.

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

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

• Start the engine of the machine.

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

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

• Set the drive to neutral – see Forward-reverse control [76] on page 53.

• Lower the bucket onto the loading area.

• Turn off the engine.

• Apply the parking brake – see Preventing the machine from rolling away on page 55.

• Remove the ignition key.

• DO NOT allow anyone to stay in the cab.

• Close the doors and the engine cover.

Printed in U.S.A.

25

918121/CP0807

Safety instructions Tieing down the machine DANGER! The machine must be loaded and transported properly –

Accident risk. ☞ – see Safety instructions on page 44.

34001b330_02.eps

• Be sure that the authorized maximum height is not exceeded – see Specifications on page 138.

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

• Firmly tie the machine onto the platform by using the eye hooks and belts or chains – see Machine overview on page 10.

34001b330_17.eps Fig. 22: Tieing down the machine

Attachments

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

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

• Coupling attachments requires special care.

• Before fitting attachments to the machine, secure the control lever of the hydraulic valve.

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

• Fit the attachments with the required devices only.

• Before uncoupling or coupling hydraulic lines (hydraulic quick couplers): • Turn off the engine.

• Move the control lever(s) of the hydraulic valve back and forth two times to relieve the hydraulic oil pressure in the hydraulic system.

• Secure the attachments against unintentional movement.

• Only operate the machine if all brake, light, hydraulic connections, and protective accessories are installed and functional.

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

• Mount the attachments only after stopping the engine.

• When driving or working with machines that have a quickhitch facility, make sure that the attachment is safely locked in the quickhitch facility. The lock pin must be visible on both sides of the holes on the attachment. Check before starting work.

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

Printed in U.S.A.

26

918121/CP0807

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

☞ Battery electrolyte and explosive gases can be lethal • Flush eyes with water for 10-15 minutes if battery acid is splashed on the face.

Anyone who swallows acid must have immediate medical aid. Call the Poison Control Center listing in the telephone directory.

• Sparks can set off explosive battery gas from incidental contact or static discharge.

Turn off all switches and the engine when working on batteries. Keep battery terminals tight. Contact between a loose terminal and post can create an explosive spark.

☞ Disconnect batteries for electrical service and before electrical welding • Remove cable to negative terminal first when disconnecting a battery. Connect positive terminal cable first when installing a battery.

☞ Use warning tag/control lockout procedures during service • Alert others that service or maintenance is being performed and tag operator’s cab controls — and other machine areas if required — with a warning notice.

☞ Do not run the engine if repairs or work is being performed alone • You should always have at least two people working together if the engine must be run during service.

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

☞ Do not work on hot engines, cooling or hydraulic systems • Wait for the engine to cool after operation. Park the machine on a firm, level surface and lower all equipment before shutting down and switching off controls. When engine lube oil, gearbox lubricant or other fluids require changing, wait for fluid temperatures to decrease to a moderate level before removing drain plugs.

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

☞ Cool-down is required prior to radiator or hydraulic reservoir checks • Stop the engine and allow it to cool before performing service on the engine radiator or hydraulic reservoir. Both assemblies have pressure vents at the filler cap for venting pressure. LOOSEN CAPS SLOWLY. Vent the pressure before removing the filler caps.

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

LOOSEN CAP SLOWLY prior to removal.

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

☞ Pressurized hydraulic oil leaks can be hazardous • Fluid leaks from hydraulic hoses or pressurized components can be difficult to see, but pressurized oil can have enough force to pierce the skin and cause serious injury.

Printed in U.S.A.

27

918121/CP0807

Safety instructions • Always use a piece of wood or cardboard to check for suspected hydraulic leaks.

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

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

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

☞ Dispose of all petroleum-based oils and fluids properly • Used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities. Never drain any petroleum-based product on the ground or dispose of used oil in municipal waste collection containers, or in metropolitan sewer systems or landfills. Check state and local regulations for other requirements.

Printed in U.S.A.

28

918121/CP0807

Safety instructions Safety instructions for maintenance • Remove the ignition key before performing any service, maintenance, or repair work.

• If you must have the engine running while performing service, maintenance, or repair work: • Only work in groups of two.

• Both persons must maintain visual contact with each other.

• Follow the safety instructions in the Operator’s Manual.

• Keep a safe distance away from all rotating and moving parts (e.g., fan blades, V-belt drives, etc.).

• Carry out service, maintenance and repair work only if the: • Machine is positioned on firm and level ground.

• Lever for selecting the travel direction is in neutral.

• Parking brake is applied.

• Hydraulic attachments and working equipment are lowered to the ground.

• Machine is secured against unintentional movement.

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

CAUTION! Never use machine parts, attachments, or superstructures as a climbing aid.

Wear a safety harness when completing maintenance work at greater heights.

Keep all handles, steps, handrails, platforms, landings, and ladders free from dirt, snow and ice.

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

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

• Tighten any loose connections.

• Avoid contact with hot parts, such as the engine block or the exhaust system during the operation of the machine and for some time afterward – risk of burns.

• Retainer pins can fly out or splinter when struck with force – risk of personal injury.

• Do not use ether starting aids. This especially applies to those cases in which a heater (intake-air preheating) is used at the same time – risk of explosions.

Service and maintenance work on ROPS superstructures (ROPS bar)

Printed in U.S.A.

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

29

918121/CP0807

Safety instructions Safety instructions for specific hazards Electric energy

• Only use original fuses with the specified current rating. Turn off the machine immediately if there are any problems with the electrical system.

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

DANGER! If your machine comes into contact with a live wire: • Do not leave the machine.

• Drive the machine out of the area of danger.

• Warn others against approaching and touching the machine.

• Have the live wire de-energized.

• Do not leave the machine until the damaged line has been safely deenergized.

• Work on the electrical system may only be done by a trained technician.

• Inspect and check the electrical equipment of the machine at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

• Follow the operating voltage of the machine/attachments.

• Always remove the ground strap from the battery when working on the electrical system or carrying out welding work.

• Jump-starting with a battery cable can be hazardous if carried out improperly. Follow the safety instructions regarding the battery.

Gas, dust, steam, smoke

• Only operate the machine in adequately ventilated premises.

• Carry out welding, flame-cutting and grinding work on the machine only if this has been authorized. Before carrying out welding, flame-cutting and grinding work, clean the machine and its surroundings from dust and other flammable substances.

Hydraulic equipment

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

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

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

Sound

• Maintain the muffler and exhaust system in good condition.

• Wear ear protectors if necessary.

Oil, grease and other chemical substances

• When handling oil, grease and other chemical substances (e.g., battery electrolyte –

Printed in U.S.A.

sulphuric acid), follow the product-related safety requirements (safety data sheet) carefully to prevent burning or scalding yourself or other persons.

30

918121/CP0807

Safety instructions Battery

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

DANGER! A hydrogen-air mixture, which creates a risk of explosion, is formed in the battery cells during normal operation, and especially during charging.

In the case of a frozen battery or of an insufficient electrolyte level, do not try to start the machine with battery jumper cables. The battery can burst or explode.

Tires

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

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

• Damage.

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

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

Printed in U.S.A.

31

918121/CP0807

Safety instructions Notes:

Printed in U.S.A.

32

918121/CP0807

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

Pre-Delivery Checklist

_______________________________________________

The following checklist is an important reminder of valuable information and inspections that MUST be made before delivering the machine to the customer. Check off each item after the prescribed action is taken.

Dealership Name _______________________________________________ Dealer Representative’s Name _______________________________________________ Date Checklist Filled Out

CHECK THAT: R

Unit has not been damaged in shipment. Check for such things as dents and loose or missing parts; correct or replace components as required.

R

Battery is securely mounted and not cracked. Be sure cable connections are tight.

R

Cylinders, hoses and fittings are not damaged, leaking or loosely connected.

R

Filters are not damaged, leaking or loosely secured.

R

Machine is properly lubricated and no grease fittings are missing or damaged.

R

Hydraulic system reservoir, engine crankcase and drive motors are filled to their proper levels.

R

All adjustments are made to comply with settings provided in Maintenance of this manual.

R

All guards, shields and decals are in place and secured.

R

Model and serial numbers for this unit are recorded in the space provided on this page, and on page 6.

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

CHECK THAT:

_______________________________________________ Model & Serial Number

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

EXPLAIN: R

The Safety and Operation chapters of this manual, regarding the safe operation of this machine.

R

The Maintenance and Troubleshooting chapters for information regarding the proper maintenance of this machine.

Explain that regular lubrication and maintenance is required for continued safe operation and long machine life.

R

Give the Operator’s Manual to the customer and instruct the customer to read and completely understand the contents before operating the unit.

R

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

R

Drive controls and boom/bucket/steering controls operate properly and are not damaged or binding.

R

Drive controls are properly adjusted for correct neutral position.

Customer’s Signature

R

The parking brake, along with the lock-out devices, are activated with the unit stationary (no pilot control pressure).

_______________________________________________

R

All hydraulic boom functions are NOT operational with the control lever lock in the lock-out position.

_______________________________________________

Date Delivered

RETAIN FOR CUSTOMER’S RECORDS

Printed in U.S.A.

33

918121/CP0807

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

Pre-Delivery Checklist

________________________________________________

The following checklist is an important reminder of valuable information and inspections that MUST be made before delivering the machine to the customer. Check off each item after the prescribed action is taken.

Dealership Name ________________________________________________ Dealer Representative’s Name ________________________________________________ Date Checklist Filled Out

CHECK THAT:

Remove dealer’s file copy at perforation.

R

Unit has not been damaged in shipment. Check for such things as dents and loose or missing parts; correct or replace components as required.

________________________________________________ Model & Serial Number

R

Battery is securely mounted and not cracked. Be sure cable connections are tight.

R

Cylinders, hoses and fittings are not damaged, leaking or loosely connected.

R

Filters are not damaged, leaking or loosely secured.

R

Machine is properly lubricated and no grease fittings are missing or damaged.

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

R

Hydraulic system reservoir, engine crankcase and drive axles are filled to their proper levels.

EXPLAIN:

R

All adjustments are made to comply with settings provided in the Maintenance chapter of this manual.

R

The Safety Instructions and Operation chapters of this manual, regarding the safe operation of this machine.

R

All guards, shields and decals are in place and secured.

R

R

Model and serial numbers for this unit are recorded in the space provided on this pagee, and on page 6.

The Maintenance and Troubleshooting chapters for information regarding the proper maintenance of this machine.

Explain that regular lubrication and maintenance is required for continued safe operation and long machine life.

R

Give the Operator’s Manual to the customer and instruct the customer to read and completely understand the contents before operating the unit.

R

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

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

CHECK THAT: R

Drive controls and boom/bucket/steering controls operate properly and are not damaged or binding.

R

Drive controls are properly adjusted for correct neutral position.

R

The parking brake, along with the lock-out devices, are activated with the unit stationary (no pilot control pressure).

R

All hydraulic boom functions are NOT operational with the control lock lever in the lock-out position.

Delivery Checklist

________________________________________________ Customer’s Signature ________________________________________________ Date Delivered

RETAIN FOR DEALER’S RECORDS

Printed in U.S.A.

34

918121/CP0807

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

Printed in U.S.A.

35

918121/CP0807

Operation

Operation

Operation This chapter describes the indicators and controls in the cab.

The pages listed in the table refer to the description of the controls.

Number/letter combinations describe the controls, for example 34/18 or 40/A, means: page no. 34/control no. 18 or position A in fig. no. 40.

You can unfold pages (37 and/or 39) for a better overview.

Cab overview: see overleaf

The following symbols are used:

• This symbol stands for a list.

• Subdivision within lists or an activity. Follow the steps in the recommended sequence.

☞ This symbol requires you to complete the activity described. ➥ This symbol marks the passages in the text describing the effects or results of an activity. n. s. = not shown.

“Option” = optional equipment. Stated whenever controls or other components of the machine are installed as an option.

Printed in U.S.A.

36

918121/CP0807

Operation 1

2

Cab: overview

3

Pos. 4

35

Description

For more information see page

Roof console

36

34

1 2

4

Interior light................................................................................................................................................................................................. 66 Sun visor

Operator compartment 33

5

6 6 32 7

9 00000

00

h

8

31 30

9

0 I

29

10

28 11 11 12

27 26

13

25

14

24

15

0

23 16 22 17

21

3 4

Instrument panel Air vent – front window

5 6

Fuse box (right) ........................................................................................................................................................................................143 Air vent – leg room

7

Steering column adjustment ....................................................................................................................................................................... 62

8

Accelerator pedal........................................................................................................................................................................................ 54

9

Door locks................................................................................................................................................................................................... 76

10

Control lever – loader unit .......................................................................................................................................................................... 81

11 12

Arrester lock – cab door ............................................................................................................................................................................. 76 Control lever base

13

Parking brake lever..................................................................................................................................................................................... 55

14 15

Preheating/start switch ............................................................................................................................................................................... 47 Switch panel in control lever base

16

Control lever lock 10 for road travel............................................................................................................................................................ 56

17 18

Drive electronics (Susmic).......................................................................................................................................................................... 58 Air vent – rear window

19 20 21 22

Bracket – cab door arrester ........................................................................................................................................................................ 76 Storage pocket for operator’s manual Side console Prepared installation for radio (option)

23

Backrest adjustment lever .......................................................................................................................................................................... 72

24

Seat belt ..................................................................................................................................................................................................... 73

25 26

Tank – washer system................................................................................................................................................................................ 70 Fixture – first-aid kit

27

Operator's seat ........................................................................................................................................................................................... 71

28

Lever – weight adjustment.......................................................................................................................................................................... 71

29

Lever – horizontal seat adjustment............................................................................................................................................................. 72

30

Air vent – leg room ..................................................................................................................................................................................... 72

31

Hydrostatic steering.................................................................................................................................................................................... 62

32 33

Service brake pedal (hydrostatic)/inching................................................................................................................................................... 54 Brake fluid tank

34

Multifunctional lever.................................................................................................................................................................................... 56

35

Fuse box (left)...........................................................................................................................................................................................143

36

Steering electronics .................................................................................................................................................................................... 62

18

18 34300b00_00.iso

19

19 20

Printed in U.S.A.

37

918121/CP0807

Instrument panel overview: see overleaf

Operation Instrument panel, multifunctional lever and drive lever: overview 37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

Pos.

55

Description

For more information see page

Instrument panel

56

57 73

60

58 74

61 75

62

63

76

64

65

66

67 85

68 76

69 77

70

71

37

Rocker switch – quickhitch lock (option) .................................................................................................................................................... 85

38

Rocker switch – rotating beacon (option)................................................................................................................................................... 67

39

Rocker switch – front working light (option) ............................................................................................................................................... 66

40

Indicator (green) – differential lock............................................................................................................................................................. 61

41 42

Indicator (red) – steering synchronization .................................................................................................................................................. 62 Switch – hazard warning system

43

Temperature indicator – diesel engine....................................................................................................................................................... 41

44

Indicator (red) – hydraulic oil filter .............................................................................................................................................................. 42

45

Indicator (yellow) – air filter ........................................................................................................................................................................ 41

46

Indicator (red) – alternator charge function ................................................................................................................................................ 41

47

Indicator (red) – parking brake ................................................................................................................................................................... 41

48

Indicator (red) – engine oil pressure .......................................................................................................................................................... 41

49 50

Temperature indicator – hydraulic oil ......................................................................................................................................................... 42 Socket/cigarette lighter

51

Indicator (green) – four-wheel steering ...................................................................................................................................................... 42

52

Indicator (green) – forward driving direction............................................................................................................................................... 42

53

Rocker switch – front socket for electrically operated attachments (option) ............................................................................................. 85

54

Tip switch – steering synchronization ........................................................................................................................................................ 62

55

Rocker switch with lock – four-wheel/front axle steering............................................................................................................................ 62

56

Rocker switch with lock – 3rd control circuit............................................................................................................................................... 82

57

Rocker switch – lights ................................................................................................................................................................................ 56

58

Rocker switch – rear working light ............................................................................................................................................................. 66

59

Not assigned

60

Indicator (green) – right/left turn indicator .................................................................................................................................................. 41

61

Indicator (yellow) – cold starter .................................................................................................................................................................. 41

62 63 64 65

Indicator (blue) – high beam ...................................................................................................................................................................... 41 Hour meter Speedometer – high speed (option) Fuel level indicator

14

66 67

Indicator (green) – right/left turn indicator for rear attachments ................................................................................................................. 41 Indicator (red) 3rd control circuit, continuous operation

82

68

Indicator (green) – reverse driving direction............................................................................................................................................... 42

83

69

Indicator (green) – front axle steering (high speed option) ........................................................................................................................ 42

70

Rocker switch – load stabilizer (option)...................................................................................................................................................... 60

71

Rocker switch – rear wiper with tip switch for wiper water ......................................................................................................................... 70

72

Rocker switch – high speed (option) .......................................................................................................................................................... 59

72

78

85 77 78

79 80

81 81

0

89 90

86 87 88

91

Printed in U.S.A.

84 16

39

918121/CP0807

Operation

Operation

Pos.

