Mustang ML52 Wheel Loader Operator's Manual 909893 - PDF DOWNLOAD

ML52 Wheel Loader



OPERATOR’S MANUAL Form No. 909893 

Mustang Manufacturing Company, Inc., A GehlR Comapny

1605 County Road 45 North P.O. Box 547 Owatonna, MN 55060-0547 USA Phone: (507) 451-7112 Fax: (507) 451-8209 PRELIMINARY 1P0702

MUSTANG MANUFACTURING COMPANY, INC. WARRANTY MUSTANG MANUFACTURING COMPANY, INC., hereinafter referred to as Mustang, warrants new Mustang equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months or 1,000 hours from the Warranty Start Date, whichever occurs first.

MUSTANG CONSTRUCTION WARRANTY INCLUDES: Genuine Mustang parts and labor costs required to repair or replace equipment at the selling dealer’s business location.

MUSTANG 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.

MUSTANG WARRANTY SERVICE DOES NOT INCLUDE: 1.

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

2.

Used equipment.

3.

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

4.

Normal maintenance service and expendable, high wear items.

5.

Repairs or adjustments caused by: improper use; failure to follow recommended maintenance procedures; use of unauthorized attachments; accident or other casualty.

6.

Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment.

No agent, employee or representative of Mustang has any authority to bind Mustang to any warranty except as specifically set forth herein. Any of these limitations excluded by local law shall be deemed deleted from this warranty; all other terms will continue to apply.

Table of contents

Table of contents I

Introduction Introduction .................................................................................................................... 1-1 Notes on this operation manual ............................................................................... 1-1 Vehicle overview....................................................................................................... 1-2 Brief description ........................................................................................................ 1-3 Hydrostatic drive ............................................................................................. 1-3 Work hydraulics and hydrostatic four wheel steering ..................................... 1-3 Cooling system ............................................................................................... 1-3 Fields of application .................................................................................................. 1-4 Regulations............................................................................................................... 1-6 Vehicle data ............................................................................................................. 1-7 Vehicle model/version: ................................................................................. 1-7 Serial number: .............................................................................................. 1-7 Commissioning/date of registration: .......................................................... 1-7 Service hours/kilometre reading: ............................................................... 1-7 Cab number: ................................................................................................. 1-7 Engine number: .............................................................................................. 1-7 Hydraulic pump Variable displacement pump model – identification number: ......................... 1-7 Hydraulic motor variable displacement motor model – identification no.: ................................. 1-7 Front axle number: ......................................................................................... 1-7 Rear axle number: .......................................................................................... 1-7 Gearbox number: ........................................................................................... 1-7 Optional implements: ................................................................................... 1-7 Your local dealer ............................................................................................ 1-7 Page left intentionally blank .................................................................................. 1-8 Type labels and component numbers....................................................................... 1-9 Other Signs and symbols ....................................................................................... 1-10 ... on the outside of the vehicle ..................................................................... 1-10 ...inside the operator’s compartment ............................................................ 1-11 Notes: ........................................................................................................... 1-12

Safety instructions Safety instructions .......................................................................................................... 2-1 Identification of warnings and dangers .................................................................... 2-1 Designated use and exemption from liability ............................................................ 2-2 General conduct and safety instructions................................................................... 2-3 Organizational measures ............................................................................... 2-3 Selection and qualification of personnel, basic responsibilities ...................... 2-5 Safety instructions regarding operation .................................................................... 2-6 Normal operation ............................................................................................ 2-6 Applications with lifting accessories ............................................................... 2-8 Trailers and implements ................................................................................. 2-9 Transport ........................................................................................................ 2-9 Safety instructions for maintenance........................................................................ 2-10 Warning of special hazards .................................................................................... 2-12 Electric energy .............................................................................................. 2-12 Gas, dust, steam, smoke .............................................................................. 2-12 Hydraulic equipment ..................................................................................... 2-13 Noise ............................................................................................................ 2-13 Oil, grease and other chemical substances ................................................. 2-13

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Table of contents Battery .......................................................................................................... 2-13 Tyres ............................................................................................................. 2-13

Operation Operation ....................................................................................................................... 3-1 Overview of cab ........................................................................................................ 3-2 Overview: switches, levers and consoles ................................................................ 3-4 Taking into service .................................................................................................... 3-6 Safety instructions ............................................................................................. 3-6 Taking the vehicle into service for the first time ................................................. 3-6 Important information ...................................................................................... 3-6 Running-in period ........................................................................................... 3-6 Checklists ........................................................................................................... 3-7 Start-up checklist ............................................................................................ 3-7 Operation checklist ......................................................................................... 3-8 Parking checklist ............................................................................................. 3-8 Driving the vehicle..................................................................................................... 3-9 Overview of control elements ............................................................................ 3-9 Preheating start switch [76] ............................................................................ 3-9 Drive range selector [77] ............................................................................... 3-9 Driving direction tip switch [72/75] ................................................................ 3-10 Accelerator pedal [25] ................................................................................... 3-10 Manual throttle lever [71] (option) ................................................................. 3-11 Brake/inching pedal [27] ............................................................................... 3-11 Control lever [84] – low-speed control (option) ............................................. 3-12 Parking brake [24] ........................................................................................ 3-12 Multifunctional lever [26] ............................................................................... 3-13 Overview Telltales and warning lights ............................................................. 3-15 Before starting the engine ................................................................................ 3-18 Start the engine ............................................................................................... 3-18 General ......................................................................................................... 3-18 Procedure ..................................................................................................... 3-19 Starting at temperatures below 0 °C ............................................................. 3-19 When the engine has started ... .................................................................... 3-20 Connecting the oil preheater (option) ........................................................... 3-20 Fuel preheater (Not available) ...................................................................... 3-20 Jump-starting the vehicle.................................................................................. 3-21 Starting the engine with starting aid (supply battery) ............................................................................................. 3-21 Before moving off.............................................................................................. 3-22 Special instructions for driving on public roads ............................................ 3-22 Preparing the vehicle for driving on public roads .......................................... 3-22 Before moving off: ........................................................................................ 3-23 Inspection of important functional units ........................................................ 3-24 Moving off ......................................................................................................... 3-26 Gear shift .......................................................................................................... 3-27 Selecting the drive range .............................................................................. 3-27 High speed (option) ...................................................................................... 3-28 Changing direction............................................................................................ 3-29 Backup warning system (option) .................................................................. 3-29 Load stabiliser................................................................................................... 3-30 Differential lock ................................................................................................. 3-31 Engaging differential lock ............................................................................. 3-31 Switching off the differential lock .................................................................. 3-31 Steering ............................................................................................................ 3-32 Synchronising the steering ........................................................................... 3-32 Changing steering mode in vehicles without high speed option ................... 3-33 I-2

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Table of contents Changing steering mode in vehicles with high speed option ........................ 3-33 Stop the vehicle ................................................................................................ 3-34 Parking the vehicle .......................................................................................... 3-34 Light system ..................................................................................................... 3-35 Signalling system.............................................................................................. 3-37 Cabheating and ventilation ............................................................................... 3-38 Front window heater (option) ........................................................................ 3-39 Air conditioning (option) ................................................................................ 3-39 Auxiliary heating (option) .................................................................................. 3-40 Remedy for malfunction: .............................................................................. 3-40 Washer system................................................................................................. 3-41 Tank ............................................................................................................. 3-41 Seat adjustment................................................................................................ 3-42 Weight setting ............................................................................................... 3-42 Height setting ............................................................................................... 3-42 Armrest setting ............................................................................................. 3-43 Backrest setting ............................................................................................ 3-43 Longitudinal setting ...................................................................................... 3-43 Seat belt ........................................................................................................... 3-44 Vehicle doors.................................................................................................... 3-46 Other controls ................................................................................................... 3-47 Tank lock ...................................................................................................... 3-47 Engine cover ................................................................................................ 3-47 Battery master switch (option) ...................................................................... 3-47 Towing the vehicle............................................................................................ 3-48 Safety instructions ........................................................................................ 3-48 Towing .......................................................................................................... 3-48 Handling the vehicle with a crane..................................................................... 3-49 Safety instructions ........................................................................................ 3-49 Crane handling ............................................................................................. 3-49 Loading and transporting the vehicle................................................................ 3-50 Safety instructions ........................................................................................ 3-50 Loading the vehicle ...................................................................................... 3-50 Lashing down the vehicle ............................................................................. 3-51 Working with the vehicle ........................................................................................ 3-52 General safety instructions .............................................................................. 3-52 Load diagram ................................................................................................... 3-52 Control valve of the loader unit: overview......................................................... 3-53 Control lever for hydraulics of lift and tilt ram of loader unit ......................... 3-53 Tip switch on control lever ............................................................................ 3-53 Control lever for implements and 3rd control circuit ..................................... 3-54 Securing control levers for driving on public roads ....................................... 3-55 3rd electrically operated control circuit (option) ............................................................................................... 3-56 Lowering the loader unit with the engine switched off ..................................... 3-57 Depressurising the quick couplers on the loader unit ...................................... 3-57 Connecting pressurised quick couplers............................................................ 3-58 Re-equipping the loader unit ............................................................................ 3-60 Fitting implements onto the quickhitch facility .............................................. 3-60 Taking an implement off the quickhitch facility ............................................. 3-63 Connection of electrically operated implements (option) ................................. 3-64 Operation of the restrictor unit on the tilt ram (option) ...................................... 3-66 Safety equipment "Hose burst valve" (option) .................................................. 3-67 Working with standard bucket and pallet forks ................................................. 3-69 Implements ................................................................................................... 3-69 Standard bucket ........................................................................................... 3-69 Working with pallet forks .............................................................................. 3-75 BA 302 01 US-Gehl - Edition 1.0 * 30201busg10IVZ.fm

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Table of contents Troubleshooting Troubleshooting ............................................................................................................. 4-1 Engine trouble........................................................................................................... 4-2

Maintenance Maintenance ................................................................................................................... 5-1 Introduction .............................................................................................................. 5-1 Fuel system .............................................................................................................. 5-1 Specific safety instructions ................................................................................ 5-1 Refuelling............................................................................................................ 5-2 Stationary fuel pumps ..................................................................................... 5-2 Specification for diesel fuel ............................................................................. 5-3 Cleaning the fuel tank ........................................................................................ 5-3 Changing the fuel filter........................................................................................ 5-4 Cleaning the screen filter of the fuel pump ......................................................... 5-5 Changing the leak oil line.................................................................................... 5-6 Engine lubrication system ......................................................................................... 5-7 Checking the oil level ......................................................................................... 5-7 Filling in engine oil .............................................................................................. 5-8 Changing the engine oil ...................................................................................... 5-9 Changing the engine oil filter cartridge ............................................................. 5-10 Engine and hydraulics cooling system.................................................................... 5-11 Specific safety instructions .............................................................................. 5-11 Engine oil cooler .............................................................................................. 5-11 Cleaning ....................................................................................................... 5-11 Hydraulic oil cooler ........................................................................................... 5-12 Cleaning ....................................................................................................... 5-12 Air filter ................................................................................................................... 5-13 Functional check of the dust valve ............................................................... 5-14 Replacing the filter cartridge ......................................................................... 5-15 V-belt....................................................................................................................... 5-16 Checking the V-belt tension .......................................................................... 5-16 Retightening the V-belt ................................................................................. 5-16 Hydraulic system..................................................................................................... 5-17 Specific safety instructions .............................................................................. 5-17 Hydraulic oil level.............................................................................................. 5-18 Checking the oil level .................................................................................... 5-18 Topping up hydraulic oil ................................................................................ 5-18 Changing the hydraulic oil ............................................................................ 5-19 Important information for the use of biodegradable oil ................................. 5-21 Hydraulic oil reflux filter..................................................................................... 5-22 Changing the filter insert ............................................................................... 5-22 Changing the breather filter ............................................................................. 5-23 Hydraulic pressure lines ................................................................................... 5-24 Specific safety instructions ........................................................................... 5-24 Gearboxes and axles ............................................................................................. 5-25 Rear axle gearbox ............................................................................................ 5-26 Checking/topping up the oil level in the rear axle gearbox ........................... 5-26 Changing the gearbox oil .............................................................................. 5-27 Rear axle differential......................................................................................... 5-28 Checking/topping up the oil level in the rear axle gearbox ........................... 5-28 Changing the oil ........................................................................................... 5-28 Front axle differential ........................................................................................ 5-29 Checking/topping up the oil level .................................................................. 5-29 Changing oil .................................................................................................. 5-29 Front and rear axle planetary drives ................................................................. 5-30 I-4

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Table of contents Checking/topping up the oil level .................................................................. 5-30 Changing the oil .......................................................................................... 5-30 Lubricating planetary drive bearings ................................................................ 5-31 Lubricating the rear axle oscillation-type bearing ............................................ 5-31 Loader unit.............................................................................................................. 5-32 Lubricating the pivots on the loader unit .......................................................... 5-32 Tyre care................................................................................................................. 5-33 Inspection work ................................................................................................ 5-33 Daily checks ................................................................................................. 5-33 Checks every week ...................................................................................... 5-33 Wheel change................................................................................................... 5-34 Removing the wheels ................................................................................... 5-34 Fitting the wheels ......................................................................................... 5-34 Heating ................................................................................................................... 5-35 Cleaning the dust filter of the heating system .................................................. 5-35 Electrical system..................................................................................................... 5-36 Specific safety instructions .............................................................................. 5-36 Service and maintenance work at regular intervals.......................................... 5-37 Instructions concerning specific components .................................................. 5-37 Cables, bulbs and fuses ............................................................................... 5-37 Alternator ...................................................................................................... 5-37 Battery .......................................................................................................... 5-38 General maintenance work..................................................................................... 5-39 Cleaning .......................................................................................................... 5-39 General instructions for all areas of the vehicle ........................................... 5-39 Inside of operator compartment ................................................................... 5-40 Exterior of the vehicle ................................................................................... 5-40 Engine compartment .................................................................................... 5-40 Screw connections ........................................................................................... 5-41 Pivots and hinges ............................................................................................ 5-41 Engine fluids and lubricants .................................................................................. 5-42 Service kits ............................................................................................................ 5-43 Proofs of maintenance ........................................................................................... 5-44 Proofs of maintenance ................................................................................. 5-44 Maintenance plan (overview) ................................................................................. 5-48 Maintenance label .................................................................................................. 5-52 valid for model ML52 ..................................................................................... 5-52

Helpful information for using the spare parts list Helpful information for using the spare parts list ............................................................ 6-1 Introduction .............................................................................................................. 6-1 Composition of spare parts list ................................................................................ 6-1 Groups ............................................................................................................... 6-1 Group overview .................................................................................................. 6-2 Figures................................................................................................................ 6-3 Number index .................................................................................................... 6-3 Symbols and abbreviations ...................................................................................... 6-4 Description of symbols ...................................................................................... 6-4 Abbreviations...................................................................................................... 6-6 Indication of position ....................................................................................... 6-6 Use ................................................................................................................. 6-6 Language codes ............................................................................................. 6-6 Colour codes .................................................................................................. 6-7 Vehicle data ............................................................................................................. 6-7 Helpful information for ordering spare parts ............................................................ 6-7 Order information................................................................................................ 6-8 Address for your spare part order ...................................................................... 6-8 BA 302 01 US-Gehl - Edition 1.0 * 30201busg10IVZ.fm

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Table of contents Specifications Specifications ................................................................................................................. 7-1 Frame ....................................................................................................................... 7-1 Engine ...................................................................................................................... 7-1 Power train................................................................................................................ 7-2 Axles ........................................................................................................................ 7-3 Brakes ..................................................................................................................... 7-3 Steering ................................................................................................................... 7-4 Work hydraulics ....................................................................................................... 7-4 Pilot control ............................................................................................................. 7-4 Loader unit ............................................................................................................... 7-5 Weights .................................................................................................................... 7-5 Electrical system ...................................................................................................... 7-6 Noise levels .............................................................................................................. 7-9 Vibration ................................................................................................................... 7-9 Tyres ....................................................................................................................... 7-10 Dimensions ........................................................................................................... 7-11 Coolant compound table ........................................................................................ 7-11 Tightening torques ................................................................................................. 7-12 General tightening torques .............................................................................. 7-12 Specific tightening torques .............................................................................. 7-12

Annex Hydraulics diagram (options) ........................................................................................ A-1 Hydraulics diagram ....................................................................................................... A-2 valid for model ML52 ..................................................................................... A-2 Legend – wiring diagram ............................................................................................... A-4 Wiring diagram .............................................................................................................. A-7 Wiring diagram legend – options ................................................................................... A-8 Wiring diagram – option ................................................................................................ A-8

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Index I

Index Numerisch 3rd electrically operated control circuit (option) ...................................3-56

A Abbreviations .........................................................................................1-1 Air filter cartridge ........................................................................ 5-13, 5-15 Auxiliary heating (option) .....................................................................3-40

B Backup warning system (option) ..........................................................3-29 Battery master switch (option) .............................................................3-47 Biodegradable oil .................................................................................5-21 Brake/inching pedal ................................................................... 3-11, 3-12

C Capacities ............................................................................................5-42 CE mark ...............................................................................................1-11 Checklists ..............................................................................................3-7 Control lever Continuous operation of implements ............................................3-54 For implements and 3rd control circuit ..........................................3-54 For lift and tilt ram .........................................................................3-53 Securing for driving on public roads ..............................................3-55 Controls .................................................................................................3-9

D Designated use and exemption from liability .........................................2-2 Differential lock ....................................................................................3-31 Documents .............................................................................................1-6 Doors ...................................................................................................3-46 Drive pedal ...........................................................................................3-10 Driving licence .......................................................................................1-6 Driving on public roads ........................................................................3-22 Driving the vehicle .................................................................................3-9 Dust filter ..............................................................................................5-35

E Electrical diagram ..........................................................................A-7, A-8 Engine fluids ........................................................................................5-42

F Fields of application Possible implements .......................................................................1-4 Fine dust filter (option) .........................................................................5-35 Front window heater (option) ...............................................................3-39 Fuel level indicator ...............................................................................3-17 Fuel preheater (option) ........................................................................3-20 Fuel system Cleaning the screen filter of the fuel pump .....................................5-6

G General conduct ....................................................................................2-3

H Hazard warning system .......................................................................3-37 Heating ................................................................................................3-38

L Legal regulations ...................................................................................1-6 Light system .........................................................................................3-35 Load diagram .......................................................................................3-52 Load stabiliser ......................................................................................3-30

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Loader unit Checking the tilt position of the bucket ......................................... 3-69 Checking the transport position of the bucket .............................. 3-69 Depressurising quick couplers ..................................................... 3-57 Lowering with the engine switched off .......................................... 3-57 Lubricating .................................................................................... 5-32 Re-equipping ................................................................................ 3-60 Loading vehicles .................................................................................. 3-75 Locking control levers for road travel .................................................. 3-23 Low speed control (option) .................................................................. 3-12 Lowering the loader unit with the engine switched off ......................... 3-57 Lubricants ............................................................................................ 5-42

M Maintenance Air filter ......................................................................................... 5-13 Biodegradable oil .......................................................................... 5-21 Changing the engine oil .................................................................. 5-9 Changing the engine oil filter cartridge ......................................... 5-10 Changing the filler and breather filter on the hydraulic oil tank .... 5-23 Changing the fuel filter ................................................................... 5-4 Changing the hydraulic oil ............................................................ 5-19 Checking the engine oil level .......................................................... 5-7 Checking the hydraulic oil level .................................................... 5-18 Cleaning ....................................................................................... 5-39 Cleaning the engine oil cooler ...................................................... 5-11 Cleaning the fuel tank ..................................................................... 5-3 Cleaning the hydraulic oil cooler .................................................. 5-12 Cleaning the screen filter of the fuel pump ..................................... 5-5 Electrical diagram (options) ............................................................A-8 Electrical system .......................................................................... 5-36 Engine and hydraulics cooling system ......................................... 5-11 Engine lubrication system .............................................................. 5-7 Filling in engine oil .......................................................................... 5-8 Front axle differential .................................................................... 5-29 Fuel system .................................................................................... 5-1 Gearboxes and axles ................................................................... 5-25 General maintenance work .......................................................... 5-39 Heating ......................................................................................... 5-35 Hydraulic oil reflux filter ................................................................ 5-22 Hydraulic pressure lines ............................................................... 5-24 Hydraulic system .......................................................................... 5-17 Instructions concerning specific components ............................... 5-37 Lubricating the loader unit ............................................................ 5-32 Lubricating the oscillation-type bearing ........................................ 5-31 Maintenance plan ......................................................................... 5-48 Pivots and hinges ......................................................................... 5-41 Planetary drives ............................................................................ 5-30 Proofs of maintenance ................................................................. 5-44 Rear axle differential .................................................................... 5-28 Rear axle gearbox ........................................................................ 5-26 Screw connections ....................................................................... 5-41 Service and maintenance work at regular intervals ...................... 5-37 Topping up hydraulic oil ............................................................... 5-18 Tyre care ...................................................................................... 5-33 V-belt ............................................................................................ 5-16 Wheel change .............................................................................. 5-34 Manual throttle (option) ..............................................................3-11, 3-23 Maximum speed .................................................................................. 1-11 Multifunctional lever ............................................................................. 3-13

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Index N Noise level ................................................................................... 1-11, 7-9

O Oil preheating (option) .........................................................................3-20 Operation ...............................................................................................3-1 Backup warning system (option) ...................................................3-29 Before moving off ..........................................................................3-22 Before starting the engine .............................................................3-18 Changing direction ........................................................................3-29 Drive ranges .................................................................................3-27 Moving off .....................................................................................3-26 Overview of cab ..............................................................................3-2 Overview of control elements .........................................................3-9 Overview of instrument panel, multifunctional lever and drive switch ..

3-4 Parking the vehicle .......................................................................3-34 Restrictor unit ................................................................................3-66 Restrictor unit on tilt ram (option) ........................................ 3-66, 3-67 Selecting the drive range ..............................................................3-27 Start the engine ............................................................................3-18 Stop the vehicle ............................................................................3-34 To fasten seat belt ........................................................................3-44 Operation manual Notes ..............................................................................................1-1

P Pallet forks ...........................................................................................3-75 Safety instructions ........................................................................3-75 Parking brake .......................................................................................3-12 Picking up an implement ......................................................................3-60 PME fuel ................................................................................................5-3 Preheating start switch ..........................................................................3-9

R Re-equipping the loader unit ................................................................3-60 Refuelling ...............................................................................................5-2 Restrictor unit on tilt ram (option) .........................................................3-66 Road travel ..........................................................................................3-22 Rotating beacon (option) .....................................................................3-37 Running-in period ..................................................................................3-6

S Safety instructions .................................................................................2-1 Identification ....................................................................................2-1 Operating ........................................................................................2-6 Special hazards ............................................................................2-12 Seat adjustment ...................................................................................3-42 Armrest setting ..............................................................................3-43 Backrest setting ............................................................................3-43 Height setting ................................................................................3-42 Longitudinal setting .......................................................................3-43 Weight setting ...............................................................................3-42 Service brake .......................................................................................3-25 Service kits ..........................................................................................5-43 Signalling system .................................................................................3-37 Signs and symbols ...............................................................................1-10

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Specifications ........................................................................................ 7-1 Axles ............................................................................................... 7-3 Brakes ............................................................................................ 7-3 Coolant compound table .............................................................. 7-11 Dimensions ................................................................................... 7-11 Electrical system ............................................................................ 7-6 Engine ............................................................................................ 7-1 Frame ............................................................................................. 7-1 Loader unit ..................................................................................... 7-5 Noise levels .................................................................................... 7-9 Pilot control ..................................................................................... 7-4 Power train ..................................................................................... 7-2 Steering .......................................................................................... 7-4 Tightening torques ........................................................................ 7-12 Tyres ............................................................................................ 7-10 Vibration ......................................................................................... 7-9 Weights .......................................................................................... 7-5 Work hydraulics .............................................................................. 7-4 Standard electrical diagram ..................................................................A-7 Starting aid .......................................................................................... 3-21 Starting with starting aid ...................................................................... 3-29 Steering ............................................................................................... 3-24 Steering angle limit ....................................................................... 7-10 Steering-column control lever ............................................................... 3-9 Symbols ................................................................................................ 1-1 Synchronous wheel position ............................................................... 3-24

T Taking into service ................................................................................ 3-6 Checklists ....................................................................................... 3-7 Safety instructions .......................................................................... 3-6 Taking the vehicle into service for the first time ............................. 3-6 Telltales ............................................................................................... 3-15 To fasten seat belt ............................................................................... 3-44 Towing the vehicle .............................................................................. 3-48 Transport ............................................................................................. 3-70 Transport position ............................................................................... 3-22 Turn indicators .................................................................................... 3-37 Type labels and component numbers ................................................... 1-9 Tyre care ............................................................................................. 5-33

V Vehicle Brief description .............................................................................. 1-3 Crane handling ............................................................................. 3-49 Data ................................................................................................ 1-7 Fields of application ........................................................................ 1-4 Loading and transporting .............................................................. 3-50 Overview ........................................................................................ 1-2 Vehicle equipment ................................................................................. 1-6 Vehicle inspections ............................................................................... 1-6 Ventilation ........................................................................................... 3-38 Ventilation, fresh air ...................................................................... 3-38

W Warning identification ............................................................................ 1-7 Washer pump ...................................................................................... 3-41 Washer system ................................................................................... 3-41 Tank ............................................................................................. 3-41 Wheel change ..................................................................................... 5-34 Window wiper ...................................................................................... 3-41 Wiring diagram ......................................................................................A-7

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Index Working ... with pallet forks .........................................................................3-75 ... with standard bucket .................................................................3-69 ... with the vehicle .........................................................................3-52 Freeing the vehicle ........................................................................3-75 General safety instructions ...........................................................3-52 Loading heaped material ..............................................................3-74 Loading loose material ..................................................................3-70 Planieren .......................................................................................3-74 Practical hints ................................................................................3-75 Removing material/digging in hard soil .........................................3-73 Removing material/digging in soft soil ..........................................3-72 Restrictor unit on tilt ram (option) ..................................................3-66 Safety equipment "Hose burst valve" (option) ..............................3-67

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Index

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Section Introduction

1

Introduction

Introduction

1

Introduction

1.1

Notes on this operation manual

1

This operation manual contains important information on how to work safely, correctly and economically with the wheel loader model ML52. Therefore, it aims not only at new operators, but is also a reference for experienced ones. It helps to avoid dangerous situations, and reduce repair costs and downtimes. Furthermore, the reliability and the service life of the vehicle will be increased by following the instructions in the operation manual. This is why the operation manual must always be kept at hand in the vehicle.

Your own safety, as well as the safety of others, depends to a great extent on how the vehicle is moved and operated. Therefore, carefully read and understand this operation manual prior to the first drive. This operation manual will help to familiarise yourself more easily with the vehicle, thereby enabling you to use it more safely and efficiently.

General safety instructions are given in Section 2 of this operation manual. The owner and the operators of the vehicle must know and follow them at all times. As a rule, keep the following in mind: Prudent and careful work is the best protection against accidents!

Special safety instructions with direct reference to service, function and operation of the vehicle are given right before the procedure to follow in the respective sections. This is to make sure that these safety instructions are read and followed when needed.

Operational safety and readiness of the vehicle do not only depend on your skill, but also on maintenance and service of the vehicle. This is why regular maintenance and service work is absolutely necessary. Extensive maintenance and repair work must always be carried out by an expert with appropriate training. Insist on using original spare parts when carrying out maintenance and repair work. This ensures operational safety and readiness of your vehicle, and maintains its value.

Your dealer will be pleased to answer any further questions regarding the vehicle or the operation manual.

Abbreviations/Symbols

• This symbol stands for an enumeration • Subdivision within lists or an activity. If possible, follow the order recommended ☞ 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 SO = option Stated whenever controls or other components of the vehicle are installed as an option.

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

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Introduction 1.2

Vehicle overview 4

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30300b03025.eps

1 Tooth guard for bucket for long-haul travel 2 Danger label 3 Front eye hooks – lifting and strapping down the vehicle 4 Horn 5 Mark – loader unit position for long-haul travel 6 Wheel chock 7 Access handle 8 Maximum driving speed label 9 EC mark 10 Noise emission label 11 Door arrester 12 Upper foothold 13 Extra clearance light (option) 14 Rear eye hooks – lifting and strapping down the vehicle 15 Tow away facility 16 Lower foothold 17 Rear registration number (possibly necessary depending on the legal regulations of your country)

1-2

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18 Signalling device – backup warning system (option) 19 Rearview mirror 20 Brake light, rear light and turn indicator 21 Label – Do not touch any moving or turning parts!

Do not open engine cover before engine is at a standstill!

22 Engine cover lock 23 Reflectors 24 Working light (option) 25 Fuel filler inlet 26 Front registration number (possibly necessary depending on the legal regulations of your country) 27 Turn indicators, clearance lights 28 Possible installation of fire extinguisher 29 Headlights 30 Protective FOPS screen (option)

Fig. 1:

Vehicle outside views

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Introduction 1.3

Brief description The wheel loader model ML52 is a self-propelled work machine.

This vehicle is a versatile and powerful helper for moving earth, gravel and debris on construction sites and elsewhere. The wide range of implements accounts for the numerous applications of the vehicle: as a fork lift, a snow plough, a spreader for grit, salt etc., a sweeper or a tree replanter. See part 1.4 Fields of application for further applications. Retrofit the vehicle with the respective safety devices when using it as a lifting accessory, see Section “Applications with lifting accessories” on page 2-8.

The main components of the vehicle model ML52 are: • ROPS-tested operator's cab with comfort seat, protective FOPS screen (option), adjustable steering column, emergency seat upon request • Oil-to-air cooled, sound-insulated 4-cylinder Deutz diesel engine • Sturdy, U-section frame in torsion-resistant box-type design, cab and engine rubber mounted • Hydrostatic drive with axle transfer gearbox and 2 drive ranges, inching function; 20 kph max. speed, 40 kph max. speed as high speed option or 30 kph max. speed as restricted high speed option • Hydrostatic four-wheel steering with emergency steering features, automatic steering synchronisation by pressing a button • Front and rear planetary steering and drive axles, rear axle with oscillation • Service brake designed as inner multi-disc brake, secondary and parking brake designed as disc brake on front axle

Hydrostatic drive

The diesel engine permanently 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 permanent four wheel drive.

Work hydraulics and hydrostatic four wheel steering

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

When the vehicle is in operation, the entire diesel engine output can be transmitted to the gear pump for work hydraulics and steering. This is made possible by the so-called inching which responds as soon as the inching brake is used, reducing or cutting off power input of the drive. Therefore, engine output is fully available for the loader unit by pressing the accelerator pedal and the inching brake pedal at the same time.

Cooling system

An oil cooler is located at the rear of the vehicle for hydraulic oil cooling. The engine oil is cooled by a separate oil cooler mounted on the engine. The telltales in the instrument panel ensure constant monitoring of the coolant and hydraulic oil temperature.

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1-3

Introduction 1.4

Fields of application The implements will decide in the first place how the vehicle can be used (see table below).

Note that not all implements listed below comply with local traffic regulations. The implements complying with local traffic regulations and the applicable provisions are listed in the vehicle documentation!

The authorities of your country may require specific permits, certifications, registrations etc. for the use of implements not authorised or listed in the vehicle documentation!

Get informed on and follow the legal regulations of your country.

The following table provides an overview of possible implements

Description of implement

Vehicle model Model

Use

Standard bucket – normal material ML52

810137

Loosening, picking up, transporting and loading loose or solid material (material density £ 1.8 kg/dm³)

Pallet forks

810138

Only with load diagram 0004353146

1-4

ML52

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Introduction

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1-5

Introduction 1.5

Regulations Driving licence Earth moving machinery may be driven on public roads only if the driver has a driving licence for the vehicle, as defined by national traffic regulations. German traffic regulations require the following driving licences for driving the vehicle: In normal version (20 kph): Driving licence category L (European Union) With high speed (40 kph): Driving licence category C1 (European Union) Get informed on and follow the legal regulations of your country.

