Gehl SL7600, SL7800 Operator's Manual

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SL7600 SL7800

SKID STEER

LOADER

Form No.

908274

English

OPERATOR’S MANUAL

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Gehl Company, in cooperation with the American Society of

Agricultural Engineers and the Society of Automotive Engineers, has adopted this Safety Alert Symbol to pinpoint precautions which, if not properly followed, can create a safety hazard. When you see this symbol in this manual or on the machine itself, you are reminded to BE ALERT! Your personal safety is involved!

Operators must have instructions before running the machine. Untrained operators can cause injury or death.

CORRECT

WRONG

Never use loader without ROPS/FOPS. Never modify the ROPS/FOPS structure.

WRONG

Read Operator's Manual before using machine.

CORRECT

Always fasten seatbelt snugly. Always keep feet on the floor/pedals when operating loader.

Never use the loader to lift personnel.

WRONG

Do not use loader around explosive dust or gas, or where exhaust can contact flammable material.

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SL7600 and SL7800 Skid Steer Loader

Operator’s Manual

TABLE OF CONTENTS

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

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

Controls And Safety Equipment..............15

Operation .........................34

Service ..........................45

Troubleshooting ......................63

Maintenance Schedule ..................71

Specifications .......................75

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

Torque Specifications ...................83

Warranty .........................84

Loader Model Number

Loader Serial Number

Engine Serial Number

All-Tach, Hydraloc and Hydraglide are trademarks of Gehl Company.

Gehl and Powerview are registered trademarks of Gehl Company.

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INTRODUCTION

This Operator’s Manual gives the owner/operator information about maintaining and servicing SL7600 and SL7800 skid steer loader models. More importantly, this manual provides anoperating plan for safe and proper use of the machine. Major points of safe operation are detailed in the Safety chapter of this manual.

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

Throughout this manual, information is provided set in italic type and introduced by the word Note or Important. Read carefully and comply with the message — it will improve your operating and maintenance efficiency, help avoid breakdowns and damage, and extend your machine’s life.

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

The attachments and equipment available for use with this machine have a wide variety of potential applications. Read the manual provided with the attachment to learn how to safely maintain and operate the equipment. Be sure the machineis suitably equipped for thetype of workto be performed.

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

The Gehl dealership network stands ready to provide you with any assistance you may require, including providing genuine Gehl service parts. All service parts should be obtained from your Gehl dealer. Give complete information about the part and include the model and serial numbers of your machine. Record these numbersin the spaceprovided on theTable of Contentspage, as a handy reference.

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

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

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Model Identification

Front Work Lights

Engine

Cover

Rear Work

Lights

Restraint Bar

Hand Holds

Tilt

Cylinders

Hitch

Lift Arm

Tires

Roll Over/ Falling Object Protective Structure (ROPS/FOPS)

Tail Lights

Rear Door

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Rear Link

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Control/Indicator Symbols

Worklight w/Flasher

Horn

H-L

High - Low

Engine Air Filter

Engine Coolant

Temperature

Worklight

Read Operator’s

Manual

Neutral

Engine Oil

Hydraulic System

Engine StartPower Off Power On

Safety Alert

Volume - Full

Forward

Engine Oil Filter Fuel Filter

Hydraulic Oil Temperature

Battery Charge

Hazard Flasher

Volume- Half Full Volume - Empty

Electrical Power

Seatbelt - Lap

Only

Reverse

Engine Oil

Pressure

Hydraulic Oil

Filter

Parking Brake

Grease

Lubrication Point

Pre-Heat

Fast

Bucket - Rollback Bucket - Dump

Lift Point

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Diesel Fuel

Slow

Tie-Down

Chaincase Oil

Bucket - Lower

Clockwise

Rotation

Power HitchRide Control

Bucket - Raise

Counterclockwise

Rotation

Bucket - Float

Service Hours

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SAFETY

This safety alertsymbol means Attention! Become alert!Your safety is involved! It stresses an attitude of “Heads Up for Safety” and can be found throughout this Operator’s Manual and on the decals on the machine.

Before operating this machine, read and study the following safety information. In addition, be sure that everyone who operates or works with this machine, whether family member or employee, is familiar with these safety precautions. It is essential to have competent and careful operators, who are not physically or mentally impaired, and who are thoroughly trained in the safe operation of the machine and the handling of loads. It is recommended that the operator be capable of obtaining a valid motor vehicle operator’s license.

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

Gehl

ALWAYS considers the operator’s safety when designing its machinery

and guards exposed moving parts for the operator’s protection. However, some areas cannot beguarded or shielded in order to assure proper operation. Furthermore, this Operator’s Manual and the decals on the machine warn of additional hazards and they should be read and observed closely.

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

Different applications may require optional safety equipment, such as a back-up alarm, horn, mirror, strobe light or an impact-resistantfront door. Be sure you know the job site hazards and equip your machine as needed.

DANGER

situation which, ifnot avoided, willresult indeath orserious injury.

WARNING

situation which, if not avoided, could result in death or serious injury.

CAUTION

situation which, if not avoided may result in minor or moderate injury. May also alert against unsafe practices.

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“DANGER” indicates an imminently hazardous

“WARNING” indicates a potentially hazardous

“CAUTION” indicates a potentially hazardous

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Mandatory Safety Shutdown Procedure

Before cleaning, adjusting, lubricating, servicing the unit or leaving it unattended:

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

2. Lower the lift arm and attachment completely. If the lift arm must be left

in the raised position,

BE SURE to properly engage the lift arm support

device (page 17).

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

4. Before exiting, move the lift/tilt control(s) to verify that the controls do not cause movement of the lift arm and hitch.

Safety Reminders

Before Starting

Ü Do not modify the ROPS/FOPS unless instructed to do so in installation

instructions. Modifications such as welding, drillingor cutting can weaken the structure and reduce the protection it provides. A damaged ROPS/FOPS cannot be repaired — it must be replaced.

Ü To ensure safe operation, replace damaged or worn-out parts with genuine

Gehl service parts.

Ü Gehl skid steer loaders are designed and intended to be used onlywith Gehl

attachments or approved referral attachments. Gehl cannot be responsible for operator safety if the loader is used with a non-approved attachment.

Ü Remove all trash and debris from the machine each day, especially in the

engine compartment, to minimize the risk of fire.

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

Never use starting fluid (ether).

Walk around the machine and warn allnearby personnel before starting the machine.

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

During Operation

Machine stability is affected by: the load being carried, the height of the load, machine speed, abrupt control movements and driving over uneven terrain.

LOADER TO TIP, THROWING THE OPERATOR OUT OF THE SEAT OR LOADER, RESULTING IN DEATH OR SERIOUS INJURY. ALWAYS operate with the seatbelt fastened and the restraint bar lowered.

DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE

Therefore,

Do not exceed the machine’s Rated Operating Load. Carry the load low. Move the controls smoothly and gradually, and operate at speeds appropriate for the conditions.