Description

For more information see page

Multifunctional lever 73 74 75

Tip switch – horn ...................................................................................................................................................................................... 56 Rotary switch and tip switch – front wiper, washer pump .......................................................................................................................... 56 Lever – turn indicator, high beam, horn ..................................................................................................................................................... 56 Control lever

76

Toggle switch – selection of driving direction1 ........................................................................................................................................... 53

77

Tip switch – unlock 3rd control circuit (electrical operation)....................................................................................................................... 82

78 79 80

Tip switch – lock 3rd control circuit (electrical operation)........................................................................................................................... 82 Tip switch – unlock 3rd/high-flow circuit (electrical operation, option) Tip switch – lock 3rd/high-flow circuit (electrical operation, option)

81

Tip switch – driving direction in neutral2..................................................................................................................................................... 53

Control lever console 82 83

Rocker switch – air conditioning system (option) Not assigned

84

Rocker switch – 3rd control circuit, continuous operation (option)............................................................................................................. 82

85 86 87

Tip switch – differential lock ....................................................................................................................................................................... 61 Not assigned Not assigned

88

Rotary switch – auxiliary heating (option) .................................................................................................................................................. 69

Left side console

1.

2.

89

Rotary switch – heater fan ......................................................................................................................................................................... 69

90

Rotary switch – heater fan temperature regulation .................................................................................................................................... 68

91

Rotary switch – fresh air/recirculated air .................................................................................................................................................... 68

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

Printed in U.S.A.

40

918121/CP0807

Operation Indicators and warning lights: overview Unfold page 37 for a better overview.

48 Indicator (red) – engine oil pressure Comes on if the engine oil pressure is too low, if the engine oil pressure is too low:

48

☞ Stop the machine. ☞ Turn off the engine immediately and check the oil level (➠ page 104).

Comes on after the ignition is turned on and turns off after the engine runs.

43 Temperature indicator – engine and cooling oil Indicates the engine oil temperature.

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

43

46 Indicator (red) – alternator charge function Comes on after the ignition is turned and goes out after the engine runs.

46

Comes on while the engine is running if: • The V-belt or charging circuit for the alternator is faulty.

• The battery is not charged anymore (➠ page 110).

45 Indicator (yellow) – air filter Indicates air filter contamination. If the air filter is contaminated:

45

Have the air filter replaced by an authorized dealer.

66 Indicator (green) – right/left turn indicator on rear attachment Flashes repeatedly:

66

• When turn indicator 34 is used.

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

52 Indicator (blue) – high beam Comes on if high beam is turned on or during headlight flashing.

62

61 Indicator (yellow) – cold starter Comes on when the key in preheating start switch 14 is in position 2 (a glow plug preheats the air in the combustion chamber of the engine when the key is in position 2).

61

47 Indicator (red) – parking brake 47

Printed in U.S.A.

P

Comes on when parking brake lever 13 is applied.

41

918121/CP0807

Operation 49 Hydraulic oil temperature indicator Comes on if the hydraulic oil temperature exceeds 203°F (95°C).

49

IMPORTANT! Risk of hydraulic damage as soon as temperature indicator 49 comes on:

☞ Relieve work and driving hydraulics. To do this: • Stop the machine.

• Move control lever 10 to neutral.

• Select neutral by using tip switch 81.

• Run the engine at increased speed until indicator 49 turns off.

44 Indicator (red) – hydraulic oil filter Indicates too high of pressure in the hydraulic reflux line to the tank. In this case: 44

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

50 Indicator (green) – right/left turn indicator Flashes repeatedly while turn indicator 37/34 is used.

60

41 Indicator (red) – steering synchronization Indicates that the wheels on both axles are aligned

41

➥ – see Synchronizing the steering system on page 62.

51 Indicator (green) – four-wheel steering Indicates that four wheel steering is turned on

51

➥ – see Changing steering mode (without high-speed) on page 62.

69 Indicator (green) – front-axle steering Indicates that front axle steering is turned on

69

➥ – see Changing steering mode (without high-speed) on page 62.

Indicators 52 and 68 (green) – driving direction

68

52

Indicates forward/reverse driving direction

➥ – see Selecting the drive range on page 58.

40 Indicator (green) – differential lock

40

Printed in U.S.A.

Indicates that the differential lock is turned on

➥ – see Turning on the differential lock on page 61.

42

918121/CP0807

Operation Notes:

Printed in U.S.A.

43

918121/CP0807

Operation Getting Started Safety instructions • Never use the controls or cables as handles.

• Never climb onto or jump off a moving machine.

• Refer to the load diagrams for the loader unit pallet forks – see on page 97.

Important information

• The machine may only be used in good operating condition in accordance with its

designated use and the instructions in the Operator’s Manual, and only by persons who are properly trained and fully aware of the risks involved in operating the machine – see Checklists on page 45.

Running-in period

The performance and service life of the machine are heavily dependent on using the machine carefully during its first 100 operating hours.

• Do not overload the machine.

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

• Increase the load gradually while varying the engine speed.

• Follow the maintenance schedule – see Maintenance schedule Model 680 (overview) on page 128.

Printed in U.S.A.

44

918121/CP0807

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

Start-up checklist

Complete the checklist below before starting the engine or putting the machine into service: ✔

No. Question

Printed in U.S.A.

1

Sufficient fuel in the tank? (➠ 102)

2

Engine oil level OK? (➠ 104)

3

Oil level in hydraulic tank OK? (➠ 112)

4

Water level in washer tank OK? (➠ 70)

5

V-belt condition and tension checked? (➠ 109)

6

Loader unit lubricated? (➠ 117)

7

Brake system (including parking brake) OK? (➠ 54)

8

Tire condition and inflation pressure OK? (➠ 119)

9

Wheel nuts securely tightened (especially after a wheel change)? (➠ 120, 147)

10

Lights, signals, indicators and warning lights OK? (➠ 66, 67, 41)

11

Windows, mirrors, lights and steps clean?

12

Is the attachment on the loader unit correctly locked? (➠ 85)

13

Is the engine cover firmly locked? (➠ 77)

14

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

15

Approved warning triangle, hazard warning light and first aid kit in the machine? (➠ 22)

16

Seat position and rearview mirror correctly adjusted? (➠ 71)

17

Seat belt fastened? (➠ 73)

45

918121/CP0807

Operation Operation checklist

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

No. Question After starting and during operation: 1

Indicators for engine oil pressure and alternator went out? (➠ 41)

2

Braking effect sufficient? (➠ 54)

3

Temperature indicator for engine coolant in normal range? (➠ 41)

4

Steering working properly? (➠ 62)

5

Is anyone hazardously close to the machine? (➠ 26, 55)

When driving on public roads:

Parking checklist

6

Bucket and attachments in the transport position? (➠ 55)

7

Control lever for lift and tilt hydraulics of the loader unit locked with the lock lever? (➠ 54)

Complete the checklist below when parking the machine: ✔

No. Question When parking: 1

Attachments on the loader unit lowered to the ground? (➠ 64, 81)

2

Parking brake applied? (➠ 55)

3

Machine cab locked (especially if the machine cannot be supervised)? (➠ 76)

When parking on public roads: 4

Machine adequately secured? (➠ 64)

When parking on uphill and downhill gradients: 5

Printed in U.S.A.

Machine additionally secured with chocks under the wheels to prevent it from rolling away? (➠ 64)

46

918121/CP0807

Operation Starting the engine

0 ☞ Complete the Start-up checklist

– see Start-up checklist on page 45.

☞ Adjust steering wheel position. To do this: • Release the lock (37/7).

• Adjust the height and width of the steering wheel.

• Firmly tighten the lock (37/7).

☞ Adjust seat position and rearview mirror.

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

☞ Fasten the seat belt.

• Parking brake (37/13) is applied.

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

General

You MUST apply parking brake (37/13) to start the engine.

DO NOT run the starter for more than 10 seconds.

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

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

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

Starting the engine After completing these procedures – see Starting the engine on page 47:

1

0

2

☞ Insert the ignition key in preheating/start switch 14. ☞ Turn the ignition key to position “1”. ☞ Check whether the following indicators come on:

3

• • • •

14 Fig. 23: Preheating/start switch

46

47

61

48

00000

Fig. 24: Indicators

Printed in U.S.A.

00

h

48 for the engine oil pressure.

46 for the alternator charge function.

61 for the cold starter.

47 if the parking brake is applied.

IMPORTANT!

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

☞ Turn the ignition key to position “2,” and hold it in this position for about 5 seconds: ➥ The intake air is preheated. ➥ Indicator 60 turns off. ☞ Press accelerator pedal 37/8 to about 25% of its maximum power. ☞ Turn the ignition key to position “3” and hold it in this position until the engine starts. ☞ Release the ignition key.

47

918121/CP0807

Operation Starting at low temperatures

☞ Turn the ignition key to position “2” and hold it in this position for about 15 seconds. ☞ Press accelerator pedal 37/8 all the way down. ☞ Turn the ignition key to position “3” and hold it in this position until the engine starts. ☞ Release the ignition key.

When the engine runs smoothly (increased engine speed):

☞ Release accelerator pedal 37/8.

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

After the engine has started

☞ Check that the following indicators have gone out: • 24/46 • 24/48

☞ Let the engine warm up.

In cold (winter-type) weather

☞ Increase the engine speeds slowly. ☞ Do not run the engine at full load until it has reached its operating temperature.

Printed in U.S.A.

48

918121/CP0807

Operation Jump-starting the engine

Safety instructions DANGER! Never jump-start the engine if the battery of the machine is frozen, because there is a risk of explosion. The Model 680 must not touch the jump-starting machine because when both machines are connected by jump leads, because there is a risk of sparking.

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

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

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

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

Procedure

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

Dead battery

12 V

☞ Connect one end of the black jump lead (–) to the – terminal of the starting battery. ☞ Clip the other end of the black jump lead (–) onto the engine block.

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

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

12 V Starting battery

After the engine has started

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

Fig. 25: Starting aid with jump leads 34001b710_05.eps

Printed in U.S.A.

49

918121/CP0807

Operation Before driving the machine Special instructions for public roads

• Follow these instructions – see Use: attachment on page 12. ☞ Carry out a functional check of: • Brakes.

• Steering.

• Lights.

A

☞ Empty the bucket. ☞ Tilt back the bucket B

B

– see Loader unit control valve overview on page 81.

C Fig. 26: Driving on public roads

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

D

IMPORTANT! Ground clearance for transport (fig. 26/C) is about 8“ (200 mm) (with the standard bucket, standard tires, and both marks D aligned).

Fig. 27: Marks for the transport position

Securing the control lever (joystick)

10

☞ Secure control lever 10 against inadvertent operation. To do this: • Lock lock lever 16 (see arrow).

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

☞ High speed (option): Press rocker switch 39/70 for the load stabilizer. ➥ – see Load stabilizer (option) on page 60.

16

Fig. 28: Lock for control levers

Inspection and adjustment of important functional units

Steering

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

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

WARNING! If the power steering fails, turning the steering wheel requires greater effort.

Take this into account especially when towing the machine.

☞ Adapt towing speed to the steering. ☞ Use a tow bar.

Printed in U.S.A.

50

918121/CP0807

Operation Wheel synchronization position

☞ – see Synchronizing the steering system on page 62.

Steering column height and angle setting

7

DANGER!

A

DO NOT adjust the steering column when driving or working –

Accident risk.

B

☞ Stop the machine. ☞ Turn off the engine. ☞ Apply the parking brake.

Fig. 29: Steering column setting

You can set the steering column height and angle.

Function

Operation

☞ Pull lever 7 upward A. ☞ Pull or push the steering column into the correct posiHeight setting

Angle setting

tion.

☞ Release lever 7. ➥ Steering column is locked. ☞ Press lever 7 rearward B. ☞ Move the steering column into the correct position. ☞ Release lever 7. ➥ Steering column is locked.

Service brake CAUTION! The rear brake lights DO NOT come on when you: • Brake by applying the parking brake.

• Brake hydrostatically with the drive.

☞ Only pressing brake/inching pedal 37/31 causes the brake lights to come on.

Dirt on or around the brake pedal may prevent it from functioning correctly:

Accident risk. ☞ Always keep brake/inching pedal 37/31 clean. ☞ Before driving the machine, press brake/inching pedal 37/32 down and check: • For resistance after pressing the pedal down to about 50% of its maximum power.

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

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

Printed in U.S.A.

51

918121/CP0807

Operation DANGER! Pressing brake/inching pedal 37/31 down slightly causes the inching valve to respond; the inching valve does NOT effectively brake the machine –

Accident risk. ☞ Press brake/inching pedal 37/31 down to its maximum power.

Driving IMPORTANT! You can only move the machine after releasing parking brake 37/13.

After starting the engine:

☞ Release parking brake 37/13. ☞ Select the driving direction by using toggle switch 39/76 on the control lever. ➥ Indicator 39/52 comes on. ☞ Gradually press down accelerator pedal 37/8. ➥ Machine is now moving.

Printed in U.S.A.

52

918121/CP0807

Operation Driving the machine Controls: overview Preheating/start switch [14]

0

1

2

IMPORTANT!

3

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

14 Fig. 30: Preheating/start switch

Position

Function

Power consumer

0

Inserting or removing the ignition key.

None.

1

ON/drive position.

➥ All functions are operational. ➥ Indicator comes on if the parking brake is applied.

2

Preheating engine (10 – 15 seconds).

➥ – see Starting the engine on page 47.

3

Starts the engine.

➥ – see Starting the engine on page 47.

Forward-reverse control [76] Function

F

• Select the driving direction by moving rocker switch 76 on the joystick into the neutral position.

76

• If your switch 76 does not have a neutral position, select the neutral position by using 81

R

52

68

switch 81 on the joystick.

• Use indicators 52 and 68 on the instrument panel to determine your driving direction.

Function

Operation

Effect

• Forward

☞ Press toggle switch 76

➥ Indicator 52 comes on.

• Reverse

☞ Press toggle switch 76

➥ Indicator 68 comes on.

• Neutral

☞ Press tip switch 81

➥ Indicators 52 and 68 turn

forward F.

rearward F.

(if equipped with switch 76 without neutral position).

off.

☞ – see Driving on page 52.

Fig. 31: Lever for selection of driving direction

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

Printed in U.S.A.

53

918121/CP0807

Operation Drive range selector

• Select the drive range by using rocker switch 72 located on the instrument panel on the right.

Rocker switch 72

A B Fig. 32: Drive range selector

72

Drive speeds

Position To do this...

☞ Press rocker switch 72 down.

A

☞ Press on the symbol on rocker switch 72.

B

Standard

High speed option

1st = 0 – 5.8 mph 1st = 0 – 5.8 mph (0 – 9.3 km/h) (0 – 9.3 km/h) 2nd = 0 – 12.4 2nd = 0 – 24.9 mph mph (0 – 20 km/h) (0 – 40 km/h)

☞ – see Drive range selection on page 58.

Accelerator pedal [8]

Accelerator pedal 37/8 controls the drive speed as follows:

• Press accelerator pedal 37/8 down. ➥ Drive speed is increased.

• Release accelerator pedal 37/8 ➥ Drive speed is reduced. slowly.

• Release accelerator pedal 37/8 fully. ➥ Hydrostatic braking.

IMPORTANT! Speed depends on the drive range selected with rocker switch 32/72.

Brake/inching pedal [32]

Function

• To brake the machine regardless of the setting of the drive lever 31/76 and accelerator pedal 37/8.

• When you inch the brake pedal (pedal pressed in lightly), the pedal responds like a

car’s clutch. The drive system is no longer supplied with hydraulic oil, which means the entire engine output is available to the work hydraulics. This allows you to raise the loader unit more rapidly.

Braking

☞ Press brake/inching pedal 37/32 down with force.

Inching

☞ Press brake/inching pedal 37/32 down slightly.

Printed in U.S.A.

54

918121/CP0807

Operation Parking brake [13] NOTE: You cannot start or drive the machine unless parking brake 33/B is released.

Function

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

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

DANGER!

B

Only use parking brake 33/B instead of the service brake if the service brake fails. When you use parking brake 33/B, the brake lights do not light up, and the machine brakes abruptly –

Accident risk.

Fig. 33: Parking brake

Preventing the machine from rolling away A

B

☞ Pull up lever 34/B up into the top notch. ➥ Indicator 47 comes on. ➥ Neutral is activated.

Releasing the parking brake

Fig. 34: Applying and releasing the parking brake

Printed in U.S.A.

☞ Pull up lever 34/B slightly. ☞ Press button A. ☞ Move lever 34/B all the way down.

55

918121/CP0807

Operation Multifunctional lever [34] 73

74

Function 75

34

• Use lever 75 to actuate the multifunctional lever (turn indicators).

• Use lever 75 to switch the high beam on and off.

• Use lever 75 to flash the headlight flasher.

• Use rotary switch 74 to start the washer pump for the front window.

• Use tip switch 73 to sound the horn.

Fig. 35: Multifunctional lever

Actuate high beam and headlight flasher

2 1 O

Position

Lever

Effect

• 0

☞ In idle position (center posi-

➥ High beam and headlight flasher

• 1

☞ Pull up to position 1 and

➥ High beam ON, if low beam is

• 2

☞ Pull up to position 2 and

➥ Headlight flasher ON,

75

tion).

release. hold.

OFF.

turned on by using switch 57. indicator 62 comes on.

Fig. 36: Actuating high beam and headlight

Actuating the turn indicators

75

L

0 R

Position

Lever

Effect

• L • 0 • R

☞ Push forward. ☞ In center position. ☞ Push rearward.