Equipment German traffic regulations require to equip the vehicle with e.g.: • 1 warning triangle with design certification • 1 warning light with design certification • 1 first-aid kit in accordance with the legal regulations in your country Get informed on and follow the legal regulations of your country.

We recommend to equip the vehicle with a fire extinguisher. The fire extinguisher can be mounted on the right B pillar in the operator's cab (see graphic “Vehicle overview” on page 1-2).

Vehicle inspections Accident prevention regulations must be followed when operating earth moving machinery in Germany.

All employer's liability insurance associations in Germany require your vehicle to be checked for technical safety according to VBG 40 §50 which must be carried out at least once a year by an expert (test report).

Provide for a label on the vehicle stating the inspection intervals (fig. 17 on page 1-11).

Vehicles with high speed option: • Your vehicle may possibly be subject to registration • Your vehicle must possibly undergo main inspections/brake checks at regular intervals Get informed on and follow the legal regulations of your country.

Documents German traffic regulations require to have the following documentation on board, e.g.:

• General certification • Driving licence • Inspection report as per VBG 40 §50 Get informed on and follow the legal regulations of your country.

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Introduction Vehicle warning identification Vehicles used on public roads for • Road building • Road maintenance • Road or park cleaning must under all circumstances be equipped according to German traffic regulations as of 01 October 1998, with the red and white identification according to DIN 30 710 in connection with the yellow rotating beacon (option).

Get informed on and follow the legal regulations of your country.

1.6

Vehicle data The following data provide a detailed description of your vehicle. Please supply your dealer with these data for all correspondence or telephone inquiries.

Please read the data valid for your vehicle/implement off the type labels, and enter these data in the list. They will immediately be at hand for all inquiries or spare parts orders ( section 6 "Helpful information for using the spare parts list" on page 6-1).

Vehicle model/version:

......................................................................................................................................

Serial number:

......................................................................................................................................

Commissioning/date of registration:

......................................................................................................................................

Service hours/kilometre reading:

......................................................................................................................................

Cab number:

......................................................................................................................................

Engine number:

......................................................................................................................................

Hydraulic pump Variable displacement pump model – identification number:

......................................................................................................................................

Hydraulic motor variable displacement motor model – identification no.:

......................................................................................................................................

Front axle number:

......................................................................................................................................

Rear axle number:

......................................................................................................................................

Gearbox number:

......................................................................................................................................

Optional implements:

...................................................................................................................................... ......................................................................................................................................

Your local dealer

• Address:

• Telephone:

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Introduction 1.7

1-8

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Introduction 1.8

Type labels and component numbers Type label The type label (Fig. 3) is located at the front right of the vehicle frame (Fig. 2/A).

A

Serial number

B

The serial number is stamped on the vehicle frame (Fig. 2/B). It is also located on the type label (Fig. 3).

20

Type label information

Type label: location

39

00 435 12 21

Fig. 2:

Fhzg-Typ Model Modèle Typ / Ausf.

Version Version Fg.-Nr. Serial no.

No. de série Baujahr Model year Année 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 30300b0010.eps

Fig. 3:

Type label

Example for vehicle model ML52: Vehicle model: ML52 Version ML52 Serial number: ML52 0100 Year of construction: 2002 Gross front axle weight rating: 4000 kg Gross rear axle weight rating: 4000 kg Gross weight rating: 6000 kg Output: 48,5 kW Check your vehicle's type label or the "Specifications" section for vehicle data.

Cab number The type label of the vehicle cab is located at the upper left, on the B pillar of the vehicle cab.

Fig. 4:

Cab type label

Engine number The engine number is located on the type label on top of the engine block (Fig. 5).

Example: BF4L 1011FT 00411134

Fig. 5:

Diesel engine number

Hydraulic pump number The type label (arrow, Fig. 6) is located at the front, on the hydraulic pump housing.

Fig. 6:

Hydraulic pump type label

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1-9

Introduction Hydraulic motor number The type label (arrow) is located on the lower side of the hydraulic motor, above the cardan shaft.

Fig. 7:

Hydraulic motor: type label

Rear axle and gearbox number The axle number is located on the type label, on the inside of the axle tube, on the left in driving direction (arrow).

The gearbox number is located on the type label, close to the cardan shaft flange, on the left in driving direction (arrow)

Fig. 8:

Rear axle and gearbox: type label

Front axle number The axle number is located on the type label, on the inside of the axle tube, on the right in driving direction (arrow).

Fig. 9:

Front axle: type label

1.9

Other Signs and symbols The following states signs and symbols which are not unequivocally comprehensible. They do not contain explanatory text and are not explained in the following sections.

... on the outside of the vehicle

A C

B Fig. 10: Labels at the vehicle rear end

Meaning General indication of danger: This sign warns persons standing or working near the vehicle of an existing danger within the area of increased danger around the vehicle.

308b0360.eps

Fig. 11: Danger sign

1-10

Location: Front left and right of the vehicle frame, and at the vehicle rear end (Fig. 10/A).

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Introduction Meaning Indicates eye hooks on the vehicle. The eye hooks are used for lifting or strapping down the vehicle.

Location: 308b0680.eps

At the rear on the counterweight (Fig. 10/B), and at the front over the front axle, to the left and right of the vehicle frame.

Fig. 12: Label: eye hooks

Meaning 1 2

Do not open engine cover before engine is at a standstill!

Do not touch any moving or turning parts!

Location: At the rear on the engine cover of the vehicle (Fig. 10/C), and on the engine block Fig. 13: Prohibitory sign

Meaning

ε L pA

XX

XX Fig. 14: Labels: noise levels

Indication of Noise levels produced by the vehicle LWA = sound power level LPA = noise level inside the cab Further indications – see section 7.12 Noise levels on page 7-9 Location: On rear left window Meaning

20

Design-specific max. vehicle speed in kph Location: Left and right of counterweight and on rear window

Fig. 15: Speed label

Meaning The CE mark means that the vehicle meets the requirements of the EC Machine Directive and that the conformity procedure has been carried out. The vehicle meets all health and safety requirements of the EC Machine Directive. ce.ai

Location: On rear left window

Fig. 16: CE mark

...inside the operator’s compartment Meaning Sicherheitstechnische Überprüfung nach VBG 40 § 50

Certification of inspection by UVV (German regulations for accident prevention) as per VBG 40 §50 (brochure of the German employer's liability insurance association for construction engineering), by means of an expert Location: In the cab on the left B pillar

Fig. 17: UVV inspection label

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Introduction Load diagram (Fig. 18) ... for operation of pallet forks with fork arms: The framed numbers indicate the maximum authorized load on the fork arms for industrial and off-road applications respectively. The maximum load varies according to the distance from the load centre.

Reading example for implement no. 810138, model ML52: Off-road operation ➝ Safety factor S=1.67 Load distance = 600 mm The maximum load amounts to e.g. 1580 kg!

1440

Tyre inflation pressure table (fig. 18) ...List of authorised types of tyres with prescribed tyre inflation pressures Further indications – see section 7.14 Tyres on page 7-10 Location: Inside the cab, on left side of front window Important!

The load diagrams shown on the front window are valid only for applications with pallet forks. Observe the specific load diagrams of other implements used, e.g. rotary crane jib!

Typ model modèle

ML52 30100b1370.eps

Fig. 18: Load diagram/tyre table for model ML52

Notes:

1-12

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Section Safety instructions

2

Safety instructions

Safety instructions

2

Safety instructions2

2.1

Identification of warnings and dangers Important indications regarding the safety of the operating personnel and the vehicle are indicated in this operation manual with the following terms and symbols: Danger!

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

☞ Measures for avoiding danger

Caution!

Failure to observe the instructions identified by this symbol may result in damage to the vehicle. ☞ Measures for avoiding danger for the vehicle

Important!

This symbol identifies instructions for a more efficient and economical use of the vehicle.

Environment!

Failure to observe the instructions identified by this symbol may result in damage to the environment.

The environment is in danger if environmentally hazardous material (e.g. waste oil) is not subject to proper use or disposal.

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Safety instructions 2.2

Designated use and exemption from liability • The vehicle is intended for:

•

•

•

• •

2-2

• Moving earth, gravel, coarse gravel or ballast and rubble as well as • Working with the implements stated in the present operation manual Every other application is regarded as not designated for the use of the vehicle. Producer will not be liable for damage resulting from this. The user alone will bear the risk.

Designated use also includes observing the instructions in the operation manual and observing the conditions of maintenance and service.

Observe the pertinent regulations relevant to accident prevention, other generally acknowledged regulations regarding safety and occupational medicine, as well as the regulations and standards relevant to motor vehicles and traffic which are valid in your country. Producer will not be liable for damage resulting from the failure to observe these regulations.

The safety of the vehicle can be negatively affected by carrying out vehicle modifications without proper authority and by using spare parts, equipment, implements and optional equipment which have not been checked and released by producer. Producer will not be liable for damage resulting from this.

Producer will not be liable for personal injury and/or damage to property caused by failure to observe the safety instructions and the operation manual, and by the negligence of the duty to exercise due care when: • Handling • Operating • Servicing and carrying out maintenance work or • Repairing the vehicle. This is also applicable in those cases in which special attention has not been drawn to the duty to exercise due care, in the safety instructions as well as in the operation and maintenance manuals (vehicle/engine).

Read and understand the operation manual before starting up, servicing or repairing the vehicle. Observe the safety instructions!

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

In applications with lifting accessories, the vehicle is used according to its designated use only if the prescribed safety devices are installed and functional.

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Safety instructions 2.3

General conduct and safety instructions

Organizational measures

• The vehicle has been designed and built in accordance with state-of-the-art standards

•

• • •

•

•

• • •

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and the recognised safety regulations. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or cause damage to the vehicle and to other material property.

The vehicle must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operation manual, and only by safetyconscious persons who are fully aware of the risks involved in operating the vehicle.

Any functional disorders, especially those affecting the safety of the vehicle, must therefore be rectified immediately!

Basic rule: Before starting up the vehicle, inspect the vehicle for safety in work and road operation!

Careful and prudent working is the best way to avoid accidents!

The operating instructions must always be at hand at the place of use of the vehicle, and must therefore be kept in the storage compartment provided for in the cab.

Immediately complete or replace an incomplete or illegible operation manual.

In addition to the operating instructions, observe and instruct the operator in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.

These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment, or traffic regulations.

With regard to specific operational features, e.g. those relevant to job organisation, work sequences or the persons entrusted with the work, supplement the operation manual by corresponding instructions, including those relevant to supervising and reporting duties.

Persons entrusted with work on the vehicle must have read and understood the operation manual and in particular, Section 2 “Safety Instructions” before beginning work. This applies especially to persons working only occasionally on the vehicle, e.g. set-up or maintenance.

The user/owner must check – at least from time to time – whether the persons entrusted with operation or maintenance of the vehicle are working in compliance with the operation manual and are aware of risks and safety factors.

The user/owner commits himself to operate and keep the vehicle in a perfect condition, and, if necessary or required by law, to require the operating or servicing persons to wear protective clothing etc.

In the event of safety-relevant modifications or changes on the vehicle or of its behaviour, stop the vehicle immediately and report the malfunction to the competent authority/person.

Safety-relevant damage or malfunctions of the vehicle must be rectified immediately.

2-3

Safety instructions • Never make any modifications, additions or conversions to the vehicle and its super-

• • •

•

• • •

2-4

structures (cab, loader unit etc.), as well as to the implements, which might affect safety without the approval of producer! This also applies to the installation and the adjustment of safety devices and valves, as well as to welding work on load-bearing elements.

Spare parts must comply with the technical requirements specified by producer.

Original spare parts from producer can be relied to do so.

Replace hydraulic hoses within stipulated and appropriate intervals even if no safetyrelevant defects have been detected.

Before working on or with the vehicle, take off jewellery, such as rings, wristwatches, bracelets etc., and tie back long hair and do not wear loose-fitting garments, such as unbuttoned or unzipped jackets, ties or scarves.

Injury may result from being caught up in the machinery or from rings catching on moving parts!

Keep the vehicle clean. This reduces • Fire hazard, e.g. due to oil-soaked rags lying around • Danger of injury, e.g. due to dirt or debris on the footholds, and • Danger of accident e.g. due to dirt or debris on the brake or accelerator pedal!

Observe all safety, warning and information signs and labels on the vehicle.

Adhere to prescribed intervals or those specified in the operation manual for routine checks/inspections and maintenance work!

For service, inspection, maintenance or repair work, tools and workshop equipment adapted to the task on hand are absolutely indispensable.

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Safety instructions Selection and qualification of personnel, basic responsibilities

• Any work on or with the vehicle must be carried out by reliable personnel only. Do not • • • •

•

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let unauthorised persons drive or work with the vehicle! Observe statutory minimum age limits!

Employ only trained or instructed staff on the vehicle, and set out clearly and unequivocally the individual responsibilities of the personnel for operation, set-up, maintenance and repair!

Define the vehicle operator's responsibilities – also with regard to observing traffic regulations. Give the operator the authority to refuse instructions by third parties that are contrary to safety.

Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the vehicle without being permanently supervised by an experienced person!

Work on the electrical system and equipment, on the chassis and the steering and brake systems may be carried out only by skilled personnel which has been specially trained for such work.

Work on the hydraulic system of the vehicle must be carried out only by personnel with special knowledge and experience of hydraulic equipment!

Seal off the area of danger should it not be possible to keep a safe distance.

Stop work if persons do not leave the area of danger in spite of warning! Keep out of the area of danger!

Area of danger: The area of danger is the area in which persons are in danger due to the movements of the • Vehicle • Work equipment • Additional equipment or • Material This also includes the area affected by falling material, equipment or by parts which are thrown out.

The danger area must be extended by 1 ft 7 in (0.5 m) in the immediate vicinity of • Buildings • Scaffolds or • Other elements of construction

2-5

Safety instructions 2.4

Safety instructions regarding operation

Normal operation

• Before beginning work, familiarise yourself with the surroundings and circumstances of •

• • • • • • • • • • • • • • •

2-6

the work site. These are e.g. obstacles in the working and travelling area, the soil bearing capacity and any necessary barriers separating the work site from public roads.

Take the necessary precautions to ensure that the vehicle is used only when in a safe and reliable state!

Operate the vehicle only if all protective and safety-oriented devices, e.g. removable safety-devices, soundproofing elements and exhausters etc., are in place and fully functional!

Check the vehicle at least once daily/per work shift for visible damage and defects.

Report any changes (incl. changes in the vehicle’s working behaviour) to the competent organization/person immediately! If necessary, stop the vehicle immediately and lock it!

In the event of malfunctions, stop the vehicle immediately and lock it! Have any defects rectified immediately!

Start and operate the vehicle from the operator seat only!

Carry out start-up and shut-down procedures in accordance with the operation manual, and observe the telltales!

Before putting the vehicle/implement into operation (start-up/moving), make sure nobody is at risk by putting the vehicle/implement into operation!

Before driving with the vehicle, and also after interrupting work, check whether the brakes, the steering, signalling and light systems are functional!

Before moving the vehicle always check whether the supplementary equipment and the implements have been safely stowed away or mounted!

When driving on public roads, ways and places, observe the valid traffic regulations and, if necessary, make sure beforehand that the vehicle is in a condition perfectly compatible with these regulations!

In conditions of poor visibility and after dark always switch on the lights!

Persons accompanying the driver must be seated on the passenger seats provided for this purpose.

No lifting, lowering or carrying of persons in the work equipment/implements!

No mounting of a man basket or working platform!

When crossing underpasses, bridges and tunnels, or when passing under overhead lines always make sure there is sufficient clearance!

Always keep at a safe distance from the edges of building pits and slopes!

When working in buildings or in enclosed areas, look out for the • Height of the ceiling/clearances • Width of the entrances and • Maximum bearing load of ceilings and floors Provide for sufficient room ventilation – danger of poisoning!

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Safety instructions • Avoid any operation that might be a risk to vehicle stability!

• During operation on slopes, drive or work uphill or downhill. If driving across a slope

• • • •

•

•

• • • •

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cannot be avoided, bear in mind the tilting limit of the vehicle!

Always keep the implements/work equipment close to the ground. This also applies to driving downhill!

When driving or working across a slope, the load must be on the uphill side of the vehicle.

On sloping terrain always adapt your driving speed to the prevailing ground conditions.

Never change to a lower gear on a slope but always before reaching it!

Before leaving the vehicle • Lower the work equipment/implements to the ground Before leaving the operator seat always secure the vehicle against accidental movement and unauthorised use!

Before starting work check whether • All safety devices are properly installed and functional • Warning triangle • Approved warning light and • First-aid kit are on hand Before moving the vehicle or before taking up work: • Make sure visibility is sufficient (do not forget rearview mirrors!)

• Adjust correct seat position (brake pedal must be depressed to the limit).

Never adjust the operator seat when driving or working!

• Fasten your seat belt • Inspect the immediate area (children!). In the work area the operator is responsible for third parties!

Caution when handling fuel – increased danger of fire!

Make sure fuel does not come into contact with hot parts!

Do not smoke during refuelling, and avoid fire and sparks! Stop the engine during refuelling and do not smoke!

Never get on or off a moving vehicle! Never jump off the vehicle!

Should the lights of the vehicle not be sufficient for the safe execution of certain work processes, provide additional lighting of the work area.

Installed work lights must not be switched on for travel on public roads. They can be switched on in work operation if users of public roads are not dazzled.

Hydrostatic four wheel steering takes time getting used to it. Therefore, adjust the driving speed to your abilities and the circumstances. Selection and change of steering mode at vehicle standstill only!

2-7

Safety instructions Applications with lifting accessories

Definition: Applications with lifting accessories are understood as procedures involving the lifting, transporting and lowering of loads with help of slings and load-securing devices (e.g. ropes, chains). In doing so, the help of persons is necessary for securing and detaching the load. This applies for example to lifting and lowering of pipes, shaft rings or containers.

• The vehicle may be used for applications with lifting accessories only if the prescribed safety devices are in place and functional.

These are e.g.: • Safe possibilities of slinging and securing a lifting attachment (load hook) • Load diagram Also, get informed on the legal regulations of your country which deal with maximum loads and overturning moments. These legal regulations may require you to provide your vehicle with the following equipment: • Safe load indicator • Hose burst valves • Loads must be secured so as to prevent them from falling or slipping.

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

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

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

• The persons attaching or securing loads may approach the boom from the side only, and only after the vehicle operator has given his permission. The vehicle operator may give his permission only after the vehicle is at a standstill and the work implement no longer moves.

• Do not use any damaged lifting attachments or such lifting attachments (ropes, chains) which are not sufficiently dimensioned. Always wear protective gloves when working with lifting attachments.

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Safety instructions Trailers and implements

• Prior to driving on public roads remove all implements which cannot be secured in • • • • •

• • • • • • •

• •

Transport

• The vehicle must be towed, loaded and transported only in accordance with the • • • •

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compliance with the legal regulations of your country!

Get informed on the legal regulations of your country which deal with the use and applications of trailers towed by the vehicle!

Trailer operation in connection with the towing device of the vehicle is not allowed!

Implements and counterweights affect handling, as well as the steering and brake capability of the vehicle!

Fit the implements with the specially required devices only!

Before uncoupling or coupling hydraulic lines (hydraulic quick couplers) • Switch off the engine • Reduce the hydraulic oil pressure in the hydraulic system. To do so, move the control levers of the hydraulic control units back and forth several times Coupling of implements requires special care!

Secure the implements against accidental movement!

Operate the vehicle only if all protective facilities have been installed and are functional, and if all brake, light and hydraulic connections have been connected!

If optional equipment is installed, all additionally required light installations, telltales etc., must be provided for and functional.

Mount the implements only if the engine has been stopped and the drive switched off.

Depressurise the hydraulic system before connecting or disconnecting hydraulic lines.

Especially when driving or working with vehicles provided with a quickhitch facility for the implements, make sure that the implement is securely locked in the quickhitch facility. The lock pin must be visible on both sides of the bores on the implement. Check before starting work.

Prior to attaching implements to the loader unit, secure the control lever of the hydraulic control unit against accidental movement.

Be careful when coupling implements to the loader unit: danger of personal injury due to crushing and shearing. Make sure nobody is between the vehicle and the equipment without securing the vehicle and the implement against movement. operation manual!

For towing the vehicle observe the prescribed transport position, admissible speed and itinerary.

Use only appropriate means of transport and lifting gear of adequate capacity/payload!

Safely secure the vehicle on means of transport! Use suitable mounting points and load-securing devices.

The recommissioning procedure must be strictly in accordance with the operation manual!

2-9

Safety instructions 2.5

Safety instructions for maintenance • Avoid any operational mode that might be prejudicial to safety!

• Observe the adjusting, maintenance and inspection activities and intervals set out in

• • •

• •

•

•

• •

2-10

the operation manual, including information on the replacement of parts/partial equipment.

These activities may be carried out by skilled personnel only.

The vehicle may not be serviced, repaired or test-driven by unauthorised personnel.

Brief operating personnel before beginning special operations and maintenance work!

Appoint a person to supervise the activities!

In any work concerning the operation, conversion or adjustment of the vehicle and its safety-oriented devices, or any work related to maintenance, inspection and repair, observe the start-up and shut-down procedures set out in the operation manual, and the information on maintenance work.

If required, secure the maintenance area appropriately!

Prior to carrying out service, maintenance and repair work, attach a warning label, such as “Repair work – do not start vehicle!”, to the ignition lock/steering wheel or to the control elements.

Remove the ignition key!

Carry out service, maintenance and repair work only if • Vehicle is positioned on firm and level ground • Lever for selecting the driving direction is in neutral position • Parking brake has been applied • All hydraulically movable implements and working equipment have been lowered to the ground • Engine is at a standstill • Ignition key is removed and • Vehicle has been secured against accidental movement Should maintenance or repair be inevitable with the engine running: • Only work in groups of two • Both persons must be authorised for the operation of the vehicle • One person must be seated on the operator seat and maintain visual contact with the other person • Observe the specific safety instructions in the respective work manual • Keep a safe distance to all rotating and moving parts, e.g. fan blades, V-belt drives, PTO shaft drives, fans etc.

Prior to carrying out assembly work on the vehicle, make sure no movable parts will roll away or start moving.

To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes must be carefully attached and secured to lifting tackle.

Use only suitable lifting gear and suspension systems in a technically perfect state with adequate lifting capacity!

Never work or stand under suspended loads!

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Safety instructions • Fastening of loads and instruction of crane operators must be entrusted to experienced •

•

•

• • • • • • • •

• • • •

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persons only!

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

For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders and working platforms.

Never use vehicle parts or implements/superstructures as a climbing aid!

Wear a safety harness when carrying out maintenance work at greater heights!

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

Clean the vehicle, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair work!

Do not use aggressive detergents!

Use lint-free cleaning rags!

Before cleaning the vehicle with water, steam jet (high-pressure cleaning) or detergents, cover or tape up all openings which – for safety and functional reasons – must be protected against water, steam or detergent penetration. Special care must be taken with the electrical system.

After cleaning, remove all covers and tapes applied for that purpose!

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

Rectify all defects without delay!

Tighten all screw connections that have been loosened during maintenance and repair!

All safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work.

Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact!

Do not use the work equipment as lifting platforms for persons!

Before taking up work on vehicle parts/implements dangerous for life and limb (bruising, cutting), always ensure safe blocking/support of these areas.

Carry out maintenance and repair work beneath a raised vehicle, work equipment/ implements or additional equipment only if a safe and secure support has been provided for (the sole use of hydraulic rams, jacks etc. does not sufficiently secure raised vehicles or equipment/implements).

Avoid contact with hot parts, such as the engine block or the exhaust system during the operation of the vehicle and for some time afterwards – danger of burns!

Retainer pins can fly out or splinter when struck with force – danger of personal injury!

Do not use starting fuel! This especially applies to those cases in which a heater plug (intake-air preheating) is used at the same time – danger of explosions!

Apply special care when working on the fuel system – increased danger of fire!

2-11

Safety instructions 2.6

Warning of special hazards

Electric energy

• Use only original fuses with the specified current rating!

•

•

• • • • • Gas, dust, steam, smoke

Switch off the vehicle immediately and rectify malfunction if trouble occurs in the electrical system!

When working with the vehicle, maintain a safe distance from overhead electric lines! If work is to be carried out close to overhead lines, the equipment/implements must be kept well away from them. Caution, danger! Get informed on the prescribed safety distances!

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

Work on the electrical system may only be carried out by a skilled technician, in accordance with the applicable electrical engineering rules.

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

Observe the operating voltage of the vehicle/implements!

Always remove the earthing strap from the battery when working on the electrical system or when carrying out welding work!

Starting with a battery jump cable can be dangerous if carried out improperly. Observe the safety instructions regarding the battery!

• Operate the vehicle only on adequately ventilated premises! Before starting internal combustion engines or operating fuel-operated heating systems on enclosed premises, make sure that there is sufficient ventilation!

Observe the regulations in force at the respective site!

• Carry out welding, flame-cutting and grinding work on the vehicle only if this has been expressly authorised. There may be a risk of explosion and fire, for example!

• Before carrying out welding, flame-cutting and grinding work, clean the vehicle and its surroundings from dust and other inflammable substances, and make sure that the premises are adequately ventilated – danger of explosions!

2-12

BA 302 01 US-Gehl – Edition 1.0 * 30300b0210.fm

Safety instructions Hydraulic equipment

• Work on the hydraulic equipment of the vehicle may be carried out only by persons having special knowledge and experience in hydraulic systems!

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

• In accordance with the operation manual/instructions for the respective assembly, depressurise all system sections and pressure pipes (hydraulic system, compressedair system) to be opened before carrying out any implementing/repair work!

• Hydraulic and compressed-air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

Noise

• During operation all sound baffles must be closed • Wear ear protectors if necessary!

Oil, grease and other chemical substances

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

Battery

• When handling the battery observe the specific safety instructions and regulations

sulphuric acid), observe the product-related safety regulations (safety data sheet)!

• Be careful when handling hot consumables – risk of burning or scalding! relevant to accident prevention. Batteries contain sulfuric acid – caustic!

• Especially when charging batteries, as well as during normal operation of batteries, a hydrogen-air mixture is formed in the cells – danger of explosion!

• Do not attempt to jump-start the vehicle if the battery is frozen or if the acid level is low.

The battery may rupture or explode!

Tyres

• Repair work on tyres and rims may be carried out by skilled personal or by an authorised workshop only!

• Damaged tyres and/or wrong tyre pressure reduce the operational safety of the vehicle.

Therefore carry out regular checks of the tyres for • Prescribed tyre pressure and • Damage • Do not inflate tyres with inflammable gas – danger of explosion!

• Carry out regular checks of the wheel nuts for tightness, however after 600 service hours at the latest. Subsequent to changing tyres check the wheel nuts after 10 service hours – tighten if necessary!

BA 302 01 US-Gehl – Edition 1.0 * 30300b0210.fm

2-13

Safety instructions

2-14

BA 302 01 US-Gehl – Edition 1.0 * 30300b0210.fm

Section Operation

3

3 3

Operation

This chapter describes the controls, and contains information on the function and handling of the telltales and controls in the operator cab.

The pages stated in the table refer to the description of the corresponding controls.

The identification of controls with a combination of digits or a combination of digits and letters, such as 39/25 or 39/A, stands for: Figure no. 39 control element no. 25 or position A in Figure no. 39.

A figure carries no number when it is placed to the left of the text.

Unfold the double pages for a better overview.

The symbols used in the description have the following meanings: • This symbol stands for an enumeration • Subdivision within lists or an activity. If possible, follow the order recommended ☞ 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 SO = option Stated whenever controls or other components of the vehicle are installed as an option.

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

BA 302 01 US-Gehl – Edition 1.0 * 30101b0310.fm

3-1

Overview: see overleaf

Operation 3.1 1

Overview of cab

2 Ref. no. Description

3

Fig. 19: Overview of cab

4 5

30

6 5 7

7

˚F 175 250

105 80 40

60

100

˚C

14

12 10

120

16

30

20

Volt

20

10 10

P

270

MPH Km/h

500

120

6

40

˚F 165 75 50

100

˚C

125

150

1/2

30

0

1/1

50

0236

8

29 9

28

10

27

11 26

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

for more information see page

Sun visor Interior light..............................................................................................................................................................................................3-35 Hydrostatic steering.................................................................................................................................................................................3-32 Instrument panel........................................................................................................................................................................................3-4 Access handle Air vents – front window Door lock..................................................................................................................................................................................................3-46 Washer fluid tank.....................................................................................................................................................................................3-41 Air vents – leg room Control lever console.................................................................................................................................................................................3-5 Control lever console lock........................................................................................................................................................................3-18 Side console ..............................................................................................................................................................................................3-5 Drink holder Rotary switch – auxiliary heating (option) ................................................................................................................................................3-40 Door arrester – left and right....................................................................................................................................................................3-46 Rear wiper ...............................................................................................................................................................................................3-41 Armrest ....................................................................................................................................................................................................3-43 Operator's seat ........................................................................................................................................................................................3-42 Seat belt...................................................................................................................................................................................................3-44 Storage compartment – operation manual Air vents – cab/operator's seat Tool kit Emergeny seat (option)/storage area Parking brake...........................................................................................................................................................................................3-12 Accelerator pedal.....................................................................................................................................................................................3-10 Multifunctional lever.................................................................................................................................................................................3-13 Brake/inching pedal .................................................................................................................................................................................3-11 Fuse box....................................................................................................................................................................................................7-6 Steering column lock ...............................................................................................................................................................................3-18 Front wiper...............................................................................................................................................................................................3-41

25 12 9 13 24 14 15

15

30300b03023.eps

23

3-2

22

21

20

19

18

17

16

BA 302 01 US-Gehl – Edition 1.0 * 30101b0310.fm

Overview: see overleaf

BA 302 01 US-Gehl – Edition 1.0 * 30101b0310.fm

3-3

Operation 3.2 26

31

32

33

34

Overview: switches, levers and consoles

Ref. no. Description

for more information see page

Multifunctional lever 31 32 33 34

Lever – turn indicators, high beam, headlight flasher ........................................................................................................... 3-14, 3-35, 3-37 Rotary switch – front wiper .............................................................................................................................................................3-14, 3-41 Tip switch – washer pump ..............................................................................................................................................................3-14, 3-41 Tip switch – horn.....................................................................................................................................................................................3-14,

Instrument panel 35 Fig. 20: Multifunctional lever

36 4

35

59

48

60

54

42

55

43

˚F 175

49

37

250

105 80 40

60

10

50

38

P

500

40

53

˚C

50

61

125 150

44

57

1/2

100

75

52

40

270

120

39

56

Volt

20

10

˚F 165

16

30

20 10

51

14

12

100 120

˚C

30 MPH Km/h 50 0002836h

62

1/1

0

45

58

46

63

47

41 30100b0080.eps

HAZARD

Fig. 21: Instrument panel

75

10

12

76

70

74 73 72

69

82

68

81

36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

Rocker switch – front window heater (option)..........................................................................................................................................3-39 or Rocker switch – 3rd electrically operated control circuit ON/OFF (option) ..............................................................................................3-56 Rocker switch – front working light (option) .............................................................................................................................................3-36 Rocker switch – electrically operated implements (option)......................................................................................................................3-64 Rocker switch – rear wiper with tip switch for wiper water.......................................................................................................................3-41 Rocker switch – load stabiliser ................................................................................................................................................................3-30 Rocker switch – lights..............................................................................................................................................................................3-35 Tip switch (red)– steering synchronisation ..............................................................................................................................................3-32 Telltales (green) – four-wheel/front axle steering ....................................................................................................................................3-32 Rocker switch – steering/high speed (option).................................................................................................................................3-28, 3-32 Rocker switch – rotating beacon (option) ................................................................................................................................................3-37 Rocker switch – rear working light...........................................................................................................................................................3-36 Rocker switch – hazard warning light ......................................................................................................................................................3-37 Telltale (red) – alternator charge function................................................................................................................................................3-15 Telltale (red) – engine oil pressure ..........................................................................................................................................................3-15 Not assigned Telltale (red) – parking brake...................................................................................................................................................................3-15 Telltale (red) – service brake pressure ...................................................................................................................................................3-15 Telltale (red) – hydraulic oil reflux filter ...................................................................................................................................................3-16 Telltale (yellow) – air filter ........................................................................................................................................................................3-16 Telltale (blue) – high beam ......................................................................................................................................................................3-16 Telltale (green) – turn indicator right/left..................................................................................................................................................3-16 Telltale (yellow) – cold starter ..................................................................................................................................................................3-16 Telltale (green) – differential lock.............................................................................................................................................................3-16 Temperature gauge – hydraulic oil ..........................................................................................................................................................3-17 Voltmeter – battery ..................................................................................................................................................................................3-17 Temperature gauge – engine and cooling oil ..........................................................................................................................................3-17 Hour meter with speedometer (speedometer only with high speed option).............................................................................................3-17 Fuel level indicator...................................................................................................................................................................................3-17

77

84 64

78 65

79 83

66 67

80

71

11 Fig. 22: Control lever console

3-4

Fig. 23: Side console

BA 302 01 US-Gehl – Edition 1.0 * 30101b0310.fm

Operation

Operation 3

Ref. no. Description

for more information see page

Control lever console 64 65 66 67 68 69 70

71 72 73 74 75

Control lever – loader unit........................................................................................................................................................................3-53 Control lever – 3rd control circuit/implements..........................................................................................................................................3-54 Lock/transport lock for 3rd control circuit/implements..............................................................................................................................3-54 Lock for loader unit and implements........................................................................................................................................................3-55 Tip switch – lock with 3rd electrically operated control circuit (option)....................................................................................................3-56 Tip switch – differential lock.....................................................................................................................................................................3-31 Tip switch – front electric socket (option)........................................................................................................................................3-53, 3-64 and/or tip switch – unlock with 3rd electrically operated control circuit (option) ................................................................................................3-56 Lever – manual throttle (option)...............................................................................................................................................................3-11 Tip switch – reverse driving direction ................................................................................................................................... 3-10, 3-29, 3-53 Telltale – reverse driving direction ....................................................................................................................................... 3-10, 3-29, 3-53 Telltale – forward driving direction ....................................................................................................................................... 3-10, 3-29, 3-53 Tip switch – forward driving direction ................................................................................................................................... 3-10, 3-29, 3-53

Side console 76 77 78 79 80 81 82 83 84

Preheating start switch ..............................................................................................................................................................................3-9 Rocker switch – drive range selection ..............................................................................................................................................3-9, 3-27 Rocker switch – air conditioning (option) .................................................................................................................................................3-39 Rotary switch – 3 level heater fan............................................................................................................................................................3-38 Rotary switch – heater fan temperature regulation..................................................................................................................................3-38 Rotary switch – fresh air/recirculated air..................................................................................................................................................3-38 Radio (option) Socket/cigarette lighter ..............................................................................................................................................................................7-6 Control lever – low-speed control (option) ...............................................................................................................................................3-12

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

3-5

Operation 3.3

Taking into service

3.3.1

Safety instructions 3 •

Only use the steps and handles provided when entering and leaving the cab

• Never use the controls or movable lines and cables as handles • Never board or jump off a moving vehicle • Refer to the corresponding load diagrammes for the loader unit pallet forks 3.3.2

Taking the vehicle into service for the first time

Important information

• The vehicle may be taken into service by authorised personnel only – see also section 1 "Regulations" on page 1-6 of this operation manual • The operating personnel must have read and understood this operation manual before taking the vehicle into service • The vehicle may only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operation manual, and only by persons who are fully aware of the risks involved in operating the vehicle • Go through the “Start-up” checklist in the following section

Running-in period

3-6

Handle the vehicle carefully during its first 100 operating hours.