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Always travel with the heavier end of the loader toward the top of the

incline for additional stability when operating on inclines or ramps. Do not raise or drop a loaded bucket or fork suddenly. Abrupt movements

under load can cause serious instability. Never push the lift control into the “float” position with the bucket or

attachment loaded or raised, because this will cause the lift arm to lower rapidly.

Do not drive too close to an excavation or ditch; be sure that the

surrounding ground has adequate strength to support the weight of the loader and the load.

Never carry riders. Do not allow others to ride on the machine or

attachments, because they could fall or cause an accident. Always look to the rear before backing up the skid steer loader.

Operate the controls only from the operator’s seat.

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

operating the machine.

Ü New operators must operate the loader in an open area away from

bystanders. Practice with the controls until the loader can be operated safely and efficiently.

Ü Exhaust fumes can kill. Do not operate this machine in an enclosed area

unless there is adequate ventilation.

Ü When you park the machine and before you leave the seat, check the

restraint bar for proper operation. The restraint bar, when raised, deactivates the lift/tilt controls and auxiliary hydraulics, and applies the parking brake.

Maintenance

Never attempt to by-pass the keyswitch to start the engine. Use only the jump starting proceduredetailed in theOperation chapter ofthis manual.

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

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

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

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Potential Hazards

A skid steer loader operator must

ALWAYS be conscious of the working

environment. Operator actions, the environmental conditions and the job at hand require thefull attention ofthe operator sothat safetyprecautions can be taken.

ALWAYS maintaina safe distance from electric power lines andavoid contact

with any electrically charged conductor or gas line. Accidental contact or rupture can result in electrocution or an explosion. Contact the North American One CallReferral System at(888) 258-0808 forthe local "Digger's Hotline" number or the proper local authorities for utility line locations

BEFORE starting to dig!

Exposure to crystalline silica (found in sand, soil and rocks) has been associated with silicosis,a debilitating andoften fatal lung disease. A Hazard Review (Pub. No. 2002-129) by the U.S. National Institute for Occupational Safety and Health(NIOSH) indicates a significant risk of chronicsilicosis for workers exposed to inhaled crystalline silica over a working lifetime. NIOSH recommends an exposure limit of 0.05 mg/m

as a time-weighted average for up to a 10-hr workday during a 40-hr workweek. NIOSH also recommends substituting less hazardous materials when feasible, using respiratory protection and regular medical examinations for exposed workers.

Safety Decals

The skid steer loader has decals that provide safety information and precautions around the loader. These decals must be kept legible. If missing or illegible, they must be replaced promptly. Replacements may be obtained from your Gehl dealer. New equipment must have all decals specified by the manufacturer affixed to their proper place.

New Decal Application

Surfaces must be free of dirt, dust, grease and foreign material before applying the decal. Remove the smaller portion of the decal backing paper and apply the exposed adhesive to the clean surface, maintaining proper position and alignment. Peel the rest of the backing paper and apply hand pressure to smooth out the decal surface. Refer to the following pages for proper decal location. Text decals begin on page 9; no-text decals begin on page 12.

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Safety Decals inside the ROPS

137628 - Located on manual box, behind seat

137647 - Located on operator’s lower left side

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Part of left instrument panel

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Safety Decals on the Outside of the Skid Loader

137655 - Located on front of loader

137755 - Located on hitch (manual hitch loaders only)

139101 - Located on hitch (power hitch loaders only)

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Safety Decals in the Engine Compartment

137657 - Located on radiator

137756 - Located on lift arm support device

137658 - Located on radiator

137760 - Located on rear door

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Safety Decals inside the ROPS

137842 - Located on manual box, behind seat

Safety alert: Read Operator’s Manual and all safety signs before using machine. The owner is responsible to ensure all users are instructed on safe use and maintenance.

Safety alert: Always follow “Mandatory Safety Shutdown Procedure” in Operator’s Manual.

1-Lower equipment to ground. 2-Reduce throttle, stop engine. 3-Apply parking brake; remove

key.

4-Check safety interlocks.

137847 – Part of left instrument panel

137849 – Part of left instrument panel

Safety alert: A-Check machine before

operating; Service per Operator’s Manual; Contact dealer (or manufacturer) for information and service parts. B-Maintain 3-point contact during entry and exit. C-Inspect work area; Avoid all hazards; Look in direction of travel; Keep children and bystanders away. D-Start and operate machine only from seat. E-Keep away from power lines; Avoid contact. F-Wear any needed Personal Protective Equipment; Do not wear loose clothing while operating or servicing machine.

137843 - Located on operator’s lower left side

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

Operating Load. D-Side tip hazard: Avoid steep slopes and high speed turns; Travel up and down slopes with heavy end uphill.

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Safety Decals on the Outside of the Skid Loader

137844 – Located on front of loader

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

137852 – Located on hitch (manual hitch loaders only)

Crush hazard: Before operating with attachment, check engagement of hitch locking pin to the attachment:

A-Incorrect attachment engagement C-Lock hitch lever B-Correct attachment engagement D-Unlock hitch lever

139101 - Located on hitch (power hitch loaders only)

Crush hazard: Before operating with attachment, check engagement of hitch locking pin to the attachment:

A-Incorrect attachment engagement B-Correct attachment engagement

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Safety Decals in the Engine Compartment

AB C D E F

137845 – Located on radiator

A-Safety alert: Keep safety devices in place and in working order; Keep guards,

screens and windows in place. B-Fire hazard: Do not smoke while fueling or servicing machine; Clean debris from engine compartment daily to avoid fire; Keep fire extinguisher nearby.

C-Run-over hazard: Jump-start per Operator’s Manual procedure. D-Oil injection hazard: Do not use hands to find hydraulic leaks; Escaping oil under

pressure can be invisible and penetrate skin; Use a piece of cardboard to find leaks. E-Burn hazard: Allow radiator to cool before removing cap; Loosen cap slowly to avoid burns.

F-Suffocation hazard: Operate only in a well-ventilated area.

137853 Located on lift arm support device

Crush hazard: Hose removal or component failure can cause lift arm to drop. Always use lift arm support device when leaving lift arm raised for service.

137846 – Located on radiator

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

137854 - Located on rear door

Crush hazard: Be sure lock mechanism is securely engaged before working under ROPS/FOPS.

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CONTROLS and SAFETY EQUIPMENT

CAUTION

Become familiar with and know how to use all safety devices and controls on the skid steer loader before operating it. Know how to stop loader operation before starting it. This Gehl loader is designed and intended to be used only with a Gehl attachment or a Gehl-approved referral attachment or accessory. Gehl cannot be responsible for operator safety if the loader is used with a non-approved attachment.

Guards and Shields

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

WARNING

Read and thoroughly understand all safety decals on the loader before operating it. Do not operate the loader unless all factory-installedguards and shields are properly secured in place.

Operator Restraint Bar

Lower the restraint bar after entering the operator’s compartment. The restraint bar is securely anchored to the ROPS. The restraint bar switch and the seat switch form an interlock for the lift arm, tilt, drive and starter circuits (refer to the “Safety Interlock System” topic on

page 16 for more information).