➥ Left turn indicators come on. ➥ None. ➥ Right turn indicators come on.

Fig. 37: Turn indicator

Actuating the wiper with the rotary switch for the washer pump

2

74 Fig. 38: Horn and washer pump

Position

Effect

• 0 • • 1 • 2 • Slide rotary switch 74/2 to the right.

➥ OFF. ➥ Intermittent wipe. ➥ Slow wipe. ➥ Fast wipe. ➥ Washer pump ON.

Actuating the horn Tip switch

Effect

☞ Press outer tip switch 73.

➥ Horn ON.

73 Fig. 39: Horn and washer pump

Printed in U.S.A.

56

918121/CP0807

Operation Notes:

Printed in U.S.A.

57

918121/CP0807

Operation

Operation Drive range selection Selecting the drive range The machine has two drive ranges. To select a drive range:

☞ Set driving direction to neutral by using tip switch 81 on the joystick. ☞ Select the required drive range by using rocker switch 72. To do this: • Press rocker switch 72/B.

➥2nd drive range selected.

A B

• Press rocker switch 72/A. 72

➥1st drive range selected.

Drive speed without high speed Symbol

Meaning

Recommended

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

Drive range B = 0 – 12.4 mph Use for long-haul travel.

(0 – 20 km/h).

Fig. 40: Rocker switch for drive range selection

Drive range A = 0 – 5.8 mph (0 – 9.3 km/h).

Drive speed with high speed (option) Symbol

Meaning

Recommended

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

Drive range B = 0 – 24.9 mph Use for long-haul travel.

(0 – 40 km/h).

Drive range A = 0 – 5.8 mph (0 – 9.3 km/h).

Printed in U.S.A.

58

918121/CP0807

Operation Selecting drive range, high speed (option)

IMPORTANT! Turning on front axle steering automatically selects high speed 12 – 25 mph (20 – 40 km/h).

76

69

51

☞ Press lock A of rocker switch 55 in the direction of the arrow and at the same time press rocker switch 55 down (OFF).

OFF A ON

➥ Indicator 69 on the instrument panel comes on. ☞ Select the required drive range by using rocker switch 72. ☞ Select the required driving direction by using toggle switch 76 (located on the joystick).

Shifting from high speed (option)

55 DANGER! Changing front-axle to four-wheel steering at high speeds is hazardous –

72

Accident risk. ☞ Slow the machine down to 12 mph (20 km/h) before changing front axle to

Fig. 41: Rocker switch for high speed (option)

four-wheel steering.

☞ Press rocker switch 55 (ON). ➥ Lock A in the rocker switch engages. ➥ Indicator 51 on the instrument panel comes on. ☞ Select the required drive range by using rocker switch 72. ☞ Select the required driving direction by using toggle switch 76 on the joystick.

Changing direction F

CAUTION! Changing direction at high speed and high engine speeds causes the machine to brake immediately.

76

R

☞ Slow the machine to a walking pace before changing direction. ☞ Reduce engine speed by removing your foot from accelerator pedal 8. ☞ Slow the machine to a walking pace. ☞ Select a new driving direction by using toggle switch 76 as follows:

52

68

Function

Operation

Effect

• Forward

☞ Press toggle switch 76

➥ Indicator 52 comes on.

• Reverse • Neutral Fig. 42: Lever for selection of driving direction

Printed in U.S.A.

forward F. ☞ Press toggle switch 76 backward F. ☞ Press tip switch 81 (if equipped with a switch 76 that does not have a neutral position).

59

➥ Indicator 68 comes on. ➥ Indicators 52/68 turn off.

918121/CP0807

Operation Load stabilizer (option) The load stabilizer protects the machine against unstable oscillating movements.

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

Accident risk. ☞ Always turn on the load stabilizer when driving on public roads. ☞ Follow these procedures when setting the transport position – see Before driving the machine on page 50.

IMPORTANT! DO NOT use the load stabilizer while performing heavy duty work.

Refer to the following table to determine when to use the load stabilizer: Load stabilizer Turned off Turned on • In general for heavy-duty • For driving on public work, e.g., picking up roads. excavated material.

May be turned on • For lighter work with the loader unit.

• For light off-road transport.

Turning on

☞ Press rocker switch 70 below A. ➥ Indicator in rocker switch comes ON. 70 A B Fig. 43: Rocker switch for load stabilizer (option)

Turning off

☞ Press rocker switch 70 on top B. ➥ Indicator in rocker switch goes OUT. Before working with the loader unit

☞ Turn off the load stabilizer.

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

Printed in U.S.A.

60

918121/CP0807

Operation Backup warning system

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

A

When backing up with the machine –

Accident risk. ☞ Make sure that nobody is within the work area of the machine. ☞ Do not rely exclusively on the backup alarm to alert others.

Fig. 44: Backup warning system

Differential lock IMPORTANT!

85

A differential lock distributes traction evenly to the front and rear wheels. The differential lock may be damaged if it is turned on at the wrong moment, e.g., when turning corners or if the wheels are already spinning.

☞ Only actuate the differential lock if you expect a wheel to spin, e.g., when working on slopes or on slippery ground.

40 Fig. 45: Tip switch for differential lock

Turning on the differential lock

☞ Proceed as follows: • Press and hold tip switch 85 on the joystick.

➥Indicator 40 on the instrument panel comes on.

Turning off the differential lock

☞ Proceed as follows: • Reduce engine speed.

• Release tip switch 85.

➥Indicator 40 on the instrument panel turns off.

Printed in U.S.A.

61

918121/CP0807

Operation Steering system Synchronizing the steering system

Definition Steering or wheel synchronization is the process of aligning the wheels so that both axles do not run in the same track.

54 41

A B

SO

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

A B

72

Fig. 46: Tip switch for steering synchronization

After starting the machine, synchronize by turning the steering wheel to the left and right.

Indicator 46/41 comes on as you turn the wheel. When both steering rams have passed through the straight-ahead position from both directions, synchronization is complete and Indicator 46/41 turns off.

Only the first drive range is active during synchronization. Use rocker switch 46/72 to select the second range, the machine shifts after it finishes synchronizing.

☞ Proceed as follows: • Machines with high speed (option): make sure high speed is turned off.

IMPORTANT! The machine must be at a standstill.

• Select low drive range 72/A – see Drive range selector on page 54.

• Drive at walking pace on level ground and press tip switch 54/B. • Steer to the left and right while driving until indicator 41 turns off.

• Complete a functional check of the steering system.

Changing steering mode (without high-speed)

☞ Turn on front axle steering as follows: • Slide the lock on rocker switch 55 rearward and press down rocker switch B.

55 51

69

➥Front axle steering is not switched until the rear axle has been set to straightahead. Indicator 69 flashes until the shift is over.

➥Indicator 69 for front axle steering comes on.

A B

• Complete a functional check of the steering system.

☞ Turn on four-wheel steering as follows: SO

• Stop the machine.

• Slide the lock on rocker switch 55 rearwards and press down rocker switch A.

➥Four-wheel steering is not switched until the front axle has been set to straightahead. Indicator 51 flashes until the shift is over.

Fig. 47:

Steering mode selection (without high speed)

➥Indicator 51 for four-wheel steering comes on.

• Complete a functional check of the steering system.

Printed in U.S.A.

62

918121/CP0807

Operation Changing steering mode (with highspeed option) Front-wheel steering SO 55

Front-wheel steering is automatically selected when shifting to high speed (option).

51

69

A B

➥ – see Selecting drive range, high speed (option) on page 59. ➥ Change-over is carried out after the rear axle has been set to straight-ahead.

Indicator 69 flashes until the shift is over.

➥ Indicator 69 for front-wheel steering comes on Four-wheel steering Four-wheel steering is automatically selected when disengaging high speed (option).

➥ – see Drive range selection on page 58. ➥ The shift is not carried out until the front axle has been set to straight ahead.

Fig. 48:

Steering mode selection (with high speed)

Indicator 51 flashes until the shift is over.

➥ Indicator 51 for four-wheel steering comes on

Stopping the machine ☞ To stop the machine, complete the following: • Reduce engine speeds by removing your foot from accelerator pedal 37/8.

• Stop the machine by pressing service brake 37/32.

• Select neutral by using tip switch 39/81 on the joystick.

• Apply the parking brake by pulling the lever up to the last notch – see Parking brake [13] on page 55.

➥Indicator 37/47 comes on.

Printed in U.S.A.

63

918121/CP0807

Operation Parking the machine DANGER! Machines parked on slopes may roll away. If you park on a slope:

☞ Apply the parking brake – see Parking brake [13] on page 55.

☞ Place chocks under the downhill sides of the tires. ☞ Stop the machine – see Stopping the machine on page 63.

☞ Select neutral by pressing tip switch 39/81 on the joystick. ☞ Apply the parking brake – see Parking brake [13] on page 55.

☞ Lower the loader unit. To do this: • Push control lever 37/10 forward out of neutral.

• Place the bucket on the ground so that the edge is flush with the ground. To do this: Push control lever 37/10 to the left or right.

➥– see Loader unit control valve overview on page 81.

After operation at full power

☞ Allow the engine to run until the temperature stabilizes. ☞ Turn off the engine. To do this: • Turn the ignition key to position “0.”

• Remove the ignition key.

➥– see Preheating/start switch [14] on page 53.

Printed in U.S.A.

64

918121/CP0807

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

Parking lights

00000

00

ON

☞ Press rocker switch 57/B into the ➥ Indicator in rocker switch comes on.

OFF

☞ Press rocker switch 61/A down.

1st position.

➥ Indicator in rocker switch turns off.

h

Low beam 62

57

ON

☞ Press rocker switch 57/B into the ➥ Indicator in rocker switch comes on.

OFF

☞ Press rocker switch 57/A down.

2nd position.

➥ Indicator in rocker switch turns off.

A IMPORTANT!

B

The parking light stays lit if the ignition is turned off. Turn off the parking light by turning the key from the preheating/start 37/14 to position 0.

Fig. 49: Light system switches

2 1 O

High beam 75

ON

OFF

☞ With low beam turned on, pull

➥ High beam and indicator 49/62 come lever 75 to position 2 toward the on. steering wheel and release. ☞ Pull lever 75 to position 2 toward ➥ High beam and indicator 49/62 turn the steering wheel and release. off.

Headlight flasher ON Fig. 50: Multifunctional lever

Printed in U.S.A.

☞ Pull lever 75 upward to position 1 ➥ High beam and indicator 49/62 come and hold.

65

on.

918121/CP0807

Operation Working light WARNING! The working light may momentarily blind motorists on public roads.

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

Front and/or rear working light (option) ON

☞ Press rocker switches 39/B front ➥ Indicator in rocker switch comes on.

OFF

☞ Press rocker switches 39/B front ➥ Indicator in rocker switch turns off.

and 58/B rear down. and 58/B rear down.

39 58 A B Fig. 51: Switch for working light

Interior light Interior light 3 ON OFF

☞ Press switch 1 to the left or right. ☞ Move switch 1 to center position.

1 Fig. 52: Switch for interior light

Printed in U.S.A.

66

918121/CP0807

Operation Signaling system 42

Hazard warning system

60

ON

OFF Fig. 53: Switch for hazard warning system

☞ Press switch for hazard warning

➥ The indicator in the switch and system 42 into the notched posiindicator 60 flash. tion. ☞ Press switch for hazard warning ➥ The indicator in the switch and system 42 from the notched posiindicator 60 turn off. tion by applying slight pressure.

Turn indicator

L

LEFT RIGHT

R

☞ Push lever 75 forward L. ☞ Pull lever 75 rearward R.

➥ Indicator 53/60 flashes. ➥ Indicator 53/60 flashes.

CAUTION!

75

If indicator 53/60 flashes about twice as fast as normally:

Fig. 54: Turn indicator

☞ Check the front and rear indicators immediately. ➥ Have the turn indicator system repaired if necessary.

Rotating beacon (option) Rotating beacon (option)

38

ON OFF

☞ Press rocker switch 38/B. ☞ Press rocker switch 38/A.

➥ Indicator in rocker switch comes on. ➥ Indicator in rocker switch turns off.

A B

Fig. 55: Switch for rotating beacon

Printed in U.S.A.

67

918121/CP0807

Operation Cab heating and ventilation NOTE: The heater can be set to any of the following four modes: • Ventilation, fresh air.

• Heating, fresh air.

• Heating, mixed mode.

• Heating, recirculated air.

The air flow is directed to the front window via two defroster vents 37/4, to the rear window via two defroster vents 37/6 on the sides and two defroster vents 37/18, and to the leg room area via two vents 37/30.

Each nozzle can be closed and positioned separately.

A 0

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

B C

89

90 K W 91

D

☞ Dial 89 in position A – C. ☞ Dial 91 in position D. Heating, fresh air

☞ Dial 89 in position B and/or C. ☞ Set the required temperature with dial 90. ➥ C = cold / W = warm. ☞ Dial 91 in position D. Heating, mixed mode

E Fig. 56: Heating adjustment

Ventilation, fresh air

☞ Dial 89 in position B and/or C. ☞ Set the required temperature with dial 90. ➥ C = cold / W = warm. ☞ Dial 91 between position D and E. Heating, recirculated air mode

☞ Dial 89 in position B and/or C. ☞ Set the required temperature with dial 90. ➥ C = cold / W = warm. ☞ Dial 91 in position E.

Printed in U.S.A.

68

918121/CP0807

Operation Auxiliary heating (option)

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

Risk of explosion. ☞ Turn off heater first. ☞ Always switch off heater before refueling.

Exhaust gases contain toxic matter –

Risk of poisoning and suffocation. ☞ Turn off the heater before entering closed rooms. ☞ Turning cab heating on and off; setting the temperature.

Rotary switch for auxiliary heating (option) ON OFF

☞ Continuously turn rotary

switch 88 to the right (MAX). ☞ Turn rotary switch 88 to the left (OFF).

➥ Indicator A in the switch comes on, green or red, when the machine lights are on.

➥ Indicator A in switch turns off.

IMPORTANT! There is a delay between when you turn rotary switch 88 and when the changes take effect. After turning off the auxiliary heating, it will run until it has cooled off. In the event of overheating, indicator A will flash steadily.

Correcting malfunctions 88

Proceed as follows:

A

☞ Turn heater off and on again, a maximum of two times. ☞ Check the fuse. ➥ Have repair work carried out by an authorized dealer only.

If the heater overheats WARNING!

Fig. 57: Controls for auxiliary heating

Indicator A flashes repeatedly if the heater overheats.

☞ Clean blocked heater ducts and hoses. ☞ Turn off and on again.

Printed in U.S.A.

69

918121/CP0807

Operation Windshield washer system Front window wiper ON ON OFF 74

☞ Turn switch 74 on lever 75 once. ☞ Turn switch 74 on lever 75 twice. ☞ Turn switch 74 on lever 75 rearward twice.

➥ Slow wipe. ➥ Fast wipe. ➥ Wipers return to starting position.

75

Fig. 58: Switch for front and rear wipers

Front window washer pump

A

ON OFF 74

☞ Press switch 74 on lever 75 to the right A and hold. ☞ Release switch 74 on lever 75.

75

Fig. 59: Washer pump

Rear wiper ON

71

Fig. 60: Washer water pump

☞ Press rocker switch 71/B down. ☞ Press rocker switch 71/A down.

A

OFF

B

Rear window washer pump OFF

➥ Rear wiper is on. ➥ Rear wiper returns to base position.

☞ Press rocker switch 71/B fully down (tip switch function).

Tank for windshield washer system The filler inlet for tank 25 is located inside the tool kit on the side wall, on the left side.

IMPORTANT!

0

Fill with clean tap water only. Add a cleaning agent if required. In winter, add antifreeze to the water – see Specific safety instructions on page 106.

25

34300b00_00.iso

Fig. 61: Tank for washer system

Printed in U.S.A.

70

918121/CP0807

Operation Operator's seat Seat adjustment Always adjust the seat to your individual needs.

WARNING! Never change the seat position when driving or working –

Accident risk. ☞ Adjust the seat before moving the machine. ☞ Make sure the levers for seat adjustment are safely engaged.

The seat can be set to the following positions:

a

b

c

d

Fig. 62: Seat adjustment

e

• Position setting with control lever base a.

• Weight setting b.

• Weight indication c.

• Position setting with control lever base d.

• Backrest setting e.

Weight setting IMPORTANT! Use lever b to adjust the seat suspension to the operator's weight. The weight indication c shows the set operator's weight (without the driver).

☞ Sit down on the operator’s seat. b Fig. 63: Weight setting

To adjust to a higher operator weight c

☞ Turn lever b clockwise. ➥ Read the weight off indication c.

To adjust to a lower operator weight

☞ Turn lever b counterclockwise. ➥ Read the weight off indication c.

Printed in U.S.A.

71

918121/CP0807

Operation

Backrest setting

☞ Sit down on the operator’s seat. ☞ Pull lever e upward and at the same time lean back to push the backrest into the required position.

☞ Allow lever e to engage.

e

Fig. 64: Backrest setting

Horizontal setting with control lever base

☞ Sit down on the operator’s seat. ☞ Pull lever d upward and at the same time move the operator’s seat forward or rearward. ☞ Allow lever d to engage.

d Fig. 65: Longitudinal seat setting with control lever

Horizontal setting without control lever base

☞ Sit down on the operator’s seat. ☞ Pull lever a upward and at the same time move the operator’s seat forward or rearward. ☞ Allow lever a to engage.

a Fig. 66: Longitudinal seat setting without control lever

Printed in U.S.A.