The future performance and service life of the vehicle are heavily dependent on the observance of the following recommendations during the running-in period.

• Do not overload the vehicle, but at the same time do not drive too cautiously either, as the vehicle will never reach the proper operating temperature • Do not run the engine at high revs for extended periods • Increase the load gradually whilst varying the engine revs • Strictly observe maintenance schedules and carry out (or have carried out) the specified maintenance work – see Maintenance plan (overview) on page 5-48

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

Operation 3.3.3

Checklists The checklists below are intended to assist you in checking and monitoring the vehicle before, during and after operation.

The check lists cannot claim to be exhaustive; they are merely intended as an aid for you in fulfilling your duties as a conscientious operator.

The checking and monitoring jobs listed below are described in greater detail in subsequent sections.

If the answer to one of the following questions is NO, first rectify the cause of the fault before starting or continuing work.

Start-up checklist

Check the following points before taking the vehicle into service or starting the engine: No. Question 1 2 3 4 5 6 7 8 9 10 11 12 13 14

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

✔

Sufficient fuel in the tank? (➠ 5-1) Engine oil level OK? (➠ 5-7) Oil level in hydraulic tank OK? (➠ 5-18) Water level in washer tank OK? (➠ 3-41) Loader unit lubricated? (➠ 5-32) Tyre condition OK? (➠ 5-33) Lights, signals, indicators, warning lights and telltales OK? (➠ 3-35, 3-37, 3-15) Windows, mirrors, lights and steps clean?

Is the implement on the loader unit correctly locked? (➠ 3-60) Is the engine cover firmly locked?

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

Approved warning triangle, hazard light and first aid kit in the vehicle? (➠ 1-6) Seat position and rearview mirror correctly adjusted? (➠ 3-18) Seat belt fastened? (➠ 3-44)

3-7

Operation Operation checklist

After starting the engine and during operation, check and observe the following points: ✔

No. Question

1 Telltales for engine oil pressure and alternator gone out? (➠ 3-15) 2 Braking effect sufficient? (➠ 3-24) 3 Temperature indicator for engine coolant in normal range? (➠ 3-15) 4 Steering working properly? (➠ 3-24) 5 Is anyone dangerously close to the vehicle? (➠ 2-5) When travelling on public roads, particular attention must be paid to the following points: 6 Bucket and implements in transport position? (➠ 3-22) 7 Transport locks installed? (➠ 3-22) 8 Control lever for lift and tilt hydraulics of the loader unit locked? (➠ 3-22) 9 Tooth guard fitted to bucket? (➠ 3-22) Parking checklist

Check and observe the following points when parking the vehicle: ✔

No. Question 1 Implements on the loader unit lowered to the ground? (➠ 3-34, 3-53) 2 Parking brake applied? (➠ 3-12) 3 Cab locked, especially if the vehicle cannot be supervised?

When parking on public roads: 4 Vehicle adequately secured? (➠ 3-34) When parking on uphill and downhill gradients: 5 Vehicle additionally secured with chocks under the wheels to prevent it from rolling away? (➠ 3-34)

3-8

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

Operation 3.4

Driving the vehicle

3.4.1

Overview of control elements

Preheating start switch [76]

0

1

2

P

Important!

3

The engine will not start unless the parking brake is applied and telltale 21/51 lights! ☞ Pull lever 19/24 up

76 Fig. 24: Preheating start switch

Position P 0 1

2 3

Drive range selector [77]

Function No function Inserting or removing the ignition key ON/drive position

Power consumer None None

➥ All functions are operational ➥ Telltale 21/51 comes on if parking brake

19/24 is applied Preheting engine (with cold start at < 0 C: 10-15 seconds) ➥ Starter is actuated Start the engine ➥ Telltales must go out

Function Drive range selection

A Rocker switch 77 Position A B

77

Change-over switch 77 ☞ Push downward ☞ Push symbol

Drive range Standard

High speed option

1st = 0 – 5 kph 2nd = 0 – 20 kph

1st = 0 – 10 kph 2nd = 0 – 40 kph

B Fig. 25: Selection of drive range with rocker switch

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

3-9

Operation Driving direction tip switch [72/75]

Function Selection of driving direction

75 74 73

64

72

Driving direction Effect ☞ Press the green tip switch ➥ Green telltale 74 in joystick comes • Forward 75 on ☞ Press yellow tip switch 72 ➥ Red telltale 73 in joystick comes • Reverse on ☞ Press both tip switches at ➥ Telltale 73 or 74 in joystick goes • Neutral the same time out

Fig. 26: Tip switch for driving direction on joystick

Important!

The driving direction can be selected only after releasing the parking brake!

Applying the parking brake automatically switches to neutral position!

Accelerator pedal [25] Function 75 50

100

˚C

125

Km/h

150

50

0236

Accelerator pedal 25 controls the drive speed as follows:

25

Position • Press pedal • Release pedal slowly • Release pedal fully

Drive speed ➥ Drive speed is increased ➥ Drive speed is reduced ➥ Hydrostatic braking

Fig. 27: Accelerator pedal

3-10

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

Operation Manual throttle lever [71] (option)

B

A

Danger!

Do not operate the manual throttle lever when driving on public roads –

Accident hazard!

71

☞ Use manual throttle only for work operations! ☞ Before driving on public roads: • Set manual throttle lever 71 to idling speed position • Regulate engine revs only with the accelerator pedal/drive pedal 27/25

Fig. 28: Lever – manual throttle

Function Sets the engine revs for work operations Important!

This function is especially useful for the operation of hydraulically operated implements to ensure constant hydraulic oil supply. The driving speed must be controlled with the brake/inching pedal or the low-speed control (option).

Position A B

Engine revs Idling speed = minimum revolutions Full speed = maximum revolutions

Brake/inching pedal [27] Function P

˚F 270

165

MPH Km/h

500

120 75 50

100

˚C

125

150

1/2

30

0

1/1

50

0236

1 2

To brake the vehicle irrespective of the driving direction and the position of accelerator pedal 19/25 In the inching range of the brake pedal (pedal pressed in lightly), the pedal can be used like a car’s clutch. The drive system is supplied with less hydraulic oil which means the entire engine output is available to the work hydraulics. This allows especially to raise the loader unit more rapidly

27

Braking

Fig. 29: Brake/inching pedal

☞ Press brake inching pedal 27 down with force Inching

☞ Press brake inching pedal 27 down lightly

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

3-11

Operation Control lever [84] – low-speed control (option) Function Regulation of maximum vehicle speed irrespective of the engine revs Important!

A

This function is identical to inching with the brake/inching pedal, whereby the maximum speed can be set with more precision.

The maximum possible speed depends on the drive range selected.

B 84

Fig. 30: Control lever – low-speed control

Position A B Parking brake [24]

Drive speed Maximum speed Vehicle at a standstill

Function 1 2

Prevents the vehicle from rolling away Emergency brake in case of a breakdown of the service brake Danger!

Use parking brake 19/24 instead of the service brake in an emergency only, i.e. in case of a breakdown of the service brake. The brake lights do not light up, and the vehicle brakes abruptly –

Accident hazard! ☞ In normal operation, only use brake/inching pedal 19/27 as a service brake

Important!

The engine will not start unless the parking brake is applied and telltale 21/51 lights! ☞ Pull lever 19/24 up

3-12

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

Operation To prevent the vehicle from rolling away

☞ Pull up lever 24 to the last notch ➥ Telltale 51 comes on

a 24 P

To release the parking brake:

51

☞ Pull up lever 24 slightly ☞ Depress button a ☞ Move lever 24 all the way down

312b0090.eps

Fig. 31: Parking brake

Using the parking brake as emergency brake when driving the vehicle Danger!

Operating the parking brake when driving causes the vehicle drive to disengage. This causes sudden deceleration at full speed –

Accident hazard! ☞ Use the parking brake as service brake only in case of emergency ☞ Before using the parking brake reduce driving speed if possible ☞ Pull lever 24 Multifunctional lever [26] Function 26

33 32 31

34

1 2 3 4 5 6

Switches on the turn indicators with lever 31 Switches high beam on and off with lever 31 Flashes headlight flasher with lever 31 Turns front wiper on and off with rotary switch 32 Switches on front window washer pump with tip switch 33 Sounds horn with tip switch 34

30300b0312.eps

Fig. 32: Multifunctional lever

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

3-13

Operation High beam, low beam and headlight flasher Lever 31

III

☞ Lower pos. I

II ☞ Centre pos. II

I 31

☞ Raise further to pos. III and

30300b0312.eps

keep in this position

Fig. 33: Actuating high beam, low beam and headlight

Effect ➥ High beam ON, telltale 21/55 comes on if low beam is switched on with rocker switch 21/41 ➥ Low beam ON if low beam is switched on with rocker switch 21/41 ➥ Headlight flasher ON, telltale 21/55 comes on

Turn indicators 31

30300b0313.eps

L

Lever 31 ☞ Push forward

R

☞ In centre position ☞ Pull back

Effect ➥ Left turn indicators actuated, telltale 21/56 flashes ➥ None ➥ Right turn indicators actuated, telltale 21/56 flashes

Fig. 34: Actuating the turn indicators

Important!

Lever 31 has an automatic reset; this means the lever is automatically set to centre position after turning the steering lock after a large steering angle.

Horn Tip switch 34 ☞ Press ☞ Release 30300b0313.eps

Effect ➥ Horn ON ➥ Horn OFF

34

Fig. 35: Actuating the horn

Front wiper 32

30300b0313.eps

Rotary switch 32 J ☞ Turn to the right to pos. J 0 ☞ Turn back to pos. 0 ☞ Turn to the left to pos. I I II ☞ Turn to the left to pos. II

Effect ➥ Intermittent wipe ON ➥ OFF ➥ Slow wipe ON ➥ Fast wipe ON

Fig. 36: Actuating the wiper

Washer pump ON 33

Tip switch 33 ☞ Slide to the left and hold ☞ Release

Effect ➥ Washer pump ON ➥ Washer pump OFF

30300b0313.eps

Fig. 37: Actuating the washer pump

3-14

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

Operation 3.4.2

Overview Telltales and warning lights 48 Telltale (red) – alternator charge function Caution!

The engine cooling fan no longer runs if the V-belt is faulty.

Danger of engine overheating or breakdown!

If telltale 48 comes on with the engine running: ☞ Switch off the engine immediately and repair or have the cause repaired The telltale comes on when the ignition is turned on and goes out as soon as the engine runs.

The V-belt for the alternator, or the charging circuit of the alternator is faulty if the telltale comes on with the engine running. The battery is not charged any more (➠ page 5-16).

49 Telltale (red) – engine oil pressure Comes on if the engine oil pressure is too low. In this case:

☞ Stop the vehicle ☞ Switch off the engine immediately and check the oil level (➠ page 5-7) The telltale comes on when the ignition is turned on and goes out as soon as the engine runs.

50 Not assigned

51 Telltale (red) – parking brake

P

Comes on when parking brake lever 19/24 is applied.

The electric drive interlock prevents driving the vehicle with the parking brake applied.

52 Telltale (red) – service brake pressure Indicates inadmissibly low pressure of the service brake.

Danger!

If telltale 52 comes on with the engine running, the accumulator of the bake system has only a small pressure reserve.

Accident hazard! ☞ Stop the vehicle immediately ☞ Have pressure loss repaired by an authorised workshop

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

3-15

Operation 53 Telltale (red) – hydraulic oil reflux filter Indicates an inadmissibly high pressure in the hydraulic reflux line to the tank. In this case: ☞ Replace the hydraulic oil reflux filter (➠ page 5-22) In cold weather telltale 53 may come on immediately when the engine is started. This is caused by increased oil viscosity. In this case: Let the engine run at idling speed for about 2 minutes 54 Telltale (yellow) – air filter Indicates air filter contamination. In this case:

☞ Clean or replace the air filter (➠ page 5-13) 55 Telltale (blue) – high beam Comes on if high beam is switched on, or during headlight flashing.

56 Telltale (green) – turn indicator right/left Flashes intermittently when the turn indicators are used (lever 19/31) 57 Telltale (yellow) – cold starter Indicates that the heater plug filament is switched on.

The telltale only lights when the preheating start switch 23/76 is in pos. 2 or in pos. 3 (= preheat intake air and start).

58 Telltale (green) – differential lock Indicates engagement of the differential lock on the front and rear axle. The telltale does not come on if the rear axle differential lock is engaged by pressing the service brake.

Caution!

The differential lock may be damaged if it is switched on at the wrong moment, e.g. when turning corners or if the wheels are already spinning. ☞ Actuate the differential lock only if you expect a wheel to spin, e.g. when working on slopes or on slippery ground!

3-16

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

Operation 59 Temperature gauge – hydraulic oil Indicates the temperature detected by a sensor on the oil tank.

Caution!

Danger of hydraulic damage when oil temperature exceeds admissible limit value (max. 90 °C, briefly) – ☞ Relieve work and driving hydraulics. To do this: • Move driving direction control lever to neutral position • Move control lever of the loader unit and implements to neutral position • Run the engine at increased revs • Clean radiator if necessary – see page 5-12

Important!

The hydraulic temperature must be between 60 and 85 °C. Max. authorised temperature is 90 °C for brief periods.

60 Voltmeter – battery Indicates battery charging state with engine off or charging voltage with engine running.

61 Temperature gauge – engine and cooling oil Indicates the engine oil temperature detected by a sensor behind the engine oil cooler.

Important!

The engine oil temperature must be between 80 and 120 °C, max. authorised temperature is 130 °C (red section).

62 Hour meter with speedometer (speedometer only in high speed option) Counts the engine service hours with the engine running.

63 Fuel level indicator Indicates fuel tank level Important!

Never drive until the fuel tank is completely empty otherwise dirt particles can be drawn into the fuel system.

BA 302 01 US-Gehl – Edition 1.0 * 30101b0320.fm

3-17

Operation

Operation 3.4.3

Before starting the engine3 ☞ Run through the “Start-up” checklist on page 3-7 ☞ Switch on the battery master switch – see Battery master switch (option) on page 3-47 ☞ Adjust steering wheel position. To do this: • Release lock 19/29 • Adjust the height and longitudinal direction of the steering wheel • Tighten the lock again ☞ Adjust seat position and rearview mirror ☞ Adjust joystick position. To do this: • Adjust control lever console 19/10 in longitudinal direction, if necessary. To do this: Release lock 22/11 and firmly retighten it • Or adjust the height of the armrest – see Armrest setting on page 3-43 Important!

All controls must be within easy reach. You must be able to move the brake and accelerator pedals to their limit positions!

☞ To fasten seat belt ☞ Make sure that: • Parking brake 19/24 is applied and • Control levers 22/64 and 22/65 for the loader unit are in neutral position • Manual throttle lever (option) 22/71 is set to idling speed

3.4.4 General

Start the engine • The engine will only start if parking brake 19/24 is applied • The starter cannot be operated if the engine is already running (start repeat interlock) • Do not run the starter for more than 10 seconds • Wait for about 1 minute to let the battery recover before trying again • The engine cannot be started by tow starting the vehicle, as there is no driving connection between the engine and gearbox when the engine is switched off • When the vehicle is used for extended periods at outside temperatures of less than –10 °C, we recommend retrofitting the vehicle with an engine preheater (“oil preheater” option)

3-18

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation Procedure

1

0

2 3

76 Fig. 38: Preheating start switch

54

48 49

˚F 175 250

105 80 40

60

10

20

51

10

16

30

Volt

20

10

P

14

12

100 120

˚C

40

After you have completed the starting preparations in accordance with 3.4.3 Before starting the engine: ☞ Turn ignition key in the preheating start switch 76 to pos. “1” ☞ Check whether the following telltales come on: • Telltale 48 for alternator charge function • Telltale 49 for engine oil pressure • Telltale 51 if the parking brake is applied • During the telltale check, telltales 51, 52, 53 and 54 must come on for about 5 seconds ☞ Replace defective telltales immediately ☞ Press accelerator pedal 19/25 through about a quarter of its travel ☞ Turn the ignition key to pos. “3” and hold in this position until the engine starts ☞ Release the ignition key

˚F 1/2

270

165

500

120 100

75 50

˚C

52 53

125 150

30 MPH Km/h 50 0002836h

0

1/1

312b0050.eps

Fig. 39: Telltales

Starting at temperatures below 0 °C

☞ Turn the ignition key to pos. 2 and hold it in this position for about 15 seconds ☞ Press accelerator pedal 19/25 all the way through ☞ Turn the ignition key to pos. “3” and hold in this position until the engine starts ☞ Release the ignition key When the engine runs smoothly (increasing engine speed): ☞ Release accelerator pedal 19/25 Important!

In general, a battery delivers less energy in cold conditions. As a result, you must make sure the battery is always well charged.

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

3-19

Operation When the engine has started ...

☞ Check that the following telltales have gone out: • Telltale 21/48 • Telltale 21/49 • Telltales 21/51, 52, 53 and 54 ☞ Let the engine warm up ... for a cold start at outside temperatures below 0 °C:

☞ Let the engine run at increased idling speed for about 1 minute ☞ Do not exceed the mean engine speed for 10 minutes, however you may start using drive and work hydraulics gently. Do not extend or retract the hydraulic rams to the limits if possible ☞ Increase the diesel engine speed and hydraulic forces gradually ... for a cold start at outside temperatures below +10 °C:

☞ Increase the engine revs slowly ☞ Do not run the engine at full load for the first 10 minutes Connecting the oil preheater (option) B

A

Fig. 40: Oil preheater (option)

This equipment is for cold-starting at temperatures below -5 °C. The engine and hydraulic oil is heated by means of heating elements in the engine oil pan and in the hydraulic oil tank according to the gravity principle (warm oil rises and is replaced by cold oil). The oil can only be thoroughly warmed up to service temperature if the oil preheater is connected over a longer period of time – preferably over night. ☞ Connect the oil preheater as follows: • Park the vehicle near a 220 V socket • First connect special cable A to vehicle socket B on the service panel on the left side of the vehicle, then • Insert the plug into the 220 V socket ☞ Before starting the engine: • Pull out the plug from the 220 V socket • Unplug special cable A from vehicle socket B Important!

The oil preheater (option) reduces pollutant emissions during the warm-up phase by up to 50%, saving fuel at the same time.

Fuel preheater (option)

3-20

The fuel preheater (option) prevents paraffin crystals forming, which otherwise clog the fuel filter at low temperatures.

A temperature switch automatically switches on a heating element in the fuel line between the tank and fuel prefilter when ignition is switched on at temperatures below + 10 °C.

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation 3.4.5

Jump-starting the vehicle

Starting the engine with starting aid (supply battery)

Safety instructions

• Never jump-start the engine if the battery of the vehicle is frozen – danger of explosion!

• The vehicle must not touch the jump-starting vehicle when connected with jump leads – • • • •

danger of sparking!

The external power source must deliver a rated voltage of 12 V; higher supply voltages will damage the electrical system of the vehicle!

Use only authorised jump leads which conform to the safety requirements and which are in perfect condition!

The jump lead connected to the positive (+) terminal of the starting battery must never be brought into connection with electrically conductive vehicle parts – danger of short circuit!

Route the jump leads so they cannot catch on rotating components in the engine compartment!

Procedure

☞ Drive the jump-starting vehicle close enough to the vehicle so that the jump leads can

Flat battery

12 V

reach to connect the two batteries ☞ Start the engine of the jump-starting vehicle ☞ First connect one end of the red jump lead (+) to the (+) terminal of the flat battery, then clip the other end to the (+) terminal of the starting battery ☞ Connect one end of the black jump lead (–) to the (–) terminal of the starting battery

☞ Clip the other end of the black jump lead (–) onto a solid metal component attached firmly to the engine block or onto the engine block itself. Do not connect it to the negative terminal of the flat battery, as otherwise explosive gas emerging from the battery may ignite if sparks are formed! ☞ Start the engine of the vehicle with the flat battery Once the engine has started:

12 V Starting Batterie

☞ With the engine running, disconnect the jump leads in exactly the reverse sequence (first remove (–) terminal, then (+) terminal) – this prevents sparking in the vicinity of the battery!

501tdi_3800.eps Fig. 41: Starting aid with jump leads

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

3-21

Operation 3.4.6

Before moving off

Special instructions for driving on public roads

The vehicle is subject to the • Applicable regulations of your country • Regulations specified in the operation license or in the vehicle papers • Only the equipment items (implements) listed in the operation licence or in the vehicle papers are admissible for driving on public roads!

• Also bear in mind the footnotes/instructions in Section 1.4 “Fields of application” on page 1-4 In addition, bear in mind the mandatory regulations relevant to accident prevention.

Preparing the vehicle for driving on public roads

☞ Remove any protective mesh (optional) fitted over the front window ☞ Dump out the bucket

A

Danger!

B

Make sure the front-edge protection for the front blade or teeth is installed, otherwise –

Accident hazard! ☞ Cover the blade or teeth of the bucket across their entire width with the

c Fig. 42: Driving on public roads

tooth guard A provided ☞ Buckets/implements which have not been authorized or released for travel on public roads must be transported with an appropriate means of transport – see section 1.4 Fields of application on page 1-4!

☞ Adjust the bucket to transport position. To do this: D

• Lower loader unit completely • Tilt the bucket to the rear B and • Raise the loader unit until the centre of rotation of the bucket is at a minimum 150 mm above the ground C Important!

Fig. 43: Marks for transport position

3-22

In transport position (with standard tyres), the two red marks D on the lift frame and on the bulkhead are aligned. These marks are visible from the operator's compartment.

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation ☞ Carry out a functional check of the:

Before moving off:

• Brakes • Steering and • Lights ☞ Dump out the bucket ☞ Adjust the bucket to transport position. To do this: • When driving on public roads: – see section Preparing the vehicle for driving on public roads on page 3-22 • When not driving on public roads (construction site, company premises): – see section Checking the transport position of the bucket on page 3-69 ☞ Secure control lever 19/10 for the loader unit and the implements against accidental operation. To do this: • Turn lever 67 counterclockwise, across the driving direction 67

30300b03015.eps

Fig. 44: Lock for control levers

A

Danger!

Do not operate the manual throttle lever (option) when driving on public roads –

Accident hazard!

71

Fig. 45: Lever – manual throttle

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

☞ Use manual throttle (option) only for work operations! ☞ Before driving on public roads: • Move manual throttle lever (option) 71 to idling speed pos. A • Regulate engine revs only with the accelerator pedal/drive pedal 19/25

3-23

Operation Inspection of important functional units

Steering Important!

The steering system is only operational when the engine is running!

In the event of a failure of the diesel engine or of the hydraulic steering aid (e.g. failure of the pump drive), the vehicle can still be steered (emergency steering feature).

After switching high speed on or off, and after synchronizing the wheels, always carry out a functional check of the steering system!

Danger!

Failure of steering assistance: Turning the steering wheel requires great effort! Take this into account especially when towing the vehicle!

☞ Adapt towing speed to the altered steering behaviour! ☞ Use a towing bar! ☞ Functional check: Move the steering wheel to the left and right Synchronous wheel position Important!

Tyre wear increases and straight-ahead driving becomes more difficult if the vehicle is not driving in exactly the correct track.

If you notice from the way the vehicle handles that the wheels of both axles are not driving in exactly the correct track: ☞ Synchronise the steering – see Synchronising the steering on page 3-32

3-24

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation Service brake Danger!

The brake lights at the rear of the vehicle do not light up when the parking brake is applied or the vehicle is braked by means of the drive with its hydrostatic braking effect

Accident hazard! ☞ When driving on public roads and during work operation, especially for abrupt brake manoeuvres, use the brake/inching pedal 19/27 to brake the vehicle. Only this causes the brake lights to light up Dirt accumulation in the area of the brake pedal can result in brake malfunctions

Accident hazard! ☞ Keep the brake/inching pedal 19/27 clean!

If telltale 21/52 comes on with the engine running, the accumulator of the bake system has only a small pressure reserve –

Accident hazard! ☞ Stop the vehicle immediately ☞ Have pressure loss repaired by an authorised workshop ☞ Before moving off, press down the brake/inching pedal 19/27 to check whether • After a maximum of half the pedal travel there is a firm resistance to be felt • Brake lights come on if the brake pedal is pressed down ☞ After moving off, check in the rearview mirror that no-one will be hindered by a brake manoeuvre ☞ Check the brake action at low speed Danger!

Especially when stopping on slopes: Pressing brake/inching pedal 19/27 (inching valve responds!) down slightly has hardly any braking effect –

Accident hazard! ☞ Depress brake/inching pedal 19/27 until the braking effect is felt

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

3-25

Operation 3.4.7

Moving off Important!

The vehicle can be moved only after releasing parking brake 19/24.

After starting the engine: ☞ Release parking brake 19/24 ➥ Telltale 21/51 goes out ☞ Select driving direction with the tip switches on joystick 64

75 74 73

64

72

Fig. 46: Tip switch for driving direction on joystick

Driving direction • Forward ☞ Press the green tip switch 75 • Reverse ☞ Press the yellow tip switch 72 ☞ Press both tip • Neutral switches at the same time

Effect ➥ Green telltale 74 in joystick comes on

➥ Red telltale 73 in joystick comes on ➥ Telltale 73 or 74 in joystick goes out

Important!

Applying the parking brake switches to neutral position!

☞ Adjust the desired maximum speed on the low-speed control (option) 23/84 ☞ Gradually depress accelerator pedal 19/25 ➥ Vehicle moves off ☞ Test the brakes at low speed

3-26

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation 3.4.8

Gear shift The vehicle has 2 drive ranges. The high speed version (option) has an additional 2 drive ranges.

Selecting the drive range

A

77

☞ Stop the vehicle with the brake/inching pedal 19/27 Select the desired drive range with rocker switch 77. To do this: ☞ Press rocker switch 77B ➥ 2nddrive range selected ☞ Press rocker switch 77A ➥ 1st drive range selected Drive speed without high speed (option)

B

Symbol

Fig. 47: Selection of drive range with rocker switch

Meaning

Recommended Specially used for work involving short load1st drive range = 0 – 5 kph ing cycles, i.e. a rapid succession of loading and unloading operations, e.g. onto a lorry, and for work requiring precise speed adjustment, e.g. rotary broom applications.

2nd drive range = 0 – 20 kph For long-haul travel

Drive speed with high speed (option) Symbol

Meaning

Recommended 1st drive range = 0 – 10 kph Specially used for work involving short loading cycles, i.e. a rapid succession of loading and unloading operations, e.g. onto a lorry, and for work requiring precise speed adjustment, e.g. rotary broom applications, however allowing for speeds above 5 kph 2nd drive range = 0 – 40 kph For long-haul travel

Drive speed with restricted high speed (option) Symbol

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Meaning

Recommended 1st drive range = 0 – 7,5 kph Specially used for work involving short loading cycles, i.e. a rapid succession of loading and unloading operations, e.g. onto a lorry, and for work requiring precise speed adjustment, e.g. rotary broom applications, however allowing for speeds above 5 kph 2nd drive range = 0 – 30 kph For long-haul travel

3-27

Operation High speed (option)

Engaging high speed (option) Caution!

Shifting to or from high speed during full operation may cause serious damage to the gearbox! ☞ Switch high speed on and off at vehicle standstill only

Important!

Front axle steering is automatically selected when shifting to high speed.

44 ON OFF

A

Fig. 48: Rocker switch for high speed

☞ Stop the vehicle with the brake/inching pedal 19/27 ☞ Press lock A of rocker switch 44 in the direction of the arrow and at the same time, press down the right-hand side of rocker switch 44 ➥ The integral red telltale comes on ☞ Select the required drive range with rocker switch 23/77 ☞ Select the required driving direction with tip switch 22/72 or 22/74 in joystick 22/64 ☞ Start the vehicle slowly ☞ Carry out a functional check of the steering system Shifting from high speed (option) Important!

Shifting from high speed automatically selects 4 wheel steering.

☞ Stop the vehicle with brake/inching pedal 19/27 ☞ Press down the left side of rocker switch 44 ➥ The integral red telltale goes out ☞ Select the required drive with rocker switch 23/77 ☞ Select the required driving direction with tip switch 22/72 or 22/75 in joystick 22/64 ☞ Start the vehicle slowly ☞ Carry out a functional check of the steering system

3-28

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation 3.4.9

Changing direction Danger!