WARNING

operator restraint bar or seat switch electrically or mechanically. Always wear your seatbelt.

Operator’s Seat

The seat is mounted on rails for backward or forward repositioning. A spring-loaded latch handle activates the seat adjustment mechanism.

Suspension seat (optional): A weight adjustment knob is provided with this seat for operator comfort.

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Never defeat the

Fig. 1: Operator’s Seat

1. Restraint Bar

2. Seatbelt

3. Seat Adjustment Lever

4. Suspension Seat Knob

(optional)

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Battery Disconnect

A battery disconnect switch is located in the rear of the skid loader. Turn the switch to the

OFF

position to disconnect the battery from the electrical system.

Safety Interlock System

Fig. 2: Battery Disconnect Switch

WARNING

NEVER defeat the safety interlock system by mechanically or electrically bypassing any switches, relays or solenoid valves.

An interlock system is provided on the loader for operator safety. Together with solenoid valves, switches and relays, the interlock system:

» Prevents the engine from starting unless the operator is sitting on the seat

and the operator restraint bar is down.

» Disables the lift arm, auxiliary hydraulics, attachment tilt and wheel drives

anytime the operatorleaves the seat, turns thekeyswitch to

OFF or raisesthe

restraint bar.

Testing the Safety Interlock System

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

Restraint Bar

With the engine running, raise the restraint bar. Test each of the controls. There should be no more than a slight movement of the lift arm, hitch and machine. If there is any significant movement, troubleshoot and correct the problem immediately. Contact your dealer if necessary.

Seat Switch

With the engine off and the restraint bar lowered, unfasten your seatbelt. Lift your weight off the seat. Try to start the engine. If the engine starts, turn off the engine, and troubleshoot and correct the problem. Contact your dealer if necessary.

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ROPS/FOPS

The ROPS/FOPS (Roll Over/Falling Object ProtectiveStructure) is designed to provide protection for the operator from falling objects and in case the loader tips or rolls over, provided the operator is secured inside the ROPS by the seatbelt and restraint bar.

WARNING

Never operate the loader with the ROPS

removed or locked back.

Parking Brake

This skid loader is equipped with a spring-applied, hydraulic-released parking brake. The parking brake engages when the operator lifts the restraint bar, leaves the operator’s seat or shuts off the engine. The brake can also be applied manually by using the switch located on the left control panel of the ROPS. A red indicator on the left control panel lights whenthe parking brake is applied.

Fig. 3: Parking Brake Switch

Horn

Pressing the

BLUE button on the left control handle sounds the horn.

Rear Window Emergency Exit

The ROPS rear window has three functions: noise reduction, falling objects barrier and emergency exit.

To use the emergency exit, unlatch the two latches, push out the window and exit.

Lift Arm Support Device

The lift arm support device is used as a cylinder lock to prevent the raised lift arm from unexpectedly lowering. Be sure to engage the support device when the lift arm is raised for service. When the support device is not being used, return it to its storage position. The support deviceis a safety device that must be kept in proper operating condition at all times. The following steps ensure correct usage:

WARNING

support device requires two people - one person inside the loader and another person to engage the support device.

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The safest method of engaging the lift arm

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Important: With the keyswitch OFF and the solenoid valve functioning properly, the lift arm will stay raised when the lift control is moved to lower the lift arm. If the valve does not hold the lift arm, lower the lift arm completely. Contact your Gehl dealer immediately to determine why the lift arm lowers while the keyswitch is

OFF.

Engagement

To engage the lift arm support device:

1. Raise the lift arm fully.

2. Stop the engine.

3. Remove the lift arm support device from its

storage location on the left rear link.

4. Place the supportdevice on theleft liftcylinder

with the long end of the support device facing the front of the loader (Fig. 4).

5. Secure the support device with the lock pin.

Disengagement

To disengage the lift arm support device:

1. Raise the lift arm completely.

2. Stop the engine.

3. Remove the support device from the lift

cylinder and return it to its storage position on the left rear link (Fig. 5).

4. Secure the support device with the lock pin.

Fig. 4:Lift Arm Support Device Engaged

1. Lock Pin

2. Long End of Support Device

Fig. 5: Lift Arm Support Device Stored

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Accessory Plug (Optional)

The optional accessory plug is located at the bottom of the left instrument panel.

Heater (Optional)

Loaders with the optional heater have a dial on the left instrument panel to control the fan operation of the heater.

Heater and Air Conditioner (Optional)

Loaders with the combined heater/air conditioner have three controls on the left instrument panel: fan speed, airconditioner on/off and temperature.

1. Fan Speed: Controls the rate at which air exits the vents

2. Air Conditioner On/Off: Turns the air conditioner unit

ON and OFF

3. Temperature: Controls the temperature of the air exiting the vents

Hint: The operator will feelcooler withjust the two front vents opened and aimed at the upper body.

Fig. 6: Heater/ Air Conditioner Controls

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Speed Control

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

T-Bar and Dual Hand Controls Only: A right-foot operated accelerator pedal is provided to control the engine RPM. The pedal linkage is spring-loaded to return to the adjusted hand-operated throttle setting.

Fig. 8: Foot Pedal (T-Bar & Dual Hand)

Fig. 7: Throttle Lever

Two-Speed Transmission (optional)

Loaders with two-speed transmissions have a

YELLOW button on the left

control handle for shifting between High (H) and Low (L). Shifting to High allows the operator to exceed the standard 8 mph (13 km/h) upto a maximum speed of 14 mph (22.5 km/h).

Note: Loaders sold to European Union nations can exceed the standard speed up to a maximum speed of 12.4 mph (20 km/h).

Hydraglide™ Ride Control System (optional)

Loaders with the optional ride control feature have a

BLUE button on the right

control handle for shifting between normal mode and ride control mode. The ride control system provides a smoother ride over uneven surfaces. Press the button once to activate and again to deactivate. The ride control system is automatically deactivated when the machine shuts down.

Note: The lift arm will drop slightly when ride control is activated.

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Attachment Mounting

Your Gehl loader may be equipped with either a manual All-Tach™ attaching mechanism (hitch) or power All-Tach™ hitch for mounting a bucket or other attachment.

Fig. 9: Manual All-Tach Hitch

Fig. 10: Power All-Tach Hitch

Manual All-Tach Hitch

A manual latchlever engages the latch pins. Rotate the lever all theway to the left to engage the latch pins. Rotate the lever all the way to the right to disengage the latch pins. Refer to page 37 for more information.

WARNING

To prevent unexpected attachment release from the hitch, be sure to secure the latch pins by rotating the lever all the way to the left.

Power All-Tach Hitch

A switch on the left control panel activates the latch pins. Flags on the pins indicated their position; the pin flags will move towards the outside of the hitch when engaging the pins and towards the inside of the hitch when disengaging the pins. Refer to page 37 for more information.