72

918121/CP0807

Operation Seat belt WARNING! Do not drive or work with the seat belt unbuckled –

Risk of personal injury. ☞ Buckle up before moving or working with the machine.

• Seat belt must not be twisted.

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

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

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

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

• Always keep seat belt clean.

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

Will not provide adequate protection. ☞ Replace the seat belt strap after an accident. ☞ Have fastening points and seat fixture checked for bearing capacity.

Seat belt 23 is designed for the operator's safety during work on construction sites and road travel.

Fastening the seat belt A

☞ Fasten seat belt 23 as follows before moving the machine: 23

B

• Hold the belt at buckle latch A and run it slowly and steadily over the hips to buckle B. • Insert buckle latch A into buckle B until it engages audibly (pull test).

• Tighten seat belt by pulling at its end.

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

0763b0007.eps Fig. 67: Fastening the seat belt

Printed in U.S.A.

73

918121/CP0807

Operation Unfastening the seat belt

☞ Unfasten seat belt 23 as follows: • Hold the seat belt.

23 A

• Press red button C on buckle B.

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

• Slowly return the seat belt to the retractor.

C B 30763b0006.eps Fig. 68: Unfastening the seat belt

Lengthen/shorten lap belt setting

A

☞ Lengthen the lap belt as follows: • Hold buckle latch A at a right angle to the seat belt and pull the seat belt to the required length.

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

IMPORTANT! D

30763b0005.eps Fig. 69: Longer/shorter seat belt setting

Printed in U.S.A.

You can install an automatic seat belt. It allows free and easy movement when pulled slowly, but locks during abrupt braking. The automatic seat belt may also lock when driving over potholes or uneven terrain.

74

918121/CP0807

Operation Notes:

Printed in U.S.A.

75

918121/CP0807

Operation Doors WARNING! Close the doors when driving and working with the machine –

Accident risk. ☞ Close the doors before moving the machine.

Opening the door from the outside

A Fig. 70:

☞ Turn the key in door handle A to the left. ☞ Pull door handle A to the outside.

Outside door opener and lock

Opening the door from the inside

☞ Pull lever B.

NOTE: Normally, enter and exit the cab by using the left door. If you leave the cab on the right side, secure the control lever (joystick) and fold back the control lever base.

– see Folding back the control lever base on page 78.

B Fig. 71: Inside door opener left/right

Securing an open door 11

19

☞ Press the door against the bracket of arrester 19 until it audibly locks.

IMPORTANT! Lubricate latch 11 weekly.

Fig. 72: Securing an open door

Locking the door

☞ Press button B of latch 11. ➥ The door is released from the lock. ☞ Close the door.

B

Fig. 73: Unlocking the door arrester

Printed in U.S.A.

76

918121/CP0807

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

☞ Safely engage lever C in door lock D.

D

C Fig. 74: Door arrester

Engine cover Opening

A

☞ Press lock A. ☞ Open the engine cover.

Closing

☞ Firmly press down the engine cover until lock A engages with an audible click.

L R

Locking and unlocking Lock the engine cover with the ignition key of the ignition switch.

Fig. 75: Engine cover lock

Printed in U.S.A.

☞ Turn the ignition key in lock A to the left (L). ➥ Engine cover locked. ☞ Turn the ignition key in lock A to the right (R). ➥ Engine cover unlocked.

77

918121/CP0807

Operation Other controls Folding back the control lever base The cab door on the right can be used as entry and exit.

☞ Do the following before entering or leaving the cab: • Stop and secure the machine – see Parking the machine on page 64.

• Lower the loader unit.

10 12

• Apply the parking brake.

• Turn off the engine.

• Remove the ignition key.

• Move control lever 10 (joystick) back and forth several times – see Lowering the loader unit with the engine turned off on page 83.

• Secure control lever 10 (joystick) – see Control lever lock (joystick) on page 81.

☞ Raise control lever base 12 with handle D to position A. ➥ The gas strut keeps the control lever base in the top position.

CAUTION!

D

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

12

A

B Fig. 76: Control lever base

Printed in U.S.A.

C

☞ Use the entrance handles in the cab. ☞ Fold control lever base 12 rearward to position B after you are in the cab. ➥ The gas strut keeps the control lever base in the lower position.

NOTE: The control lever base height can be set with stop bolt C.

78

918121/CP0807

Operation Notes:

Printed in U.S.A.

79

918121/CP0807

Operation

Operation Working with the machine General safety instructions • Never drive up to the edge of a pit from the outside – risk of cave-in.

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

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

• When using lifting accessories such as pallet forks, comply with the load diagrams – see Load diagram on page 96.

• The hydraulic system of the machine is still pressurized even when the engine is not

running. Depressurize the sections of the system and hydraulic lines that you want to open before starting setup or repair work (e.g., fitting/removing an attachment with hydraulic functions) – see Depressurizing the quick couplers on the loader unit on page 83.

• If your machine is equipped with a load stabilizer (option): IMPORTANT! Turn off the load stabilizer before working with the loader unit. If you leave the load stabilizer on, the lifting capacity of the machine is only about 60% of the rated force, and it is difficult to complete precise lifting movements.

Printed in U.S.A.

80

918121/CP0807

Operation Loader unit control valve overview Control lever for lift and tilt cylinder hydraulics

WARNING! Unintentional operation of control lever 77/10 when driving on public roads –

Accident risk. ☞ Lock the lock lever 78/32 – see Control lever lock (joystick) on page 81.

E C

10 B

A

Position Lever 10

Function

• A • B • C • D • E

➥ Tilts in attachment ➥ Dumps out attachment ➥ Lowers loader unit ➥ Raises loader unit ➥ Lowers loader unit to float position

☞ Left ☞ Right ☞ Forward ☞ Rearward ☞ Fully forward

NOTE:

D

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

Complete the following procedures to turn on the float position:

Fig. 77: Control lever for loader unit

☞ Push control lever 10 fully forward to final position E. ➥ Control lever stays in final position E. Control lever lock (joystick) The lock lever for locking the control lever is located on the control lever base console.

Locking the lock lever

16

☞ Push lock lever 16 lever forward A. ➥ The control valve is cut off from the hydraulic oil circuit. ➥ Follow these instructions – see Before driving the machine on page 50.

A

Opening the lock lever B

☞ Push lock lever 16 lever rearward B. ➥ The control valve is connected to the hydraulic oil circuit.

Fig. 78: Lock for driving on public roads

Printed in U.S.A.

81

918121/CP0807

Operation Operation of 3rd control circuit 77

78

WARNING! When working with attachments without a hydraulic function, press tip switch 77 on control lever 10 to unlock the quickhitch facility –

10

78

Risk of personal injury. ☞ Turn on rocker switch 56/A

10

– see Locking 3rd control circuit on page 82.

C

☞ Use rocker switch 56 to lock the 3rd control circuit as follows: Locking 3rd control circuit A

56

ON

Function

☞ Press rocker switch 56 down to position A.

B

function.

OFF 00

h

turns off.

➥ Rocker switch 56 is locked. ➥ Tip switches 77 and 78 do not

67

00000

➥ Indicator 67 on the instrument panel

☞ Push lock C down. ☞ At the same time press rocker switch 56 down to position B.

➥ Indicator 67 on the instrument panel comes on.

➥ Tip switches 77 and 78 are functional.

Fig. 79: Locking 3rd control circuit

☞ The 3rd control circuit is actuated by using tip switches 77 and 78 on control lever 10, with rocker switch 56/A turned off.

77 78

Operation of 3rd control circuit

Function

➥ With the quickhitch facility connected: Unlocking:

78

• Unlocks the quickhitch facility.

☞ Press tip switch 77.

10

➥ With an attachment connected: • Pressurizes right hydraulic line.

➥ With the quickhitch facility connected: Locking:

• Locks the quickhitch facility.

☞ Press tip switch 78.

➥ With an attachment connected:

Continuous setting:

➥ With an attachment fitted. ➥ Continuous hydraulic movements/procedures. ➥ Operation of hydraulic motors (e.g., rotary broom). ➥ Operation of hydraulic equipment with a control valve

• Pressurizes left hydraulic line.

84

☞ Press rocker switch 84 down to position B.

adjusted to maximum oil flow, with an unpressurized reflux.

• Indicator in rocker switch 84 comes on.

• Indicator 67 on the instrument panel comes on.

Fig. 80: Operation of 3rd control circuit

Printed in U.S.A.

82

918121/CP0807

Operation Lowering the loader unit with the engine turned off Lower the loader unit as follows:

☞ Make sure no one is near the machine. ☞ Push and hold control lever 10 forward C. ➥ Until the loader unit is completely lowered. ☞ Return control lever 10 to neutral.

C

10

Fig. 81: Lowering the loader unit with the engine turned off

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

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

Depressurize as follows:

☞ Apply the parking brake – see Parking brake [13] on page 55.

77

78

☞ Turn off the engine. ➥ Do not turn off the ignition. ☞ Press and hold tip switches 77 and 78 on the control lever for about 5 – 8 seconds. ➥ Hydraulic lines are depressurized. ☞ Turn off the ignition and remove the ignition key.

Fig. 82: Depressurizing hydraulic lines

Printed in U.S.A.

83

918121/CP0807

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

Fitting attachments onto the quickhitch facility

WARNING! The attachment must always be locked onto the quickhitch facility –

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

Re-install as follows:

C

☞ Drive the machine up to the attachment. ☞ Lower loader unit E by pressing control lever 10 forward C. ☞ Tilt the quickhitch facility forward by pushing control lever 10 to the right B. ☞ Adjust the height of pin shanks G of the quickhitch facility so that they are under catch

10

hooks F of the attachment.

B

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

D E

F

G

Fig. 83: Driving up to the attachment

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

E

C

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

to the left A.

10

A H D Fig. 84: Raising the attachment

Printed in U.S.A.

84

918121/CP0807

Operation Locking: attachments without hydraulic function Secure the attachment with lock pins H of the quickhitch facility. To do this:

☞ Press tip switch 78 on the control lever. ➥ Lock pin H engages in the mounting holes of the attachment. ➥ Make sure that the attachment is safely locked with lock pins H. ☞ Lock the 3rd control circuit by using rocker switch 56: ➥ – see Locking 3rd control circuit on page 82.

WARNING! 78

H

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

Locking: attachments with hydraulic function

☞ Turn off the engine. ➥ Do not turn off the ignition. ☞ Apply the parking brake. ☞ Unlock the 3rd control circuit with the rocker switch 56 – see Locking 3rd control circuit on page 82.

Fig. 85: Locking the attachment

☞ Depressurize the 3rd control circuit ➥ – see Depressurizing the quick couplers on the loader unit on page 83. ☞ Attach the hydraulic and electrical connections (if used) for the attachment by following its Operator’s Manual.

Connection of electrically operated attachments (option) A

The machine can be fitted with a 4-pole front and/or rear socket. Rocker switch 53 turns the electric power supply on or off for electrically operated attachments (such as a spray water pump for a rotary broom).

B Power supply for front attachments (option) 53

Fig. 86: Switch for attachments (option)

Printed in U.S.A.

ON

☞ Press rocker switch 53 down ➥ Power supply at the front socket is

OFF

➥ Indicator in switch comes on. ☞ Press rocker switch 53 down ➥ Power supply is interrupted. to position A. ➥ Indicator turns off.

to position B.

85

turned on.

918121/CP0807

Operation Removing an attachment from the quickhitch facility WARNING! The attachment must be placed on the ground so that it will not fall over when removed –

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

Take the attachment off the quickhitch facility as follows:

C

☞ Be sure that the attachment is empty and up. ☞ Tilt in the quickhitch facility by pushing control lever 10 to the left A. ☞ Lower the loader unit until the attachment is about 2–4“ (5–10 cm) above the ground

10 A

by pushing control lever 10 forward C.

H D

☞ Unlock the 3rd control circuit by using rocker switch 56: – see Locking 3rd control circuit on page 82.

Fig. 87: Lowering and tilting in the attachment

For attachments with hydraulic function 77

☞ Turn off the engine. ➥ Do not turn off the ignition. ☞ Apply the parking brake. ☞ Unlock the 3rd control circuit by using rocker switch 56:

C B

– see Locking 3rd control circuit on page 82.

10

☞ Depressurize the quick couplers: – see Depressurizing the quick couplers on the loader unit on page 83.

A

☞ Change over the quick couplers on the lock cylinder: • Connect flexible line A onto the right plug D of the quickhitch facility.

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

C

• Remove electrical connections (if necessary).

D B

☞ Start the engine. ☞ Open the lock on the quickhitch facility. To do this: ➥ Press tip switch 77 on control lever 10. ☞ Slightly tilt the quickhitch facility forward. To do this: Push control lever 10 to the right B.

E

☞ Lower the loader unit. To do this: ➥ Push control lever 10 forward C. As soon as the pin shanks of quickhitch facility F are beneath the catch hooks of attachment E: F

☞ Release the parking brake. ☞ Reverse the machine away from the attachment.

Fig. 88: Changing over hydraulic connections – setting down an attachment

Printed in U.S.A.

86

918121/CP0807

Operation Working with the standard bucket The following section describes work operations with the machine equipped with the standard bucket.

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

Checking the tilt position of the bucket IMPORTANT!

A

Angle of mark A = angle of blade B. B

Fig. 89: Tilt position of the bucket

Checking the transport position of the bucket IMPORTANT!

A

The bucket is in the transport position if: • Bucket is tilted back completely A.

B Fig. 90: Transport position of the bucket

• Marks on the loader unit and the machine frame are lined up C. The distance of the bucket (with standard tires) to the ground B is about 8” (20 cm).

C

Fig. 91: Marks on loader unit and machine frame

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Operation Transporting with a full bucket WARNING! Transporting full buckets in the raised position is an –

Accident risk.

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

To avoid accidents:

☞ Tilt the bucket fully back. ☞ Raise the loader unit to the transport position – see fig. 92.

A

☞ Tilt the bucket all the way back A. ☞ Raise the loader unit to the transport position: ➥ B and C.

B Fig. 92: Transport position of the bucket

C

Fig. 93: Marks on loader unit and machine frame

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Operation Loading loose material

☞ Align the blade flush with the ground A C

10

– see Checking the tilt position of the bucket on page 87.

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

B A Fig. 94: Lowering the loader unit

☞ Drive forward into the material A.

10

When the engine speed decreases due to too much material: D

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

B A

Fig. 95: Driving into the material

Loading if the material is hard to penetrate

A

B

10

☞ Proceed as for loading loose material. ☞ Tilt the bucket in and out slightly by moving control lever 10 to the left and right A and B.

Fig. 96: Loading, if the material is hard to penetrate

A 10

Ending loading

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

C

Fig. 97: Tilting back the bucket

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Operation ☞ Reverse out of the material A. ☞ Raise the bucket to transport position B. A B Fig. 98: Reversing out of the material

Removing material/digging in soft soil C

10

WARNING! If foundations or walls are undermined – risk of collapse.

Accident risk.

B

☞ Never undermine foundations or walls. ☞ Place the bucket horizontally on the ground B by pushing control lever 10 forward C. Fig. 99: Lowering the loader unit horizontal to the ground

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

10

α

B

1 1

Fig. 100: Setting the digging angle

10

A

☞ Drive the machine forward 1.

After the bucket has penetrated the soil:

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

1

• Layer being removed is as even as possible.

• Wheel spin is reduced.

2 Fig. 101: Removing an even layer

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Operation Digging in hard soil C 10

A

3

☞ Lower the bucket horizontally to the ground 1 by pushing 10 forward C. ☞ Set the digging angle α (flatter) 2 by pushing control lever 10 to the left A. ☞ Drive the machine forward 3. ☞ Press the bucket rearward slightly by pushing control lever 10 forward C.

1

2 Fig. 102: Removing hard soil

A

B

10

After the bucket has penetrated the soil:

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

• Layer being removed is as even as possible.

• Wheel spin is reduced.

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

1

loosen the material.

Fig. 103: Setting the digging angle flatter

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Operation Loading heaped material (non-compacted material) WARNING! Digging under heaped material can cause it to collapse –

Accident risk. ☞ Never undermine heaped material. ☞ Set the blade parallel to the ground by pushing control lever 10 to the left or right A and B.

C A

B

10

☞ Lower the loader unit horizontally to the ground by pushing control lever 10 forward C. ☞ Drive forward.

After penetrating the heaped material:

☞ Raise the loader unit. ☞ Keep the bucket level.

Fig. 104: Penetrating heaped material

When the loader unit cannot be raised further:

☞ Tilt in the bucket 1. ☞ Raise the loader unit 2. ☞ Reverse out of the material 3. ☞ Lower the loader unit into the transport position.

1

3 2

Fig. 105: Reversing away from heaped material

Loading heaped material (compacted material) A

B

10

☞ Proceed as for non-compacted material. ☞ When raising the loader unit through the heaped material: tilt the bucket slightly in and out 1.

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

1 Fig. 106: Heaped compacted material

Grading After having finished removing/loading the material:

☞ Lower the loader unit horizontally to the ground 1. ☞ Reverse across the surface to be graded 2.