When changing the driving direction with the vehicle –

Accident hazard! ☞ Make sure that nobody is within the area of danger of the vehicle when changing the driving direction!

Changing direction at high speed and full throttle causes the vehicle to brake abruptly.

☞ Switch over driving direction at vehicle standstill only. Depending on the legal regulations of your country, this may be necessary when driving on public roads

☞ Stop the vehicle: release accelerator pedal 19/25 ☞ Select the new driving direction with tip switch 72 or 75 in joystick 64: Driving direction

75

• Forward

74 73

64

72

• Reverse • Neutral

Effect

☞ Press green tip switch 75 ☞ Press yellow tip switch 72 ☞ Press both tip switches at the same time

➥ Green telltale 74 in joystick comes on ➥ Red telltale 73 in joystick comes on ➥ Telltale 73 or 74 in joystick goes out

Fig. 49: Tip switch for driving direction on joystick

Backup warning system (option) Danger!

When backing up with the vehicle –

Accident hazard! ☞ Make sure that nobody is within the area of danger of the vehicle when changing the driving direction! ☞ Do not rely exclusively on the backup warning system (option)!

A

Important!

In certain countries, a backup warning system is mandatory.

The backup warning system consists of a signal transmitter A, fitted to the rear top left of the cab. The signal transmitter generates an acoustic signal when shifting into reverse. The acoustic level is 103 dB (A) at a distance of 1 m, and at a frequency of 2800 Hz.

Fig. 50: Backup warning system (option)

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

3-29

Operation 3.4.10

Load stabiliser Danger!

Driving on public roads: Beware of vehicle instability when the load stabiliser is not switched on –

Accident hazard! ☞ Always switch on the load stabiliser when driving on public roads.This increases drive safety and comfort ☞ Observe the procedure described in Section 3.4.6 “Before moving off” when setting the transport position!

Caution!

The load stabiliser may be damaged when it is switched on during heavy-duty work. ☞ Switch off load stabiliser during heavy-duty work!

It depends on the individual situation whether the load stabiliser must be switched on or off. We recommend: Load stabiliser Switched off Switched on • In general for heavy-duty • For driving on public work, e.g. picking up roads excavated material

40

A Fig. 51: Rocker switch for load stabiliser

3-30

B

May be switched on • For lighter work with the loader unit • For light off-road transport

Switched on ☞ Press rocker switch on the left 40A ➥ Telltale in rocker switch comes ON Switched off ☞ Press rocker switch on the right 40B ➥ Telltale in rocker switch goes OUT

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation 3.4.11

Differential lock 58

Important!

69

The differential lock neutralises the compensating effect of the differential, i.e. traction is distributed evenly to the front and rear wheels.

64 Caution!

Fig. 52: Tip switch for differential lock

Engaging differential lock

The differential lock may be damaged if it is switched on at the wrong moment, e.g. when turning corners or if the wheels are already spinning. ☞ Actuate the differential lock only if you expect a wheel to spin, e.g. when working on slopes or on slippery ground!

☞ Proceed as follows: • Press and hold tip switch 69 ➥Telltale 21/58 comes on

Switching off the differential lock

☞ Proceed as follows: • Reduce engine revs • Release tip switch 69 ➥Telltale 21/58 goes out

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

3-31

Operation 3.4.12

Steering

Synchronising the steering Definition 42 a

Fig. 53: Tip switch for steering synchronisation

A

Steering synchronisation or wheel synchronisation designates the line-up of the wheels so that the wheels of both axles run in the same track.

The steering must be synchronised at the latest if the wheels of the vehicle no longer follow the same track when driving straight-ahead on level ground. Synchronisation is only possible in the slow drive range. ☞ Proceed as follows: • For vehicles with high speed option: Check that high speed is disengaged (with the vehicle at standstill!)

• Select low drive range • Drive at walking pace on level ground and press switch 42A • Move on while steering to the left and right until telltale 42a goes out • Carry out a functional check of the steering system Important!

Although the steering electronics automatically synchronises the front and rear axles, the synchronisation process is not complete until the steering rams have passed through the straight-ahead position from both directions. Telltale 42a in the synchronrisation switch 42 goes out.

The following applies to all vehicle models with automatic steering synchronisation: Only the first drive range is active during synchronisation – telltale 42a flashes. You can use rocker switch 23/77 to select the second range, but the shift into the second range is delayed until the synchronisation process has been completed.

3-32

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation Changing steering mode in vehicles without high speed option

☞ Switch on front axle steering as follows: 42 a 43

a

b

44 e

d c

Fig. 54: Controls for steering mode selection

Changing steering mode in vehicles with high speed option

• Stop the vehicle • Push lock 44c to the right and depress right-hand side d of rocker switch 44 (telltale 43b for front axle steering) • However, front-axle steering is not switched until the rear axle has been set to straight-ahead. Telltale 43a flashes until the shift is completed • Carry out a functional check of the steering system ☞ Switch on 4 wheel steering as follows: • Stop the vehicle • Push lock c to the right and depress left-hand side e of rocker switch 44 (telltale 43a for 4 wheel steering) • However, 4 wheel steering is not switched until the front axle has been set to straightahead. Telltale 43b flashes until the shift is completed • Carry out a functional check of the steering system Front wheel steering ... is automatically selected when shifting to high speed. Change-over is carried out only after the rear axle has been set to straight-ahead. Telltale 43b flashes until the shift is completed.

Four wheel steering ... is automatically selected when shifting from high speed. In this case the shift is not carried out until the front axle has been set to straight ahead. Telltale 43a flashes until the shift is completed.

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

3-33

Operation 3.4.13

Stop the vehicle ☞ Proceed as follows: • Reduce engine revs: Take your foot off the accelerator pedal 19/25 • Stop the vehicle with service brake 19/27 • Set driving direction to neutral position • Apply the parking brake to ensure permanent braking action. To do this: Pull up lever 19/24 to the last notch ➥Telltale 22/51 comes on

3.4.14

Parking the vehicle Danger!

Vehicles parked on slopes may roll away

Accident hazard! ☞ Use the parking brake to park the vehicle safely and to prevent it rolling away! See Section 3.4.13 “Stop the vehicle” ☞ Additionally secure the vehicle by placing chocks under the downhill sides of the wheels!

☞ Stop the vehicle ☞ Apply the parking brake permanently – see Section 3.4.13 “Stop the vehicle” ➥ Telltale 22/51 comes on ☞ Lower the loader unit. To do this: Push control lever 22/64 forward, out of neutral ☞ Align the bucket with the ground so that the blade rests on the ground. To do this: Move control lever 22/64 to the left or right After operation at full power: ☞ Allow the engine to run idle and without load for a while so that the temperature can stabilise ☞ Switch off the engine by turning the ignition key to pos. “0” ☞ Remove the ignition key! ☞ Lock the doors of the operator’s compartment after leaving the cab On uphill and downhill gradients: ☞ Additionally secure the vehicle by placing chocks under the downhill sides of the wheels!

3-34

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation 3.4.15

Light system Parking lights ☞ Press rocker switch 41A down ➥ Telltale in rocker switch 41 comes on ON 1 step OFF ☞ Press rocker switch 41B down ➥ Telltale in rocker switch 41 goes out

41

B

A

Low beam ON

OFF

Fig. 55: Light switches

☞ Press rocker switch 41A down ➥ Telltale in rocker switch 41 comes on 2 steps ➥ Telltale 21/55 comes on with high beam switched on ☞ Press rocker switch 41B down ➥ Telltale in rocker switch 41 goes out Important!

Only the parking light stays lit if the ignition is switched off (with low beam switched on) – key in preheating start switch 23/76 in pos. 0!

High beam

III

ON

II I

OFF

31

☞ With low beam switched on,

➥ Telltale 21/55 comes on move lever 31 downward until it locks in pos. I ☞ Move lever 31 upward until it ➥ Telltale 21/55 goes out locks in pos. II

30300b0312.eps

Fig. 56: Actuating high beam, low beam and headlight flasher

Headlight flasher ON

☞ Pull lever 31 upward to pos. III ➥ Telltale 21/55 comes on

OFF

☞ Release lever 31

and hold in this position

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

➥ Telltale 21/55 goes out

3-35

Operation

Danger!

The working light may dazzle motorists on public roads –

Accident hazard! ☞ Do not switch on the working light when driving on public roads. When operating the vehicle, only switch the working light on when no-one can be dazzled by it!

37

Front working light (option) ☞ Press rocker switch 37B ON OFF ☞ Press rocker switch 37A

➥ Telltale in rocker switch 37 comes on ➥ Telltale in rocker switch 37 goes out

Rear working light (option) ☞ Press rocker switch 46B ON OFF ☞ Press rocker switch 46A

➥ Telltale in rocker switch 46 comes on ➥ Telltale in rocker switch 46 goes out

A

B

Fig. 57: Switch for front working light

46

B

A

Fig. 58: Switch for rear working light

2

A

B

Interior light ☞ Press switch 2A at front ON OFF ☞ Press switch 2B at rear

Fig. 59: Interior light

3-36

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation 3.4.16

Signalling system Hazard warning system ☞ Press rocker switch 47B ON OFF ☞ Press rocker switch 47A

47

➥ Telltale in rocker switch flashes ➥ Telltale in rocker switch goes out

B

A HAZARD Fig. 60: Signalling system switch

31

Turn indicators ☞ Push lever 31 forward ➥ Telltale 20/56 flashes LEFT Pull lever 31 to the rear ☞ ➥ Telltale 20/56 flashes RIGHT ☞ Lever 31 in centre position ➥ Telltale 20/56 goes out OFF

L R

30300b0313.eps

Fig. 61: Turn indicators

Caution!

The turn indicator system is not in order if telltale 22/56 flashes about twice as fast as normally! ☞ Check the front and rear indicators immediately

Important!

Lever 31 has an automatic reset; this means the lever is automatically set to centre position after turning the steering lock after a large steering angle.

Rotating beacon (option) ☞ Rocker switch 45B ON OFF ☞ Rocker switch 45A

45

A

➥ Telltale in rocker switch flashes ➥ Telltale in rocker switch goes out

B Important!

Fig. 62: Switch for rotating beacon

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Legal regulations of your country may require you not to switch on the rotating beacon on public roads unless the road is within the vehicle’s working range and the vehicle is an obstruction to the normal flow of traffic when the vehicle is in working operation. Get informed on and follow the legal regulations of your country.

3-37

Operation 3.4.17

Cabheating and ventilation Important!

The heater of the vehicle can be set to 4 operating modes: • Ventilation, fresh air • Heating, fresh air • Heating, mixed mode • Heating, recirculated air.

The flow of air is directed to the windscreen via a defroster nozzle and to the operator compartment via a footwell nozzle.

The footwell nozzles can be closed and directed separately.

Fresh air is directed into the cabin via a fine dust filter (option).

Ventilation, fresh air 79

0

1 2

☞ Rotary switch 79 in pos. 1 (ventilation) ☞ Lever 81 in pos. B (fresh air)

3 Fig. 63: Fan switch

Heating, fresh air 80

cold

warm

☞ Rotary switch 79 in pos. 2 or 3 (fan level 1 or 2) ☞ Set the required temperature with rotary switch 80 ☞ Lever 81 in pos. B (fresh air)

Fig. 64: Heating adjustment

B 81

☞ Rotary switch 79 in pos. 2 or 3 (fan level 1 or 2) ☞ Set the required temperature with rotary switch 80 ☞ Lever 81 between pos. A and B (mixed mode)

A

Heating, recirculated air

Fig. 65: Change-over lever recirculated air – fresh air

3-38

Heating, mixed mode

☞ Rotary switch 79 in pos. 2 or 3 (fan level 1 or 2) ☞ Set the required temperature with rotary switch 80 ☞ Lever 81 in pos. A (recirculated air)

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation Front window heater (option)

To avoid misting on the front window in winter service, the window can be heated by an optional electric front window heater.

The switch for the optional front window heater is located on the left side of the instrument panel

35

Front window heater (option) ☞ Press rocker switch 35B ON OFF ☞ Press rocker switch 35A

➥ Telltale in rocker switch 35 comes on ➥ Telltale in rocker switch 35 goes out

Air conditioning (option) ☞ Press rocker switch 78B ON OFF ☞ Press rocker switch 78A

➥ Telltale in rocker switch 78 comes on ➥ Telltale in rocker switch 78 goes out

A

B

Fig. 66: Switch for front window heater (option)

Air conditioning (option) 78

Fig. 67: Fan switch

B

A Important!

See the separate operator manual on using the air conditioning.

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

3-39

Operation 3.4.18

3-40

Auxiliary heating (Not available)

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation 3.4.19

Washer system 32

Front wiper Position I 0 1 2

30300b0313.eps

Fig. 69: Front wiper rotary switch

33

Function Intermittent wipe OFF Slow wipe Fast wipe

Front window washer pump ☞ Press tip switch 33 ON ☞ Release tip switch 33 OFF

30300b0313.eps

Fig. 70: Washer pump tip switch

39

B

A

Rear wiper ☞ Press rocker switch 39A ON ☞ Press rocker switch 39B OFF Rear window wash pump ☞ Press actuated rocker switch 39A further down (touch function) ON

Fig. 71: Rear wiper rocker switch

Tank

Important!

8

Fill with clean tap water only! Add a suitable cleaning agent if required. In winter: Add antifreeze for washer systems to the water. Refer to the instructions for using the antifreeze, which give information on concentrations.

312b0220.eps

Fig. 72: Tank for washer system

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

3-41

Operation 3.4.20

Seat adjustment Danger!

Never change the seat position when driving or working –

d

Accident hazard! ☞ Adjust the seat before moving the vehicle

c

e f

a

The seat can be set to the following positions: • Weight setting a with weight indicator b • Height setting c • Armrest inclination d • Backrest setting (depending on version) e • Longitudinal setting f

b

Fig. 73: Seat adjustment

Weight setting

Important!

Adjust the seat suspension correctly to ensure a high level of driving comfort. Use lever a to set the seat suspension to the operator's weight. The weight indicator b shows the set operator weight [kg].

☞ Sit down on the operator’s seat

a b Fig. 74: Weight setting

To set to a higher operator weight:

☞ Turn lever a clockwise To set to a lower operator weight: ☞ Turn lever a counterclockwise

Height setting

c

Upwards: ☞ Raise seat as required until it engages with an audible click Downwards: ☞ Raise seat as far as possible and ☞ Lower seat to bottom position

Fig. 75: Height setting

3-42

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation Armrest setting The armrest can be folded back as required. Set the armrest as follows: Upwards: ☞ Turn handwheel d clockwise as required Downwards: ☞ Turn handwheel d counterclockwise as required

d

Fig. 76: Armrest setting

Backrest setting

☞ Sit down on the operator’s seat ☞ Pull lever e upwards and at the same time ☞ Lean back to push the backrest into the required position ☞ Let lever e lock into place

e

Fig. 77: Backrest setting

Longitudinal setting

☞ Sit down on the operator’s seat ☞ Pull lever f upwards and at the same time ☞ Move the operator’s seat forward or backward

f Fig. 78: Longitudinal setting

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

3-43

Operation 3.4.21

Seat belt Danger!

Do not drive or work with the seat belt unbuckled –

Danger of personal injury! ☞ Buckle up before moving or working with the vehicle!

• Seat belt must not be twisted!

• Seat belt must run over the hips – not over stomach – and must always be applied tightly!

• Do not place seat belt over hard, edged or fragile items (tools, meterrule, glasses, pen) carried inside your clothes!

• Never buckle up 2 persons (children!) with a single seat belt!

• Check seat belts regularly. Have damaged parts immediately replaced in an authorised workshop!

• Always keep seat belt clean, as coarse dirt may impair proper functioning!

• Seat belt buckle must not be obstructed by foreign bodies (paper or similar); otherwise the buckle latch cannot lock into place!

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

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

The seat belt 19 is designed for the driver's safety during work on construction sites and during road travel.

To fasten seat belt 19:

A 19

B

☞ Before starting, fasten seat belt 19 as follows: • Hold belt on 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!

30763b0007.eps Fig. 79: To fasten seat belt

3-44

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation To unfasten seat belt 19:

☞ Unfasten seat belt 19 as follows: 19 A

• Hold the seat belt • Press red button C on buckle B ➥Latch A is released from buckle B by spring pressure • Slowly return the belt to the seat belt retractor (option)

C B 30763b0006.eps

Fig. 80: Unfastening the seat belt

To extend/shorten the seat belt 19 (lap belt only):

☞ Lengthen the lap belt as follows:

A

• Hold the buckle latch at a right angle to the seat belt and pull the seat belt to the required length – see Fig. 81 ☞ To shorten the lap belt, just pull on the free end D of the belt – see Fig. 81.

Important!

D

30763b0005.eps Fig. 81: Longer/shorter seat belt setting

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

When pulled slowly, the automatic seat belt (option) offers full freedom of movement. It locks however during abrupt braking.

The automatic seat belt (option) may also lock when passing through potholes or uneven terrain.

3-45

Operation 3.4.22

Vehicle doors Opening from outside: ☞ Press door button a Lock door: ☞ Turn ignition key in door lock to the right Unlock door: ☞ Turn ignition key in door lock to the left

a

Fig. 82: Outside door lock

Opening from inside: ☞ Pull lever 7 up

7 Fig. 83: Inside door lock

Securing open driver's door

☞ Press the operator's door against the door arrester 15 until it engages

15

Important!

Lubricate the door arrester at regular intervals, at least every 600 service hours.

Fig. 84: Securing open doors

Unlocking the door arrester 15

☞ In the cab, pull lever a forward or ☞ From the outside, pull lever b downward

a

b Fig. 85: Unlocking the door arrester

3-46

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation 3.4.23

Other controls

Tank lock Unlocking: ☞ Turn the filler cap key in lock a to the left ☞ Turn filler cap counterclockwise Closing: ☞ Turn the filler cap key in lock a to the right ☞ Turn filler cap clockwise

a

Fig. 86: Filler cap

Engine cover Unlocking: ☞ Pull handle c to the front ☞ Pull the engine cover upwards Closing: ☞ Press the engine cover firmly down Locking: ☞ Turn key in lock b to the left Unlocking: ☞ Turn key in lock b to the right

b

c

Fig. 87: Engine cover lock

Battery master switch (option)

Important!

D

0 1

The vehicle can be equipped with a battery master switch (option, Fig. 88). This allows interruption of the electrical supply • Before working on the electrical system and • As an antitheft precaution Key D can be removed in OFF position (crosswise direction)!

38b03600.ai

Fig. 88: Battery master switch (option)

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

3-47

Operation 3.4.24

Towing the vehicle • The vehicle may only be towed using suitable towing equipment (towing bar or cable) in

Safety instructions

connection with suitable towing facilities, such as a towing coupling, hooks and eyes!

• Move off slowly! Make sure no-one is dangerously close to the towing bar • The vehicle may only be towed with a cable if the service brakes and steering are fully operational!

Towing Danger!

Turning the steering wheel requires greater effort if the diesel engine breaks down. Take this into account, especially when towing the vehicle!

☞ Use a towing bar!

Caution!

The hydrostatic drive can be damaged when towing the vehicle! ☞ Set driving direction to neutral position ☞ Short-circuit the hydraulic circuit before towing (see below) ☞ Do not tow the vehicle for more than 100 metres and do not tow it faster than 3 – 4 kph!

☞ Tow away the vehicle as follows:

C

B

A

A

B

• Switch driving direction to neutral position (➠ page 3-10) • Apply the parking brake (➠ page 3-12) • Switch off the engine • Fit an adequately sized towing bar to the towing facilities • Switch over the HP pressure relief valves A on the hydraulic pump. To do this: • Release hexagon lock nuts B on both HP valves A • Screw in hexagon socket head screws C on both HP valves A until they are flush with lock nuts B • Secure hexagon socket head screws C on both HP valves A with lock nuts B • If possible, run the engine at idling speed when towing the vehicle • The HP valves must be changed over before the vehicle is taken back into service!

Do this by unscrewing hexagon socket head screws C up to the stop and secure them with lock nuts B

C Fig. 89: Hydraulic pump when towing the vehicle

3-48

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation 3.4.25

Handling the vehicle with a crane • The crane and the lifting gear must be sufficiently dimensioned – see section Specifica-

Safety instructions

tions for the vehicle's dimensions and weights!

• Crane handling requires lifting gear with 4 cables or chains of equal length • Secure the vehicle against accidental movement!

Crane handling Danger!

Handle the vehicle with a crane with due care –

Accident hazard! ☞ Make sure no-one is in the vehicle! ☞ Loads must be fastened, and crane operators instructed by experienced persons only! The person giving the instructions to the crane operator must be within sight or sound of him. ☞ Make sure the crane and the lifting gear (cables, chains) have sufficient lifting capacity! ☞ Vehicle must be fitted with an empty standard bucket in transport position during crane handling. (See Fields of application on page 1-4)! ☞ Stay clear of the suspended load! ☞ Under all circumstances, read the safety instructions at the beginning of this chapter and follow any other safety instructions relevant in your country!

☞ Handle the vehicle with a crane as follows:

30101b3002.iso

• Fit the standard bucket and lock it safely – See Re-equipping the loader unit on page 3-60 • Empty the standard bucket • Set the drive to neutral position – see Driving direction tip switch [72/75] on page 3-10 • Tilt in the standard bucket and lower it to transport position – see section 3.5.7 Reequipping the loader unit on page 3-60 • Switch off the engine • Apply the parking brake – See Parking the vehicle on page 3-34 • Remove the ignition key!

• Get out of the cab, close the vehicle doors and the engine cover • Fasten the loader to the 4 lashing points – see section 1.2 Vehicle overview on page 1-2 – with sufficiently dimensioned lifting gear Danger!

Stay clear of suspended loads!

• Carefully raise the vehicle

30101b3001.iso

Fig. 90: Crane handling

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

3-49

Operation 3.4.26

Loading and transporting the vehicle • The transport vehicle must be of adequate size – refer to section Specifications for the

Safety instructions

vehicle's dimensions and weights!

• Remove any mud, snow or ice from the tyres so that the vehicle can be safely driven onto the ramps • Secure the vehicle against accidental movement!

Loading the vehicle Danger!

Load and transport the vehicle properly, otherwise

Accident hazard! ☞ Under all circumstances, read the safety instructions at the beginning of this chapter and follow all other safety instructions relevant in your country!

☞ Load as follows:

30864brampe.eps

Fig. 91: Ramps

3-50

• Secure the transport vehicle with chocks to prevent it rolling • Position the ramps so that the angle is as small as possible. Do not exceed an angle of 30 °. Only use ramps with an anti-skid surface.

• Make sure the loading area is clear and access to it is not obstructed – e.g. by superstructures • Make sure the ramps and the wheels of the vehicle are free of oil, grease and ice • Start the engine of the vehicle • Raise the bucket sufficiently so that it will not touch the ramps • Carefully drive the wheel loader onto the middle of the transport vehicle • Set the drive to neutral position – see Driving direction tip switch [72/75] on page 3-10 • Lower the bucket to the loading area • Switch off the engine • Apply the parking brake – See Parking the vehicle on page 3-34 • Remove the ignition key!

• Get out of the cab, close the vehicle doors and the engine cover

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

Operation Lashing down the vehicle

Danger!

Load and transport the vehicle properly, otherwise

Accident hazard! ☞ Under all circumstances, read the safety instructions at the beginning of 30101b3003.iso

30101b3004.iso

Fig. 92: Lashing down the vehicle

BA 302 01 US-Gehl – Edition 1.0 * 30101b0330.fm

this chapter and follow all other safety instructions relevant in your country!

• Make sure the authorised maximum height is not exceeded • Secure all tyres of the wheel loader with chocks in front of, behind and at the sides of each wheel • Securely lash the wheel loader onto the loading area using straps and chains of adequate size at the lashing points provided – see section 1.2 Vehicle overview on page 1-2 • Before transporting the vehicle for a longer period through heavy rain: Close the outlet of the exhaust silencer with a simple cap or suitable adhesive tape • Make sure the driver of the transport vehicle knows the overall height, width and weight of his vehicle (incl. loader) before departure, as well as the legal transport regulations of the country or countries where transport is to take place!

3-51

Operation

Operation 3.5

Working with the vehicle

3.5.1

General safety instructions 3 •

• • • • • •

• 3.5.2

Increased caution when working off-road: Work only on firm ground, as far as possible!

Never drive up to the edge of a pit from outside – danger of cave-in!

Never undermine the foundations of walls – danger of collapse!

Operation of the vehicle by unauthorised personnel is prohibited!

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

When using lifting accessories such as pallet forks, comply with the load diagrams valid for this vehicle The hydraulic system of the vehicle is still pressurised even when the engine is not running! Depressurise the sections of the system and hydraulic lines which are to be opened before starting setup or repair work, e.g. fitting/removing an implement with hydraulic functions – see Section 3.5.5 “Depressurising the quick couplers on the loader unit” Also pay attention to the operation manuals of the implements used!

Load diagram Compliance with the load diagram is mandatory when using pallet forks with fork arms on the loader unit. This diagram specifies maximum load on the fork arms for industry and offroad applications – see section 1.9 Other Signs and symbols on page 1-10. The maximum load varies according to the distance from the load centre.

Important!

The load diagrams shown on the front window are valid only for applications with pallet forks. Observe the specific load diagrams of other implements used, e.g. rotary crane jib!

3-52

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Operation 3.5.3

Control valve of the loader unit: overview

Control lever for hydraulics of lift and tilt ram of loader unit

Danger!

Accidental operation of control lever 64 when driving on public roads –

Accident hazard! ☞ Lock the control lever – see Before moving off on page 3-22

D 64

Position A

C

A

B E

Symbol

Lever 64 ☞ To the left

Function ➥ Tilts in implement

B

☞ To the right

➥ Dumps out implement

C

☞ Forward

➥ Lowers lift frame

D

☞ Fully forward

➥ Lift frame remains lowered in float

E

☞ Backward

➥ Raises the lift frame

position (option)

Fig. 93: Loader unit: control lever

Tip switch on control lever

70

75

58 69

72

68 64

Tip switch no. Function with tip switch pressed ➥ Electric front socket (option) ON 68 ➥ Differential lock ON 69 ➥ Tip switch not assigned 70 ➥ Forward driving direction 72 ➥ Reverse driving direction 75 Selection of driving direction – see Driving direction tip switch [72/75] on page 3-10

Fig. 94: Tip switch on joystick

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

3-53

Operation Control lever for implements and 3rd control circuit

Important!

Control lever 65 can be locked separately in neutral position by pressing lock lever 66C down. This is a safeguard against accidental unlocking of the quickhitch facility.

64

65

Position

A

A

Lever 65 ☞ Forward

B

☞ Backward

C B

Function ➥ Unlocks the quickhitch facility Implement with hydraulic function: ➥ E.g. opens the multipurpose bucket ➥ Locks the quickhitch facility Implement with hydraulic function: ➥ E.g. closes multipurpose bucket

Lock control lever 65 in neutral position (centre position) 66 Fig. 95: Control lever for implements

☞ Lock in neutral position as follows: • Press lock lever 66 down (C) ➥Control lever remains in neutral position ☞ To unlock • Pull lock lever 66 up ➥Control lever can be moved forward and backward Locking control lever 65 for continuous operation in final position Important!

The control lever can be locked in final pos. B. This enables the following functions: • Hydraulic movements/procedures over a longer period of time or operation of hydraulic motors • Operation of hydraulic equipment with a control valve adjusted to maximum oil flow, with a bypass

☞ For continuous operation, proceed as follows: • Pull control lever 65 fully back to final position B until it locks ➥Control lever stays in rear pos. B ☞ To stop continuous operation • Push control lever 65 forward and release it ➥Control lever returns automatically to neutral

3-54

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Operation Securing control levers for driving on public roads

Danger!

When driving on public roads, accidental operation of the control lever of the loader unit may result in

Accident hazard! ☞ Before moving off, engage transport locks 67 and 22/66! ☞ If the 3rd control circuit is electrically operated (option) also switch off rocker switch 36 !

67

To lock the control lever: ☞ Follow the instructions given in Section 3.4.6 “Before moving off” ☞ Turn lever 67 counterclockwise, across the driving direction To unlock the control lever: ☞ Turn lever 67 upward

30300b03015.eps

Fig. 96: Lock for control levers

☞ If the 3rd control circuit is electrically operated (option) also switch off rocker switch 36 !

36

OFF Fig. 97: Rocker switch – 3rd electrically operated control circuit ON/OFF (option)

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

3-55

Operation 3rd electrically operated control circuit (option)

Danger!

When working with implements without hydraulic function: Operating control lever 65 or tip switch 70 unlocks the quickhitch facility

Danger of personal injury! ☞ Lock control lever 65 with transport lock 67 and switch off rocker switch 36 !

Important!

The vehicle can be equipped with an extra electrically operated 3rd control circuit (option).

The electrically operated 3rd control circuit (option) is beneficial for working with implements with extra hydraulic functions used for short intervals only (e.g. multipurpose bucket, heavy duty bucket etc.). Continuous operation of the 3rd control circuit is carried out with control lever 65.

36 ON

A

OFF

3rd electrically operated control circuit (option) ☞ Slide lock A to the left and press ➥ Telltale in rocker switch 36 comes on ON rocker switch 36 on the symbol ➥ Tip switches 68 and 70 are functional (left) OFF ☞ Press rocker switch 36 in position ➥ Telltale in rocker switch 36 goes out B (top)

Fig. 98: Rocker switch – 3rd electrically operated control circuit ON/OFF (option)

Important!

The vehicle is equipped with a safety circuit.

The rocker switch has no function if the vehicle is started even though rocker switch 36 was switched on. To switch on the function of the 3rd control circuit, first switch off rocker switch 36 and then switch it on again.

With rocker switch 36 switched on, the 3rd control circuit can be operated as follows:

70

Press tip switch ... ☞ Press tip switch 70

68

☞ Press tip switch 68

64

Fig. 99: Tip switch for 3rd electrically operated control circuit (option)

3-56

Function With the quickhitch facility fitted: ➥ Unlocks the quickhitch facility With an implement fitted: ➥ Pressurises the right-hand blue hydraulic line (e.g. close multipurpose bucket) With the quickhitch facility fitted: ➥ Locks the quickhitch facility With an implement fitted: ➥ Pressurises the left-hand red hydraulic line (e.g. open multipurpose bucket)

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Operation 3.5.4

Lowering the loader unit with the engine switched off Important!

A pressure accumulator in the pressure line of the hydraulic pilot control system maintains the control pressure so the loader unit can be lowered when the engine is switched off!

64

☞ Proceed as follows:

C

• Make sure no-one is dangerously close to the vehicle • Push and hold control lever 64C to the front until the loader unit is fully lowered • Return control lever 64 to neutral

Fig. 100: Lowering the loader unit with the engine switched off

3.5.5

Depressurising the quick couplers on the loader unit Important!

The hydraulic system of the 3rd control circuit/implement is still pressurised even when the ingine is not running! The hydraulic quick couplers can be released, however they cannot be fitted back on since the pressure in the hydraulic lines is too high. Therefore: ☞ Depressurise sections of the system and hydraulic lines which are to be opened before starting setup or repair work, e.g. fitting/removing an implement!

65

A

Depressurise as follows: ☞ Apply parking brake 19/24 – see Parking brake [24] on page 3-12 ☞ Switch off the engine ☞ Push lever 65 forward A and backward B once ➥ Hydraulic pressure is released

B

Fig. 101: Depressurising hydraulic lines

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

3-57

Operation 3.5.6

Connecting pressurised quick couplers Danger!

Careful when connecting pressurised quick couplers –

Accident hazard! ☞ Depressurise sections of the system and hydraulic lines which are to be opened before starting setup or repair work, e.g. fitting/removing an implement!

See Depressurising the quick couplers on the loader unit on page 3-57 ☞ Never connect pressurised quick couplers by force

Important!

Oil temperature, and hence the pressure in the ram can rise if an implement (e.g. side swing bucket or multipurpose bucket) or the quickhitch facility (lock ram) is exposed to the sun for a longer period of time, without being connected to the vehicle via the flexible lines. This pressure cannot be lowered by means of depressurisation as described in section 3 "Depressurising the quick couplers on the loader unit" on page 3-57 .