WARNING

To prevent unexpected attachment release from the hitch, be sure the latch pins are secure by verifying that the pin flags havemoved as faras possibleto theoutside ofthe hitch.

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Instrument Panel

The instrument panel contains the following switches and indicators. Symbols on the panel represent various functions and conditions, and are visible only when indicator lamps are on.

Left Panel

Note: Items 1 through 3 are indicator lights which display the following:

1. Two-Speed High (optional) – Lights when high speed is engaged.

2. Parking Brake – Lights when the parking brake is applied.

3. Ride Control System (optional) – Lights when the ride control system is activated.

4. Parking Brake Switch– Used tomanually apply the parking brake.

5. Fan (optional) – Used to manually control the fan for the air conditioner or heater.

6. Accessory Plug (optional) – A 12 VDC power outlet.

7. Power All-Tach Hitch (optional) – Used to operate the power All-Tach hitch.

Fig. 11: Left Panel

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Right Panel

Note: Items 1 through 8 are indicator lights which display the following:

1. Air Filter Restriction (optional) -Lights if the air filter becomes restricted, warning the operator to stop the engine. Inspect the air cleaner filters and replace if necessary. During normal operation, thisindicator should be

2. Engine Coolant Temperature – Lights if the

OFF.

engine coolant gets too hot, warning the operator to stop the engine. Allow the engine to cool, determine the cause for the high

temperature and correct the problem before restarting the engine. During normal operation, this indicator should be

OFF.

3. Hydraulic Oil Filter Restriction– Lights if the hydraulic return filter becomes restricted, warning the operator to stop the engine. Allow the engine tocool then change the oiland filter.

During normal operation, this indicator should be

OFF.

4. Hydraulic Oil Temperature – Lights if the hydraulic oil becomes too hot, warning the

operator to stop engine. Allow the hydraulic system to cool and determine the cause of the high temperature. During normal operation, this indicator should be

OFF.

5. Fasten Seatbelt – A momentary visual (and audible) indicator to remind the operator to fasten the seatbelt.

6. Engine Oil Pressure – Lights if the engine oil

pressure drops toolow, warning theoperator to immediately stop theengine and determine the cause for the pressure drop. During normal operation, this indicator should be

OFF.

7. Battery – Lights if the charging voltage is too high or too low. During normal operation, this indicator should be

OFF.

8. Preheat Indicator Lamp – Lights when the preheat is active. During normal operation, this indicator should be

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OFF.

Fig. 12: Right Panel

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9. Hourmeter – Indicates the total operating hours of the loader.

10. Fuel Level Gauge – Indicates the amount of fuel in the tank.

11. Engine Coolant Temperature Gauge – Indicates the engine coolant

temperature.

12. Light Switch – Controls all the lights (standard and optional) on the loader. Symbols denote the four positions of the light switch. In a clockwise direction these are: Off, Flashers (Hazards), Work Lights with Flashers, and Tail Lights. For thelights to function,the keyswitch must be in the

RUN position.

13. Keyswitch – In a clockwise rotation, these positions are:

Off Position – With the key vertical (

OFF) in the keyswitch, power from

the battery is disconnected from the controls and instrument panel electrical circuits. This is the only position the key can be inserted or removed from the keyswitch.

On or Run Position – With the key turned one position clockwise ( from the vertical (

OFF) position, power from the battery is supplied to all

RUN)

control and instrument panel electrical circuits.

Start Position – With the key turned fully clockwise (

START) and held in

position, the electric starter energizes, startingthe engine. Releasethe key after the engine starts (it returns to the

RUN position by itself).

Note: The engine cannot be started unless the operator sits in the seat and the restraint bar is lowered.

14. Circuit Breakers – Four circuit breakers on the instrument panel protect the loader’s electrical circuits.

Important: Do not attempt to defeat the circuit protection by jumping across a circuit breaker or by using a higher amperage circuit breaker.

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T-Bar Controls

Your Gehl loadermay be equipped with the T-Bar control option. The left T-Bar controls the drive and the right T-Bar

controls the lift/tilt.

Drive Control

Forward, reverse, speed and turning maneuvers are accomplished by movement of the left T-Bar. To go

forward, push the control forward; for reverse, pull the control rearward. To

Fig. 13: T-Bar Controls

1. Drive Control

2. Lift/Tilt Control

turn right, turn the control clockwise; to turn left, turn the control counterclockwise. For gradual turns, move the T-Bar slightly forward or rearward. For sharp turns, do not move the control forward or rearward, turn only clockwise or counterclockwise.

Moving the T-Bar farther from neutral increases the speed steadily to the maximum travel speed. Tractive effort decreases as speed increases. To get maximum tractive effort, move the T-Baronly slightly away from the neutral position. The engine will stall if the control is moved too far forward when loading the bucket.

WARNING

Be sure the T-Bar controls are in neutral before starting the engine. Operate the T-Bars gradually and smoothly. Excessive speed and quick T-Bar movements without regard for conditions and circumstances are hazardous and could cause an accident.

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Lift/Tilt Control

Moving the lift arm and tilting the attachment are accomplished by movement of the right T-Bar. To raise the lift arm, pull the control straight rearward; to lower the lift arm, push the control straight forward. To tilt the

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

Note: The speed of the lift/tilt motion is directly proportional to the amount of

T-Bar movement and engine RPM.

To place the lift arm in the detent (float) position, push the right T-Bar all the way forward, intothe detent. This position allows the lowered lift arm tofloat while traveling over changing ground conditions.

WARNING

Never push thelift/tilt T-Bar controlinto thefloat position with the attachment loaded or raised, because this will cause the lift arm to lower rapidly.

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Hand/Foot Controls

Your Gehl loader may be equipped with the hand/foot control option.

The handles controlthe drive andthe foot pedals control the lift/tilt.

Drive Controls

Forward, reverse, speed and turning maneuvers are accomplished by movement of thecontrol handles. To go forward, push both handles

Fig. 14: Hand/Foot Controls

1. Right Drive Control Handle

2. Left Drive Control Handle

3. Tilt Control Pedal

4. Lift Control Pedal

forward; for reverse, pull both handles rearward. For turning, move one handle farther forward or rearward than the other handle. Turn direction is determined bywhich handleis moved farther forward; to turn left, move the right handle farther forward than the left handle. For sharp turns, move the handles in opposite directions.

Moving the handles farther from neutral increases the speed steadily to the maximum travel speed. Tractive effort decreases as speed increases. To get maximum tractive effort, move the handles only slightly away from the neutral position. The engine will stall if the control is moved too far when loading the bucket.

WARNING

Be sure the controls are in neutral before starting the engine. Operate the controls gradually and smoothly. Excessive speed and quick control movements without regard for conditions and circumstances are hazardous and could cause an accident.

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Lift/Tilt Controls

Moving the lift arm and tilting the attachment are accomplished by movement of the foot pedals. Theleft pedal raises and lowers the lift arm; the right pedal tilts the attachment. To raise the lift arm, use your heel to push down on theleft pedal; to lower the lift arm,use your toesto push downon the left pedal. To tilt the attachmentdownward, use your toes to push down on the right pedal;to tiltthe attachmentup orback, use yourheel topush down on the right pedal.