2

1

Fig. 107: Grading

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Operation Digging tips When completing digging work, we recommend the following:

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

• Dig by removing adjacent strips.

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

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

Loading trucks When loading trucks, we recommend the following:

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

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

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

Fig. 108: Loading machines

Freeing the machine If your machine gets stuck in soft ground:

☞ Dump out the bucket until the blade is vertical above the ground. ☞ Completely lower the loader unit. ☞ Gradually tilt back the bucket ➥ The machine is pushed rearward. ☞ Reverse slowly. ☞ Repeat this procedure until the wheels reach firm ground. ☞ Reverse the machine away.

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Operation Working with the pallet forks a

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

• Maintain a minimum distance of 19’7” (6 m) between loader unit/load and overhead lines.

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

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

• Always transport the load close to the ground.

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

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

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

• Only place loads in designated areas within the construction site.

• Move the fork arms all the way under a pallet, as far as they will go, so that the load is picked up as closely as possible to the fork frame.

• Move under the load with the straight fork arms as far apart as possible and at an equal

b

distance to the left and right side of the load (figure b).

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

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

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

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

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

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

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

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

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

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• Load the vehicles or trailers evenly.

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

• Never raise a load with only one fork arm.

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

• Never leave the machine with the load raised.

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

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

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

• DO NOT transport people in the attachment.

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

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

• DO NOT exceed the authorized maximum pallet height.

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

Overview of fork arms

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

• Only use fork arms according to their designed use.

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

• Always keep fork arms clean.

• Load both fork arms evenly.

• Tie down loads to avoid losing them.

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

• DO NOT exceed the load center and lifting capacity.

• DO NOT use standard fork arms as reverse forks.

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

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

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

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

• DO NOT transport people on the fork arms.

• DO NOT transport molten material.

• DO NOT perform any cable-laying work.

• The operator must regularly check: • Lock:

Functional check.

• Hooks:

Visual check for cracks and deformations.

• Bend:

Visual check for dents, nicks and cracks.

• Bend and blade:

Do not use any longer if worn over 10%.

• Blade and tip:

Check for deformations.

• Wear on fork arms:

See service manual or manufacturer.

• In case of damage: Stop using the fork arms.

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Operation Fitting the pallet forks onto the quickhitch facility ☞ Pick up the attachment ➥ – see Locking: attachments without hydraulic function on page 85.

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

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

➥ You must be able to see the lock pins on both sides of the mounting Checking the lock pins

holes on the attachment.

Removing the pallet forks from the quickhitch facility WARNING! The attachment must be placed on the ground so that it will not fall over when removed –

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

Load diagram The load diagram is located in the cab (front window) of the machine, values are calculated for the respective machine model – see Use: attachment on page 12.

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

24” (610 mm) load center.

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

4365 (1980)

Printed in U.S.A.

96

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

3582 (1625)

918121/CP0807

Operation Adjusting the fork arms WARNING! If the fork arms are not secured –

Accident risk. ☞ Before using the pallet forks, make sure that both locking levers on the fork

arms are folded down. This locks the safety pins of the fork arms in the notches on the fork frame, and prevents the fork arms from slipping or sliding.

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

Always evenly align the fork arms to the fork frame.

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

☞ Set the locking lever to vertical position a. ➥ The fork arms can be moved on the fork frame. ☞ Slide the fork arms to the required distance until the safety pin engages in a slot on the

a

fork frame.

☞ Fold down locking lever again, to position b. ➥ The upper edge of the locking lever must be flush with the edge c.

IMPORTANT! Locking mechanism must be replaced immediately if damaged.

b c

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Operation Picking up loads with the pallet forks ☞ Move the wheel loader up to the load so that the forks are at a right angle to the load. ➥ The fork arms must be at the farthest possible distance apart, and at an equal distance to the left and right side of the load.

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

➥ The load must fit closely to the fork frame.

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☞ Carefully raise the load.

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

☞ Follow the load diagram – see on page 97.

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☞ Tilt the load slightly rearward.

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

Accident risk.

When turning or driving on slopes, the center of gravity must always be in the

☞To avoid accidents: • Tilt the pallet forks slightly rearward.

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

• Never raise the load over persons.

• Never park the machine with a raised load.

• Avoid any operation that might be a risk to machine stability.

☞ Only move the load after it is placed on the fork arms. ☞ Only move the machine after you have sufficient visibility.

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☞ Lower/raise loads to the transport position before moving and transporting them

(ground clearance – see Checking the transport position of the bucket on page 87).

If necessary, increase ground clearance for off-road applications

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☞ Always tilt the pallet forks slightly back (toward the machine) for transport. ☞ Always drive slowly (especially in off-road applications) to avoid strong swinging movements.

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

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

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

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Troubleshooting

Troubleshooting

Troubleshooting Use this section to determine malfunctions and repair solutions.

Engine trouble Problem

Possible causes

See page

Parking brake not applied

55

Steering-column control lever 28 not in neutral

58

Engine starting temperature is too low

Engine does not start or is not easy to start

Wrong SAE grade of engine lubrication oil

127

Fuel quality does not comply with specifications

127

Battery defective or dead

123

Loose or oxidized cable connections in starter circuit Starter defective, or pinion does not engage Wrong valve clearance Fuel injector defective Fuel quality does not comply with specifications Engine starts, but does not run smoothly

127

Wrong valve clearance Injection line leaks Fuel injector defective

Engine overheats. Temperature warning system responds

Oil level too low

104

Oil level too high

104

Air filter not working

108

Air filter maintenance switch or gauge defective Oil cooler fins not working Fan defective, V-belt torn or loose

109

Cooling air heats up Resistance in cooling system too high, flow capacity too low Fuel injector defective

Insufficient engine output

Oil level too high

104

Fuel quality does not comply with specifications

127

Air filter not working

108

Air filter maintenance switch or gauge defective Wrong valve clearance Injection line leaks Fuel injector defective

Engine does not run on all cylinders

Injection line leaks Fuel injector defective Oil level is too low

Insufficient or no engine oil pressure

Engine oil consumption too high

Printed in U.S.A.

104

Engine inclination too high Wrong SAE grade of engine lubrication oil

127

Oil level is too high

104

Engine inclination is too high

100

918121/CP0807

Troubleshooting Problem

Possible causes Blue

Oil level is too high

See page 104

Engine inclination is too high Engine starting temperature is too low

White Engine smoke

Fuel quality does not comply with specifications

127

Wrong valve clearance Fuel injector defective Air filter not working

Black

108

Air filter maintenance switch or gauge defective Wrong valve clearance Fuel injector defective

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Maintenance

Maintenance

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

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

• – see Safety instructions on page 18.

• The Operator’s Manuals of the attachments.

Daily service and maintenance work, and maintenance according to maintenance schedule “A” must be completed – see Maintenance schedule Model 680 (overview) on page 128.

Fuel system Safety instructions DANGER! • When handling fuel, there is a high risk of fire.

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

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

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

• Do not refuel in closed rooms.

• Wipe up fuel spills immediately.

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

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

DANGER! All work involving fuel carries an increased:

Risk of fire and poisoning. ☞ Do not refuel in closed rooms. ☞ Never work on the fuel system in the vicinity of open flame or sparks.

A

Environment!

Fig. 109: Fuel filler inlet

Collect and dispose of the fuel in accordance with environmental laws.

Stationary fuel pumps

General IMPORTANT! Only refuel from stationary fuel pumps. Fuel from barrels or canisters can be contaminated.

Even the smallest particles of dirt can cause: • Increased engine wear.

• Malfunctions in the fuel system.

• Reduced effectiveness of the fuel filters.

Diesel fuel specification

Only use high-grade fuels.

Cetane number

Grade

• No. 2-D according to DIN

Use For normal outside temperatures.

51601.

• No. 1-D according to DIN 51601.

Min. 45

For outside temperatures below 39°F (4°C) or for operation above 4’9“ (1500 m) altitude.

Bleeding the fuel system IMPORTANT! The fuel system of the machine is bled automatically.

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Maintenance Engine lubrication system IMPORTANT! If the engine oil level is too low or if an oil change is overdue, this may cause engine damage or loss of output.

☞ Have oil changed by an authorized dealer – see Maintenance schedule Model 680 (overview) on page 128.

Checking the oil level IMPORTANT! Check the oil level before starting the engine and after every 10 service hours or daily (if you use the machine for less than 10 service hours in one day).

After turning off a warm engine, wait at least 5 minutes before checking the oil level.

Checking the oil level Proceed as follows:

☞ Park the machine on level ground. ☞ Turn off the engine. ☞ Remove the key

max min

– see Parking the machine on page 64.

A

☞ Apply the parking brake. ☞ Open the engine cover. ☞ Pull out oil dipstick A. • Wipe it with a lint-free cloth.

• Push it back in as far as possible.

Fig. 110: Checking the oil level

• Pull it out and read the oil level.

☞ You must fill the oil tank when the oil level reads at the MIN mark on the oil dipstick A – see Adding engine oil on page 105.

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Maintenance Adding engine oil IMPORTANT! Excessive or incorrect engine oil may result in engine damage. For this reason:

☞ Do not add engine oil above the MAX mark of oil dipstick 110/A. ☞ Only use the engine oil specified – see Fluids and lubricants on page 127.

Environment!

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

Adding engine oil

☞ Proceed as follows: • Clean the area around oil filler cap B by using a lint-free cloth.

OIL

B

• Open filler cap B. • Raise oil dipstick A slightly to allow any trapped air to escape.

• Add engine oil.

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

A

• Check the oil level – see Checking the oil level on page 104.

• Add oil if necessary and check the level again.

• Close filler cap B.

Fig. 111: Oil dipstick and oil filler cap

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

• Completely clean any oil spilt on the engine.

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

Specific safety instructions • Dirt on the cooling fins reduces the cooler’s heat dissipation capacity. To avoid this: ☞ Clean the outside of the cooler at regular intervals – see Maintenance schedule Model 680 (overview) on page 128.

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

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

☞ Check the oil level at regular intervals – see Maintenance schedule Model 680 (overview) on page 128.

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

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

Risk of burns. ☞ Wait at least 10 minutes after turning off the engine. ☞ Wear protective goggles, gloves, and clothing. ☞ Proceed as follows: • Park the machine on level ground.

• Lower the loader unit.

• Apply the parking brake.

A

• Turn off the engine.

• Let the engine cool down.

• Remove the key.

• Open the engine cover.

• Clean the cooling fins by blowing compressed air from side A of the cooler.

Fig. 112: Cleaning the oil cooler

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Maintenance Notes:

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Maintenance

Maintenance Air filter IMPORTANT! The filter cartridge will be damaged if it is washed or brushed out.

To avoid premature engine wear:

☞ DO NOT clean the filter cartridge. ☞ Replace the filter cartridge when the indicator comes on. ☞ Never reuse a damaged filter cartridge. ☞ Ensure cleanliness when replacing the filter cartridge.

Weekly air filter contamination check

Air filter restriction indicator 45 on the instrument panel monitors the filter cartridge.

☞ Filter cartridge A must be replaced:

45

• If indicator 45 comes on.

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

– see Replacing the filter cartridge on page 109.

IMPORTANT! 00000

00

h

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

A

IMPORTANT! 34001b520_02.iso

B

C

Fig. 113: Air filter with safety cartridge

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

☞ Replace filter cartridge A and safety cartridge C after 500 service hours

– see Replacing the filter cartridge on page 109.

Dust valve weekly functional check

The air filter is located in the engine compartment on the right side of the machine.

☞ Proceed as follows: • Turn off the engine.

• Apply the parking brake – see Parking the machine on page 64.

• Squeeze the discharge slot of dust valve B.

B

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

☞ Clean the discharge slot if necessary.

Fig. 114: Air filter – dust valve

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918121/CP0807

Maintenance Replacing the filter cartridge ☞ Change filter cartridge A as follows:

D

• Turn off the engine.

• Prevent the machine from rolling away and remove the ignition key – see Parking the machine on page 64.

• Open the engine cover.

E

• Fold bow hook D on lower housing section E to the outside.

• Remove lower housing section E. • Carefully remove filter cartridge A.

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• Every third time you replace the filter:

Fig. 115: Removing the lower housing section

• Carefully remove safety cartridge 113/C.

A

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

• Carefully insert a new safety cartridge 113/C into the upper housing section.

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

• Position lower housing section E (make sure it is properly seated).

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• Close both bow hooks D.

Fig. 116: Removing the filter element

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

Risk of personal injury. ☞ Turn off the engine before working on or around the engine.

IMPORTANT! Cracked and stretched V-belts cause engine damage.

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

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

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

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Maintenance Checking V-belt tension ☞ Check the V-belt tension as follows: • Turn off the engine.

• Prevent the machine from rolling away and remove the ignition key – see Parking the machine on page 64. approx.0.4” (10 mm)

1

• Open the engine cover.

• Carefully inspect V-belt 1 for damage.

• If the V-belt is damaged: • Have the V-belt replaced by authorized staff.

• Press with your thumb to check whether the V-belt cannot be deflected between the pulleys by more than about 0.4” (10 mm).

Fig. 117: Checking V-belt tension

• Retighten the V-belt if necessary. See below.

Retightening the V-belt

☞ Retighten as follows:

4

• Turn off the engine.

• Prevent the machine from rolling away and remove the ignition key – see Parking the machine on page 64.

A

• Open the engine cover.

• Slacken attachment screws 3 of alternator 4.

3 Fig. 118: Re-tensioning the V-belt

• Use a suitable tool to push the alternator in the direction of arrow A until the correct V-belt tension is obtained (fig. 117).

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

• Check the V-belt tension (fig. 117) again.

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Maintenance Hydraulic system Safety instructions • You must depressurize all lines carrying hydraulic oil before performing any maintenance or repair work. To do this:

• Lower all hydraulically controlled attachments to the ground.

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

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

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

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

☞ Contact your Gehl dealer immediately.

IMPORTANT! Insufficient, incorrect, or contaminated hydraulic oil –

Risk of severe damage to the hydraulic system. ☞ Always add hydraulic oil by using the filling screen. ☞ Only use the same type of authorized oils – see Fluids and lubricants on page 127.

☞ Always add the hydraulic oil before the level gets too low. ☞ If the hydraulic system is filled with biodegradable oil, only use the same type of biodegradable oil, following the label on the hydraulic oil tank.

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

Environment!

Collect hydraulic oil, including biodegradable oil, with a container. Dispose of drained oil and used filters in accordance with environmental laws.

Always contact the authorities or establishments in charge of oil disposal before disposing of biodegradable oil.

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Maintenance Checking the hydraulic oil level ☞ Proceed as follows:

A

✓

• Park the machine on level ground.

• Retract all hydraulic cylinders.

• Turn off the engine.

• Apply the parking brake.

• Open the engine cover.

• Check the hydraulic oil level in sight glass (119/A).

If the oil level is lower than in fig. 119/A, add hydraulic oil.

Fig. 119: Oil level sight glass on the hydraulic oil tank

Adding hydraulic oil IMPORTANT! Only add hydraulic oil to the hydraulic oil tank if the engine is turned off. If the engine is turned on, hydraulic oil will run out of the filler opening and onto the hydraulic tank.

B

☞ Add oil as follows: • Park the machine on level ground.

• Retract all hydraulic cylinders.

• Turn off the engine.

• Apply the parking brake.

• Open the engine cover.

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

• Open breather filter B.

Fig. 120: Hydraulic oil tank

With the filter insert in place: • Add hydraulic oil until the tank is full.

• Check the hydraulic oil level by using the oil level sight glass (119/A).

• Add more oil if necessary and check again.

• Firmly close breather filter B.

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Maintenance Monitoring the hydraulic oil reflux filter Refer to the instrument panel, red indicator 44 monitors the reflux filter.

44

The filter must be replaced by an authorized dealer: • If indicator 44 comes on when the hydraulic oil is at operating temperature.

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

00000

00

h

In cold weather, indicator 44 may come on when you start the engine because of increased oil viscosity. In this case:

☞ Set engine speed so that indicator 44 turns off Fig. 121: Indicator for reflux filter

– see Starting the engine on page 47.

Important information about the use of biodegradable oil • Only use biodegradable hydraulic fluids that are approved by Gehl – see Fluids and

lubricants on page 127. Always contact your Gehl dealer for the use of other products that have not been recommended. In addition, ask the oil supplier for a written guarantee. This guarantee is applicable to damage occurring on the hydraulic components, which can be proved to be due to the hydraulic fluid.

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

IMPORTANT! Replace missing decals.

• Using two different biodegradable oils at the same time can affect the quality of one of

the oils. When changing biodegradable oil, be sure that the remaining amount of initial hydraulic fluid in the hydraulic system does not exceed 8% (manufacturer indications).

• DO NOT top off with mineral oil – the content of mineral oil should not exceed 2%.

• If hydraulic attachments are mounted or operated, use the same type of biodegradable oil for these attachments to avoid mixtures in the hydraulic system.

• If you are running the machine with biodegradable oil, the same oil and filter

replacement intervals used for mineral oil are valid – see Maintenance schedule Model 680 (overview) on page 128.

• Have an authorized dealer drain the condensation water in the hydraulic oil tank after

every 500 service hours (or before the cold season if you have not yet used your machine for 500 service hours). The water content must NOT exceed 0.1% by weight.