65

66 Fig. 102: Locking the lever

3-58

Connection of pressurised quick couplers of the lock ram of the quickhitch facility to the hydraulic system of the vehicle is described below. Proceed accordingly when fitting implements with pressurised quick couplers.

Connect pressurised quick couplers as follows: ☞ Apply parking brake 19/24 – see Parking brake [24] on page 3-12 ☞ Start the engine and run it at idling speed for about 30 seconds ➥ The pressure accumulator of the pilot control is filled! ☞ Lower the loader unit to the ground ☞ Switch off the engine ☞ Depressurise – see section 3.5.5 Depressurising the quick couplers on the loader unit on page 3-57 ☞ Pull lever 65 fully backward until it locks into place

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Operation ☞ Disconnect flexible line A from the implement ☞ Connect flexible line A (in driving direction on the right) on the vehicle, to blue plug C of

A

the quickhitch facility (in driving direction on the left, crosswise!) ☞ Disconnect flexible line A again

C

Fig. 103: Depressurisation

☞ Connect flexible line A to blue plug D of the quickhitch facility (in driving direction on

A

the right) ☞ Connect flexible line B to red plug C of the quickhitch facility (in driving direction on the left)

D B C Fig. 104: Connecting hydraulic lines

☞ Return lever 65 back to neutral position ☞ Unlock/lock the implement – see section 3.5.7 Re-equipping the loader unit on page 3-60

65

66 Fig. 105: Releasing the lock

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

3-59

Operation 3.5.7

Re-equipping the loader unit Re-equipping the loader unit is described below for the standard bucket! If you are fitting or removing implements with their own hydraulic functions – e.g. multipurpose or side swing bucket – you must follow the special information given in the operation manual of the implement.

Fitting implements onto the quickhitch facility

Danger!

The implement must always be safely locked onto the quickhitch facility; otherwise –

Accident hazard! ☞ Before starting work, make sure the implement is securely locked onto the quickhitch facility by means of the lock ram. You must be able to see the lock pins on both sides of the mounting holes on the implement ☞ When working with implements without additional hydraulic function: Switch off lock control lever 65 and rocker switch 36 for 3rd electrically operated control circuit (option)!

☞ Proceed as follows: • Release the transport lock. To do this: ☞ Turn lever 67 upward in driving direction 67

30300b03015.eps

Fig. 106: Lock for control levers

• Approach the vehicle to the implement • Tilt the quickhitch facility all the way forward. To do this: ☞ Move lever 64B to the right

64

C B

• Adjust the height of the pin shanks L of the quickhitch facility so that they are under the catch hooks of implement K. To do this:

D 30300b03060.eps

K L Fig. 107: Driving up to the implement

Loader unit • Lower or • Raise

Lever 64 ☞ Push forward C

☞ Pull backward D

• Drive forward until the pin shanks L of the quickhitch facility are directly beneath the catch hooks of implement K

K L

Fig. 108: Picking up the implement

3-60

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Operation • Raise the loader unit. To do this: ) backward and ☞ Pull lever 64D ( • Tilt in the quickhitch facility. To do this: ) to the left ☞ Push lever 64A ( 64 A D 30300b03060.eps

Fig. 109: Raising the implement

• Secure the implement with the lock pins of the quickhitch facility. To do this: ☞ Pull lever 65F backward

65 F

➥ Lock pin G engages in the mounting bores of the implement

30300b03060.eps

G Fig. 110: Locking the implement

G

• Make sure the implement is securely locked onto the quickhitch facility by means of the lock ram. ☞ Carry out a visual check!

Important!

Fig. 111: Checking the lock pins

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Lock pin G must be visible on both sides of the mounting bores on the implement, as in Fig. 111.

3-61

Operation Vehicle with implements without extra hydraulic functions: • Lock control lever 65 in neutral position with lock lever 66

66

Fig. 112: Locking the control lever

Additionally on vehicles with a 3rd electrically operated control circuit (option): 36

• Switch off rocker switch 36!

OFF

Fig. 113: Rocker switch – 3rd electrically operated control circuit ON/OFF (option)

Implements with hydraulic function: • Switch off the engine • Apply the parking brake • Depressurise the quick couplers – see section 3.5.5 Depressurising the quick couplers on the loader unit on page 3-57 • Fit the hydraulic and, if used, electrical connections for the implement in accordance with its operation manual • Follow the instructions given in Section 3.5.6 “Connecting pressurised quick couplers” on page 3-58 • Section 3.5.8 “Connection of electrically operated implements (option)” on page 3-64

3-62

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Operation Taking an implement off the quickhitch facility

Danger!

The implement must be placed on the ground so that it will not fall over; otherwise

Danger of personal injury! ☞ Position the implement so that after unlocking it will stand safely and not tip over

☞ Take the implement off the quickhitch facility as follows:

64

C

• Drive the vehicle with the empty implement up to the drop-off position • Tilt in the quickhitch facility. To do this: ) to the left ☞ Push lever 64A (

A

30300b03060.eps

• Lower the loader unit until the implement is about 5 – 10 cm above the ground. To do this ) forward ☞ Push lever 64C (

Fig. 114: Lowering and tilting in the implement

• In addition, in the case of implements with hydraulic and/or electrical connections: • Switch off the engine • Apply the parking brake • Depressurise the quick couplers – see section 3.5.5 Depressurising the quick couplers on the loader unit on page 3-57 • Connect flexible line A to blue plug D of the quickhitch facility (in driving direction on the right) • Connect flexible line B to red plug C of the quickhitch facility (in driving direction on the left) • Remove the electric connections • Start the engine again

A

C

D B

Fig. 115: Changing round the hydraulic connections

• Retract the catch bolt of the quickhitch facility. To do this: Push lever 65E forward • Tilt the quickhitch facility slightly forward. To do this: ) to the right ☞ Push lever 64B ( C B 64

E

• Lower the loader unit. To do this: ) forward ☞ Push lever 64C (

65

Fig. 116: Setting down the implement 30300b03060.eps

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

3-63

Operation As soon as the pin shanks of quickhitch facility L are below catch hooks K of the implement: • Reverse away from the implement K

L

Fig. 117: Reversing from the implement

3.5.8

Connection of electrically operated implements (option) Operation with rocker switch on instrument panel As an option, a 4 pole socket can be fitted at the front of the vehicle. Rocker switch 38 is used to permanently switch the power supply for electrically operated implements ON and OFF, e.g. a spray water pump for the rotary broom. Tip switch 70 in joystick 64 is used to switch the power supply ON for a short time for electrically operated implements.

Electrical connection of an implement

☞ Connect the electric consumers of the implement as follows: • Open the protective cap on the socket • Fully insert the 4 pole plug (cable connection to implement) into the socket

Fig. 118: 4 pole socket on front side of vehicle

Permanently switching on and off the electric function of the implement

☞ Permanently switch on or off the electric function of the implement (e.g. water pump ON or OFF) as follows:

B

A 38

To permanently switch the power supply for implements (option) ☞ Press rocker switch 38A ➥ Power supply at front socket is switched ON on ➥ Telltale in switch comes on Press rocker switch 38B ☞ ➥ Power supply is interrupted OFF ➥ Telltale goes out

Fig. 119: Switch for electrically operated implements (option)

Briefly switching on the electric function of the implement on joystick 64 70

☞ Briefly switch on the electric function of the implement (e.g. water pump briefly ON) as follows: Briefly switching the power supply for implements (option) ☞ Push tip switch 70 and ➥ Power supply at front socket is switched ON hold down on Release tip switch 70 ☞ ➥ Power supply is interrupted OFF

64 Fig. 120: Tip switch on joystick

3-64

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Operation Briefly switching on the electric function of the implement with the tip switch (option) on control lever 65 of the 3rd control circuit E

65

☞ Briefly switch the electric function of the implement on and off (e.g. solenoid valve for verge grading bucket) as follows: Briefly switching the power supply for implements (option) ☞ Press tip switch S on ➥ Power supply at front socket is switched ON lever 65 on ☞ Release tip switch S on ➥ Power supply is interrupted OFF lever 65 ➥ Telltale goes out

S

Fig. 121: Tip switch for electrically operated implements (option)

To switch the lights on the implement on and off

☞ Switch the additional lights on the implement on and off as follows: Lights for implements (option) ☞ Press rocker switch 41A ON 41 OFF A

B

☞ Press rocker switch 41B

➥ Lights are switched on ➥ Telltale in switch comes on ➥ Lights are switched off ➥ Telltale goes out

Fig. 122: Light switch of vehicle

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

3-65

Operation 3.5.9

Operation of the restrictor unit on the tilt ram (option) Important!

Fit the tilt ram of the loader unit with a restrictor unit for operation of heavy implements – see table “Fields of application” on page 1-4 marked with footnote 3. The restrictor unit avoids damage to the tilt ram and other vehicle parts by reducing dump-in and dump-out speed.

A

Stop cock A is ....

Description of implement

Closed (Fig. 123, across driving direction)

Heavy implements are marked in table “Fields of application” on page 1-4 with footnote 3

Stop cock A is ....

Description of implement

Open (Fig. 124, in driving direction)

For use of all other implements released for vehicles model ML52

Fig. 123: Stop cock closed

A

Fig. 124: Stop cock open

3-66

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Operation 3.5.10

Safety equipment "Hose burst valve" (option) Important!

When working with lifting gear and specific implements, the hydraulic rams of the loader unit must be equipped with “hose burst valves” – see Applications with lifting accessories on page 2-8.

Hose burst valves avoid the loader unit from being lowered or dumped without being braked, in the event of a bursting hose or pipe.

Danger!

Damage to the hydraulic system leads to activation of the “hose burst valve” –

Accident hazard! ☞ Unlock the emergency lowering of the hose burst valve in an emergency only ☞ Have damage to the hydraulic system and to the hose burst valve immediately repaired and checked by trained and skilled personnel In case of damage to the hydraulic system: ☞ Stop the vehicle immediately ☞ Apply the parking brake ☞ Switch off the engine ☞ Remove the ignition key! ☞ Secure the vehicle Environment!

Collect drained hydraulic oil and biodegradable oil in a suitable container. Dispose of drained hydraulic oil by an ecologically safe method!

Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil.

☞ Collect the drained oil and dispose of it by an ecologically safe method!

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

3-67

Operation ☞ Actuate emergency lowering as follows: Danger!

Emergency lowering of loader unit –

Accident hazard! ☞ Keep clear of area of danger under loader unit, always approach from the sides! ☞ Always actuate emergency lowering with extreme care

B

A

• Unscrew locknut B • Carefully turn in screw A by 1 to 2 turns until the loader unit starts lowering Environment!

Collect drained hydraulic oil and biodegradable oil in a suitable container. Dispose of drained hydraulic oil by an ecologically safe method!

Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil.

Fig. 125: Hose burst valve (option)

• Collect the drained oil and dispose of it by an ecologically safe method!

• Carefully lower the loader unit to transport position • Turn out screw A again by the equal number of turns and secure it with locknut B • Drive the vehicle out of the area of danger with the loader unit lowered ☞ If necessary, have the setting of the hose burst valve and damage to the hydraulic system immediately checked and replaced by a specialist workshop

3-68

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Operation 3.5.11

Working with standard bucket and pallet forks

Implements

Read and follow the operation manuals of the implements before and when using them (special buckets, pallet forks, rotary broom etc.)!

Standard bucket

The following section describes work operations with the vehicle equipped with the standard bucket (called bucket in the following).

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

Checking the tilt position of the bucket Important!

A Angle of red mark A = angle of cutting blade B

B Checking the transport position of the bucket Fig. 126: Tilt position of the bucket

Important!

C

D

307b0460.eps

The bucket is in transport position if • Bucket C is fully tilted in and • Target marks E on the loader unit and the vehicle frame are lined up Distance D of the centre of rotation of the bucket to the ground is about 150 mm.

Fig. 127: Transport position of the bucket

E

Fig. 128: Marks for transport position

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

3-69

Operation Transporting with a full bucket Danger!

Never transport full buckets in raised position, even over a short distance –

Accident hazard!

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

☞ To avoid accidents: • Tilt the bucket all the way in • Lower or raise the bucket to transport position

Important!

Tax and safety regulations in your country may prohibit the transport of material when driving on public roads!

☞ Proceed as follows: • Tilt the bucket all the way in • Lower or raise the loader unit to transport position • When transporting over longer distances: select 2nd drive mode (transport mode)

C 64 30300b03060.eps

A Fig. 129: Horizontal lowering of the loader unit

64

Picking up/ loading loose material ☞ Proceed as follows: • Select the1st drive mode • Align blade A of the bucket parallel with the ground – see also “Checking the tilt position of the bucket” on page 3-69“ • Lower the loader unit to the ground. To do this: ☞ Push lever 64C ( ) forward • Drive into the material When the engine revs decrease: • Raise the loader unit slightly. To do this: ☞ Pull lever 64D ( ) backward

D 30300b03060.eps

Fig. 130: Driving into the material

3-70

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Operation If the material is hard to penetrate:

☞ Proceed as for loading loose material, but in addition:

B

A

• Tilt the bucket in and out slightly to release the material. To do this: ☞ Move lever 64 to the left A and right B

64 30300b03060.eps

Fig. 131: Loading, if the material is hard to penetrate

Ending loading: A

☞ Proceed as follows:

64 30300b03060.eps

• Tilt the bucket in. To do this: ) to the left ☞ Push lever 64A ( • Reduce engine revs • Reverse out of the material • Raise the bucket to transport position. To do this: ☞ Pull lever 64D ( ) backward

Fig. 132: Tilting in the bucket

64 D 30300b03060.eps

Fig. 133: Reversing out of the material

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

3-71

Operation Removing material/digging in soft soil Danger!

If foundations or walls are undermined – danger of collapse!

Accident hazard! ☞ Never undermine foundations or walls! ☞ Proceed as follows: • Select the 1st drive range • Lower the loader unit horizontally to the ground. To do this: ) forward ☞ Push lever 64C (

C 64 30300b03060.eps

Fig. 134: Lowering the loader unit horizontal to the ground

• Set digging angle. To do this: ☞ Move lever 64B to the right • Drive forward Once the bucket has penetrated the soil: • Set digging angle slightly flatter (see Fig. 136). To do this: ☞ Push lever 64A to the left, so that:

➥ Layer being removed is as even as possible ➥ Wheel spin is reduced

B 64

• Proceed as for loading loose material 30300b03060.eps

α

α

Fig. 135: Setting the digging angle

A

64 30300b03060.eps

a Fig. 136: Removing an even layer

3-72

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Operation Removing material/digging in hard soil Proceed as follows: • Select the 1st drive range • Lower the bucket horizontal to the ground. To do this: ) forward ☞ Push lever 64C (

C A

1.

• Set digging angle flatter than for digging in soft soil. To do this: ☞ Push lever 64A to the left

64 30300b03060.eps

2. a

• Drive forward (1.) and in doing so • Press the bucket downward slightly (2.). To do this: ☞ Push lever 64C slightly forward

Fig. 137: Removing hard soill

A

Once the bucket has penetrated the soil: • Set digging angle slightly flatter. To do this: ☞ Push lever 64A to the left, so that:

B

➥ Layer being removed is as even as possible ➥ Wheel spin is reduced

64 30300b03060.eps

α

• Push lever 64A to the left, or • Move it alternately to the left A and right B , to loosen the material • Proceed as for loading material hard to penetrate

Fig. 138: Setting the digging angle flatter

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

3-73

Operation Loading heaped material (non-compacted material) Danger!

Digging under heaped material can cause it to collapse

Accident hazard! ☞ Never undermine heaped material! ☞ Proceed as follows:

C A

B

64 30300b03060.eps

Fig. 139: Penetrating heaped materiall

C A

B

1.

3.

64 30300b03060.eps

• Select the1st drive range • Set the cutting blade of the bucket parallel to the ground. To do this: ☞ Push lever 64 to the left A or right B • Lower the loader unit horizontal to the ground. To do this: ☞ Push lever 64C forward • Drive forward After penetrating the heaped material: • Smoothly raise the loader unit • Keep the bucket level 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 to transport position

2.

Fig. 140: Reversing away from heaped materiall

A

Loading heaped material (compacted material)

B 64 30300b03060.eps

Proceed as follows: • Select the 1st drive range • Proceed as for non-compacted material, however when raising the loader unit through the heaped material: • Tilt the bucket in and out slightly. To do this: ☞ Push lever 64 alternately to the left A and right B

➥ Material is loosened

Fig. 141: Heaped compacted materiall

Grading

2.

1.

After having finished removing/loading the material: ☞ Select the 1st drive range ☞ Lower the loader unit parallel to the ground (1.) ☞ Reverse across the surface to be graded (2.)

Fig. 142: Grading

3-74

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Operation Further practical hints for digging When planning and carrying out digging work, we recommend that you observe the following points: • Exits from pits must be outside the digging line and as level as possible • Dig by removing adjacent strips if possible • Make sure you can drive forward when driving out of the digging area with a fully loaded bucket • Whenever possible, drive in reverse when transporting a full bucket down a steep slope Loading vehicles When loading vehicles, we recommend to take into account the following: • Select the 1st drive range • If possible, the lorry and the working direction of the loader should form an angle of 45° (Fig. 143) • Only raise the full bucket to the dumping height when you are driving in a straight line toward the lorry • If possible dump with the wind behind you to keep the dust away from your eyes, air filters and fans!

Fig. 143: Loading vehicles

Freeing the vehicle

☞ If your vehicle gets stuck in the ground: • Dump out the bucket until the blade is vertical above the ground • Lower the loader unit all the way down • Reverse slowly and at the same time • Gradually tilt in the bucket ➥The vehicle is pushed backward • Repeat this procedure until the wheels reach firm ground • Reverse the vehicle away Working with pallet forks

Safety instructions

• Always follow the “Load diagram (Fig. 18)” on page 1-12. Never exceed maximum load!

• Follow the special instructions in the operation manual of the implement!

• Approach the material as closely as possible!

• Always approach the material with the vehicle wheels in straight-ahead position!

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

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

loaded vehicle)!

Never raise a load with only one fork arm!

Maintain a distance of at least 6 m between boom/load and overhead lines!

Before starting work, make sure the fork arms on the fork frame are securely locked – visual check!

Never operate boom and implements at higher vehicle speed!

Never leave the vehicle with the load raised!

Always transport the load close to the ground!

3-75

Operation

3-76

BA 302 01 US-Gehl – Edition 1.0 * 30101b0340.fm

Section Troubleshooting

4

Troubleshooting

Troubleshooting

4

Troubleshooting

4

The information given in this section is intended for operating personnel when carrying out repair work. It allows for fast and reliable detection of errors and malfunctions so that appropriate measures can be taken for troubleshooting.

The detailed description of repair work is limited to the work which can be carried out by persons without special training.

BA 302 01 US-Gehl – Edition 1.0 * 30101b0410.fm

4-1

Troubleshooting 4.1

Engine trouble Problem

Engine does not start or is not easy to start

Engine starts, but does not run smoothly or faultless

Engine overheats. Temperature warning system responds

Insufficient engine output

Engine does not run on all cylinders

Insufficient or no engine oil pressure

Engine oil consumption too high

4-2

Possible causes Parking brake not applied Engine starting temperature too low Wrong SAE grade of engine lubrication oil Fuel quality does not comply with operation manual Battery defective or flat Loose or oxidised cable connections in starter circuit Starter defective, or pinion does not engage Wrong valve tip clearance Fuel injector defective Fuel quality does not comply with operation manual Wrong valve tip clearance Injection line leaks Fuel injector defective Oil level too low Oil level too high Air filter fouled/exhaust turbocharger defective Air filter maintenance switch or gauge defective Radiator fins soiled Fan defective/V-belt torn or loose Cooling air heats up/overheating interruption Resistance in cooling system too high/flow capacity too low Fuel injector defective Oil level too high Fuel quality does not comply with operation manual Air filter fouled/exhaust turbocharger defective Air filter maintenance switch or gauge defective Charge-air line leaks Wrong valve tip clearance Injection line leaks Fuel injector defective Injection line leaks Fuel injector defective Oil level too low Engine inclination too high Wrong SAE grade of engine lubrication oil Oil level too high Engine inclination too high

See 3-18 5-42 5-42 5-38

7-1 5-42 7-1

5-7 5-7

5-11

5-7 5-42

7-1

5-7 7-1 5-42 5-7 7-1

BA 302 01 US-Gehl – Edition 1.0 * 30101b0410.fm

Troubleshooting Problem

Possible causes Blue

White Engine smokes

Black

BA 302 01 US-Gehl – Edition 1.0 * 30101b0410.fm

Oil level too high Engine inclination too high Engine starting temperature too low Fuel quality does not comply with operation manual Wrong valve tip clearance Fuel injector defective Air filter fouled/exhaust turbocharger defective Air filter maintenance switch or gauge defective Full-load stop (dependent on charge-air pressure) defective Charge-air line leaks Wrong valve tip clearance Fuel injector defective

See 5-7 7-1

7-1

7-1

4-3

Troubleshooting

4-4

BA 302 01 US-Gehl – Edition 1.0 * 30101b0410.fm

Section

5

Maintenance 5

Maintenance

Maintenance

5

Maintenance

5.1

Introduction

5

Before carrying out service and maintenance work, always read, understand and follow the instructions given in • Section 2 “SAFETY INSTRUCTIONS” of this operation manual • The operation manual for the engine Daily service and maintenance work, and maintenance work according to maintenance plan A, can be carried out by specially trained operators. All other maintenance work must be carried out by qualified mechanics only.

The intervals for the maintenance work described below are listed in the maintenance plans in the annex.

5.2

Fuel system

5.2.1

Specific safety instructions • Extreme caution is essential when handling fuel – high risk of fire!

• Never work on the fuel system if the engine is hot – e.g. for changing filters!

• Never carry out work on the fuel system in the vicinity of naked flames or sparks!

• Do not smoke when working on the fuel system or when refuelling!

• Before refuelling, switch off the engine and remove the ignition key!

• Do not refuel in closed rooms!

• Wipe away fuel spills immediately!

• Keep the vehicle clean to reduce the risk of fire!

BA 302 01 US-Gehl – Edition 1.0 * 30101b0510.fm

5-1

Maintenance 5.2.2

Refuelling Danger!

All work involving fuel carries an increased

Danger of fire and poisoning! ☞ Do not refuel in closed rooms ☞ Never carry out work on the fuel system in the vicinity of naked flames or sparks!

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!

Stationary fuel pumps

General If possible, only refuel from stationary fuel pumps. Fuel from barrels or canisters is usually contaminated.

Even the smallest particles of dirt can cause • Increased engine wear • Malfunctions in the fuel system and • Reduced effectiveness of the fuel filters Refuelling from barrels

wrong

right

✗

If refuelling from barrels cannot be avoided, note the following points (see Fig. 144): • Barrels must neither be rolled nor tilted before refuelling • Protect the suction pipe opening of the barrel pump with a fine-mesh strainer • Immerse it down to max. 15 cm above the floor of the barrel • Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter • Keep all refuelling containers clean at all times

✓

Fig. 144: Refuelling from a barrel

5-2

BA 302 01 US-Gehl – Edition 1.0 * 30101b0510.fm

Maintenance Specification for diesel fuel

Only use high-grade fuels according to DIN 51601 : Cetane number

Grade

• No. 2-D as per DIN 51601 • No. 1-D as per DIN 51601

Use For normal temperatures

Min. 45

For temperatures below 4°C or for operation above 1500 m altitude

Caution!

Do not add petrol (regular and premium-grade petrol) to diesel fuel! ☞ Refuel winter-grade diesel fuel to avoid the formation of paraffin at low temperatures!

PME fuel The vehicle cannot be operated with PME fuels (Plant Methyl Ester).

PME fuels have not been tested and approved by producer. They may have a negative effect on the safety of the vehicle. Producer assumes no liability for resulting damage.

5.2.3

Cleaning the fuel tank Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!

B A

Deposits of dirt particles and water in the tank cannot be entirely avoided. The fuel tank should therefore be cleaned occasionally, particularly before winter operation.

Clean the fuel tank when the fuel level in the tank is as low as possible! ☞ Clean the fuel tank as follows: • Place a drip tray under the fuel tank • Remove drain plug A • Flush out the fuel tank with fuel, several times if necessary • Screw in drain plug A with a new gasket B • Fill the tank • Check for tightness after a test run

Fig. 145: Drain plug on fuel tank

BA 302 01 US-Gehl – Edition 1.0 * 30101b0510.fm

5-3

Maintenance 5.2.4

Changing the fuel filter Danger!

If the fuel, as it drains, comes into contact with hot engine parts or the exhaust system, there is an increased

Danger of burns!

B

A

☞ Never change the fuel filter if the engine is hot!

Fig. 146: Fuel filter position

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!

☞ Change the fuel filter 146/A as follows: • Pinch off fuel feed line 146/B with a suitable tool • Thoroughly clean the outside surfaces of fuel filter 146/A • Release and unscrew fuel filter cartridge using a commercially available tool • Collect the drained fuel!

Fig. 147: Unscrewing the fuel filter

• Clean the sealing surface of the filter carrier if it is fouled • Lightly oil the rubber gasket of the new filter cartridge or apply a thin coat of clean diesel fuel to it • Screw on the cartridge by hand until the gasket makes contact

Fig. 148: Cleaning the sealing surface and oiling the gasket

• Tighten the fuel filter cartridge by turning it a further half revolution • Remove the tool which has been used to pinch off fuel feed line 146/B • Make a test run – and check for tightness!

• Dispose of the old fuel filter cartridge by an ecologically safe method Important!

The fuel system bleeds itself automatically!

Fig. 149: Screwing down the fuel filter

5-4

BA 302 01 US-Gehl – Edition 1.0 * 30101b0510.fm

Maintenance 5.2.5

Cleaning the screen filter of the fuel pump Danger!

If the fuel, as it drains, comes into contact with hot engine parts or the exhaust system, there is an increased

Danger of burns! ☞ Never clean the screen filter when the engine is hot!

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!

☞ Proceed as follows:

B

C

A

Fig. 150: Removing the screen filter

• Pinch off fuel feed line 146/B with a suitable tool • Release and unscrew hexagon head screw A • Remove fuel screen B (cover and screen come out together) • Clean fuel screen B with fuel, replace if necessary • Position sealing rings C • Fit fuel screen B (cover with screen) back on • Tighten hexagon head screw A • Remove the tool which has been used to pinch off the fuel feed line 146/B • Make a test run – and check for tightness!

Important!

The fuel system bleeds itself automatically!

BA 302 01 US-Gehl – Edition 1.0 * 30101b0510.fm

5-5

Maintenance 5.2.6

Changing the leak oil line Danger!

If the fuel, as it drains, comes into contact with hot engine parts or the exhaust system, there is an increased

Danger of burns! ☞ Never change the fuel leak oil line when the engine is hot!

Caution!

Always replace the complete fuel leak oil line when the hose is pulled off from the hose stem (fuel injector/hose connecting pieces) ☞ On pulling off the hose, the inner area of the hose and the textile coating can be damaged. Slide the hose onto the hose stem as far as possible

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!

1

2

4

3

leckoel.eps

Fig. 151: Changing the leak oil line

☞ Proceed as follows: • Pinch off fuel feed line 146/B with a suitable tool • Remove rubber hoses 3 from the fuel injector valves • Remove rubber hose 1 from the fuel tank • Remove rubber hoses 4, 3 and 1 from connecting pieces 2 and dispose of them in an environmentally friendly manner • Install the new fuel leak oil line. To do this: • Connect the rubber hoses 3 to the fuel injector valves • Connect rubber hose 1 to the fuel tank • Open the fuel stop cock • Check for leakage after start-up Important!

The fuel system bleeds itself automatically!

5-6

BA 302 01 US-Gehl – Edition 1.0 * 30101b0510.fm

Maintenance 5.3

Engine lubrication system

5.3.1

Checking the oil level 38b07601.eps

Important!

Check the oil level every 10 service hours or every day.

We recommend checking the oil level before starting the engine. After switching off a warm engine, wait at least 5 minutes before checking.

A

Fig. 152: Oil dipstick

☞ Check the oil level as follows: A

max min

Fig. 153: Checking the oil level

BA 302 01 US-Gehl – Edition 1.0 * 30101b0510.fm

• Park the vehicle on level ground • Lower the loader unit • Lower the bucket blade to the ground • Apply the parking brake • Switch off the engine • Open the engine cover In addition, if the engine has been started: • Wait about 5 minutes for the oil to return to the sump • Oil dipstick A • Pull it out and wipe it with a lint-free cloth • Push back in as far as possible • Withdraw and • Read off the oil level • Top up the oil level if necessary, at the latest when the oil reaches the MIN mark on the dipstick

5-7

Maintenance 5.3.2

Filling in engine oil Caution!

Excessive or incorrect engine oil may result in engine damage! For this reason: ☞ Do not add engine oil above the MAX mark of the oil dipstick 153/A ☞ Use only the specified engine oil – see section 5.14 Engine fluids and lubricants on page 5-42

Environment!

Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner!

☞ Top up the oil level as follows:

OIL

• Park the vehicle on level ground

38b07601.eps

B A

Fig. 154: Topping up engine oil

5-8

• Lower the loader unit • Lower the bucket blade to the ground • Apply the parking brake • Switch off the engine • Open the engine cover • Clean the area around oil filler cap B with a lint-free cloth • Open filler cap B • Raise oil dipstick A slightly to allow any trapped air to escape • Filling in engine oil • Wait a moment until all the oil has run into the oil sump • Check the oil level – see section 5.3.1 Checking the oil level on page 5-7 • Top up if necessary and check the oil level again • Shut the filler cap B • Push in oil dipstick A into the filler inlet as far as it will go • Completely remove all oil spills from the engine

BA 302 01 US-Gehl – Edition 1.0 * 30101b0510.fm

Maintenance 5.3.3

Changing the engine oil Danger!

Caution when draining hot engine oil –

Danger of burns! ☞ Wear protective gloves ☞ Use suitable tools

+ 80°C

OIL

Environment!

Fig. 155: Optimum engine oil temperature

Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner!

D

E

C

38b02700.eps

☞ Change the engine oil as follows: • Park the vehicle on level ground • Lower the loader unit • Lower the bucket blade to the ground • Apply the parking brake • Let the engine run until reaching service temperature (oil temperature about 80 °C) • Switch off the engine • Open the engine cover • Remove cover plate • Place an oil drip tray (with a capacity of about 12 litres) under the opening • Unscrew filler cap C of oil drain valve D

Fig. 156: Drain plug on vehicle rear end

D E F G

Fig. 157: Drain coupling with hose

BA 302 01 US-Gehl – Edition 1.0 * 30101b0510.fm

• Screw on drain coupling with a hose F of adequate length. The hose end must be well in oil collector G ➥Oil drain valve D opens and the engine oil drains • Completely drain the oil • Unscrew drain coupling E • Screw on filler cap C of the oil drain valve • Fill with engine oil – see section 5.3.2 Filling in engine oil on page 5-8 • Check the oil level – see section 5.3.1 Checking the oil level on page 5-7 • Start the engine and run it at low speed for a short time • Switch off the engine • Wait a moment until all the oil has run into the oil sump • Check the oil level again • Top up if necessary and check again • Completely remove all oil spills from the engine

5-9

Maintenance 5.3.4

Changing the engine oil filter cartridge Danger!

Caution when draining hot engine oil – H

Danger of burns! ☞ Wear protective gloves

Fig. 158: Engine oil filter position

Environment!

Use a suitable container to collect the engine oil as it drains.

Dispose of used oil and filters in an environmentally friendly manner!