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

To place thelift arm inthe detent (float) position, use your toes to pushthe left pedal all the way down, into the detent. This position allows the lowered lift arm to float while traveling over changing ground conditions.

WARNING

Never push the left pedal into the float position with the attachment loaded or raised, because this will cause the lift arm to lower rapidly.

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Dual Hand Controls

Your Gehl loader may be equipped with the dual hand control option. The left handle controls the left side drive and the lift. The right handle controls the right side drive and the tilt.

Drive Controls

Forward, reverse, speed and turning maneuvers are accomplished by

Fig. 15: Dual Hand Controls

1. Left Drive/Lift Control

2. Right Drive/Tilt Control

pushing and pulling the handles. To go forward, push both handles forward; for reverse, pull both handles rearward. For turning, move one handle farther forward or rearward than the other handle. Turn direction is determined by which handle is moved farther forward; to turn left, move the right handle farther forward than the left handle. For sharp turns, move the handles in opposite directions.

WARNING

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Lift/Tilt Controls

Moving the lift arm and tilting the attachment are accomplished by rotating the control handles. To raise the lift arm, rotate the left control up; to lower the lift arm, rotate the left control down. To tilt the attachment downward, rotate the right control up; to tilt the attachment up or back, rotate the right control down..

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

To place the lift arm in the detent (float) position, push the left control all the way down, into the detent. This position allows the lowered lift arm to float while traveling over changing ground conditions.

WARNING

Never push the lift/tilt control into the float position with the attachment loaded or raised, because this will cause the lift arm to lower rapidly.

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Auxiliary Hydraulic Controls

Auxiliary hydraulics are used with an attachment that has a mechanism requiring hydraulic power of its own.

Important: Always be sure the auxiliary hydraulic control is in neutral before starting the loader or removing the auxiliary hydraulic couplers.

Fig. 16: Auxiliary Couplers

1. High Flow Couplers

2. Standard Couplers

Standard Flow Auxiliary Hydraulics

Coupler hookup is located on the left lift arm. “A” port is pressure, “B” port is return when the auxiliary control is in the detent position (refer to page 38). The flow can be manually adjusted from 2 - 29 gpm (7,6-110 L/min)by turning the flow control knob.

T-Bar and Dual Hand Controlled Loaders: A foot pedal is used to control

the direction of oil flow. A stop is provided to lock the foot pedal for continuous operation.

Fig. 17: T-Bar and Dual Hand Auxiliary Control

Hand/Foot Controlled Loaders: The right handle controls the direction of oil flow. A locking pin locks it in the up position for continuous operation.

Fig. 18: Hand/ Foot Auxiliary Control

1. Locking Pin

Fig. 19: Standard Flow Control Knob

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High Flow Auxiliary Hydraulic Controls

In addition to standard flow auxiliary hydraulic connections, some loaders are shipped with reversible high flow auxiliary hydraulics. Coupler hookup is located on the right lift arm. High flow auxiliary hydraulics are used for operating high oil flow hydraulic attachments (cold planer, snowblower, etc.)

A 3-position control lever is located behind the right control handle. The lever is spring centered with a detent in the forward position for continuous operation.

Fig. 20: High Flow Control

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NOTES

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OPERATION

WARNING

Before starting the engine and operating the loader, review and comply with all safety recommendations in the Safety chapter of this manual. Know how to stop the loader before starting it. Also, be sure to fasten and properly adjust the seatbelt and lower the operator restraint bar.

Before Starting the Engine

Before starting the engine and running the loader, refer to the Controls and Safety Equipment chapter and familiarize yourselfwith the various operating

controls, indicators and safety devices on the loader.

Starting the Engine

The following procedure is recommended for starting the engine:

1. Carefully step up onto the back of the bucket or attachment and grasp the

ROPS hand holds to get into the operator’s compartment.

2. Fasten the seatbelt and lower the restraint bar.

3. Verify the following:

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

» the parking brake is on.

4. Push the throttle lever forward to half speed. Note: When the key is turned to the

RUN position, an indicator will light on the

instrument panel and a buzzer will sound momentarily to remind you to check that your seatbelt is fastened.

5. Turn the keyswitch to the

light to go out, then turn the key to the

RUN position. Wait for the preheat indicator

START position. Preheat is

automatically controlled and activates if the temperature is 32°F (0°C) or below.

Important: Do not engage the starter for longer than 15 seconds at a time. Longer use can overheat and damage the starter. If the engine fails to start within 15 seconds, return the key to the

OFF position and repeat step 5. Allow

the starter to cool for 20 seconds between uses.

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

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

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Cold Starting Procedure

WARNING

Do not use starting fluid (ether) with preheat systems. An explosion can result which can cause engine damage, injury or death.

Turn the key to the comes on, wait until it goes out before turning the key to the

RUN position. If the preheat light on the instrument panel

START position.

If the temperature is below 32° F (0° C),try the following to make starting the engine easier:

Replace the engine oil with SAE 10W30

Make sure the battery is fully charged

Install a block heater on the engine.

Let the engine run for a minimum of five minutes to warm the engine and hydraulic fluid before operating the loader.

A block heater is recommended forstarting in temperatures of20°F (-7°C) or lower. See your Gehl dealer for heater options.

Stopping the Loader

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

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

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

3. Pull the throttle lever back to the idle position (and/or take your foot off

the accelerator pedal for hands-only controlled machines).

4. Turn the keyswitch to the

OFF position and remove the key.

5. Raise the restraintbar, unlatch the seatbelt and grasp the hand holds while

climbing out of the operator’s compartment.

Note: The skid loader is equipped with a spring-applied automatic parking brake. The parking brake is engaged when the operator lifts the restraint bar, leaves the operator’s seat, shuts off the engine or when the brake switch is applied (the top half of the switch is pushed in).

Parking the Loader

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

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Jump-starting

If the battery becomes discharged or does not have enough power to start the engine, use jumper cables and the following procedure to jump-start the engine. Remote battery connectors are located at the rear of the loader.

WARNING

The only safe method for jump-starting a discharged battery is for two people to perform the following procedure. The second person removes the jumper cables so that the operator does not have to leave the operator’s compartment with the engine running.

Never make jumper cable connections directly to the starter solenoid of either engine. Do not startthe engine from any position other than the operator’s seat and then only after being sure all controls are in neutral.

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

Do not jump-start the battery if it is frozen, because it may rupture or explode. Warm the battery to 60°F (16°C) before connecting to a charger.

Note: Be sure the jumper battery is a 12 volt D.C. battery.

1. Turn the keyswitches of both machines to

in neutral and

NOT touching each other.

OFF. Be sure the machines are

2. Connect the positive (+) jumper cable to the positive (+) remote battery

terminal on the disabled loader first. Do not allow the jumper’s positive cable clamps to touch any metal other than the positive (+) remote terminal. Connect theother end of the positive jumper cable to the jumper machine’s positive (+) terminal.