• All environmental instructions stated in this manual are valid for the use of biodegradable oil.

IMPORTANT! A change from mineral to biodegradable oil must be carried out by an authorized dealer.

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Maintenance Checking hydraulic pressure lines Safety instructions DANGER! Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries.

Risk of personal injury. ☞ Always consult a doctor immediately, even if the wound appears insignificant, to be sure that serious infections do not set in.

☞ Always follow these instructions: • Only tighten leaking screwed fittings and hose connections after you have released the pressure.

• Only use paper or wood to check for minor leaks, never use an unprotected light or open flame.

• Only authorized dealers should replace damaged flexible lines.

• Never weld faulty or leaking pressure lines and connections, always replace damaged parts with new ones.

• Never search for leaks with your bare hands, wear protective gloves.

• An authorized dealer or after-sales staff should immediately repair or replace any leaking or damaged pressure lines.

• Replace hydraulic hoses every six years from the date of manufacture, even if they do not appear to be damaged.

1 Q/05

The date of manufacture (month or quarter and year) is stated on the flexible line.

Example: The indication “1 Q/05” means manufactured in the 1st quarter of 2005.

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Maintenance Notes:

Printed in U.S.A.

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918121/CP0807

Maintenance

Maintenance Lubrication points Lubricate all points listed below with lithium-based brand-name grease – see Fluids and lubricants on page 127.

Lubricating the rear axle oscillation-type bearing IMPORTANT! The machine has an oscillation-type rear axle. The bearing must be greased after every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week).

A

The grease zerk is located above the axle tube, on the left side.

☞ Lubricate grease zerk A of the oscillation-type bearing.

Fig. 122: Grease zerks for oscillation-type bearing

Lubricating the planetary drive bearing ☞ Lubricate grease zerks B twice on each planetary drive bearing every 50 service

hours (or weekly if you use the machine for less than 50 service hours during one week).

B

Fig. 123: Grease zerks on planetary drive bearings

Printed in U.S.A.

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918121/CP0807

Maintenance Lubricating the loader unit Lubricate the following points on the loader unit

C

☞ Lubricate grease zerk C on the tilt cylinder bearing on the frame with grease every 50

service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease zerk D on the loader unit bearing every 50 service hours (or weekly

D

if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease zerk E on the lift cylinder bearing on the frame every 50 service

E

hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

Fig. 124: Lubrication points on frame

☞ Lubricate grease zerk F on the tilt rod bearing every 10 service hours (or weekly if you F G

L

use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease zerk G on the tilt cylinder bearing every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease zerk H on the lift cylinder bearing every 50 service hours (or weekly

if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease zerk I on the tilt lever bearing every 10 service hours (or weekly if

you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease zerks K on the quickhitch bearing every 10 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

K

I

H

Fig. 125: Lubrication points for lift and tilt cylinder bearings

☞ Lubricate grease zerks L on the tilt lever bearing every 10 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

Maintenance of attachments IMPORTANT! Correct maintenance and service improves operation and increases the service life of attachments. Follow the lubrication and maintenance instructions in the attachments Operator’s Manuals.

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Maintenance Maintenance of the brake system Environment!

Use a container to collect brake fluid as it drains and dispose of it in accordance with environmental laws.

Safety instructions

WARNING! Brakes are necessary for safety. Incorrect maintenance or repair may cause brake failure.

IMPORTANT! • All maintenance and repair work on the brakes must be completed by authorized technicians.

• The operator must check the brake fluid level in the tank daily.

• Have an authorized technician immediately replace damaged brake lines or hoses – risk of accidents.

Checking/adding brake fluid The brake fluid tank is located at the front, left side in the cab (next to the brake/inching pedal).

DANGER!

A

An incorrect brake fluid grade or an insufficient brake fluid level may impair the safety of the brake system –

Accident risk.

MAX MIN Fig. 126: Checking the brake fluid level in the tank

☞ Check the brake fluid in the tank regularly. ☞ Fill the brake fluid up to the upper edge of the sight glass. ☞ The brake fluid must comply with the SAE specification – see Fluids and lubricants on page 127.

☞ Replace brake fluid every two years.

If the level is below the upper edge of the sight glass:

• Open tank cover A. ☞ Fill the brake fluid up to the upper edge of the sight glass.

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Maintenance Tire care WARNING! Improper tire repairs are an –

Accident risk. ☞ All repair work on tires and rims may only be completed by authorized personnel.

IMPORTANT! Regular inspection of the tires: • Improves operating safety.

• Increases the service life of the tires.

• Can reduce machine downtime – see Specifications on page 138 for the authorized tire types and the correct tire pressures. Machines are also delivered with a tire table decal on the front window or the loader unit bulkhead.

Tire check Daily check

☞ Complete the following maintenance work daily: • Check tire pressure.

• Check the inside and outside of tires and rims for damage (cracks, aging, etc.).

• Remove objects from the tire tread.

• Remove oil and grease.

Weekly check

☞ Complete the following maintenance work weekly: • Check tires for wear and measure tread depth.

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918121/CP0807

Maintenance Wheel change DANGER! Using the wrong tires or wheels –

Accident risk. ☞ Only use authorized wheels and tires – see Tires on page 146.

☞ Check the wheel nuts for tightness after every wheel or tire change.

IMPORTANT! The wheels are heavy and can damage the wheel stud threads if not handled correctly.

☞ Use the correct assembly tools, such as covering sleeves for the studs, a jack, etc.

Removing the wheels

☞ Proceed as follows: • Park the machine on level and firm ground, prevent it from rolling away – see Parking the machine on page 64.

• Slightly loosen the wheel nuts of the tire that you want to remove.

• Place a jack under the axle beam and make sure that it is secure.

• Be sure that the jack is firmly positioned.

• Raise the side of the axle from which you want to remove the wheel.

• Be sure that the machine is firmly positioned.

• Remove the wheel nuts.

• Remove the wheel.

Fitting the wheels

☞ Proceed as follows: • Place the wheel onto the wheel studs.

• Partially tighten all wheel nuts.

• Lower the raised axle.

• Tighten the wheel nuts to the correct tightening torque – see Specific torques on page 147.

Printed in U.S.A.

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918121/CP0807

Maintenance Heating The machine’s heating system is equipped with a dust filter that must be cleaned regularly and replaced yearly.

The filter is located in the cab behind the operator's seat.

Cleaning the dust filter of the heating system A dust filter cleans the air taken in by the heater. Clean the filter with compressed air as required, but at least yearly. The air that flows from the vents decreases as dust on the filter increases.

A

☞ Clean the filter as follows: • Remove cover A at the rear left beside the operator's seat. To do this: B

☞ Remove screws B. • Remove dust filter C. To do this:

☞ Remove the screws.

• Clean dust filter C, replace it if necessary.

• Install cover A.

C

Fig. 127: Replacing the dust filter of the heating system

Printed in U.S.A.

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918121/CP0807

Maintenance Electrical system Safety instructions

IMPORTANT! Always disconnect the negative (–) pole from the battery before starting repair work on the electrical system.

Use only 12-V power sources. Higher voltages will damage the electric components.

DO NOT interrupt voltage-carrying circuits at the battery terminals because of the risk of sparking.

Never place tools or other conductive items on the battery – risk of short circuit.

When connecting the battery leads, make sure the poles +/– are not reversed, reversing the poles will damage the electrical components.

Service and maintenance work at regular intervals Before driving the machine

☞ Check every time before driving the machine: • Light system.

• Signaling and warning system.

Weekly

☞ Check weekly: • Electric fuses – see Fuse box on left and right of steering column on page 143.

• Battery terminal, battery cable, cable and ground connections.

• Charge condition of battery – see Battery on page 123.

Instructions for cables, fuses, bulbs, alternator Cables, bulbs and fuses

Follow these instructions:

• Failed electrical system components must always be replaced by an authorized technician. The operator or other persons may change bulbs and fuses.

• Ensure good contact in leads and fuses.

• Blown fuses indicate overloading or short circuits. Check the electrical system before installing the new fuse.

• Only use fuses with the specified amperage – see Fuse box on left and right of steering column on page 143.

Alternator

Follow these instructions:

• Only test run the engine with the battery connected.

• When connecting the battery, make sure that the poles (+/–) are not reversed.

• Always disconnect the battery before completing welding work or connecting a quick battery charger.

• Replace failed charge indicators immediately

– see 39 Rocker switch – front working light (option) 66 on page 39.

Printed in U.S.A.

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918121/CP0807

Maintenance Battery DANGER! Battery acid is highly caustic:

Risk of acid burn.

When recharging and/or working near the battery:

☞ Always wear goggles and protective clothing with long sleeves.

If acid is spilt:

☞ Thoroughly rinse all affected surfaces immediately with plenty of water. ☞ Thoroughly wash any body part touched by the acid immediately with plenty of water and seek medical attention at once.

During charging in particular, but also during normal battery operation, an oxygen-hydrogen mixture is formed in the battery cells –

Risk of explosion. ☞ Avoid open flame and sparks in the vicinity of the battery, and do not smoke.

☞ Do not jump-start the machine if the battery is frozen or if the acid level is low. The battery may rupture or explode.

☞ Always disconnect the negative pole (–) from the battery before starting repair work on the electrical system.

-

Battery A is located on the left side of the engine compartment. The original equipment manufacturer battery does not need any fluid to be refilled under normal operating conditions. However, have the battery checked at regular intervals.

+

Always follow the safety instructions for the battery.

A

Fig. 128: Battery

Printed in U.S.A.

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918121/CP0807

Maintenance General maintenance work Cleaning Cleaning the machine consists of three separate cleaning areas:

• Machine interior.

• Machine exterior.

• Engine compartment.

The wrong cleaning equipment and agents can affect machine safety and undermine the health of the persons cleaning the machine.

Follow these instructions: General instructions for all areas of the machine

When using washing solvents

• Ensure adequate room ventilation.

• Wear suitable protective clothing.

• DO NOT use flammable liquids, such as gasoline or diesel fuel.

When using compressed air

• Wear goggles and protective clothing.

• DO NOT aim the compressed air at the skin or at other people.

• DO NOT use compressed air for cleaning your clothing.

When using a high-pressure or steam jet cleaner

• Cover electrical components and damping materials.

• Cover the vent filter on the hydraulic oil tank, the filler caps for fuel, hydraulic oil, etc.

• Protect the following components from moisture: • Engine.

• Electrical components (such as the alternator, etc.).

• Control devices and seals.

• Air intake filters, etc.

When using volatile and flammable anticorrosion agents and sprays

• Ensure adequate room ventilation.

• DO NOT use unprotected lights or open flames.

• DO NOT smoke.

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Maintenance Cleaning inside the cab CAUTION! Never use high-pressure cleaners, steam jets, or high-pressure water to clean the inside of the cab. Water under high-pressure may: • Penetrate into the electrical systems and cause short circuits.

• Damage seals and disable the controls.

Use any of the following to clean the cab:

• Broom • Vacuum cleaner • Damp cloth • Bristle brush • Water with mild soap solution Cleaning the seat belt

• Only clean the seat belt (DO NOT disconnect the seat belt from the machine) by using a mild soap solution; DO NOT use chemical agents because they may destroy the fabric.

WARNING! Debris or water on automatic seat belts (option) may affect winding –

Risk of personal injury. ☞ Only rewind the seat belt if it is both clean and dry.

Exterior of the machine

Use any of the following to clean the outside of the cab:

• High-pressure cleaner • Steam jet Engine compartment WARNING! Only clean the engine after it is turned off and stopped –

Risk of personal injury. ☞ Turn off the engine before cleaning.

CAUTION! When cleaning the engine with a steam or water jet:

☞ The engine must be cold. ☞ DO NOT point the jet directly at electrical sensors, such as the oil pressure sender.

Any humidity penetrating these sensors causes them to fail and leads to engine damage.

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Maintenance Checking bolted connections

IMPORTANT! Check all bolted connections regularly, even if they are not listed in the maintenance schedules. Tighten all loose connections immediately – see Specifications on page 138 for the tightening torques.

Checking pivots and hinges

IMPORTANT! All mechanical pivot points on the machine (e.g., door hinges, joints) and fittings (e.g., door arresters) must be lubricated regularly, even if they are not listed in the lubrication plan.

Printed in U.S.A.

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918121/CP0807

Maintenance Fluids and lubricants Component/ application

Diesel engine

Fluid

Engine oil with oil filter2

SAE grade Specification

Season / temperature

SAE 10W; EO103

Below 23°F (-5°C)

SAE 20W20; EO203

14 ° to 50 °F (-10 ° to 10 °C)

SAE 30; EO303

41 °F to 86 °F (5 °C to 30 °C)

HD-C 10W/40; EO1040B3 HD-C 15W/40; EO1540B3

Capacities1

2.8 gal. (10.5 L)

Year-round

12 mph (20 km/h) gearbox

0.3 gal. (1.25 L)

25 mph (40 km/h) gearbox

1.0 gal. (4.0 L

Planetary drives – left and right, front axle Planetary drives – left and right, rear axle

Gearbox oil

4

80W/90 API GL5 or SAE 90 LS (hypoid gear oil)

Year-round

Differential – front and rear axle

0.4 gal. (1.5 L) each 0.2 gal. (0.7 L) each 1.2 gal. (4.5 L) each

SAE 5W/30

Up to -13°F (-25°C)

SAE 5W/40; EO 0540B3 Engine oil

2

Hydraulic oil tank Hydraulic oil5 Biodegradable oil

SAE 10W/40; EO 0540B3

Up to 5°F (-15°C)

SAE 15W/40; EO 1540B3

Up to 14°F (-10°C)

About 22 gal.

(85 L)

HVLPD 46 (HYD05303) (ATF 46) AVILUB Syntofluid 46 (bio-oil)

Year-round

PANOLIN HLP Synth 46 (bio-oil)

Grease zerks

Multipurpose grease

Lithium-based brand-name grease, MPG-A3

Year-round

As required

Battery terminals

Acid-proof grease

SP-B3

Year-round

As required

Year-round

As required

Mounting of pins, shafts, etc.

Special grease

Fuel tank

Diesel fuel7

Brake system Washer system 1.

2.

3.

4.

5.

6.

7.

8.

6

Optimoly paste “TA” White paste Grade no. 2-D

Over 39°F (4 °C)

Grade no. 1-D

Below 39°F (4 °C)

Brake fluid8

Agip LHM Super / Shell LHM

Year-round

About 0.1 gal.

(0.5 L)

Cleaning agent

Water + antifreeze

Year-round

About 0.4 gal.

(1.5 L)

About 21 gal.

(80 L)

The capacities indicated are approximate values; only the oil level check is accurate for the correct oil level.

MIL-L-2104C; API CD/CE/CF4; CCMC-D4.

Abbreviation for lubricants.

MIL-L-2105B; API-GL5.

DIN 51 521 T3.

250 gr tube, order no.: 0 00 441 32 10.

DIN 51 601, min 45 Cetane.

Standard: B 71 2710.

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918121/CP0807

“C” every 1500 hours (yearly)

128

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● ● ● ● ● ● ● ● ● ●

● ● ● ●

):

Carry out the following oil and filter changes (check oil levels after test run): • Engine oil • Engine oil filter • Fuel filter • Air filter3, 4 replace safety cartridge every third time the air filter is replaced • Gearbox oil in front and rear axle differentials and in rear axle gearbox • Gearbox oil in front and rear axle planetary drives, left and right side • Gearbox oil in 25 mph (40 km/h) gearbox (option) • Hydraulic oil5 • Hydraulic oil filter • Breather filter – hydraulic oil tank 4 Inspection work (

“B” every 500 hours2 2nd Inspection

Oil and filter changes (

“A” every 50 hours (weekly)

For service and maintenance work on the attachment, also refer to the operation and maintenance manual of the attachment manufacturer.

Delivery inspection

Work description

1st Inspection1 at 100 hours

Maintenance schedule Model 343-01 (overview)

Regular maintenance (daily)

Printed in U.S.A.

Maintenance schedule/service hours

● ● ● ●

):

Check the following material. Refill if necessary: • Engine oil • Hydraulic oil • Gearbox oil in front and rear axle differentials and in rear axle gearbox • Gearbox oil in front and rear axle planetary drives, left and right side • Brake fluid6

● ●

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Check cooler for engine and hydraulic oil for contamination. Clean if necessary7

● ●

●

●

●

● ● ● ●

●

●

●

●

●

●

When using biodegradable oil: Drain the condensation water in the hydraulic oil tank 5 ●

●

●

●

●

●

●

●

●

Check the fuel/water separator. Drain water if necessary

●

●

●

●

Clean filter insert on fuel pump, replace if necessary

●

●

●

●

918121/CP0807

V-belt: Check condition and pretension. Tighten or replace if necessary8

●

Maintenance

●

Clean dust valve on air filter housing 3

Battery: Check charge condition

●

●

Other inspection work (

):

●

Heating: Clean dust filter, replace every 1500 service hours if necessary9 Check and set service and parking brake pads. Replace if necessary Tire check (damage, air pressure, tread depth)

129

Check screws and nuts or screw connections for tightness on the following assemblies/components. Tighten if necessary • Engine and engine bearing • Steering system • Hydraulic system • Loader unit (pin locking) • Axle mounting, axle suspension • Counterweight (attachment) • Attachment cap screws of propshafts • Attachment cap screws of cab • Wheel nuts Electrical system: Check electrical and ground connections, chafing on wiring harness, battery terminals Lubrication service (

●

●

●

● ●

●

●

●

●

●

●

● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

):10

918121/CP0807

Lubricate the following assemblies/components: • Rear axle oscillating bearing • Front and rear axle planetary drive bearings, left and right • Loader unit– see Lubricating the loader unit on page 117 • Lift frame bearing • Tilt rod bearing • Tilt lever bearing • Lift cylinder bearing • Tilt cylinder bearing

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● ●

● ●

● ● ● ● ●

● ● ● ● ●

● ● ● ● ●

● ● ● ● ●

● ● ● ● ●

Maintenance

“C” every 1500 hours (yearly)

●

1st Inspection1 at 100 hours

●

For service and maintenance work on the attachment, also refer to the operation and maintenance manual of the attachment manufacturer.