☞ Change the filter as follows: • Park the vehicle on level ground • Lower the loader unit • Lower the bucket blade to the ground • Apply the parking brake • Switch off the engine • Open the engine cover • Place a suitable container under the oil filter to collect the oil • Unscrew oil filter cartridge H using a commercially available tool

H

Fig. 159: Unscrewing the engine oil filter

I

• Make sure the thread adapter is correctly placed in the filter head • Clean the inside of the filter head • Apply a thin coat of fresh engine oil to rubber seal I of the new oil filter cartridge • Tighten the new filter cartridge by hand until the gasket makes contact • Tighten oil filter cartridge H by hand with about a further half revolution • Check the oil level and top up if necessary – see section 5.3.1 Checking the oil level on page 5-7 • Run the engine for a short time • Switch off the engine

Fig. 160: Cleaning the filter head and oiling the gasket

H

• Check the seal of oil filter cartridge H and retighten by hand • Check the oil level again and top up if necessary • Completely remove all oil spills from the engine • Dispose of the used oil filter in an environmentally friendly manner

Fig. 161: Tightening the filter cartridge

5-10

BA 302 01 US-Gehl – Edition 1.0 * 30101b0510.fm

Maintenance 5.4

Engine and hydraulics cooling system Engine oil and hydraulic oil are cooled via separate radiators.

The oil cooler is located in the engine compartment, on the right side behind the engine. It cools the hydraulic oil of the drive and work hydraulics. The engine oil is cooled via the oil cooler fitted to the diesel engine.

5.4.1

Specific safety instructions • Dirt on the cooling ribs reduces the cooler’s heat dissipation capacity! To avoid this: • Clean the outside of the cooler at regular intervals. Refer to the maintenance plans in the Annex for the cleaning intervals • In dusty or dirty work conditions, clean more frequently than indicated in the maintenance plans

5.4.2

Engine oil cooler

Cleaning Danger!

Never remove cooling air cover A if the engine is warm.

Danger of burns! ☞ Wait at least 10 minutes after switching off the engine! ☞ Wear protective goggles, gloves and clothing! ☞ Proceed as follows: A

B

• Park the vehicle on level ground • Lower the loader unit • Lower the bucket blade to the ground • Apply the parking brake • Switch off the engine and let it cool down • Open the engine cover

Fig. 162: Removing the engine cooling air cover

• Remove cooling air hood A. To do this: • Release screws B • Blow compressed air, starting from the exhaust end 1, to clean the engine • Remove dirt which has been blown into area 2 • Clean cooling fan 3 • Fit cooling air hood A

1.

2.

3.

Fig. 163: Direction of blown air when cleaning the oil cooler

BA 302 01 US-Gehl – Edition 1.0 * 30101b0510.fm

5-11

Maintenance 5.4.3

Hydraulic oil cooler

Cleaning

Danger!

Warm engine –

Danger of burns! ☞ Wait at least 10 minutes after switching off the engine! ☞ Wear protective goggles, gloves and clothing!

A

B

☞ Proceed as follows: • Park the vehicle on level ground • Lower the loader unit • Lower the bucket blade to the ground • Apply the parking brake • Switch off the engine and let it cool down • Open the engine cover • Clean radiator fins 164/A by blowing compressed air from fan end 164/B

Fig. 164: Cleaning the oil cooler

5-12

BA 302 01 US-Gehl – Edition 1.0 * 30101b0510.fm

Maintenance

Maintenance 5

5.5

Air filter Caution!

The filter cartridge will be damaged if it is washed, blown or brushed out! ☞ Do not clean the filter cartridge! ☞ Replace the filter cartridge when the telltale comes on! ☞ Never reuse damaged filter cartridges. Replace them if you are unsure! ☞ Ensure cleanliness when replacing the filter cartridge!

Telltale 54 in the instrument panel monitors the filter cartridge. The filter cartridge must be replaced: • If telltale 54 comes on • At the latest after 1200 service hours (once every year)

˚F 175 250

105 80 40

60

54 10

30

20

16

Volt

20

10 10

P

14

12

100 120

˚C

40

˚F 1/2

270

165

500

120 100

75 50

˚C

125 150

MPH Km/h

0

30

1/1

50

0 002836h

Important!

312b0050.eps

The air filter is fitted with a safety cartridge which cannot be cleaned. Replace the safety cartridge every third time maintenance is carried out!

Fig. 165: Telltale in the instrument panel

Caution!

The filter cartridge may degrade prematurely when in service in acidic air for longer periods of time. This risk is present for example in acid production facilities, steel and aluminium mills, chemical plants and other nonferrous-metal plants. ☞ Replace the filter cartridge and safety cartridge as per telltale 54, after 300 service hours at the latest! ☞ Clean dust valve regularly according to the maintenance plan!

A Important!

The air filter is located behind the maintenance flap in the engine compartment on the right side of the vehicle.

☞ Open maintenance flap A as follows: Fig. 166: Dust valve position

BA 302 01 US-Gehl – Edition 1.0 * 30101b0520.fm

• Park the vehicle on level ground • Apply the parking brake • Switch off the engine • Open the engine cover • Open the maintenance flap on the right. To do this • Press button A on the inside

5-13

Maintenance Functional check of the dust valve

☞ Proceed as follows: • Compress the discharge slot of dust valve B • Remove hardened dust by compressing the upper area of the valve ☞ Clean the discharge slot if necessary ➥ The discharge slot must close again upon releasing it B Fig. 167: Dust valve position

5-14

BA 302 01 US-Gehl – Edition 1.0 * 30101b0520.fm

Maintenance Replacing the filter cartridge Caution!

The filter cartridge will be damaged if it is washed, blown or brushed out!

Dust on the clean side of the filter causes accelerated engine wear!

Danger of engine damage! ☞ Do not clean the filter cartridge! ☞ Replace the filter cartridge when the telltale comes on! ☞ Never reuse damaged filter cartridges. Replace them if you are unsure! ☞ Proceed as follows:

C

• Pull bow clip C on lower housing section D to the outside • Remove lower housing section D D

Fig. 168: Opening the air filter housing

• Remove filter cartridge E with a slightly turning movement E

308b1040.eps

Fig. 169: Removing the main filter element

• In addition after every 3rd replacement of the filter cartridge E: • Remove safety cartridge F with slightly turning movements • Carefully insert new safety cartridge F into the upper housing section • Carefully insert new filter cartridge E into the upper housing section

E

F Fig. 170: Air filter with safety cartridge (option)

• Position lower housing section D so that dust valve B shows downward • Close bow clip C ➥The filter cartridge is automatically pressed into the correct position

C

D

Fig. 171: Closing the air filter housing

BA 302 01 US-Gehl – Edition 1.0 * 30101b0520.fm

B

5-15

Maintenance 5.6

V-belt Danger!

Only check or retighten/replace the V-belt when the engine is switched off –

Danger of personal injury! ☞ Switch off the engine before carrying out maintenance work in the engine compartment!

Check the V-belt every day or every 10 hours of operation and retighten it if necessary.

New V-belts: ☞ Retighten after about 15 minutes of running time ☞ Check V-belt tension again after the first 25 service hours, retighten if necessary Checking the V-belt tension about 10 mm

Fig. 172: Checking V-belt tension

Retightening the V-belt B

A C

D

Fig. 173: Retightening the V-belt

☞ Check as follows: • Switch off the engine • Prevent the vehicle from rolling away and remove the ignition key • Open the engine cover • Carefully inspect the V-belt for damage If the V-belt is damaged: • Replace the V-belt (or have it replaced) • Press with your thumb in the middle of the longest section between two pulleys (figure 172) to check whether the V-belt can be deflected, by no more than about 10 mm • Retighten the V-belt if necessary

☞ Proceed as follows: • Switch off the engine • Prevent the vehicle from rolling away and remove the ignition key • Open the engine cover • Loosen screws B and C • Use a suitable tool to move tensioning pulley D until the correct V-belt tension is obtained • Maintain tensioning pulley D in this position • Retighten screws B and C • Check V-belt tension once again

38B03300.eps

Important!

Check V-belt tension again after the first 25 service hours if a new V-belt is mounted!

5-16

BA 302 01 US-Gehl – Edition 1.0 * 30101b0520.fm

Maintenance 5.7

Hydraulic system

5.7.1

Specific safety instructions • All lines carrying hydraulic oil must be depressurised prior to all maintenance and repair work. To do this: • Lower all hydraulically controlled implements to the ground • Move all control levers of the hydraulic control valves several times • Apply the parking brake to prevent the vehicle from rolling away before you carry out service and maintenance work • Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries. Always consult a doctor immediately even if the wound seems insignificant – otherwise serious infections could set in!

• If the hydraulic oil in the level glass is cloudy, this indicates that water or air has penetrated the hydraulic system. This may cause damage to the hydraulic pump! ☞ Contact your dealer immediately Caution!

Contaminated hydraulic oil, lack of oil or wrong hydraulic oil –

Danger of severe damage to the hydraulic system! ☞ Take care to avoid contamination when working! ☞ Always use the filling screen when filling in hydraulic oil! ☞ Only use authorised oils of the same type – see Engine fluids and lubricants on page 5-42 ☞ Always top up the hydraulic oil before the level gets too low ☞ If the hydraulic system is filled with biodegradable oil, then only use biodegradable oil of the same type for topping up – observe the sticker on the hydraulic oil tank! ☞ Always contact customer service if the hydraulic system filter is contaminated with metal chippings. Otherwise, follow-on damage may result!

Environment!

Collect drained hydraulic oil and biodegradable oil in a suitable container! Dispose of drained oil and used filters by an ecologically safe method.

Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil.

BA 302 01 US-Gehl – Edition 1.0 * 30101b0520.fm

5-17

Maintenance 5.7.2

Hydraulic oil level

Checking the oil level

☞ Proceed as follows:

✓

• Park the vehicle on level ground • Retract all hydraulic rams. To do this: • Fully lower the loader unit • Tilt the bucket all the way in • Switch off the engine • Apply the parking brake • Open the engine cover • Check hydraulic oil level A in the sight glass:

A

If the oil level is: • Visible in the sight glass • Below the sight glass • Above the sight glass

Fig. 174: Oil level glass on the hydraulic oil tank

In working order ☞ Top up the hydraulic oil ☞ Drain the hydraulic oil

Topping up hydraulic oil Important!

Do not top up the hydraulic oil unless the engine is switched off, otherwise hydraulic oil will flow out of the hydraulic oil tank filler inlet.

The hydraulic oil tank is located on the left in the engine compartment.

☞ Top up as follows: • Park the vehicle on level ground • Retract all hydraulic rams. To do this: • Fully lower the loader unit • Tilt the bucket all the way in • Switch off the engine

B

C A

38b03400.eps

Fig. 175: Hydraulic oil tank

5-18

• Apply the parking brake • Open the engine cover • Clean the area around the filler inlet of the hydraulic oil tank with a cloth • Open filler cap B With filter screen C installed: • Top up the hydraulic oil • Check the hydraulic oil level on oil level sight glass A • Top up the hydraulic oil if necessary and check again

BA 302 01 US-Gehl – Edition 1.0 * 30101b0520.fm

Maintenance Changing the hydraulic oil Danger!

Draining hot hydraulic oil and removing the filter element is hazardous:

Danger of burns! ☞ Wear protective gloves ☞ Fit a sufficiently long hose to the oil drain coupling

Environment!

Collect drained hydraulic oil and biodegradable oil in a suitable container! Dispose of drained hydraulic oil by an ecologically safe method!

Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil.

☞ Proceed as follows: • Park the vehicle on level ground • Retract all hydraulic rams. To do this: • Fully lower the loader unit • Tilt the bucket all the way in • Switch off the engine and prevent the vehicle from rolling away • Open the engine cover • Unscrew breather filter D to depressurise the hydraulic oil tank – the hydraulic system must be depressurised!

• Place a suitable container J underneath the vehicle rear end (minimum capacity: 90 litres) • Unscrew filler cap F of oil drain valve E • Hold the end of the hose of oil drain coupling G into container J

E F

B H

G D

C

38b04900.eps

Fig. 176: Overview of the hydraulic oil tank

I 38b05700.eps

about ca.

Liter 6060litres

Fig. 177: Hose routing for draining hydraulic oil

BA 302 01 US-Gehl – Edition 1.0 * 30101b0520.fm

J

• Screw oil drain coupling G onto oil drain valve E ➥Oil drain valve G opens and the oil drains into the container • Open cover B • Remove filter insert C and clean with diesel • Re-insert cleaned filter insert C • Flush out the hydraulic oil tank with a little hydraulic oil • Remove oil drain coupling G on oil drain valve E • Screw filler cap F of oil drain valve E • Screw breather filter D onto the hydraulic tank. If necessary, use a new breather filter as per the maintenance intervals – see section 5.7.4 Changing the breather filter on page 5-23 • Follow the maintenance intervals for hydraulic oil filter insert H, if necessary replace the filter insert – see section Changing the filter insert on page 5-22

5-19

Maintenance

Caution!

Contaminated hydraulic oil can cause serious damage to the hydraulic system! ☞ Always fill in hydraulic oil through the screen filter insert C! • Fill the system with fresh hydraulic oil up to the middle of oil level sight glass A • Screw on cover B of the hydraulic oil tank • Start the engine With the engine running at low speed: • Raise the loader unit as far as it will go • Fully dump out the bucket • Turn the steering wheel to the left and right several times, from lock to lock • Retract all hydraulic rams again. To do this: • Fully lower the loader unit • Tilt the bucket all the way in • Switch off the engine • Check the hydraulic oil level again and top up again if necessary

5-20

BA 302 01 US-Gehl – Edition 1.0 * 30101b0520.fm

Maintenance Important information for the use of biodegradable oil

• Use only the biodegradable hydraulic fluids which have been approved by producer

• • • • • •

– see Engine fluids and lubricants on page 5-42. Always contact producer for the use of other, not recommended products. In addition, ask the oil supplier for a written declaration of guarantee. This guarantee is applicable to damage occurring on the hydraulic components, which can be proved to be due to the hydraulic fluid The remaining amount of initial hydraulic fluid in the hydraulic system must not exceed 8 % when using another type of biodegradable oil (manufacturer indications) Do not top up with mineral oil – the content of mineral oil must not exceed 2 % in order to avoid foaming problems and to ensure biological degradability (hazardous waste!)

When running the vehicle with biodegradable oil, the same oil and filter replacement intervals are valid as for mineral oil – see maintenance plans in the Annex Drain the condensation water in the hydraulic oil tank every 600 service hours, in any case before the cold season. The water content must not exceed 0.1 % by weight The instructions in this operation manual concerning environmental protection are also valid for the use of biodegradable oil If additional hydraulic implements are mounted or operated, use the same type of biodegradable oil for these implements to avoid mixtures in the hydraulic system

Subsequent change from mineral oil to biodegradable oil

☞ Completely flush the hydraulic components. To do this:

H

38b04900.eps

• Park the vehicle on level ground when it is at operating temperature • Retract all hydraulic rams. To do this: • Fully lower the loader unit • Tilt the bucket all the way in • Switch off the engine and prevent the vehicle from rolling away • Open the engine cover • Completely drain the hydraulic oil • Fill up the hydraulic system with the new oil type • Start the engine • Operate all components of the hydraulic system, such as rams, to “flush” the lines, rams and pumps • Retract all hydraulic rams • Switch off the engine • Completely drain the hydraulic oil again • Replace hydraulic oil filter insert H • Fill up the hydraulic system with fresh oil up to the required level • Check the oil level and top up if necessary

Fig. 178: Hydraulic oil filter insert

BA 302 01 US-Gehl – Edition 1.0 * 30101b0520.fm

5-21

Maintenance 5.7.3

Hydraulic oil reflux filter ˚F 175 250

105 80 40

60

10

16

30

20

Volt

20

10 10

P

14

12

100 120

˚C

40

˚F 1/2

270

165

500

120 100

75 50

˚C

125 150

MPH Km/h

0

30

1/1

50

0002836h

53 Fig. 179: Telltale for reflux filter

312b0050.eps

The red telltale 53 on the instrument panel monitors the reflux filter. The filter insert must be replaced: • If telltale 53 comes on when the hydraulic oil is at operating temperature • At the latest after 1200 service hours (once every year) In cold weather telltale 53 may come on immediately when the engine is started. This is caused by increased oil viscosity. In this case: ☞ Set engine speed so that telltale 53 goes out ☞ Bear in mind the instructions concerning warmup – see Starting at temperatures below 0 °C on page 3-19

Changing the filter insert Danger!

Be careful when removing the filter element –

Danger of burns! ☞ Wear protective gloves

Caution!

Insufficiently filtered hydraulic oil can cause serious damage to the hydraulic system! ☞ Take care to avoid contamination when working! ☞ The filter insert H must not be cleaned!

Environment!

Collect drained hydraulic oil and biodegradable oil in a suitable container! Dispose of drained hydraulic oil by an ecologically safe method!

5-22

BA 302 01 US-Gehl – Edition 1.0 * 30101b0520.fm

Maintenance ☞ Proceed as follows: • Park the vehicle on level ground • Apply the parking brake • Switch off the engine • Open the engine cover • Unscrew breather filter D to depressurise the hydraulic oil tank – the hydraulic system must be depressurised!

• Loosen and remove cover D • Pull out filler pipe M with filter insert H upward, turning them slightly • Pull filter insert H off filler pipe M and dispose of the filter element in an environmentally friendly way • Check sealing rings N and L for proper condition • Replace damaged sealing rings • Slide filler pipe M on new filter insert H and insert • Tighten cap D by hand (tightening torque 20 Nm) • Carry out a test run • Switch off the engine • Check the filter for leakage • Check the hydraulic oil level, top up oil if necessary

O N M L H D

38b04900.eps

Fig. 180: Filter insert and sealing rings

5.7.4

Changing the breather filter D

38b04900.eps

Replace breather filter D for the hydraulic oil tank every 1200 service hours or at least once a year. ☞ Proceed as follows: • Unscrew breather filter D • Screw in new breather filter D

Fig. 181: Breather filter on hydraulic oil tank

BA 302 01 US-Gehl – Edition 1.0 * 30101b0520.fm

5-23

Maintenance 5.7.5

Hydraulic pressure lines

Specific safety instructions

Danger!

Caution when checking hydraulic lines, especially when searching for leaks.

Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries –

Danger of personal injury! ☞ Always consult a doctor immediately, even if the wound seems insignificant – otherwise serious infections could set in! ☞ Always observe the following instructions: • Retighten leaking screwed fittings and hose connections only when the system is not under pressure; i.e. release the pressure before working on pressurised lines!

• Never weld or solder faulty or leaking pressure lines and connections.

Replace damaged parts with new ones!

• Never search for leakages with your bare hands, but wear protective gloves!

• Use paper or wood to check for minor leaks. Never use an unprotected light or naked flame!

• When replacing hose lines, ensure that they are not twisted!

• Leakages and damaged lines must be repaired or replaced as quickly as possible. This

1 Q/00

not only increases the operating safety of the vehicle, but also helps to protect the environment • Replace hydraulic hoses every 6 years from the date of manufacture, even if they do not seem to be damaged In this respect, we recommend that you observe all relevant safety regulations for hydraulic lines, as well as the safety regulations regarding accident prevention and occupational health and safety in your country. Also observe DIN 20066, Part 5.

The date of manufacture (month or quarter and year) is indicated on the flexible line.

Example: The indication “1 Q/00” means manufactured in the 1st quarter of 2000.

Fig. 182: Date of manufacture of hydraulic lines

5-24

BA 302 01 US-Gehl – Edition 1.0 * 30101b0520.fm

Maintenance

Maintenance 5

5.8

Gearboxes and axles Maintenance of these components is limited to checking the oil levels and to changing the oil at prescribed intervals – see Maintenance plan (overview) on page 5-48.

Danger!

Handling hot gear oil causes

Danger of burns! ☞ Wear protective gloves ☞ Use suitable tools, e.g. for unscrewing the drain plug

Important!

Only use new sealing rings for oil filler and drain plugs. Drain oil only after running the vehicle for a longer period of time!

Environment!

Use a suitable container to collect the gearbox oil as it drains and dispose of it in an environmentally friendly manner!

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

5-25

Maintenance 5.8.1

Rear axle gearbox

Checking/topping up the oil level in the rear axle gearbox

Important!

The rear axle differential and the gearbox have separate oil circuits.

Standard gearbox

A B ca142280_lubrif.eps

☞ Proceed as follows: • Park the vehicle on level ground when the gearbox is at operating temperature • Clean and unscrew oil filler and inspection plug A on the gearbox. Hold a cloth under the opening as you do so If the oil level is below the opening or if the oil level cannot be seen at all: • Fill in fresh oil through bore A up to the lower edge of the bore, oil grade – see Engine fluids and lubricants on page 5-42 If the oil level is correct: • Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal

High speed gearbox (option)

A ca142281_lubrif.eps

B Fig. 183: Checking the gearbox oil level

5-26

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

Maintenance Changing the gearbox oil Danger!

Handling hot gear oil causes

Danger of burns! ☞ Wear protective gloves ☞ Use suitable tools, e.g. for unscrewing the drain plug Standard gearbox

A B ca142280_lubrif.eps

High speed gearbox (option)

☞ Proceed as follows: • Park the vehicle on level ground when the gearbox is at operating temperature • Place a suitable container under the rear axle gearbox to collect the oil • Clean and unscrew oil filler and inspection plug A • Unscrew drain plug B • Completely drain the old gearbox oil • Fit a new sealing ring to drain plug B and screw in to make an oil-tight seal • Fill in fresh oil through bore A up to the lower edge of the bore, oil grade – see Engine fluids and lubricants on page 5-42 If the oil level is correct: • Tighten plug A with a new sealing ring to make an oil-tight seal After carrying out a test run: • Check the oil level again after about 5 minutes, and fill in oil if necessary

A ca142281_lubrif.eps

B Fig. 184: Changing the gearbox oil

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

5-27

Maintenance 5.8.2

Rear axle differential

Checking/topping up the oil level in the rear axle gearbox

Important!

The rear axle differential and the gearbox have separate oil circuits.

A

☞ Proceed as follows:

Fig. 185: Oil filler and inspection plug on the differential

• Park the vehicle on level ground when the differential is at operating temperature • Clean and unscrew oil filler and inspection plug A on the differential. Hold a cloth under the opening as you do so If the oil level is below the opening or if the oil level cannot be seen at all: • Fill in fresh oil through bore A up to the lower edge of the bore, oil grade – see Engine fluids and lubricants on page 5-42 If the oil level is correct: • Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal

Changing the oil

☞ Proceed as follows:

B

• Park the vehicle on level ground when the differential is at operating temperature • Place an adequately sized container under the differential housing of the rear axle to collect the oil • Clean and unscrew plug 185/A • Unscrew drain plug B • Completely drain the old gearbox oil • Fit a new sealing ring to drain plug B and screw in to make an oil-tight seal • Fill in fresh oil through bore 185/A up to the lower edge of the bore, oil grade – see Engine fluids and lubricants on page 5-42 If the oil level is correct: • Tighten plug 185/A with a new sealing ring to make an oil-tight seal After carrying out a test run: • Check the oil level again after about 5 minutes, and top up if necessary

Fig. 186: Drain plug on rear axle differential

5-28

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

Maintenance 5.8.3

Front axle differential Important!

Only use new sealing rings for oil filler and drain plugs. Drain oil only after running the vehicle for a longer period of time (operating temperature)!

Checking/topping up the oil level

☞ Proceed as follows:

A Fig. 187: Oil filler and inspection plug on the differential

• Park the vehicle on level ground • Clean and unscrew oil filler and inspection plug A on the differential. Hold a cloth under the opening as you do so If the oil level is below the opening or if the oil level cannot be seen at all: • Fill in fresh oil through bore A up to the lower edge of the bore, oil grade – see Engine fluids and lubricants on page 5-42 If the oil level is correct: • Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal

Changing oil

☞ Proceed as follows:

B A Fig. 188: Oil filler and inspection plug on the differential

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

• Park the vehicle on level ground when it is at operating temperature • Place a drip tray under plug B to collect the oil • Clean and unscrew oil filler and inspection plug A • Clean and unscrew drain plug B • Completely drain the old oil • Fit a new sealing ring to drain plug B and screw in to make an oil-tight seal • Fill in fresh oil through bore A up to the lower edge of the bore, oil grade – see Engine fluids and lubricants on page 5-42 • Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal

5-29

Maintenance 5.8.4

Front and rear axle planetary drives Important!

Fit new sealing rings! Drain oil only after running the vehicle for a longer period of time!

☞ Proceed as follows:

Checking/topping up the oil level

• Park the vehicle on level ground and secure it against rolling away • Place plug C in the position shown in Fig. 189 (plug must be at the top) • Clean and unscrew plug C (to relieve possible overpressure) C

Fig. 189: Oil filler and inspection plug on planetary drive

C

• Place plug C in the position shown in Fig. 190 (plug must be horizontal) • Unscrew plug C If the oil level is below the opening or if the oil level cannot be seen at all: • Fill in fresh oil through bore C up to the lower edge of the bore, oil grade – see Engine fluids and lubricants on page 5-42 • Screw in plug C with a new sealing ring to make an oil-tight seal

Fig. 190: Oil filler and inspection plug on planetary drive

Changing the oil

☞ Proceed as follows: • Park the vehicle at operating temperature on level ground and secure it against rolling away • Place a suitable container under drain plug C • Place plug C in the position shown in Fig. 191 (plug must be at the top) • Clean and unscrew plug C (to relieve possible overpressure) Never raise the vehicle on one side only for the following work!

• Turn planetary drive downward (plug must be at the bottom) • Unscrew plug C • Completely drain the old oil • Place opening C in the position shown in Fig. 192 (plug must be in horizontal position) • Fill in fresh oil through bore C up to the lower edge of the bore, oil grade – see Engine fluids and lubricants on page 5-42 • Screw in plug C with a new sealing ring to make an oil-tight seal

C

Fig. 191: Drain plug on planetary drive

C

Fig. 192: Oil filler and inspection plug on planetary drive

5-30

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

Maintenance 5.8.5

Lubricating planetary drive bearings ☞ Proceed as follows: • Apply lithium-saponified multipurpose grease to both grease nipples D on each planetary drive bearing every 50 service hours or once a week – see section 5.14 Engine fluids and lubricants on page 5-42

D

Fig. 193: Grease nipples on planetary drive bearings

5.8.6

Lubricating the rear axle oscillation-type bearing Important!

The vehicle has an oscillation-type rear axle. Lubricate the bearing every 50 service hours or once a week, at the latest, through the 2 grease nipples E on the axle bearing.

☞ Lubricate oscillation-type bearing through grease nipple E with lithium-saponified multipurpose grease – see section 5.14 Engine fluids and lubricants on page 5-42 E Fig. 194: Grease nipples for oscillation-type bearing

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

5-31

Maintenance 5.9

Loader unit

5.9.1

Lubricating the pivots on the loader unit Lubricate the following lubrication points on the loader unit of the vehicle:

☞ Lubricate grease nipple A of the tilt ram bearing every 50 service hours (or once a week). Lubricate daily for heavy-duty operation ☞ Lubricate grease nipple B (2 x) of the loader unit bearing every 50 service hours (or once a weak). Lubricate daily for heavy-duty operation ☞ Lubricate grease nipple C of the lift ram bearing every 50 service hours (or once a week). Lubricate daily for heavy-duty operation

A

B C

Fig. 195: Upper lubrication points on loader unit

☞ Lubricate grease nipple D of the tilt ram bearing every 10 service hours (or daily), or more often for heavy-duty operation

☞ Lubricate grease nipple E of the tilt ram bearing every 50 service hours (or once a

D

week). Lubricate daily for heavy-duty operation ☞ Lubricate grease nipple F of lift ram and tilt lever bearing every 10 service hours (or daily), or more often for heavy-duty operation

E

F Fig. 196: Centre lubrication points on loader unit

☞ Lubricate grease nipple G of the tilt lever bearing every 10 service hours (or daily, or more often for heavy-duty operation

☞ Lubricate grease nipple H of the tilt lever bearing every 10 operating hours (or daily), or more often for heavy-duty operation

G

H

Fig. 197: Lower lubrication points on loader unit

5-32

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

Maintenance 5.10 Tyre care Danger!

Improper tyre repairs constitute an

Accident hazard! ☞ All repair work on tyres and rims may only be carried out by authorised specialist workshops

Important!

Regular tyre inspection improves operating safety and the service life of the tyres, and reduces vehicle downtimes.

Refer to the table in section “Specifications” on page 7-10 for the authorised tyre types and the correct tyre pressures. This table is also on the label fixed to the front window ex works.

5.10.1

Inspection work

Daily checks

☞ Carry out the following maintenance work daily: • Visual check of the tyre condition, especially: • Tyre pressure • Outside and inside damage of tyres and rims • Wear • Remove foreign bodies from the tyre tread • Remove traces of oil and grease from the tyres Checks every week

☞ Carry out the following maintenance work every week: • Check the tread depth of the tyres • Check tyre pressure and correct as necessary

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

5-33

Maintenance 5.10.2

Wheel change Caution!

The wheels are heavy and can damage the threads on the wheel studs if they are handled incorrectly! ☞ Use suitable assembly tools, such as covering sleeves for the studs, a jack etc.

Removing the wheels

☞ Proceed as follows: • Park the vehicle on level and firm ground and prevent it from rolling away • Slightly loosen the wheel nuts of the tyre you want to remove • Place a jack under the axle beam, making sure it is standing firmly • Raise the side of the axle from which you want to remove the tyre • Check the vehicle is standing firmly • Completely remove the wheel nuts • Remove the wheel

Fitting the wheels

☞ Proceed as follows: • Place the wheel onto the wheel studs • Tighten all wheel nuts part-way • Lower the raised axle • Tighten the wheel nuts to the prescribed tightening torque – see section 7.17.2 Specific tightening torques on page 7-12

5-34

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

Maintenance 5.11 Heating The vehicle heater is equipped with a dust filter or a fine dust filter (EU4, option) which must be cleaned at regular intervals or replaced once a year if necessary.

It is located under the access, on the left in driving direction.

5.11.1

Cleaning the dust filter of the heating system A

B

A dust or fine dust filter (option) cleans the air taken in by the heater. The plastic filter cloth must be cleaned with water, adding a mild cleaning agent if necessary, or replaced. The volume of warm air flowing out of the air vents decreases as filter cloth contamination increases. ☞ Clean/replace the filter cloth as follows: • Remove trim panel A on the right cab side. To do this: • Remove screws B

Fig. 198: Removing/installing the trim panel

C

• Remove dust filter C • Clean or replace dust filter C as required • Insert cleaned dust filter and install trim panel A

Fig. 199: Replacing the dust filter of the heating system

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

5-35

Maintenance 5.12 Electrical system 5.12.1

Specific safety instructions • Battery A contains sulphuric acid! This acid must not come into contact with the skin,

A

+ – 38b03600.eps

Fig. 200: Battery

5-36

the eyes, clothing or the vehicle.

Therefore when recharging or working near the battery: ☞ Always wear goggles and protective clothing with long sleeves If acid is spilt: ☞ Thoroughly rinse all affected surfaces immediately with plenty of water ☞ Thoroughly wash any part of the body touched by the acid immediately with plenty of water and seek medical attention at once!

• During charging in particular, but also during normal battery operation, an oxyhydrogen mixture is formed in the battery cells – danger of explosion!

• Do not attempt to jump-start the vehicle if the battery is frozen or if the acid level is low.

The battery may rupture or explode!

• Avoid sparks and unprotected light sources, and refrain from smoking in the vicinity of opened battery cells – otherwise the gas produced during normal battery operation may ignite!

• Use only 12 V power sources. Higher voltages will damage the electrical components • When connecting battery A ensure that the poles are not reversed, otherwise sensitive electrical components will be damaged • Do not interrupt voltage-carrying circuits at the battery terminals, because of the danger of sparking!

• Never place tools or other conductive articles on the battery – danger of short circuit!

• Disconnect the negative battery terminal before starting repair work on the electrical system • Dispose of used batteries properly

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

Maintenance 5.12.2

Service and maintenance work at regular intervals Before driving the vehicle

☞ Check every time before driving the vehicle: • Is the light system OK? Every week:

☞ Check every week: • Cable and earth connections • Chafing on wiring harnesses • Condition of battery terminals

5.12.3

Instructions concerning specific components

Cables, bulbs and fuses

Alternator

Always observe the following instructions: • Defective components of the electrical system must always be replaced by an expert.