3. Connect the negative (-) jumper cable to the jumper machine’s negative

(-) terminal.

4. Make the final negative (-) jumper cable connection to the disabled

negative (-) remote terminal.

5. Be sure the brake switch is engaged and that the controls are in neutral.

Start the engine. If it does not start at once, start the jumper machine’s engine to avoid excessive drain on the booster battery.

6. After the disabled loader isstarted and runningsmoothly, have thesecond

person remove the jumper cables (negative (-) jumper cable first) from the jumper machine’s battery and then from the disabled loader while being sure NOT to short the two cables together.

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

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Changing Attachments

WARNING

To prevent unexpected release of the attachment from thehitch, be sure to properly secure the hitchlatch pins by rotating the latch lever all the way to the left (manual All-Tach hitch) or by ensuring that the pin flags are all the way to the outside (power All-Tach hitch)

The skid loader features either a manual or power All-Tach™ attaching mechanism (hitch) for mounting a bucket or other attachment conforming to SAE J2513 standards.

On a manual All-Tach (Fig. 21) hitch, a latch lever engages the latch pins to secure the attachment. On a power All-Tach (Fig. 22) hitch, a switch on the left control panel engages the latch pins to secure the attachment.

Connect Attachment

1. Manual hitch: Rotate the latch

lever to the right to fully retract the latch pins.

Power hitch: Activate the switch to unlock the hitch and fully retract the latch pins.

2. Start the loader engine and make

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

3. Align the loader squarely with the

Fig. 21: Manual Hitch - disengaged

1. Latch Lever

2. Latch Pins

back of the attachment.

4. Tilt the hitch forward until the top

edge of the hitch is below the flange

on the back side of the attachment and centered between the vertical plates.

5. Slowly drive the loader forwardand,

at the sametime, tilt the hitch backto engage the flangeon theback sideof

Fig. 22: Power Hitch - disengaged

1. Pin Flags

2. Latch Pins

the attachment.

6. Stop forward travel when the flange is engaged, but continue to tilt the

hitch back to lift the attachment off the ground.

7. Manual hitch: Exercise the

PROCEDURE

(page 6). Leave the operator’s compartment and rotate the

MANDATORY SAFETY SHUTDOWN

latch lever to the left to fully engage the latch pins.

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Page 41

Power hitch: Activate the switch to lock the hitch and fully engage the latch pins.

Important: To check that the attachment is properly installed, apply downward pressure to the attachment prior to operating.

Connect Auxiliary Hydraulic Couplings

Note: With theengine

OFF, key inthe ON position and therestraint bar down,the

auxiliary hydraulic controlcan be moved to relieveany pressure in the hydraulic system.

Standard Auxiliary Hydraulics

Coupler hookup islocated on theleft lift arm.The top coupler is pressure, the bottom coupler is return when the auxiliary control is in the detent position.

High Flow Auxiliary Hydraulics

Coupler hookup is located on the right lift arm. The top coupler is pressure, the middle coupler is return when the auxiliary control is in the detent position. The bottom coupler is the dedicated case drain.

Remove Attachment

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

2. Exercise the

MANDATORY SAFETY SHUTDOWN PROCEDURE (page 6).

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

ON (do not start the engine).

b. With the restraint bar down, move the auxiliary hydraulic control

back and forth.This will relievethe pressure inthe hydraulic system.

4. With the engine

OFF, leave the operator’s compartment and disconnect

the auxiliary hydraulic hoses.

5. Manual hitch: Rotate the hitch’s latchlever to theright to fully retract the latch pins.

Power hitch: Turn the key

ON (do not start the engine) and activate the

switch to unlock the hitch and fully retract the latch pins.

6. Start the engine and be sure that the lift arm is fully loweredand in contact with the loader frame.

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

Self-Leveling

The feature isdesigned tokeep theattachment levelwhile thelift armis being raised.

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Using a Bucket

WARNING

Always maintain a safe distance from electric power lines and avoid contact with any electrically charged conductor or gas line. Accidental contact or rupture can result in electrocution or an explosion. Contact the “Digger’s Hotline” or proper local authorities for utility line locations before starting to dig.

Driving over Rough Terrain

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

Driving on an Incline

When traveling on an incline, the loader must travel with the heavy end pointing uphill.

Digging with a Bucket

Approach the digging site with the lift arm slightly raised and the bucket tilted forward until the edge contacts the ground. Dig into the ground by driving forward and gradually lowering the lift arm.

With the bucket filled, tilt the bucket back, back the loader away from the material and rest the lift

Fig. 23: Digging

arm against the loader frame before proceeding to the dumping area.

WARNING

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

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Loading a Bucket

Approach the pile with the lift arm fully lowered and the bucket tilted slightly forward until the edge contacts the ground. Drive forward, lifting the lift arm and tilting back the bucket to fill it. Back away from the pile.

Fig. 24: Loading

Dumping the Load Onto a Pile

Carry a loaded bucket as low as possible until the pile is reached. Gradually stop forward motion and raise the lift arm high enough so that the bucket clears the top of the pile. Then, slowly move the loader ahead to position the bucket to dump the material on top of the pile. Dump the material and then back the loaderaway while tilting the bucketback and loweringthe lift arm.

WARNING

Never push the controls into the float position with the bucket or attachment loaded or raised, because this will cause the lift arm to lower rapidly.

Dumping the Load Into a Box

Carry the loaded bucket low and approach the vehicle or bin. Stop your approach as close to the side of the box as possible while allowing for clearance to raise the lift arm and loaded bucket. Next, raise the lift armuntil the bucket clears the top of the box and move the loader ahead to position the bucket over the inside of the box. Dump the material and then back

Fig. 25: Dumping Into a Box

away from the box while tilting the bucket back and lowering the lift arm.

Dumping the Load Over an Embankment

WARNING

Do not drive too close to an excavation or ditch. Be sure the surrounding ground has adequate strength to support the weight of the loader and the load.

Carry the loaded bucket as low as possible while traveling to the dumping area. Stop the loader where the bucket extends half-way over the edge of the embankment. Tilt the bucket forward and raise the lift arm to dump the material. Dump the material and then back away fromthe embankment while tilting the bucket back and lowering the lift arm.

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Scraping with a Bucket

For scraping, the loader should be operated in the forward direction. Position the lift arm down against the loader frame. Tilt the bucket cutting edge forward at a slight angle to the surface being scraped. While traveling slowly forward with the bucket in this position, material can flow over the cutting edge and collect inside the bucket.

Leveling the Ground

Drive the loader to the far edge of the area to be leveled. Tilt the bucket forward to place the bucket cutting edge at a 30 to 45 degree angle to the surface being leveled. Then place the lift arm into the float position and drive the loader rearward, dragging the dirtand, at the same time,leveling it.

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

Fig. 26: Scraping

Fig. 27: Leveling the Ground

WARNING

Check that the work area is clear of people and

obstacles. Always look in the direction of travel.