“A” every 50 hours (weekly)

Check valve tip clearance (engine timing). Set if necessary

Work description

Delivery inspection

“B” every 500 hours2 2nd Inspection

Maintenance schedule Model 343-01 (overview)

Regular maintenance (daily)

Printed in U.S.A.

Maintenance schedule/service hours

130

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● ●

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● ● ● ● ● ● ●

● ● ● ● ● ● ●

):

Check the function of the following assemblies/components. Rectify if necessary: • Service and parking brake • Steering system • Lights and electrical system Leakage check (

“C” every 1500 hours (yearly)

Functional check (

“B” every 500 hours2 2nd Inspection

• Quickhitch facility: Bearing on lift frame • Hinges, joints and fittings (e.g., door arrester)

1st Inspection1 at 100 hours

For service and maintenance work on the attachment, also refer to the operation and maintenance manual of the attachment manufacturer.

Delivery inspection

Work description

“A” every 50 hours (weekly)

Maintenance schedule Model 343-01 (overview)

Regular maintenance (daily)

Printed in U.S.A.

Maintenance schedule/service hours

● ● ●

):

Check for tightness, leakage and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Correct if necessary: • Air intake line (air filter – engine) ● ● ● • Engine lubrication (engine – filter) ● ● ● • Fuel lines11 ● ● ● • Cooling system (engine – hydraulic oil) ● ● ● • Steering system (flexible lines and rams) ● ● ● 12 ● ● ● • Hydraulic system/loader unit (flexible lines and rams) • Brake system (flexible lines and rams) ● ● ● Work to be carried out after the first 100 service hours. This work must be carried out by an authorized dealer for warranty claims to be acknowledged.

Work after the first 500 service hours (2nd Inspection) must be carried out by an authorized dealer for warranty claims to be acknowledged.

Replace filter as indicated by the indicator on the instrument panel, however at least every 12 months or 1500 service hours.

When working in an acidic environment, replace the filter every 300 service hours.

When using biodegradable oil: Drain the condensation water in the hydraulic oil tank every 500 service hours, and in any case before the cold season.

Replace every two years.

Depending on operation and dust conditions, it may necessary to clean the cooler more frequently.

Replace the toothed belt every 3000 service hours or after five years at the latest (toothed belt must be replaced by authorized staff).

Depending on operation and dust conditions, it may be necessary to replace the dust filter more frequently.

Lubricate attachment according to manufacturer's instructions.

Replace flexible fuel leak oil lines every two years.

Replace flexible lines every six years (UVV, DIN 20066 part 5).

918121/CP0807

Maintenance

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Maintenance

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Notes:

131

918121/CP0807

Maintenance

Maintenance

Maintenance log Use the following table to record the maintenance and service work that you complete after a certain amount of service hours – see Maintenance schedule Model 343-01 (overview) on page 128.

Check off the columns in the boxes below after the work is completed.

The 1st and 2nd Inspections must be carried out by an authorized dealer for warranty claims to be acknowledged. For information on maintenance material, consumables, and lubricants – see Fluids and lubricants on page 127.

650

A

50

A

700

A

100

1st Inspection

750

A

150

A

800

A

200

A

850

A

250

A

900

A

300

A

950

A

350

A

1000 B

400

A

1050 A

450

A

1100 A

500

B 2nd Inspection

1150 A

550

A

1200 A

600

A

1250 A

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132

Company/ signature

Service hours

Maintenance schedule

After service hours

Company/ signature

Service hours

Date

Maintenance schedule

After service hours

Delivery

Date

Maintenance log

Maintenance log

918121/CP0807

Maintenance

1300 A

2150 A

1350 A

2200 A

1400 A

2250 A

1450 A

2300 A

1500 C yearly

2350 A

1550 A

2400 A

1600 A

2450 A

1650 A

2500 B

1700 A

2550 A

1750 A

2600 A

1800 C

2650 A

1850 A

2700 A

1900 A

2750 A

1950 A

2800 A

2000 B

2850 A

2050 A

2900 A

2100 A

2950 A

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133

Company/ signature

Service hours

Date

Maintenance schedule

After service hours

Company/ signature

Service hours

Maintenance log

Date

Maintenance schedule

After service hours

Maintenance log

918121/CP0807

Maintenance

3000 C

3850 A

3050 A

3900 A

3100 A

3950 A

3150 A

4000 B

3200 A

4050 A

3250 A

4100 A

3300 A

4150 A

3350 A

4200 A

3400 A

4250 A

3450 A

4300 A

3500 B

4350 A

3550 A

4400 A

3600 A

4450 A

3650 A

4500 B

3700 A

4550 A

3750 A

4600 A

3800 A

4650 A

Printed in U.S.A.

134

Company/ signature

Service hours

Date

Maintenance schedule

After service hours

Company/ signature

Service hours

Maintenance log

Date

Maintenance schedule

After service hours

Maintenance log

918121/CP0807

Maintenance Notes:

Printed in U.S.A.

135

918121/CP0807

Maintenance Maintenance decal Location Inside the cab on the rear window.

Explanation of symbols on maintenance decals Symbol

Explanation Before starting maintenance work, read the safety instructions in the Operator’s Manual.

Before starting maintenance work, read the “Maintenance” section in the Operator’s Manual.

Check that the light system functions correctly.

Check tires for damage, pressure and tread depth.

Complete a functional check and synchronize the steering system.

Complete a functional check of the brake system.

Check hydraulic oil level. Fill up if necessary.

Check engine oil level. Fill up if necessary.

Compress the dust valve.

Check cooler for engine coolant and hydraulic oil for contamination. Clean if necessary.

Check condition and initial tension of V-belt. Tighten or replace if necessary.

Leakage check: Check for tightness, leakage and chafing: pipes, flexible lines and screw connections. Correct if necessary.

Leakage check: Check the fuel/water separator. Drain water if necessary.

Lubrication service: Lubricate the assemblies.

Printed in U.S.A.

136

918121/CP0807

100 010 40 14

Maintenance

10 h

T glich Daily Tous les jours

50 h I=> 343 01 0001

Printed in U.S.A.

137

918121/CP0807

Specifications

Specifications

Specifications Frame Sturdy steel frame, rubber-mounted engine

Engine Engine Product

Deutz diesel engine

Model

BF4M 2011

Design

In-line

No. of cylinders Displacement

190 in.³ (3109 cm.³)

Bore and stroke

4 x 5” (94 x 112 mm)

Compression ratio

17.5:1 75 hp (56 kW)/76 DIN hp at 2300 rpm 199 lb.-ft. (270 Nm) at 1600 rpm

Output (as per ISO 9249) Max. torque Specific minimum fuel consumption Fuel injection system

282 g/hph (210 g/kWh) Direct fuel injection

Firing order

1-3-4-2

Starting aid

Glow plug Max. lateral left/right inclination: 30/57% Max. uphill/downhill inclination: 30/57% Follow tilting limit of the machine.

44 – 65 psi (3.0 – 4.5 bar) at 2300 rpm

Max. inclined position (engine no longer supplied with oil): Oil pressure Valve clearance (engine at cold temperature)

Printed in U.S.A.

4

138

Intake valve 0.01” (0.3 mm) Exhaust valve 0.02” (0.5 mm)

918121/CP0807

Specifications Power train Variable displacement pump Automotive, infinitely variable hydrostatic axial-piston gearbox 0 – 5 in.³/rev (0 – 74 cm.³/rev)

Type

Displacement

6527 psi (450 bar) 1050 – 1150 rpm at 725 psi (50 bar) HP 2250 ±100 rpm, 5802 psi (400 bar) high pressure

Max. operating pressure Δp Starting RPMs Droop Boost Pump

Internal gear pump

Type

0.8 in.³/rev (13 cm.³/rev)

Displacement

435 psi (30 bar) at 1500 rpm Speed-sensitive, hydraulic displacement adjustment with pressure cut-off Electro-hydraulic control

Charging/boost pressure Control

Driving direction

Electric (potentiometer)

Inching Variable displacement motor Type Standard Displacement

High speed option Standard

Drive speed

High speed option

Tractive effort

Printed in U.S.A.

139

Axial piston motor (swash plate design) 2.3 to 4.9 in.³/rev (37.3 to 80 cm.³/rev) 3.3 to 14 in.³/rev (54.7 to 233 cm.³/rev) 1st drive range: 0 – 5.8 mph (0 – 9.3 km/h), forward and reverse 2nd drive range: 0 – 12.4 mph (0 – 20 km/h), forward and reverse 1st drive range: 0 – 5.8 mph (0 – 9.3 km/h), forward and reverse 2nd drive range: 0 – 25 mph (0 – 40 km/h), forward and reverse 9217 lbf (41.0 kN)

918121/CP0807

Specifications Axles Front axle (with 100% differential lock) Planetary drive steering axle, rigid screw connection with frame 7°

Type King-pin inclination Camber

1.5°

Steering angle

40° 0” (0 mm)

Toe-in

4’8” (1475 mm)

Tread width Rear axle (with 100 % differential lock)

Oscillating planetary drive steering axle

Type King-pin inclination

7°

Camber

1.5°

Oscillation angle

+/- 9° 40°

Steering angle

0” (0 mm)

Toe-in

4’8” (1475 mm)

Tread width

Brakes Service brake Type

Foot-operated, hydraulic multi-disc brake + hydrostatic

Location

Front axle, drive (rear axle)

Effect

On both axles via cardan shaft

Brake fluid

Special hydraulic fluid based on basic mineral oil – see Fluids and lubricants on page 127

Parking brake Type

Manual, mechanical disc brake

Location

Front axle input

Steering Steering Type Steering mode

Assemblies

Max. pressure of hydraulic lines Hydraulic pump Maximum steering angle

Printed in U.S.A.

140

Hydrostatic four-wheel steering with emergency steering feature 1st four-wheel steering 2nd front-axle steering High-speed version: 2nd speed allows for front-axle steering only.

Hydraulic pump, servostat with safety valves, one steering cylinder per axle, electronically synchronized 2538 – 2611 psi (175 – 180 bar) Gear pump Displacement 0.8 in.³/rev (13 cm.³/rev) ±40°

918121/CP0807

Specifications Work hydraulics Loader hydraulics Hydraulic pump Displacement Control valve

Gear pump 2 in.³/rev (38 cm.³/rev) 22 gpm (84 L/min) at 2300 rpm 3-fold pilot control 3191 psi (220 bar)

Max. service pressure Secondary pressure limiting

Tilt cylinder

Rod side 3916 psi (270 bar) Bottom side 1450 psi (100 bar)

Lift cylinder

Bottom side psi 4351 psi (300 bar) Reflux filter

Filter

Pilot control Pilot control pump = boost pump of hydraulic pump 0.8 in.³/rev (13 cm.³/rev)

Displacement Charging/boost pressure

435 psi (30 bar) at 2300 rpm

Pilot control unit Four-way lever – control of lift and tilt cylinders Electrical control of lock cylinder or attachments via tip switches

Joystick

Locked via lock lever with universal lever and rocker switch (electrical system)

Lock against unintentional operation (for long-haul travel and transport)

Additional control circuit + high-flow control circuit (option) Additional control circuit + high-flow control circuit Hydraulic pump displacement: Max. service pressure

Printed in U.S.A.

2 in.³/rev (38 cm.³/rev) ≡ 21 gpm (80 L/min) at 2300 rpm 3481 psi (240 bar)

Hydraulic connections front Pressure line: Unpressurized reflux:

1 x nw 16 (red) 1 x nw 25 (blue)

Hydraulic connections rear Pressure line: Unpressurized reflux:

1 x nw 16 (red) 1 x nw 25 (blue)

141

918121/CP0807

Specifications Loader unit Loader unit with bucket 1, 2 37 ft.³ (1.05 m³) according to ISO 8730 lbs. (3960 kg) 4167 lbs. (1890 kg)

Bucket capacity Tipping capacity (SAE J732) Rated operating load (SAE J818) Bucket width

6’7” (2050 mm)

Dump height

8’7” (2660 mm) 11’2” (3400 mm)

Pin height

2’5” (765 mm) 2” (51 mm)

Dump reach Digging depth below ground Tilt-back angle

50°

Dump angle

45°

Breakout force (lift cylinder)

9127 lbf (40.6 kN)

Breakout force (tilt cylinder)

9285 lbf (41.3 kN)

Fork arms (payloads stated for 24” [610 mm] load center) Payload, safety factor 2.00 (SAE J1197)

3498 lbs. (1587 kg)

Lifting height

124” (3150 mm)

Movable payload in the transport position (safety factor 2.00)

4234 lbs. (1921 kg)

1.

2.

With tires 16/70-20.

With standard bucket.

Electrical system Electrical system

Printed in U.S.A.

Alternator

12-V, 95 A

Starter

12-V, 3.0 hp (2.3 kW)

Battery

12-V, 72 Ah

Socket (e.g., for cigarette lighter)

15 A

142

918121/CP0807

Specifications Fuse box on left and right of steering column

F25 F26 F27 F28 F29 F30 F31 F32

Rated No. current (A)

F17 F18 F19 F20 F21 F22 F23 F24

F1

3

F2

5

F3

3

F4

15

F5

15

Switching relay wiper 1st/2nd speed, intermittent wipe relay, front wiper, washer pump, horn Right/left low beam, right/left high beam

F6

10

Rear wiper, washer pump

F7

7.5

Brake lights

F9 F10 F11 F12 F13 F14 F15 F16

F1

F2

F3

Fig. 129: Fuse box

Printed in U.S.A.

F4

F5

F6

F7

Protected circuit Control lever, reverse driving relay, differential lock relay, forward driving direction indicator, reverse driving direction indicator Switching relay: Front attachments, load stabilizer, 3rd control circuit, reversing horn, reversing light Front and rear axle sensor

F8

3

F9

10

F10

5

Hour meter, hydraulic temperature indicator, coolant temperature indicator, fuel level indicator, speedometer Indicator: Parking brake, air filter, 3rd control circuit, engine oil pressure, hose burst valve, hydraulic oil filter, alternator Unlock/lock solenoid valve, front socket, solenoid valve differential lock Cutoff solenoid

F11

7.5

Turn indicators

F12

5

F13

25

Solenoid valve high-speed, steering electronics, switch 1st/2nd speed Solenoid valve four-wheel steering/front-axle steering Indicator: Four-wheel steering, front-axle steering, synchronicity Heater fan, magnetic coupling compressor

F14

10

Susmic (drive electronics)

F15

3

Load sensor Switching relay:

F16

7.5

F17

7.5

High beam (right)

F18

7.5

High beam (left)

F19

7.5

Low beam (right)

F20

7.5

Low beam (left)

F21

5

F22

5

F23

10

Parking light (right), rear light (right), rear clearance light (right), front clearance light (right), switch lights Parking light (left), rear light (left), rear clearance light (left), front clearance light (left), instrument lights Front/rear working light

F24

10

Rotating beacon

F25

10

Mounting parts

F8

Solenoid valve:

143

Retract/extend loader unit, front socket bucket repositioning, radio Retract/extend loader unit, quickhitch lock, tilt cylinder lock

918121/CP0807

Specifications

Rated No. current (A)

Protected circuit

F26

7.5

Solenoid valve high-flow control circuit and additional control circuit

F27

7.5

F28

5

Radio (option)

F29

10

Cigarette lighter

F30

7.5

Turn indicator relay, turn indicator, radio

F31

7.5

F32

3

Solenoid valve:

Load stabilizer, hose burst valve, bucket repositioning

Front parking light (right/left), rear light (right/left), rear socket, front socket, switch lights, instrument lights, light for cigarette lighter, interior light High current relay, switching relay heating and starting, indicator for preheating

Main fuse box with relays The main fuse box is located in the engine compartment, on the left side.

F34

F35

F37

K20 K21 F33

F36

Fig. 130: Main fuse box in the engine compartment

Printed in U.S.A.

Fuse no.

Rated current (A)

Protected circuit

F33

50 A

– Main fuse

F34

60 A

– Ignition lock

F35

60 A

– Ignition lock

F36

40 A

– Preheating/start fuse (starter)

F37

10 A

– Multiple quantity valve

Relay no.

Protected circuit

K 20

– Preheating

K 21

– Start

144

918121/CP0807

Specifications Relays The relays are installed on the left and right next to the fuse box.

K3

K14

K8

K7

K5

K6

K9

K11

K10

K2

Switching relay no.