Bulbs and fuses may be changed by unqualified persons • When carrying out maintenance work on the electrical system, pay particular attention to ensuring good contact in leads and fuses • Blown fuses indicate overloading or short circuits. The electrical system must therefore be checked before installing the new fuse • Only use fuses with the specified load capacity (amperage) – see Electrical system on page 7-6 Always observe the following instructions:

• Only test the engine with the battery connected • When connecting the battery, ensure that the poles are not reversed • Always disconnect the battery before carrying out welding work or connecting a quick battery charger • Replace a defective charge telltale as quickly as possible

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

5-37

Maintenance Battery Danger!

The battery electrolyte is highly caustic!

Danger of caustic injury!

Therefore when recharging and/or working near the battery:

☞ Always wear goggles and protective clothing with long sleeves If acid is spilt:

☞ Thoroughly rinse all affected surfaces immediately with plenty of water ☞ Thoroughly wash any part of the body touched by the acid immediately with plenty of water and seek medical attention at once!

In particular when charging, but also during normal battery operation, an oxyhydrogen mixture is formed in the battery cells –

Risk of explosion! ☞ Avoid sparks and unprotected light sources, and refrain from smoking in the vicinity of the battery! ☞ Do not attempt to jump-start the vehicle if the battery is frozen or if the acid level is low. The battery may rupture or explode! ☞ Always disconnect the negative battery terminal first before starting repair work on the electrical system!

Battery A is located in the engine compartment, on the right side. Battery A is maintenance-free, and there is no need to top up the electrolyte level under normal operating conditions. However, check battery A at regular intervals to make sure the electrolyte level is between the MIN and MAX marks.

A

+ – 38b03600.eps

Fig. 201: Battery

5-38

Always observe the special safety instructions! ☞ Check the battery charge condition as follows: • Park the vehicle on level ground • Switch off the engine • Open the engine cover When the battery caps are open: • Measure the acid density with the acid meter If the acid density is below 1.21 kg/l: • Recharge disconnected battery

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

Maintenance 5.13 General maintenance work 5.13.1

Cleaning Cleaning the vehicle is divided into 3 separate areas: • Inside the operator compartment • Exterior of the vehicle • Engine compartment The wrong choice of cleaning equipment and agents may impair the operating safety of the vehicle on the one hand, and on the other undermine the health of the persons in charge of cleaning the vehicle. It is therefore essential to observe the following instructions.

General instructions for all areas of the vehicle

Washing solvents

• Ensure adequate room ventilation • Wear suitable protective clothing • Do not use flammable liquids, such as petrol or diesel Compressed air

• Work carefully • 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 cleaner or steam jet

• Electrical components and damping materials must be covered and not directly exposed to the jet

• Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.

• Protect the following components from moisture: • Engine • Electrical components, e.g. alternator, plug and socket connections etc.

• Control devices and seals • Air intake filters etc.

When using volatile and easily flammable anticorrosion agents and sprays:

• Ensure adequate room ventilation • Do not use unprotected lights or naked flames • Do not smoke!

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

5-39

Maintenance Inside of operator compartment Caution!

Never use high-pressure cleaners, steam jets or high-pressure water to clean the inside of the operator compartment. Water under high-pressure may • Penetrate into the electrical systems and cause short circuits • Damage seals and disable the controls!

For cleaning the operator compartment, we recommend using the following aids: • Broom • Vacuum cleaner • Damp cloth • Bristle brush • Bucket of water Cleaning seat belt

• Clean the seat belt (which remains fitted in the vehicle) only with a mild soap solution; do not use chemical agents as they may destroy the fabric!

Danger!

In the case of automatic seat belts (option) soiled belts may impair winding and thereby affect safety

☞ Only wind seat belt when it is dry!

Exterior of the vehicle

The following articles are generally suitable: • High-pressure cleaner • Steam jet

Engine compartment Danger!

Clean the engine at engine standstill only –

Danger of personal injury! ☞ Switch off the engine before cleaning

Caution!

When cleaning the engine using a water jet or steam jet, do not point the jet directly at electrical measurement sensors such as the oil pressure switch.

Otherwise, liquid penetrating such units can lead to corrosion and failure of the measuring function!

5-40

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

Maintenance 5.13.2

Screw connections All screw connections must be checked regularly, even if they are not listed in the maintenance schedules.

Tighten loose connections immediately. Tightening torques can be found in section 7 "Tightening torques" on page 7-12

5.13.3

Pivots and hinges All mechanical pivot points on the vehicle (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.

BA 302 01 US-Gehl – Edition 1.0 * 30101b0530.fm

5-41

Maintenance

Maintenance 5

5.14 Engine fluids and lubricants Component/ application

Engine/vehicle fluid

Diesel engine

Engine oil2

SAE grade Specification

Season/ temperature

SAE 10W; EO10 3

Below -5°C

SAE 20W/20; EO20 3

-10°C to +10°C

SAE 30; EO30 3

+5°C up to +30°C

HD-C 10W-40; EO1040B 3 HD-C 15W-40; EO1540B 3

10.5 ltr.

Year-round 1.25 ltr.

20 kph gearbox (standard)

1.50 ltr.

40 kph high speed gearbox (option) Planetary drives – front/rear axle

1Capacities

Gearbox oil4

SAE 80W -90EP; GO90 GL-4/GL-53

Year-round

0.80 ltr. each

Differential – front axle

7.50 ltr.

Differential – rear axle

4.50 ltr.

SAE 5 W/30

Hydraulic oil tank Engine oil 2

Up to -25°C 3

Up to -25°C

SAE 10 W/40; EO 1040B 3

Up to -15°C

3

Up to -10°C

SAE 5 W/40; EO 0540B

SAE 15 W/40; EO 1540B ATF

ATF 66 M/ATF 86 (ATF )

Hydraulic oil 5

HLVPD 46 6 (HYD0530 3)

Biodegradable oil

About 57 ltr.

3

Year-round

AVILUB Syntofluid 46 PANOLIN HLP Synth 46

Grease nipples

Multipurpose grease

Lithium-saponified brand-name grease MPG-A3

Year-round

As required

Battery terminals

Acid-proof grease

SP-B 3

Year-round

As required

Mounting of pins, shafts etc.

Special grease

Optimoly paste “TA”7

Year-round

As required

Fuel tank

Diesel fuel 8

Grade no. 2-D

Over 4 °C

Grade no. 1-D9

Below 4 °C

Water + antifreeze

Year-round10

Washer system 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Cleaning agent

90 ltr.

About 1.2 ltr.

The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level MIL-L-2104C; API -CD/CE/CF4; CCMC-D4 Abbreviation for lubricants (Hauptverband der Deutschen Bauindustrie e. V. – German construction engineering association e.V.) MIL-L-2105/MIL-L-2105D; API-GL4/API-GL 5 with EP additive (“Limited Slip”) DIN 51 ML52 T3 Viscosity category as per ISO VG46 250 gr tube: order no. 0 00 441 32 10 DIN 51 601, min 45 cetane Applications above 1500 m Observe the antifreeze compound table – see manufacturer's instructions on packaging

5-42

BA 302 01 US-Gehl – Edition 1.0 * 30101b0540.fm

Maintenance 5.15 Service kits Service kits Part number

Description

Qty

Remarks

Service kit f o r “ 1 st Inspection” 1380030530

Service kit

1 Parts for maintenance plan “ B ”

0009962406 0000808520

O-ring (for planetary drives, front axle, 20 kph gearbox) Ring (40 kph gearbox, option)

9 2

27 x 32 x 2.5 31 x 38 x 2.5

Service kit for “ 2 nd Inspection” and Maintenance plan “ C ” 0380031530

Service kit

1 Service kit for Maintenance plan “ D ”

0380031830

Service kit

1 Additional parts for Maintenance plan “ D ”

0000805188

Safety cartridge Fine dust filter (EU4) for heating

BA 302 01 US-Gehl – Edition 1.0 * 30101b0540.fm

1 1

(not included in service kit)) (option, not included in service kit)

5-43

Maintenance

Maintenance 5

5.16 Proofs of maintenance The following table provides clear information on the maintenance and service work to be carried out after a certain amount of service hours.

The maintenance work to be carried out is shown in section “Maintenance plan (overview)” on page 5-48.

Confirm the proper execution of the work in the respective box in the following table.

“1st and 2nd Inspections” must be carried out by an authorized workshop for warranty claims to be acknowledged. Information on maintenance material and lubricants can be found in section “Engine fluids and lubricants” on page 5-42 or in section “Service kits” on page 5-43.

Proofs of maintenance

Proofs of maintenance

100

1st Inspection

750

A

150

A

800

A

200

A

850

A

250

A

900

B

300

B

950

A

350

A

1000

A

400

A

1050

A

450

A

1100

A

500

A

1150

A

550

A

1200

D

600

2. Inspection

1250

A

5-44

Company/ signature

A

Service hours

700

Date

Maintenance plan

A

Company/ signature

After service hours

Service hours

50

Date

A

Maintenance plan

650

After service hours

Delivery

BA 302 01 US-Gehl – Edition 1.0 * 30101b0550.fm

Maintenance

Proofs of maintenance

Proofs of maintenance

A

2200

A

1400

A

2250

A

1450

A

2300

A

1500

B

2350

A

1550

A

2400

D

1600

A

2450

A

1650

A

2500

A

1700

A

2550

A

1750

A

2600

A

1800

C

2650

A

1850

A

2700

B

1900

A

2750

A

1950

A

2800

A

2000

A

2850

A

2050

A

2900

A

2100

B

2950

A

BA 302 01 US-Gehl – Edition 1.0 * 30101b0550.fm

Company/ signature

1350

Service hours

A

Date

Maintenance plan

2150

Company/ signature

After service hours

Service hours

Maintenance plan A

Date

After service hours 1300

5-45

Maintenance

Proofs of maintenance

Proofs of maintenance

A

3900

B

3100

A

3950

A

3150

A

4000

A

3200

A

4050

A

3250

A

4100

A

3300

B

4150

A

3350

A

4200

C

3400

A

4250

A

3450

A

4300

A

3500

A

4350

A

3550

A

4400

A

3600

D

4450

A

3650

A

4500

B

3700

A

4550

A

3750

A

4600

A

3800

A

4650

A

5-46

Company/ signature

3050

Service hours

A

Date

Maintenance plan

3850

Company/ signature

After service hours

Service hours

Maintenance plan C

Date

After service hours 3000

BA 302 01 US-Gehl – Edition 1.0 * 30101b0550.fm

Maintenance

Proofs of maintenance

Proofs of maintenance

A

5600

A

4800

D

5650

A

4850

A

5700

B

4900

A

5750

A

4950

A

5800

A

5000

A

5850

A

5050

A

5900

A

5100

B

5950

A

5150

A

6000

D

5200

A

6050

A

5250

A

6100

A

5300

A

6150

A

5350

A

6200

A

5400

C

6250

A

5450

A

6300

B

5500

A

6350

A

BA 302 01 US-Gehl – Edition 1.0 * 30101b0550.fm

Company/ signature

4750

Service hours

A

Date

Maintenance plan

5550

Company/ signature

After service hours

Service hours

Maintenance plan A

Date

After service hours 4700

5-47

5-48

):

Service work every 10 hours (daily) Delivery inspection ● ●

●

● ●

●

●

V-belt: check condition and pre-tension. Retighten or replace if necessary Check glow plugs. Replace if necessary Check valve tip clearance (engine timing). Adjust if necessary Battery: check electrolyte level and charge condition Heating: clean dust filter and replace every 1200 service hours if necessary Check and adjust brake linings of service and parking brake. Replace if necessary Tyre check (damage, air pressure, tread depth)

●

●

● ●

“A” every 50 hours every week

Clean dust valve on air filter housing 4

● ● ● ●

●

●

●

●

●

●

●

● ●

●

●

●

●

● ● ● ●

„B“ every 300 hours monthly

Check engine oil cooler and hydraulic oil cooler for contamination. Clean if necessary7

● ●

1st Inspection1 at 100 hours ● ● ● ●

● ● ● ●

● ●

●

●

● ● ●

● ● ● ●

“C” every 600 service hours2 2nd Inspection

Inspection work ( ): Check the following material. Refill if necessary: • Engine oil • Hydraulic oil • Gearbox oil in front and rear axle differentials and in rear axle gearbox • Gearbox oil in front and rear axle planetary drives, left and right side

Maintenance plan/service hour

● ● ● ● ● ● ●

●

●

● ● ● ● ● ● ● ● ● ● ●

“D” every 1200 service hours yearly

Carry out the following oil and filter changes (check oil levels after test run): • Engine oil • Engine oil filter • Fuel filter • Clean screen filter of fuel feed pump. Replace if necessary • Replace fuel leak oil line and connecting pieces3 • Replace air filter insert 4, 5, safety cartridge after every 3rd replacement of the air filter insert • 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 • Hydraulic oil 6 • Hydraulic oil filter insert 4 • Breather – hydraulic oil tank

Oil change and filter replacement (

For service and maintenance work on the implement, please refer to the operation and maintenance manual of the implement manufacturer as well.

Work description

5.17 Maintenance plan (overview)

5

Maintenance

Maintenance

BA 302 01 US-Gehl – Edition 1.0 * 30101b06w2.fm

BA 302 01 US-Gehl – Edition 1.0 * 30101b06w2.fm

? ):

Check the function of the following assemblies/components. Rectify if necessary: • Service and parking brake • Steering system • Light system

● ● ●

● ● ●

● ● ● ● ● ●

● ● ● ● ● ●

● ● ●

● ●

“A” every 50 hours every week

● ●

● ● ●

● ● ● ● ● ●

● ●

● ● ●

● ● ● ● ● ● ●

● ●

„B“ every 300 hours monthly

Functional check (

●

Service work every 10 hours (daily)

Lubrication service ( Lubricate the following assemblies/components: • Rear axle oscillating bearing • Front and rear axle planetary drive bearings, left and right • Loader unit • Lift frame bearing • Tilt rod bearing • Tilt lever bearing • Lift ram bearing • Tilt ram bearing • Quickhitch facility: bearing on lift frame • Hinges, joints and fittings (e.g. door arrester)

Delivery inspection ●

● ● ●

● ● ● ● ● ● ●

● ●

●

“C” every 600 service hours2 2nd Inspection

):8

1st Inspection1 at 100 hours ● ● ● ● ● ● ● ● ● ●

● ● ●

● ● ● ● ● ● ●

● ●

● ● ● ● ● ● ● ● ● ●

“D” every 1200 service hours yearly

Check screws and nuts or screw connections for tightness on the following assemblies/components. Retighten if necessary • Engine and engine bearing • Steering system • Hydraulic system • Loader unit (pin locking) • Axle mounting, axle suspension • Counterweight/additional counterweight (attachment) • Fastening screws of propshafts • Attachment screws of cab • Wheel nuts • Electrical system: wire and earthing lead connections, chafing on wiring harness, battery terminals

For service and maintenance work on the implement, please refer to the operation and maintenance manual of the implement manufacturer as well.

Work description

5.17 Maintenance plan (overview)

Maintenance plan/service hour

Maintenance

5-49

5-50

):

“A” every 50 hours every week

Delivery inspection

Service work every 10 hours (daily)

Work to be carried out after the first 100 service hours only. This work must be carried out by an authorised workshop for warranty claims to be acknowledged Work after the first 600 service hours (2nd Inspection) must be carried out by an authorized workshop for warranty claims to be acknowledged Replace fuel leak oil line and the connecting pieces at least every 2 years Replace filter insert as indicated by the telltale in the instrument panel, however at least every 12 months or 1200 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 600 service hours, in any case before the cold season It may be necessary to clean the cooler more frequently depending on operating and dust conditions Lubricate implement as per manufacturer's instructions!

Replace flexible lines every 6 years or in accordance with the legal regulations of your country

„B“ every 300 hours monthly ● ● ● ● ● ● ●

● ● ● ● ● ● ●

“C” every 600 service hours2 2nd Inspection

1.

2.

3.

4.

5.

6.

7.

8.

9.

1st Inspection1 at 100 hours ● ● ● ● ● ● ●

● ● ● ● ● ● ●

“D” every 1200 service hours yearly

Check for tightness, leakage and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary.

• Air intake line (air filter – engine) ● ● • Engine lubrication (engine – filter) ● ● • Fuel lines ● ● • Cooling system (engine oil and hydraulic oil) ● ● • Brake system ● ● • Steering system (flexible lines and rams) ● ● 9 • Hydraulic system/loader unit (flexible lines and rams) ● ●

Leakage check (

For service and maintenance work on the implement, please refer to the operation and maintenance manual of the implement manufacturer as well.

Work description

5.17 Maintenance plan (overview)

Maintenance plan/service hour

Maintenance

BA 302 01 US-Gehl – Edition 1.0 * 30101b06w2.fm

Maintenance

BA 302 01 US-Gehl – Edition 1.0 * 30101b06w2.fm

5-51

Maintenance

Maintenance 5

5.18 Maintenance label valid for model ML52 Symbol

Explanation of symbols on maintenance label

Description Before starting maintenance work, take note of the safety instructions in the operation manual!

Before starting maintenance work, take note of the Section “Maintenance” in the operation manual!

Carry out a functional check of the light system!

Check tyres for damage, pressure and tread depth!

Carry out a functional check of the steering, synchronise the steering!

Carry out a functional check of the brake system!

Check hydraulic oil level. Top up if necessary!

Check engine oil level. Top up if necessary!

Clean dust valve on air filter housing!

Check cooler for engine coolant and hydraulic oil for contamination. Clean if necessary!

Check condition and initial tension of V-belt. Retighten or replace if necessary!

Leakage check: Check for tightness, leakage and chafing: pipes, flexible lines and screw connections. Rectify if necessary!

Lubrication service: Lubricate the assemblies concerned!

5-52

BA 302 01 US-Gehl – Edition 1.0 * 30101b06w3.fm

P

BA 302 01 US-Gehl – Edition 1.0 * 30101b06w3.fm 50

40

75

165

60

˚F

˚C

˚F

˚C

80

175

500

250

150

120

125

100

270 100

10

0236

10

20

MPH Km/h

30

30

20

50

40

0

10

12

1/2

14 16

Volt

1/1

HAZARD

10 h

120

105

0 00 435 28 89

Maintenance

Täglich Daily Tous les jours

50 h ML52 0001

30100w01a.eps

5-53

Maintenance

5-54

BA 302 01 US-Gehl – Edition 1.0 * 30101b06w3.fm

Section Helpful information for using the spare parts list

6

Helpful information for using the spare parts list

Helpful information for using the spare

6

Helpful information6 for using the spare parts list

6.1

Introduction This operation manual and a separate spare parts list have been handed over to you together with your vehicle.

Please read this section carefully. It will make it easier for you to carry out your work and find spare parts.

The illustrations in the spare parts list are not binding for design.

Subject to further development and technical modifications.

6.2

Composition of spare parts list

6.2.1

Groups The spare parts list is divided in functional groups.

Groups are identified by numbers (e.g. 01 = engine)

01

Group

Fig. 202: Title page of a group

BA 302 01 US-Gehl – Edition 1.0 * 30300b0610.fm

6-1

Helpful information for using the spare 6.2.2

Group overview The spare parts list contains the following groups:

6-2

Group

Description

00

Service kits

00/1

Electrical components

01

Engine

08

Fuel system

10

Air filter

15

Cooling

17

Speed regulation

20

Vehicle frame

22

Hydrostatic drive

23

Front axle

24

Brakes

26

Rear axle

27

Steering

29

Operator's seat

30

Sheet-metal parts

31

Wheels and tyres

32

Exhaust system

33

Electrical system

34

Cab

36

Hydraulic system

41

Heating

41/3

Buckets

43

Tools, labels, vehicle documentation

A

Number index

BA 302 01 US-Gehl – Edition 1.0 * 30300b0610.fm

Helpful information for using the spare 6.2.3

Figures Groups consist of one or more figures. They are identified at the upper right by the figure number.

The number before the hyphen identifies the group (e.g. 01).

The reference numbers in the figures identify the individual spare parts. The corresponding part numbers are listed in the number index.

The figures are reduced representations of assemblies and component parts, and are not binding for design.

Subject to further development and technical modifications.

01-58

Reference numbers

Figure number

17

20 21 22 21

18 19

19

Fig. 203: Example for figure

6.2.4

Number index The number index is included at the end of the spare parts list and contains all part numbers corresponding to the reference numbers in the figures.

Part numbers are listed in the order of figures, and of reference number.

Part number Reference number Figure

00-2

Symbol

2 23

1234567890

01-7. . . . . . . . 1 . . . . 7571646012 01-7. . . . . . . . 2 . . . . 7578646001 01-7. . . . . . . . 3 . . . . 7578646002 01-7. . . . . . . . 4 . . . . 0003330367 01-7. . . . . . . . 5 . . . . 7571646041 01-7. . . . . . . . 6 . . . . 7571646042 01-7. . . . . . . . 7 . . . . 7571646043 01-7. . . . . . . . 8 . . . . 7578646011 01-7. . . . . . . . 9 . . . . 7578646012 01-7. . . . . . . . 10 . . . 7578646013

BA 302 01 US-Gehl – Edition 1.0 * 30300b0610.fm

Validity

l=> 301 56 0129 301 56 0151

<=l 301 56 0128 301 56 0150

1410/04 C 39/3

6-3

Helpful information for using the spare 6.3

Symbols and abbreviations Symbols and abbreviations are used in the figures for clear identification of parts.

Combinations of symbols and abbreviations are also used.

6.3.1

Description of symbols Symbols may have the following meanings: Symbol

Description

Reference number

20

22

Identifies a component part.

17

The circled number identifies an assembly which may consist of several component parts.

Assemblies are delivered as finished assemblies, or preassembled with all necessary component parts.

17 21

22

21

18 19

19

Component parts can be grouped in brackets or in boxes, or appear below the reference number of the assembly, e.g. reference numbers 18 and 19.

A component part can consist of several parts which may be deliverable as a whole only, e.g. reference number 19.

5 1

4

10 12 11 8

6-4

3

6

2

Component parts grouped in a box, without reference number for the assembly, identify details.

BA 302 01 US-Gehl – Edition 1.0 * 30300b0610.fm

Helpful information for using the spare Symbol

Description

Validity

➜❙ or <=l ❙➜ or l=>

Components valid only up to including the number stated Components valid only starting including the number stated Identification of serial number Symbol for axle Symbol for cab Symbol for engine

Instructions for assembly Do not disassemble parts. Components cannot be repaired.

Tighten parts with a torque spanner to the prescribed torque. Use the standard torques if no specific torque is stated – see section 7 Tightening torques and "Specific torques" Safety part! For reasons of safety, parts may be dismantled or repaired by qualified mechanics only. Otherwise parts must be replaced as a whole!

Check parts for wear before reassembly, e.g. bearings, rotary shaft lip seals etc.

Parts are not reusable and must be replaced during repair work, e.g. sealing elements Pay special attention to direction of installation when removing or fitting parts, e.g. rotary shaft lip seals, bearings, bushings etc.

Use specified locking and sealing compounds, e.g. Loctite 242 Determine length/thickness of new component, e.g. shims, edge guard, sealing strip etc.

Round up to full metres when using material by the metre!

6 7 8

0.15 0.2 0.5

Measure thickness of new part, due to availability in various sizes.

State all dimensions in mm (millimetres).

Special symbols Symbol for special version with float position Symbol for hydraulic ram Symbol for sealing kit Identification of repair kit Symbol for tool kit Identification of machine documentation

BA 302 01 US-Gehl – Edition 1.0 * 30300b0610.fm

6-5

Helpful information for using the spare 6.3.2

Abbreviations

Indication of position

Abbreviations specify position of spare part on/in vehicle in driving direction.

Combinations of abbreviations are also possible, e.g. HLO (upper rear left).

Abbreviation

Use

V

Front

H

Rear

L

Left

R

Right

O

Upper

U

Lower

M

Centre

A

Outer

I

Inner

Abbreviations specify use of spare part on/in vehicle.

Abbreviation

Language codes

Description

BA

Specifies operation manual

ET

Specifies spare parts list

CD

Identification for CD-ROM

MC

Specifies microfiches

SO

Specifies special equipment

n. B

As required

n. l.

Not available

Abbreviations specify language versions.

Abbreviation

6-6

Description

Description

De

German

En

English

Fr

French

Nl

Dutch

Fi

Finnish

It

Italian

Es

Spanish

Pl

Polish

BA 302 01 US-Gehl – Edition 1.0 * 30300b0610.fm

Helpful information for using the spare Colour codes

Abbreviations specify colour of spare part on/in vehicle.

Abbreviation

6.4

Description

WH

White

YE

Yellow

GN

Green

RD

Red

VT

Violet

BN

Brown

BU

Blue

BK

Black

GN

Grey

OG

Orange

Vehicle data Always include the exact vehicle data in your orders to ensure correct delivery of spare parts required.

Refer to section 1 "Vehicle data" and “Type labels and implement numbers” for your relevant vehicle data.

6.5

Helpful information for ordering spare parts Delivery of spare parts cash on delivery.

Damaged samples will be scrapped if no request for return has been forwarded within 4 weeks.

Spare parts can be returned only upon agreement with our Spare Parts Department.

Return excludes: Seals, O-rings, sealing kits, electrical parts, special purchases and parts ordered without exact vehicle data.

BA 302 01 US-Gehl – Edition 1.0 * 30300b0610.fm

6-7

Helpful information for using the spare 6.5.1

Order information Always include the following information in your orders to ensure correct delivery of spare parts: • Customer and address e.g.

Jason Miller High Street 7 Leighton Buzzard LU5 8RT • Delivery address if not identical with customer's address e.g.

Construction site: Jeff Mason Church Street 9 High Wycombe HP9 3ER • Mode of shipment e.g.

United Parcel Service (UPS) Shipment will be made at our own discretion if no indications are made • Vehicle description e.g.: • Model and serial no. (see type label on vehicle) e.g.

ML52, ML52 0001 • Spare parts list and edition (see spare parts list cover) e.g. edition 1.0 • Figure, reference (in spare parts list) e.g.

01-8, reference 15

• Part number (in number index in spare parts list) e.g.: 0000801987 • Quantity and unit e.g.

1 off • For component, identification number (see type label)

6.5.2

6-8

Address for your spare part order

BA 302 01 US-Gehl – Edition 1.0 * 30300b0610.fm

Section Specifications

7

Specifications

Specifications

7

Specifications

7.1

Frame

7

Sturdy U-section frame, rubber-mounted operator's cab and engine.

7.2

Engine Engine Product Model Design No. of cylinders Displacement Bore and stroke Compression ratio Output (as per ISO 9249) Max. torque Specific minimum fuel consumption Fuel injection system Firing order Starting aid Max. inclined position (engine no longer supplied with oil): Oil pressure Valve tip clearance (engine at cold temperature)

BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

Deutz diesel engine BF4L 1011 In line 4 2732 cm³ 91 x 105 mm 17:1 48.5 kW/66 DIN HP at 2300 rpm 218 Nm, 1800 rpm 215 g/kWh Direct fuel injection 1-3-4-2 Glow plug Max. lateral inclination left/right:58/58 Max. inclination upward/downward:47/84 Observe tilting limit of the vehicle!

Min. 2.3 bar at 2500 rpm Intake valve 0.3 mm Exhaust valve 0.5 mm

7–1

Specifications 7.3

Power train Variable displacement pump model A4VG56DA1D4/32R – directly flanged on the engine Design Displacement Max. operating pressure p Starting RPMs Droop Boost pump:

Axial piston pump (swash plate design) 0 – 56 cm³/rev 450 bar 1050 – 1150 rpm at 50 bar HP 1800 ±100 rpm, 400 bar high pressure

Internal gear pump 11.6 cm³/rev 25 bar, 1500 rpm Speed-sensitive, hydraulic feed volume adjustment with pressure cut-off Electrohydraulic control Driving direction Hydraulic inching valve, controlled via the master Inching brake cylinder Variable displacement motor model A6VM80DA5/63W – on rear axle intermediate gearbox Design Displacement Charging/boost pressure Control

Design Capacity Standard High speed option Restricted high speed (option)1 Max. traction force Drive speed

1.

7–2

Axial piston motor (swash plate design) 27.1 to 80 cm³/rev 1st drive range: 0 – 5 kph, forward and reverse 2nd drive range: 0 – 20 kph, forward and reverse 1st drive range: 0 – 9,5 kph, forward and reverse 2nd drive range: 0 – 40 kph, forward and reverse 1st drive range: 0 – 7,5 kph, forward and reverse 2nd drive range: 0 – 30 kph, forward and reverse 49.0 kN (ML52)

For countries (e.g. Switzerland) with specified maximum speeds!

BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

Specifications 7.4

Axles Front axle (with 100% differential lock) Design King-pin inclination Camber Positive/negative wheel castor Steering angle Toe-in Track width Rear axle (with 100 % differential lock) Design King-pin inclination Camber Total oscillation angle Positive/negative wheel castor Steering angle Toe-in Track width

7.5

Planetary drive steering axle, rigid screw connection with frame 0° 0° 0° 40° 0° 1460 mm Oscillating planetary drive steering axle 0° 0° +/- 9 ° 0° 40° 0° 1460 mm

Brakes Service brake Design Mounted in Effect Brake fluid

Foot-operated, hydraulic power brake + hydrostat Front axle, drive (rear axle) On both axles via cardan shaft Hydraulic oil from hydraulic oil circuit – see Engine fluids and lubricants on page 5-42

Parking brake Design Mounted in Effect

BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

Manual, mechanical disc brake Front axle input On both axles via cardan shaft

7–3

Specifications 7.6

Steering Steering Design Steering mode

Assemblies

Max. pressure of hydraulic lines Manual pump: Hydraulic pump Maximum steering angle

7.7

Hydrostatic four-wheel steering with emergency steering features (closed version) 1. 4 wheel steering 2. Front axle steering On vehicles with high speed, only front axle steering is possible in the 2nd drive mode!

Manual pump, hydraulic pump, priority valve, safety valves, 1 steering ram per axle, solenoid valve for steering/wheel synchronisation.

160 – 180 bar Servostat Displacement 120 cm³/rev Gear pump (priority valve) Displacement 32 cm³/rev ±40°

Work hydraulics Gear pump 32 cm³/rev 70 litres minimum at 2300 rpm 3-fold pilot control 235 bar

Hydraulic pump Displacement Control valve Max. service pressure Secondary pressure limiting

Filter

7.8

Tilt ram

Rod side 280 bar Bottom side 120 bar Lift ram Bottom side 300 bar Reflux suction filter (0.5 bar initial stress)

Pilot control Pilot control pump = boost pump of hydraulic pump

7–4

Displacement Charging/boost pressure Pilot control unit:

11.6 cm³/rev 25 bar, 1500 rpm

Joystick Pilot control unit (simple): Ball-type stop cock:

Four-way lever – control of lift and tilt rams Control of lock ram and implements Lock against accidental actuation (for long-haul travel and transport)

BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

Specifications 7.9

Loader unit Loader unit with bucket 1, 2 Bucket capacity heaped as per ISO Tipping load Payload (tipping load x 0.5) Lift load at max. height Bucket width Dumping height Fulcrum height of quickhitch facility Dumping reach Scraping depth Tilt-back angle Dump-out angle Breakout force (lift ram) Breakout force (tilt ram)

0.95 m³ 3680 kg 1840 kg 3298 kg 1950 mm 2532 mm 3235 mm 668 mm 45 mm 50° -45° 45.2 kN 38.8 kN

Fork arms 3 (payloads stated for 500 mm load distance) Tipping load (ISO 8313): Payload (ISO 8313) at: (S= 1,25)4 (S= 1,67)5 Pallet height Movable payload in transport position (S=1.25):4 1.

2.

3.

4.

5.