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Highway Travel

If it becomes necessary to move the loader a long distance, obtain and use a properly rated trailer. For short distance highway travel, attach an SMV (Slow Moving Vehicle)emblem (purchased locally) to theback of theloader. For highway operation, obtain and install dual amber flashers or a strobe light. Check state and local laws and regulations.

Storing the Loader

If your skid loader is to be stored for a long period of time, the following procedure is suggested:

1. Fully inflate the tires.

2. Lubricate all grease zerks.

3. Check all fluid levels and replenish as necessary.

4. Add stabilizer to the fuel per the fuel supplier’s recommendations.

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

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

and temperature.

Towing the Loader

The loader must be towed only atslow speed for a short distance (e.g., towing the loader onto a trailer).

The loader canbe towed usingthe front or rear tie downs(Figs. 28 and29).

WARNING

Be sure the area is clear before towing. The towing chain must be rated at least 1-1/2 times the weight of the loader (see Specifications chapter - p. 75).

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Transporting the Loader

WARNING

Park the truck or trailer on a level surface. Be sure the vehicle and its ramps have the weight capacity to support the loader. Be sure the vehicle surface and its ramps are clear of debris and slippery material that may reduce traction. Move the loader on and off the vehicle ramp slowly and carefully. Failure to follow these instructions could result in an overturn accident.

Observe all local regulations governing the loading and transporting of equipment. Ensure that the hauling vehicle meets all safety requirements before loading the skid loader.

1. Place blocks at the front and rear of

the hauling vehicle’s tires.

2. If the loader has an attachment, lift it

slightly off the ground.

Fig. 28: Front Tie Down

3. Back the loader slowly and carefully

up the ramp onto the vehicle.

4. Lower the loader attachment to the

vehicle deck, turn off the engine and remove the key.

5. Fasten the loader to the hauling vehicle

at the points indicated by the tie-down decals.

6. Measure the clearance height of the

loader and hauling vehicle. Post the clearance height in the cab of the vehicle.

Fig. 29: Rear Tie Down

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Lifting the Loader

The loader can be lifted using a single-point or four-point lift kit, which are available from your authorized Gehl dealer.

WARNING

Before lifting, check the lift kit for proper installation.

•

Never allow riders in the operator’s compartment (ROPS) while

•

the loader is lifted.

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

•

lifted.

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

•

forks, or with no attachment. Never lift the loader with attachments other than those stated.

Lift equipment used and its installation is the responsibility of the party conducting the lift. All rigging

MUST comply with applicable

regulations and guidelines.

1. Using suitable lift equipment, hook into the lift eyes (refer to Figs. 30, 31 and 32). Adjust the length of the slings or chains to lift the loader level.

Important: As needed, use a spreader bar to prevent the slings or chains from rubbing the sides of the ROPS.

2. Center the hoist over the ROPS. To prevent shock loading of the equipment and excessive swinging of the load, slowly lift the loader off the ground. Perform all movements slowly and gradually.

Fig. 30: Four-Point Front Lift Eye

Fig. 31: Four-Point Rear Lift Eye

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Fig. 32: Single-Point Lift Eye

Page 48

SERVICE

WARNING

expressly instructed to the contrary, exercise the

SAFETY SHUTDOWN PROCEDURE

Before servicing the machine, unless

MANDATORY

(page 6).

After service has been performed, be sure to restore all guards, shields and covers to their original positions before resuming loader operation.

This Service chapter details procedures for performing routine maintenance checks, adjustments and replacements. Most procedures are referred to inthe Troubleshooting and Maintenance Schedule chaptersof this manual. Refer to the Maintenance Interval Chart (page 71) for service intervals. Refer to the separate engine manual provided for engine-related adjustments, lubrication and service procedures.

Note: All service procedures, except those described under the “Dealer Services” topic are owner-operator responsibilities.

Important: Always dispose of waste lubricating oils and hydraulic fluids according to local regulations or take to a recycling center for disposal. Do not pour onto the ground or down the drain.

Dealer Services

The following areas of component service, replacement and adjustments require special tools and knowledge for proper servicing and should be performed only by your authorized Gehl skid steer loaderdealer: Hydrostatic Components, Hydraulic System Axial Pump, Valves, Cylinders, Electrical Components (other than the battery, circuit breakers) .

Replacement Parts

Part Description Gehl Part No.

Air Cleaner Element, Primary 137498 Air Cleaner Element, Secondary 137501 Hydraulic Oil Filter Element 137359 Hydrostatic Oil Filter Element 074830 Engine Oil Filter Element 137500 In-line Fuel Filter 137794 Spin-on Fuel Filter Cartridge 137499 Fresh Air Intake Filter (heater option) 138551 Recirculation Air Filter (heater option) 138545

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

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Loader Raising Procedure

To raise the skid loader so that all four tires are off the ground, use the procedure below:

WARNING

Do not rely on a jack or hoist to maintain the raised position without additional blocking and supports. Serious personal injury could result from improperly raising or blocking the skid loader.

1. Using a jack or hoist capable of lifting the fully-equipped weight of the

loader (with allattached options, except hitch attachments),lift the rearof the loader until the rear tires are off the ground.

2. Stack wooden blocksunder the flat part ofthe loader chassis.They should

be parallel to, but not touch, the rear tires (Fig. 33).

3. Slowly lower theloader untilits weightrests on theblocks. Ifthe tiresstill

touch the ground,raise the loaderagain, add moreblocks and loweragain.

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

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

Loader Lowering Procedure

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

1. Using a jackor hoist,raise thefront of the loader until its weight no longer

rests on the front blocks.

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

3. Slowly lower the loader until the front tires are resting on the ground.

4. Repeat Steps 1 through 3 for the rear of the loader. Whenthe procedure is

finished, all four tires will be on the ground and the blocks removed from under the loader.

Fig. 33: Skid Loader Properly Blocked (Tires and wheels removed to show blocks)

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Engine Compartment Access

Important: Do not raise the lift arm with the engine cover raised.

To open the engine compartment, turn the

rear door latch and carefully lower the rear door. Lift the engine cover. The side panels are removed by turning the butterfly bolts and pulling the panels out.

The side panels are easier to access if the lift arm is raised and secured (page 17).

Note: The rear door may be stood on.

Fig. 35: Engine Compartment Access Doors

1. Engine Cover

2. Side Panels

3. Rear Door

Tilting the ROPS Back

A manual hydraulic pump in the engine compartment isused to tilt the ROPS back. The pump handle is stored on the right side of the compartment. A manual lock mechanism engages to lock the ROPS in a rolled-back position. To tilt the ROPS back, use the following procedure:

1. Remove the two anchor bolts at the frontof the ROPS.

2. Place the pump handle in the pump.

3. Tighten the needle valve.

4. Pump until the ROPS is tilted enough that the

lock mechanism underneath the right side of the ROPS engages.