Protected circuit

K1

High current relay

K2

High current relay

K3

Switching relay reverse driving

K5

Switching relay front socket (option)

K6

Turn indicator relay

K7

Switching relay wiper 1st speed

K8

Switching relay wiper 2nd speed

K9

Intermittent-wipe relay

K10

Switching relay (lock)

K11

Switching relay (unlock)

K14

Switching relay differential lock Switching relay load stabilizer (option)

K1

Switching relay bucket repositioning (option)

Fig. 131: Relays

Printed in U.S.A.

145

918121/CP0807

Specifications Tires Tire pressure

Tire size

Front

Rear

Wheel rims Wheel rim

Wheel offset

16/20-20 MPT04 10 PR 141 B 13 x 20

405/70 R20 SPT9 136 B 375/75 R20 XZSL 148 B 14.5-20 MPT04 12 PR 132 E

40 psi (2.75 bar)

33 psi (2.25 bar)

375/75 R20 XM27 143 P

0.8” (20 mm) 11 x 20

375/75 R20 XZSL 143 P

Weights Weight Operating weight1

12,015 lbs. (5450 kg.)

Gross weight rating

15,432 lbs. (7000 kg.)

Front axle weight rating

9370 lbs. (4250 kg.)

Rear axle weight rating

9370 lbs. (4250 kg.)

Max. authorized load for towing facility 1.

13,228 lbs. (6000 kg.)

With standard bucket, operator and full fuel tank

Sound levels Sound power level Measured value Guaranteed value Sound level in the cab

102 dB (A) 104 dB (A) 78 dB (A)

NOTE: Measurements carried out on an asphalt surface.

Printed in U.S.A.

146

918121/CP0807

Specifications Vibration Vibration Effective acceleration value for the upper extremities of the body

m < 2.5 ----2

Effective acceleration value for the body

m < 0.5 ----2

s

s

Hardware torques General torques Cap screw dimensions

Torques in lb.-ft. (Nm)1 Grade 6.5 (8.8)

M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 1.

2 (3) 4 (5.5) 7 (10) 17 (23) 34 (46) 58 (79) 92 (125) 144 (195) 207 (280) 291 (395) 398 (540) 502 (680) 738 (1000) 996 (1350)

Grade 8.0 (10.9) Grade 9.5 (12.9) 3 (4) 6 (8) 10 (14) 25 (34) 49 (67) 85 (115) 136 (185) 214 (290) 295 (400) 413 (560) 561 (760) 715 (970) 1069 (1450) 1438 (1950)

4 (5) 7 (10) 12 (16) 30 (40) 58 (79) 100 (135) 162 (220) 251 (340) 347 (470) 487 (660) 656 (890) 848 (1150) 1254 (1700) 1696 (2300)

These values are valid for cap screws with untreated, non-lubricated surfaces

Specific torques

Printed in U.S.A.

Description

Torque

Wheel nut

295 ±15 lb.-ft. (400 ±20 Nm)

Track-rod end (steering cylinder)

148 lb.-ft. (200 Nm)

Piston rod (steering cylinder/track rod)

184 lb.-ft. (250 Nm)

147

918121/CP0807

Specifications

8’9” (2710 mm) 9’5” (2910 mm) 6’9” (2090 mm)

6’7” (2050 mm) 18’4” (5600 mm)

4’8” (1460 mm)

8” (200 mm)

2’ (600 mm)

8’7” (2660 mm)

10’7” (3250 mm)

11’2” (3400 mm)

Dimensions model 343-01

58” (1475 mm) 81” (2050 mm)

Fig. 132: Machine dimensions

Dimensions Overall length1

18’4” (5600 mm)

Overall height 2, 3

8’9” (2710 mm)

Overall height2 with rotating beacon

9’5” (2910 mm)

Overall width without bucket4

6’2” (1880 mm)

Overall width1

6’7” (2050 mm)

Ground clearance in the transport position of loader unit Ground clearance below rear axle gearbox Tread width, front/rear

4’8” (1475 mm)

Wheelbase

6’7” (2050 mm)

Turning radius5

9’2” (2790 mm)

1.

2.

3.

4.

5.

Printed in U.S.A.

8” (200 mm) 13” (340 mm)

2

With standard bucket.

With tires 16/70-20.

Overall height with protective screen (FOPS option) 9’3“ (2820 mm).

With outside mirrors folded in.

Measured at outer edge of tires.

148

918121/CP0807

Specifications Notes:

Printed in U.S.A.

149

918121/CP0807

Index I

A Abbreviations ........................................................................................... 8 Accelerator pedal ................................................................................... 54 Air filter ................................................................................................. 108 Applications with lifting gear .................................................................. 21

B Backup warning system ......................................................................... 61 Biodegradable oil ................................................................................. 113 Brake system ....................................................................................... 118 Brake fluid ................................................................................... 118 Safety instructions ....................................................................... 118 Brake/inching pedal ............................................................................... 54

C

Checklists ....................................................................................... 33, 45 Pre-delivery and Delivery .............................................................. 34 Controls ................................................................................................. 53

D Decals on the outside of the machine .................................................... 16 Designated use and exemption from liability ........................................... 8 Differential lock ...................................................................................... 61 Drive lever .............................................................................................. 53 Driving on public roads .......................................................................... 50 Driving the machine ............................................................................... 46 Dust filter .............................................................................................. 121

E Electrically operated implements (option) .............................................. 85

F Fluids and lubricants ............................................................................ 127 Fork arms Adjusting distance ......................................................................... 97 Overview ....................................................................................... 95 Functional check Dust valve ................................................................................... 108

H Hazard warning system ......................................................................... 67 Heating .................................................................................................. 68 Heating, fresh air ........................................................................... 68 Heating, mixed mode .................................................................... 68 Heating, recirculated air ................................................................ 68

I Indicators ............................................................................................... 41 Interior light ............................................................................................ 66

J Jump-starting the engine ....................................................................... 49

L Legal regulations ................................................................................... 16 Light system ........................................................................................... 65 Load diagram ......................................................................................... 96 Load stabilizer (option) .......................................................................... 60 Loader unit Checking the tilt position of the bucket ......................................... 87 Checking the transport position of the bucket ............................... 87 Depressurizing quick couplers ...................................................... 83 Lowering with the engine turned off .............................................. 83 Lubrication .................................................................................. 117 Lock cylinder .......................................................................................... 96 Locking lever .......................................................................................... 97 Lowering the loader unit with the engine turned off ............................... 83

M Machine Brief description ............................................................................ 11

Printed in U.S.A.

150

Index Fields of application .......................................................................12 Loading and transporting ...............................................................25 Overview .......................................................................................10 Maintenance Adding hydraulic oil .....................................................................112 Air filter cartridge .........................................................................109 Biodegradable oil .........................................................................113 Bolted connections ......................................................................126 Brake system ...............................................................................118 Checking the engine oil level .......................................................104 Checking the hydraulic oil level ...................................................112 Cleaning ......................................................................................124 Cleaning the oil cooler .................................................................106 Electrical system .........................................................................122 Engine and hydraulics cooling system ........................................106 Engine lubrication system ...........................................................104 Filling up the engine oil ................................................................105 Fluids and lubricants ...................................................................127 Fuel system .................................................................................102 General maintenance work .........................................................124 Heating ........................................................................................121 Hydraulic pressure lines ..............................................................114 Hydraulic system .........................................................................111 Instructions for cables, fuses, bulbs, alternator ...........................122 Maintenance log ..........................................................................132 Maintenance of attachments .......................................................117 Maintenance plan ........................................................................128 Pivots and hinges ........................................................................126 Service and maintenance work at regular intervals .....................122 Tire care ......................................................................................119 Tire change .................................................................................120 V-belt ...........................................................................................109 Multifunctional lever ...............................................................................56

O Operation ...............................................................................................36 Cab (overview) ..............................................................................37 Driving the machine .......................................................................50 Gearbox operation .........................................................................58 Instrument panel, multifunctional lever and drive lever (overview) 39 Maneuvering ..................................................................................52 Parking the machine ......................................................................64 Seat belt height setting ..................................................................73 Selecting the drive range ...............................................................58 Starting the engine ........................................................................58 Operational safety ..................................................................................18

P Parking brake .........................................................................................55 Preheating start switch ...........................................................................53

Q Quickhitch facility ...................................................................................96 Fitting an attachment .....................................................................96 Removing an attachment ..............................................................96

R Refuelling .............................................................................................103 Rotating beacon .....................................................................................67 Running-in period ...................................................................................44

S Safety Decals .........................................................................................16 Safety instructions ..................................................................................18 Applications with lifting gear ..........................................................21 Attachments ..................................................................................26 Maintenance ..................................................................................29

918121/CP0807

Index Specific hazards ........................................................................... 30 Transport ...................................................................................... 27 Seat adjustment ..................................................................................... 71 Backrest setting ............................................................................ 72 Horizontal setting .......................................................................... 72 Weight setting ............................................................................... 71 Seat belt ................................................................................................ 73 Seat belt height setting .......................................................................... 73 Service brake ......................................................................................... 51 Signalling system ................................................................................... 67 Sound levels ................................................................................. 16, 146 Specifications ...................................................................................... 138 Axles ........................................................................................... 140 Brakes ......................................................................................... 140 Electrical system ......................................................................... 142 Engine ......................................................................................... 138 Frame ......................................................................................... 138 Hardware torques ....................................................................... 147 Loader unit .................................................................................. 142 Pilot control ................................................................................. 141 Power train .................................................................................. 139 Sound levels ............................................................................... 146 Steering ...................................................................................... 140 Tires ............................................................................................ 146 Vibration ...................................................................................... 147 Weights ....................................................................................... 146 Work hydraulics .......................................................................... 141 Stability .................................................................................................. 96

Working light .......................................................................................... 66

T Taking into service ................................................................................. 44 Checklists ..................................................................................... 45 Controls overview ......................................................................... 53 Safety instructions ........................................................................ 44 Tire care .............................................................................................. 119 Towing and transporting the machine ................................................... 23 Transport ............................................................................................... 88 Transporting loads ................................................................................. 99 Turn indicator ......................................................................................... 67

U Unlocking ............................................................................................... 96

V Ventilation .............................................................................................. 68 Ventilation, fresh air ...................................................................... 68

W Wheel change ...................................................................................... 120 Wheel synchronization position ............................................................. 51 Windshield washer pump Front window ................................................................................ 70 Rear window ................................................................................. 70 Windshield washer system .................................................................... 70 Tank .............................................................................................. 70 Wiper Front Window ................................................................................ 70 Rear .............................................................................................. 70 Working Freeing the machine ..................................................................... 93 Grading ......................................................................................... 92 Loading heaped material .............................................................. 92 Loading loose material .................................................................. 89 Removing material/digging in hard soil ......................................... 91 Removing material/digging in soft soil .......................................... 90 Using pallet forks .......................................................................... 94

Printed in U.S.A.

151

918121/CP0807

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.

Hydraulic fittings with various seals (light application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE) Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

Identification aid outside Ø

M10X1.0

7 (9)

13 (18)

11 (15)

13 (18)

0.4 in. (10 mm)

M12X1.5

15 (20)

18 (25)

18 (25)

18 (25)

0.5 in. (12 mm)

M14X1.5

26 (35)

33 (45)

26 (35)

26 (35)

0.6 in. (14 mm)

M16X1.5

33 (45)

41 (55)

30 (40)

37 (50)

0.6 in. (16 mm)

M18X1.5

41 (55)

52 (70)

33 (45)

52 (70)

0.7 in. (18 mm)

M22X1.5

48 (65)

92 (125)

44 (60)

92 (125)

0.9 in. (22 mm)

M27X2.0

66 (90)

133 (180)

74 (100)

107 (145)

1.0 in. (27 mm)

M33X2.0

111 (150)

229 (310)

118 (160)

155 (210)

1.3 in. (33 mm)

M42X2.0

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (42 mm)

M48X2.0

214 (290)

398 (540)

192 (260)

398 (540)

1.9 in. (48 mm)

G1/8A

7 (9)

13 (18)

11 (15)

13 (18)

0.4 in. (9.73 mm)

G1/4A

26 (35)

26 (35)

22 (30)

26 (35)

0.5 in. (13.16 mm)

G3/8A

33 (45)

52 (70)

33 (45)

37 (50)

0.7 in. (16.66 mm)

G1/2A

48 (65)

66 (90)

41 (55)

48 (65)

0.8 in. (20.96 mm)

G3/4A

66 (90)

133 (180)

74 (100)

103 (140)

1.0 in. (26.44 mm)

G1A

111 (150)

229 (310)

118 (160)

140 (190)

1.3 in. (33.25 mm)

G1 1/4A

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (41.91 mm)

G1 1/2A

214 (290)

398 (540)

192 (260)

398 (540)

1.9 in. (47.80 mm)

Thread

Hydraulic fittings with various seals (heavy application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE) Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

Identification aid outside Ø

M12X1.5

15 (20)

26 (35)

26 (35)

26 (35)

0.5 in. (12 mm)

M14X1.5

26 (35)

41 (55)

33 (45)

33 (45)

0.6 in. (14 mm)

Thread

M16X1.5

33 (45)

52 (70)

41 (55)

41 (55)

0.6 in. (16 mm)

M18X1.5

41 (55)

66 (90)

52 (70)

52 (70)

0.7 in. (18 mm)

M20X1.5

41 (55)

92 (125)

59 (80)

74 (100)

0.8 in. (20 mm)

M22X1.5

48 (65)

100 (135)

74 (100)

92 (125)

0.9 in. (22 mm)

M27X2.0

66 (90)

133 (180)

125 (170)

100 (135)

1.0 in. (27 mm)

M33X2.0

111 (150)

229 (310)

229 (310)

155 (210)

1.3 in. (33 mm)

M42X2.0

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (42 mm)

M48X2.0

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (48 mm)

G1/8A

26 (35)

41 (55)

33 (45)

33 (45)

0.5 in. (13.16 mm)

G1/4A

33 (45)

59 (80)

44 (60)

44 (60)

0.7 in. (16.66 mm)

G3/8A

48 (65)

85 (115)

55 (75)

74 (100)

0.8 in. (20.96 mm)

G1/2A

66 (90)

133 (180)

125 (170)

107 (145)

1.0 in. (26.44 mm)

G3/4A

111 (150)

229 (310)

229 (310)

192 (260)

1.3 in. (33.25 mm)

G1A

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (41.91 mm)

G1 1/4A

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (47.80 mm)

With coarse-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

Threads according to DIN 7984

12.9

8.8

10.9

M5

4.1 (5.5)

6 (8)

7 (10)

4 (5)

5 (7)

M6

7 (10)

10 (14)

13 (17)

6.3 (8.5)

9 (12)

M8

18 (25)

26 (35)

31 (42)

15 (20)

22 (30)

M10

33 (45)

48 (65)

59 (80)

30 (40)

44 (59)

M12

64 (87)

81 (110)

108 (147)

51 (69)

74 (100)

M14

100 (135)

133 (180)

170 (230)

81 (110)

118 (160)

M16

155 (210)

203 (275)

258 (350)

125 (170)

184 (250)

M18

207 (280)

302 (410)

354 (480)

181 (245)

254 (345)

M20

302 (410)

420 (570)

509 (690)

251 (340)

361 (490)

M22

406 (550)

575 (780)

686 (930)

339 (460)

487 (660)

M24

524 (710)

738 (1000)

878 (1190)

435 (590)

620 (840)

M27

767 (1040)

1092 (1480)

1305 (1770)

642 (870)

922 (1250)

M30

1047 (1420)

1482 (2010)

1770 (2400)

885 (1200)

1254 (1700)

With fine-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

Threads according to DIN 7984

12.9

8.8

10.9

M8X1.0

18 (25)

27 (37)

32 (43)

16 (22)

24 (32)

M10X1.0

37 (50)

55 (75)

65 (88)

32 (43)

48 (65)

M10X1.25

36 (49)

52 (71)

61 (83)

31 (42)

46 (62)

M12X1.25

64 (87)

96 (130)

111 (150)

55 (75)

81 (110)

M12X1.5

61 (83)

92 (125)

107 (145)

53 (72)

77 (105)

M14X1.5

100 (135)

148 (200)

173 (235)

89 (120)

129 (175)

M16X1.5

155 (210)

229 (310)

266 (360)

133 (180)

195 (265)

M18X1.5

232 (315)

332 (450)

391 (530)

199 (270)

284 (385)

M20X1.5

325 (440)

465 (630)

538 (730)

277 (375)

391 (530)

M22X1.5

435 (590)

620 (840)

723 (980)

369 (500)

524 (710)

M24X2.0

546 (740)

789 (1070)

922 (1250)

465 (630)

664 (900)

M27X2.0

811 (1100)

1143 (1550)

1328 (1800)

679 (920)

959 (1300)

M30X2.0

1106 (1500)

1586 (2150)

1844 (2500)

959 (1300)

1364 (1850)

Notes:

WARNING THIS OPERATOR'S MANUAL IS PROVIDED FOR OPERATOR USE DO NOT REMOVE FROM THIS MACHINE Do not start, operate or work on the machine until you carefully read and thoroughly understand the contents of this Operator’s Manual.

Failure to follow safety, operating and maintenance instructions can result in serious injury to the operator or bystanders, poor operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or maintenance of the 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. www.gehl.com 918121/CP0807

© 2007 GEHL Company. All rights reserved.

Printed in U.S.A.