2750 kg 2200 kg 1650 kg mm 2875 kg

With standard tyres 12.5-20 With standard bucket 10204-00 With pallet forks 01369-03 On firm and level ground Off-road

7.10 Weights Weights1 Kerb weight2 Gross weight rating Front axle weight rating Rear axle weight rating Max. authorised load for towing facility 1.

2.

BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

5050 kg 6000 kg 4000 kg 4000 kg 5500 kg

With standard bucket 10204-00 and standard tyres 12.5-20 Without driver

7–5

Specifications 7.11 Electrical system 14 V/80 A 12 V/2.2 kW 12 V/72 Ah1 278x175x190 mm) E.g. for cigarette lighter; max. 15 A

Alternator Starter Battery Socket 1.

Low-temperature test current 570 A and vibration-proof according to EN 60095-1

Electrical fuses and relays – fuse box in cab

F1

F2

F3

F4

F5

F6

F7

F8

F9

F10

F11

F12

F13

F14

F15

F16

F17

F18

F19

F20

F21

F22

F23

F24

F25

F26

F27

F28

K1

K2

K3

K4

K5

K6

K7

K8

K9

K10

K14

30100b1900.eps

Fig. 205: Fuse box in cab

7–6

Relay no.

Protected circuit

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K14

– Solenoid valve – forward driving – Solenoid valve – reverse driving – Not assigned – Solenoid valve differential lock – 4thcontrol circuit (option), implements – Front wiper motor, speed II – Front wiper motor, speed I – Not assigned – Hazard light unit – Solenoid valve load stabilizer – Not assigned

BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

Specifications Fuse no.

Rated current (A) Protected circuit

F1

25 A

F2

15 A

F3 F4 F5

3A 3A 15 A

F6 F7 F8 F9 F10 F11

7.5 A 7.5 A 7.5 A 7.5 A 7.5 A 5A

F12

5A

F13 F14 F15 F16 F17 F18 F19 F20 F21

7.5 A 3A 7.5 A 7.5 A 7.5 A 3A 25 A 3A 5A

F22 F23

7.5 A 15 A

F24 F25

10 A 15 A

F26 F27 F28

25 A 15 A 5A 3A 5A 7.5 A 15 A 0390010191b – 11/01

BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

– Heating – Air conditioning (option) – Rear wipe/wash system – Front wipe system – Control lever, left half – Control lever, right half – Solenoid valves: telescopic loader unit (option, telescopic loader unit only) differential lock, high speed lock, front attachment, quickhitch lock – Start/drive solenoid valve – High beam (right) – High beam (left) – Low beam (right) – Low beam (left) – Parking light (right) – Switch and numberplate lights – Parking light (left) – Instrument lights – Working light, interior light – Preheating/starting relay – Hazard warning system, direction indicator – Steering electronics – Steering, high speed (option) – Steering sensor mechanism – Condenser fan (option) – Instrument – Radio (option) – Safe load indicator (option, telescopic loader unit only) – Front wash system, horn, compressor (option) – Seat motor (option) – Load stabiliser – Lights – Auxiliary heating (option) – Cigarette lighter/socket – Main headlight – Rotating beacon (option) – Brake lights – Spare – Spare – Spare – Spare

7–7

Specifications Electric relays – above the fuse box in the cab

K11

K12

K13

K14

K15

Relay no.

Protected circuit

K11 K12 K13 K14 K15

– High current relay – terminal 15 – High current relay terminal 15 – Switching relay – high beam – Switching relay – low beam – Pulse generator – intermittent wiper

Fig. 206: Relay above fuse box

Electrical fuses – main fuse box in engine compartment F29

F31

F30

F32

30101b720.eps Fig. 207: Main fuse box in engine compartment

Fuse no.

F29 F30 F31 F32

Rated current (A) 50 A 50 A 50 A 40 A

Protected circuit Power supply Power supply Power supply Preheating system, starter

Electric relay – in the engine compartment

K16

Relay no.

Protected circuit

K16 K17

– Preheating system – Starter

K17

Fig. 208: Relay in the engine compartment

Electric relays – instrument panel/side console

7–8

Relay no.

Protected circuit

K18 K19 K20 K21

– Time lag relay for telltale check (in the instrument panel) – Switching relay – condenser grade 1/2 (option, in side console) – Switching relay – condenser (option, in side console) – Switching relay – condenser (option, in side console)

BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

Specifications 7.12 Noise levels Noise levels Sound power level Measured value Guaranteed value Noise level in the cab

98 dB (A) 99 dB (A) 76 dB (A)

Important!

Noise emission level measured according to EC Directive 2000/14 EC. Noise level in the cab measured according to EC Directives 84/532/EEC, 89/514/EEC and 95/27/EEC. Measurements carried out on asphalted surface.

7.13 Vibration Vibration Effective acceleration value for the upper extremities of the body Effective acceleration value for the body

BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

< 2.5 m/s2 < 0.5 m/s2

7–9

Specifications 7.14 Tyres Caution!

Extreme steering angles cause some tyres (optional tyres!) to touch the vehicle frame. This can damage the tyres! ☞ The steering angle must be limited by a specialist workshop according to the assembly instructions when using these tyre models which are specially marked in the following tyre table!

Bear in mind the label on the front window of the vehicle!

Tyre size

Tyre pressure1 (bar)

Wheel rims

Front

Rear

Wheel rim

Wheel offset

2,50

2,00

11 x 20

20 mm

3,00

2,50

13 x 18

10 mm

12.5-20 MPT 04 10PR 375/702 R20 MPT AC 70G 136G 375/752 R20 XZSL 143B 405/702 R18 SPT 9 141B 1.

2.

7–10

Increase front tyre pressure by 0.5 bar during pallet forks operation!

Steering angle must be limited to 35 ° !

BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

Specifications 7.15 Dimensions

B

d

e

38b09200.ai

38b09300.ai

g

f c

A Fig. 209: Vehicle dimensions

Vehicle dimensions1 Overall length a

5090 mm

Overall height b2 Overall width c Ground clearance d (gearbox on rear axle) Ground clearance e in transport position of loader unit Front/rear track width f Wheelbase g Turning radius Between kerbs Between walls

2740 mm

1.

2.

1950 mm 315 mm 150 mm 1460 mm 1910 mm 2825 mm 4050 mm

With standard bucket 10204-00 and standard tyres 12.5-20 MPT 04 With FOPS screen b = b + 125 mm

7.16 Coolant compound table Outside temperature Up to °C 4 -10 -20 -25 -30

BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

Water % by volume 99 79 65 59 55

Coolant Anticorrosion agent

Antifreeze agent

cm³/ltr.

% by volume

% by volume

1

20 34 40 44

10

7–11

Specifications 7.17 Tightening torques 7.17.1

General tightening torques Screw dimensions M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 1.

7.17.2

12.9 5 10 16 40 79 135 220 340 470 660 890 1150 1700 2300

Values valid for screws with slightly oiled surfaces

Specific tightening torques Description

Tightening torque

Wheel nut

400±20 Nm 200 Nm 250 Nm

Track-rod end (steering ram) Front axle mounting

7–12

8.8 3 5,5 10 23 46 79 125 195 280 395 540 680 1000 1350

Tightening torques in Nm1 10.9 4 8 14 34 67 115 185 290 400 560 760 970 1450 1950

BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

Annex

Annex

Annex

Hydraulics diagram (options) A

valid for model ML52 Ref.

Ref.

Description

Description

10

Option – high speed (40 kph – 0382603101)

Float position option

11

Fast drive range valve block

2

Control valve float position ML52 = 235 bar

12

High speed control ram

13

3

Pilot valve float position

Option – hose burst valve for lift and tilt rams (01376-02)

4

Option – depressurised reflux for implements (0383604198)

14

Lift ram

15

Tilt ram

5

Standard control valve: ML52 = 235 bar

16

6

Connecting piece

Option – hose burst valve for lift and tilt rams export version for France

7

Option – side swing bucket (01369-06)

17

Lift ram

8

Option – pallet forks with sliding fork arms

18

Tilt ram

9

Option – multipurpose bucket (01369-04/01369-05)

1

4

1 C1 A1 B1 C2

F A2 B2

C3 A3 B3

2

X2

X1

X3

3

C1 A1 B1

5

P P

P

T

6

T

T Y2

Y1

Y3

D3

D2

D1

F

D1 0383604198

9

7

10 T1 T3 T2

G A B

C

230 bar

11

D

E

8

01369-06

18

15

)

)

V2

)

C1 )

XM

2

C2

X

C2

V1

A3 A2 C1 A1 B1 C2 B2 C3 B3

P

T

T D2

D3

01376-02

16

D1

D2

D3

)

0380011125a - 09/01 0380011225a - 09/01

BA 302 01 US-Gehl – Edition 1.0 * 30101b07hyd_so.fm

C2 XM

V2

P

D1

)

V2

2

A3 A2 C1 A1 B1 C2 B2 C3 B3

13

)1

M

)

17

)

X

V2

X

)

1

C1

)

X

X

M

V1 X

)

C1 C2 )

C1

)

V1

V1

01369-04 01369-05

10086-00

14

12

F

a) .................... b) 0383603898

0380011125a_SO.eps

A-1

A-2

Drive variable displacement motor

Gear motor for fan drive V=8 cm³/rev, Pmax=230 bar

Oil temperature controller

Oil cooler

Pressure switch

Temperature sensor

Reflux suction filter

Hydraulic oil tank V total = 77 l, V oil level = 62 l

Vent filter

Manifold block

Standard control valve 235 bar

Control ram for quickhitch facility

Lift ram

Tilt ram

Pressure accumulator PV = 20 bar

Solenoid valve – load stabiliser

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

Stop cock for road travel

Valve block for differential lock

Pressure accumulator for pilot control

Rear axle differential lock

Front axle differential lock

Gear pump – brakes V = 13 cm³/U, Q = 28 l/min

Cut-off valve with integrated flow divider (switch-on pressure 120 +10 bar, switch-off pressure 150 -10 bar)

23

24

25

26

27

28

29

Standard control valve

Work hydraulics pump V = 32 cm³/rev, Q = 70 l/min

5

22

Drive variable displacement pump

Boost pressure pump V = 11.6 cm³/rev, Q = 25.6 l/min

Priority valve (dynamic signal)

2

4

Hydrostatic steering 58.7 – 117.4 cm³

1

3

Ref.

Description

Hydraulics diagram

A

Brake pedal valve 69 bar with multi-disc brake in axle casing 77 bar with multi-disc brake in planetary drive

32

40

39

38

37

36

35

34

Check block

Solenoid valve – steering mode

Front axle steering ram ø 75/38, 171 mm stroke

Rear axle steering ram ø 75/38, 171 mm stroke

Multi-disc brake front axle right

Multi-disc brake front axle left

Inching valve 12 bar

Brake light switch 6 bar

Membrane accumulator for brake pressure

31

33

Pressure switch 80 bar

Description

30

Ref.

Annex

Annex

BA 302 01 US-Gehl – Edition 1.0 * 30101b07hyd.fm

BA 302 01 US-Gehl – Edition 1.0 * 30101b07hyd.fm

38

39

B1

T

B

A

B2

P

EF

T

T

40

LS

CF

37

10 bar

A2

0,5 bar

A1

210 bar

LS

R

P

L

10 bar

1

PA1

35

36

185 bar

P

PA 2

A

T

34

12 bar

Pst

P

T

x X1

Z

PA--

x X2

490 bar

5-20 bar

3

G

x S

x

31

A (21)

69 bar

460 bar

25 bar

x

PS x Fa x

33

x

PA 7

PA 6

PA 5

PA 8

(51) T (11) P

32

A

B

30

80 bar

4

PA 9

T2

5

PA--

M1

6

X1

29

2

T G

X3 B

A

U

1

5

PA 10

28

11

P

T

))

2

T

A

HA

26

27

VA

PA 11

ø4

pmax =230 bar

P2

12

9

X B2

P1

B

A

24

B

13

0,5 bar

2,5 bar

7

8

A

C

F

E

T1 T3 T2

14

25

0,5 bar

G

10

PA12

15

T

P

D1

C1 A1 B1

220 bar (301-01) 235 bar (302-01)

16

17

B2

C3 A3

P

B B

PB

140 bar

Y1

X1

20 T

A S

PA

Y3

X2 X3

21

T

P

23

(0380011125a/0380011225a) 0380011125a.eps

Y2

22

Pv=20 bar

5 +3 bar

B3

19

300 bar 280 bar 120 bar D3 D2

C2 A2

ø3,5

18

Annex

A-3

Annex

Annex

Legend – wiring diagram A

Ref.

Description

Section

Pos.

Ref.

A1

Radio (option)

4

S

H12

B1

Sensor – front axle centre position

2

-

H13

Description

Section

Pos.

Telltale – alternator charge function

4

MI

Telltale – turn indicators

4

MI

B2

Sensor – rear axle centre position

2

-

H14

Telltale – differential lock

4

MI

B3

Fuel level sensor

3

-

H15

Telltale – high beam

4

MI

B4

Temperature sensor – engine oil

2

-

H16

Turn indicator (front left)

4

+

B5

Temperature sensor – hydraulic oil

4

-

H17

Turn indicator (front right)

4

+

B6

Horn

4

-

H18

Turn indicator (rear left)

4

-

B7

Load sensor (option only for telescopic loader unit)

3

-

H19

Turn indicator (rear right)

4

-

H20, H21 Brake lights (left, right)

4

-

B8

Speed sensor (option)

2

-

H22/23 Rotating beacon (option)

4

D

B9

Backup warning system (option)

4

D

H24/25 LED telltale – driving direction

2

-

Loudspeakers (option)

4

-

H27

Telltale – hydraulic 2nd gear

4

S

D1

Steering electronics

2

-

K1

Switching relay driving direction forwards

2

Z

D2

Power electronics – control lever

2

-

K2

Switching relay driving direction backwards

2

Z

E1...E4 Instrument panel lights P1...P6

3

MI K3

Switching relay – telescopic extension (option, only telescopic loader unit)

2

Z

B10/11

E5

Rear light (left)

4

-

E6

Front parking light (left)

4

+

K4

Switching relay – differential lock

2

Z

E7

Front parking light (right)

4

+

K5

Switching relay front implement (option)

2

Z

E8

Rear light (right)

4

-

K6

Switching relay – wiper, 2nd speed

4

Z

4

F

K7

Switching relay – wiper, 1st speed

4

Z

K8

Switching relay – telescopic retraction (option, only telescopic loader unit)

2

Z

K9

Hazard light unit

4

Z

E9...E12 Switch light S10, S12, S15, S18 E14

Switch light S17

4

F

E15

High, low beam (left)

4

D

E16

High, low beam (right)

4

D

E17

Rear left working light

4

D

K10

Switching relay – load stabiliser

2

Z

High current relay (terminal 15)

1

+

E18

Rear right working light (option)

4

D

K11/12

E19/20

Front working light (option)

4

D

K13

Switching relay – high beam

4

+

K14

Switching relay – low beam

4

+

E21

Numberplate light (option)

4

D

E22

Interior light with switch

4

D

K15

Pulse generator – intermittent wiper

4

+

K16

High current relay – preheating

2

-

E23

Cigarette lighter

6

S

E25/26

Clearance lights

4

-

K17

High current relay – starting

2

-

Time lag relay – telltale check

3

+

Z

K18

1

-

K19

Switching relay – condenser stage 1/2 (option)

5

S

K20

Switching relay – condenser (option)

5

S

K21

Switching relay – air conditioning (option)

5

S

M1

Starter

2

-

M2

Front wiper motor

4

+

M3

Front washer fluid pump

4

+

M4

Rear washer fluid pump

4

+

M5

Rear wiper motor

4

+

M6

Fan motor for heating (3 speeds)

5

+

M7

Fan motor – condenser (option)

5

-

P1

Fuel level indicator

3

MI

P2

Temperature gauge – engine oil

3

MI

P3

Temperature gauge – hydraulic oil

3

MI

P4

Speedometer (option)

3

MI

F1...F28 Fuses (central electrics) F29...F32 Fuses (power supply) G1

Alternator with current regulator

2

-

G2

Battery

1

-

H1

Telltale – synchronisation

2

F

H2

Telltale – four wheel steering

2

F

H3

Telltale – front wheel steering

2

F

H4

Telltale – parking brake

4

MI

H5

Telltale – preheating

4

MI

H6

Telltale – hydraulic oil filter

4

MI

H7

Telltale – engine oil pressure

4

MI

H8

Telltale – brake pressure

4

MI

H9

Telltale – coolant level (no function)

4

MI

H10

Telltale – air filter

4

MI

H11

Telltale – not assigned

4

MI

A-4

BA 302 01 US-Gehl – Edition 1.0 * 30101b06e10.fm

Annex Ref.

Description

Section

Pos.

Ref.

Description

Section

Pos.

2

-

P5

Hour meter

3

MI

P6

Voltmeter

3

MI

P7

Safe load indicator (option, only telescopic loader unit)

3

-

R1

Heater-plug filament

2

-

R2

Resistor

5

-

S1

Preheating start switch

2

S

S2

Drive switch forward (in control lever)

2

-

W1

Rod aerial – radio (option)

4

-

W2

Aerial cable (option)

4

+

S3

Drive switch reverse (in control lever)

2

-

S4

Tip switch – telescopic extension (option, only telescopic loader unit) and front implement tip switch (option)

2

-

S5

Tip switch – telescopic retraction (option, only telescopic loader unit)

2

-

S6

Tip switch – differential lock (in control lever)

2

-

S7

Parking brake switch

2

+

V20

Blocking diode – telescopic loader unit/ implement (option)

V21

Blocking diode – high speed (option)

2

+

F22

Blocking diode – parking brake switch

3

+

V23

Blocking diode – bucket repositioning (control lever)

2

-

2

+

V25...V32 Blocking diode – telltale check

X1...X4 Plug and socket connections – cab/frame

S8

Tip switch – quickhitch lock (option)

2

F

S9

Switch – front implements (option)

2

F

S10

Switch – load stabiliser

2

F

S11

Switch – 1st./2nd gear

2

S

2

+

X5

8-pole connection – shift lever

2

-

X6

12-pole connection – shift lever

2

+

X7

2-pole plug bucket repositioning

2

-

X8/9

8-pole connection – steering electronics

2

+

X10

4-pole socket front implements (option)

2

-

X11

2-pole plug – front washer pump

4

+

X12/13

12-pole plug – telltale check

3

+

X14

2-pole plug – rear wash water pump

4

+

X15

8-pole plug – radio connection

4

S

X16

8-pole plug – loudspeaker connection

4

S

X17

Aerial connection

4

+

X18

6 pole plug and socket connection safe load indicator (option, telescopic only)

4

-

X19

4-pole connection – rear window washer

4

+

X20

4-pole connection – front wiper motor

4

+

X21.1

12-pole plug – steering-column control lever

4

+

X21.2

4-pole plug – steering-column control lever

4

+

S12

Switch – steering/high speed

2

F

S13

Tip switch – synchronisation

2

F

S14

Switch – front working light (option)

4

F

S15

Switch – rear working light

4

F

S16

Switch – rotating beacon (option)

4

F

S17

Switch – rear wiper/washer

4

F

S18

Switch – lights, parking light

4

F

Multifunctional lever – steering column, right

X22

2-pole plug – seat motor connection

6

+

S19

4

+

X23

2-pole plug – auxiliary heating connection

6

+

S20

Hazard warning light switch with telltale

4

F

X24

5

+

S21

Brake light switch – service brake

4

+

4-pole plug and socket connection – heating

S22

Switch – heater fan

5

S

X25

8-pole plug and socket connection – cowl

4

-

S23

Pressure switch – load stabiliser (only telescopic loader unit)

2

-

X26

3-pole plug and socket connection – safe load indicator sensor

3

-

S24

Oil pressure switch – engine

2

-

X27

2-pole plug and socket connection – fuel level indicator

3

-

S25

Pressure switch – air filter

2

X28

-

3

-

3-pole plug and socket connection – rear axle steering sensor

2

S26

Pressure switch – brake pressure (normally closed contact)

S27

Pressure switch – oil reflux filter

4

-

X29

3-pole plug and socket connection – front axle steering sensor

2

-

S28

Tip switch – additional control circuit (option)

2

-

X30

2 pole plug – driving direction recognition – black

2

-

X30.1

2-pole plug – driving direction indicator 40 kph – red

2

-

X30.2

2-pole plug – driving direction indicator 20 kph – black

2

-

X31

3-pole plug – quitckhitch lock

2

-

X32

2-pole plug – cutoff solenoid

2

-

X33/34

2-pole plug and socket connection – clearance lights

4

-

S29

Battery master switch (option)

1

-

S30

Air conditioning switch (option)

5

S

S31

Thermostat (option)

5

-

S32

Pressure switch – air conditioning (option)

5

-

U1

Amplifier – level switch

3

+

V1...V14 Suppressor diode (in solenoid valve plug)

2

-

V16...V18 Blocking diode (in multi-instrument)

3

MI

BA 302 01 US-Gehl – Edition 1.0 * 30101b06e10.fm

A-5

Annex Ref.

Description

Section

Pos.

Ref.

Description

Section

X35

Starter earthing connection

2

-

X36

Fuse box earthing connection

2

+

+

Any location in/on the vehicle

X37

Cab/frame partition earthing connection

2

-

D

Roof

X38/39

1-pole plug and socket connection – front implements

2

F

F

Front instrument panel

MI

Multi-instrument in instrument panel

X40...X43 2-pole plug – switch lights S8/S9/S14/S16

4

F

S

Side instruments

4

S

Z

Central electrics

-

Not included in scope of delivery for cab

Explanation of symbols (location in vehicle)

X44

2 pole plug switch lights S30

X45

2-pole plug and socket connection – connection S11

2

-

X46

2-pole plug and socket connection – connection S28

2

-

Y1

Solenoid valve – driving direction indicator

2

-

Y2

Solenoid valve – reversing 20 kph (X30/30.2) forward driving 40 kph (X30/30.1)

2

-

Y3

Solenoid valve – forward driving 20 kph (X30/30.2) reversing 40 kph (X30/30.1)

2

50 A

F29, F30, F31

Y4

Solenoid valve – 1st gear / 2nd gear

2

-

40 A

F32

Y5

Solenoid valve – 4 wheel steering

2

-

25 A

F1, F19, F26

Y6

Solenoid valve – front axle steering

2

-

15 A

F2, F5, F23, F25, F27

Y7, Y8

Fixed connections Current From – to path 15

F1 – F2, F3 – F4 – F5 – F6

15

F15 – F16 – F17, F18 – F19 – F20, F21 – F22 – F23

30

F7 – F8, F9 – F10, F11 – F12

30

F24 – F25 – F26 – F27 Fuses

Solenoid valve – load stabiliser

2

-

10 A

F24

Y9

Solenoid valve – high speed (option)

2

-

7.5 A

F6, F7, F8, F9, F10, F13, F15, F16, F17, F22

Y10

Solenoid valve – high speed lock (option)

2

-

5A

F11, F12, F21, F28

Y11

Solenoid valve – differential lock

2

-

3A

F3, F4, F14, F18, F20

Y12

Solenoid valve – telescopic retraction (option, only telescopic loader unit)

2

-

Y13

Solenoid valve – telescopic extension (option, only telescopic loader unit)

2

-

Y14

Solenoid valve – quickhitch lock (option, only telescopic loader unit)

2

-

Y16

Cutoff solenoid

2

-

Y17

Magnetic clutch /compressor (option)

5

-

A-6

Pos.

Fuse assignment – see Electrical system on page 7-6

BA 302 01 US-Gehl – Edition 1.0 * 30101b06e10.fm

Annex A

Annex 1. Power supply

2 Starting and drive system

3 Controls and indicators (multi-instrument) 30 15 15

30 15 15

5 Cooling Heating

4 Lights/signal and wiper system/radio/roof electrics 30 15 15

30 15 15

F6 7,5A

F4 3A

F3 3A

F16 7,5A

F5 15A

F17 7,5A

F18 3A

F20 3A

F21 5A

F13 7,5A

F27 15A

F2 15A

F24 10A

F22 7,5A

F26 25A S19

56 30 H24

2

S2

6 S6

S5

S3

19

49

15

F15 7,5A

F19 25A

F28 5A

F1 25A

F25 15A

3 X23

1

56a 56b

53b

53

31bJ

L

R

53C H

3

1

2

6 (2)

9

11

7

X21.1 12 4

Indicator instrument

F12 5A

H25

5

F11 5A

P

S21

(4) (1) 10 8 (X21.2)

E23

5 7

XC

X7

6 1 XB

S22

6 5 1 4 3 7

S11

S28

X45

3

2

1

4

5 8

7

6

7

X46

5

P3 H4

P6

4 1 6 2

9

S9

5 X39

S13

3

7

1

5

Kl. 15

7

1

2

4

5

8

4

7

1

3

K12 K3

86

30 86

30

86

85 87

85

87 85

87 85

85

87

85

87

X9

6

3

7

1

2

4

5

2

1 54

3

4

58R 58L

H2

86

86

87

85

85

85

X42

30

86

87

85

5

K21

S10

1

5 1

X11

E7

X17 H13

W2

H16

1

7

H17 M3

X44

4 3

XA

X15

8

X36

2 8 10 11 12

U1

5

6 X16

F8 7,5A

2 4

F7 7,5A

F9 7,5A

F10 7,5A

30

3 1

86

3 1

X24

K20

87

X19

V29

2

X20

4 3 2

K10

85

30

86

87

85

1 6

V28 M6

53

V27

53a

4 6 1 2 X18

30

31

K18

53b 53a 53 31b

M5

31

V25

87a 87 86 56a

V26

P7

B11 E19

B10

E20

E17

E18

H22

85

K19

t

6

X10

4

V30

7 1 9

H1

H3

31

3

V31

9 7 8 6

31

Cab

10

49a 49 (87) (85) K9 G C 31 (30) (86)

A1

V22

S7

30

(30) (87) 30 3086 53M I 15 G T (85) 87 87 85 53S 31 (87a)K15(86)

S30

H14

6

86

K6

E6 X43

Q

K14

X41

H27

M

M4

H11

K13

30

X14

5

K7

87

V32

10

30

K5

87

7

5

8 7

7 8

D1

K4

30 86

6 3

E12

X12

8

86

16

K8

K1

15

86 30

12

K2

9

30

13

87

30

1

E4

P1 P4

H6

11 11

86 86 85 85

E22

H5

5

5

6

X8

14

87

1

P2

Kl. 31

12

30

1

2

1 S20

X40

E11

H12

X38

V20

K11

W1

2 S17 4

S16 5

V21

1

2

6

6

7

E2

5 S15

E3

6

5 8

5 S14

V

10

4

E1 V18

V16

E14

E10

h P5

H9

XD

3

E9

H15

H8

7

1

1

2

V17

S12

S8

1

t˚

B

C L M H

H10

H7

5

3

X6

X22

1 2

V23

X5

F23 15A

15

S18

S4 D2

30 S1 15 50a

30 15 15

Steering-column control

Control lever F14 3A

6 Other consumers

H23

56b

56b

56a

M2

E16

E21

T

S33

B9

X13

X36

Engine compartment fuse box

Telltale check

A

Frame/engine/cowl/implements

F29 50A

B

F30 50A

X3

X2

X1

C

1

2

3

4

5

6

7

8

9

10

11 12

1

2

3

4

5

6

7 8

9

X4

10

11 12

14

16 17

4 5

6

7 8

31

31

F31 50A

15

S24

X4

9

10

11 12

13

31

14

15

18

2 1

19 20 21

31

31

31

R2

2

1

4

3

B6

30

86 30

87

85 87

K17

X25

85

B+ 50 30

M1

X37 S34

B4

86

K16

R1

17

S23

F32 40A

G2

16

X30.2-BK

D+

3

4

8

1

2

5

6

7

2

1

5

4

3

8

7

6

S25

G1 B-

X30.1-RD

31

X30-BK

A

B

A

B

C A B

31

C A B

X28

X31

2

1

2

1

X27

X29

C A B

C A B

B

A

M7

X26

A

B

X33 B5

S31

t˚ X32

V2

V3

V1

V12

V13

V11

V10

V14

V8

V7

V9

V4

V6

V5

P

2

1

2

1

2

1

2

1

X34 E5

H18

E8

H20

H19

S27 H21

P

X35 Y16

Y2

Y3

Y1

E25

Y12

Y13

Y11

Y10

Y14

Y8

Y7

Y9

Y4

Y6

Y5

B2

B1

B8

S26

B3

B7

E24

0380011390e.eps

Y17

Wiring diagram valid for model ML52 from serial no.: 0 38 001 13 90e – (10/01)

BA 302 01 US-Gehl – Edition 1.0 * 30101b06e20.fm

ML52 0001

A-7

Annex

Wiring diagram legend – options K8 (86)

X40

K3 (86) F3

F5

Component

Description

Section

Pos.

3rd electrically operated control circuit (option)

0380011590.eps

F3

Fuse

1

-

F5

Fuse

1

-

K3

Switching relay – unlocking

1

-

K8

Switching relay – locking

1

-

K102

Switching relay

1

-

K103

Switching relay – changing-over

1

-

K104

Switching relay – changing-over

1

-

S102

Switch with actuation interlock

1

-

V12

Suppressor diode

1

-

V13

Suppressor diode

1

-

V103

Blocking diode

1

-

X38

Diode connection front socket

1

-

X40

Connection switch lighting

1

-

Y102

Solenoid valve, unlock

1

-

Y103

Solenoid valve, lock

1

-

Wiring diagram – option valid for model ML52 from serial no.: 0380011590 – (12/01)

A-8

ML52 0001

BA 302 01 US-Gehl – Edition 1.0 * 30101b06e20.fm

TORQUE SPECIFICATIONS NOTE:

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

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

Unified National Thread

Grade 2

Grade 5

Dry

Lubed

Dry

Lubed

Dry

Lubed

8-32 8-36

19* 20*

14* 15*

30* 31*

22* 23*

41* 43*

31* 32*

10-24 10-32

27* 31*

21* 23*

43* 49*

32* 36*

60* 68*

45* 51*

1/4-20 1/4-28

66* 76*

50* 56*

9 10

75* 86*

12 14

9 10

5/16-18 5/16-24

11 12

9

17 19

13 14

25

18 20

3/8-16 3/8-24

20 23

15 17

30 35

23 25

45 50

35

7/16-14 7/16-20

32 36

24 27

50 55

35 40

70 80

55 60

1/2-13 1/2-20

50 55

35 40

75 90

55 65

110 120

80 90

9/16-12 9/16-18

70 80

55 60

110 120

80 90

150 170

110 130

5/8-11 5/8-18

100 110

75 85

150 180

110 130

220 240

170 180

3/4-10 3/4-16

175 200

130 150

260 300

200 220

380 420

280 320

7/8-9 7/8-14

170 180

125 140

430 470

320 360

600 660

460 500

1-8 1-14

250 270

190 210

640 710

480 530

900 1000

680 740

Metric Course Thread

Grade 8.8

8.8

Grade 10.9

Grade 8

10.9

Grade 12.9

12.9

Dry

Lubed

Dry

Lubed

Dry

Lubed

M6-1

8

6

11

8

13.5

10

M8-1.25

19

14

27

20

32.5

24

M10-1.5

37.5

28

53

39

64

47

M12-1.75

65

48

91.5

67.5

111.5

82

M14-2

103.5

76.5

145.5

108

176.5

131

M16-2

158.5

117.5

223.5

165.5

271

200

WARNING THIS OPERATOR’S MANUAL IS PROVIDED FOR OPERATOR USE DO NOT REMOVE FROM THIS MACHINE DO NOT start, operate or work on this machine until you have carefully read and thoroughly understand the contents of this manual.

Failure to follow safety, operating and maintenance instructions could 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 this machine, contact your dealer or the Gehl Company Service Department before starting or continuing operation.

California Proposition 65 Warnings: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer and birth defects and other reproductive harm.

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



Mustang Manufacturing Company, Inc., A GehlR Comapny

909893/1P0702

2002 Mustang Manufacturing Company, Inc. All rights reserved.

Printed in U.S.A.