5. To lower the ROPS, return the lock mechanism to the unlocked position. Loosen the needle valve and the ROPS will slowly tilt back down. Reinstall the anchorbolts, washers

Fig. 34: ROPS Tilt Pump

1. Pump

2. Pump Handle

3. Needle Valve

4. Handle Storage

and locknuts.

WARNING

loader with the ROPS removed or locked back. Be sure the lock mechanism is securely engaged when the ROPS is tilted back. Be sure to reinstall the anchor bolts, washers and locknuts before resuming loader operation.

47 908274/BP1202

Never operate the

Fig. 36: ROPS Lock Mechanism - Engaged

Page 51

Adjustments

Control Handles

The control handles do not require routine adjustment. Refer to the Service Manual for the initial setup procedure.

Fuel Sender

The fuel sender, located on the fuel tank, sends a signal to the fuel gauge indicating the amount of fuel in the fuel tank.

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

Engine Speed Control

The throttle does notrequire routine adjustment. Referto the Service Manual for the initial setup procedure.

The throttle lever friction pad pressure can be adjusted if the throttle lever does not hold its position. Belleville washers and a lock nut on the throttle lever are used for making this adjustment.

Foreign Material Removal

The loader should be cleared daily of dirt and other foreign materials in the following areas:

•

around the rear link and lift cylinder

•

at the front of the loader

•

on the hitch, especially around the linkage

•

around the hydraulic oil level sight gauge

•

around the hydraulic oil reservoir breather

•

in the engine compartment

•

in the operator’s compartment

The build-up of foreign materials in these areas can interfere with the operation of the loader, cause component damage or become a fire hazard.

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Lubrication

Listed below are the locations, temperature ranges andtypes of lubricants for this machine. Refer to the separate engine manual for more information regarding engine lubricants, quantities and grades required.

Note: Refer to the specific service sections for detailed information on periodic checking and replenishing of lubricants.

Use Petro Canada HVI60, Mobil DTE 15M or equivalent

Hydraulic System Oil

Chaincase Oil

Grease Fittings

Engine Oil

which contains anti-rust, anti-foam and anti-oxidation additives, and conforms to ISO VG46. Capacity: 15 U.S. gallons (56,8 liters)

Use hydraulic system oil or SAE grade 15W-40 motor oil. Capacity (each side): 3 U.S. gallons (11,4 liters)

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

Above 32°F (0°C) - Use SAE Grade* 15W-40 *Service Classification: API - CF-4/CG-4 Capacity: 14.8 U.S. quarts (14 liters)

Refer to Fig. 37 for grease fitting locations. Wipe dirt from the fittings before greasing them to prevent contamination. Replace any missing or damaged fittings. To minimize dirt build-up, avoid excessive greasing.

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50/1000

50/500

1000

Fig. 37: Service Locations

500 Hours

(or Yearly)

Lubrication Procedure

10 Hours (or Daily)

250 Hours

Check Engine Oil Level (p56) l Check Hydraulic Oil Level (p57) l

Grease Lift Arm, Hitch, Cylinder Pivots and Latch Pins

(p49)

Check Oil Level in Chaincases (p51) l Change Engine Oil and Filter (p56) ovl Change Hydrostatic Oil Filter (p57) ol Change Hydraulic Oil Filter (p57) l Change Hydraulic Oil (p57) t Change Chaincase Oil (p51) ot

o Perform the initial procedure at 50 hours then at “l”or“t” intervals. v Severe operating conditions. t Perform the procedure at 1000 hours.

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Chaincases

There is a chaincase on each side of the loader. Refer to the Maintenance Interval Chart (page 71) for change intervals. Refer to the “Lubrication”

topic (page 49) for information on oil type and quantity.

Checking and Adding Oil

1. Park the loader on a level surface. Stop the engine.

2. Remove the check plug from each chaincase housing. Theoil level should be at theplug level orno more than1/4” below.

3. If the level is low, add fluid through the fill plug until the oil level reaches the

Fig. 38: Front Cover

edge of the check plug hole. Reinstall the plugs.

Draining Oil

1. Park the loader on a level surface or on a sloping surface with the loader facing uphill.

2. Remove the drain plug on each

chaincase and drain the oil into a suitable container.

3. Reinstall and tighten the drain plugs.

4. Refill the chaincases at the fill plugs

located under thecover at thefront of the loader.

Fig. 39: Check and Drain Plugs

1. Check Plug

2. Drain Plug

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Drive Chains

Drive chains are located inthe chaincase on each sideof the machine.Refer to the Maintenance Interval Chart (page 71) for tension check interval.

Check Chain Tension

1. Raise the loader following the “Loader Raising Procedure” (page 46).

2. Rotate each tire by hand. The proper amount of rotation should be

1/8” - 1” (3 - 25 mm) forward and rearward. If the rotation is more than 1” (25 mm) or less than 1/8” (3 mm) in either direction, the chains should be adjusted.

Adjust Chain Tension

1. Raise the loader following the “Loader Raising Procedure” (page 46).

2. Remove the tire from the axle to be adjusted.

3. Loosen (

DO NOT remove) the bolts holding the axle to the chaincase.

4. Front Chain Tension - To tighten the front chain, move the front axle

assembly towards the front of the loader. To loosen the chain, move the front axle assembly toward the rear of the loader.

Back Chain Tension - To tighten the back chain, move the rear axle assembly rearward. To loosen the chain, move the rear axle assembly toward the front of the loader.

5. After the proper tension is obtained, retighten the bolts. Important: Over-tightening the drive chain will cause premature drive

chain and axle sprocket wear.

6. Reinstall the tire.

7. Repeat Steps 2 through 6 for any axle requiring adjustment.

8. Lower the loaderfollowing the “LoaderLowering Procedure” (page46).

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Engine Air Cleaner

Important: Failure to follow proper filter servicing instructions could result in catastrophic engine damage.

The air cleaner consists of an outer (primary) filter element and an inner (secondary) filter element. An air filter restriction indicator for monitoring the condition of the elements is located on the right side of the front of the air cleaner. If the airfilter becomes restricted, this indicator turnsred to warn the operator that the element(s) require service. Push the reset button located at the end of the indicator after fitting a clean element. For replacement elements, refer to the “Replacement Parts” topic (page 45).

Note: Before replacing the filter element(s), push the reset button on the indicator. Start the engine and adjust the throttle to full speed. If the indicator does not turn red, do not replace the element(s).

The outer element should be replaced only when the restriction indicator turns red. The inner element should be replaced every third time the outer element is replaced, unlessthe outer element is damaged or the inner element is dirty.

Along with a daily check of the restriction indicator, check the air cleaner intake hose andclamps, and the mounting brackethardware for secureness.

Fig. 40: Dual Element Air Cleaner

1. Restriction Indicator

2. Element Housing

3. Inner Filter Element

4. Outer Filter Element

5. Element Cover

6. Dust Ejector

Access

1. Open the rear door and engine cover (page 47).

2. Unlatch the three latches on the air cleaner and remove the cover. Clean

out any dirt built up in the cover assembly.

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Outer Element

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

2. Clean out any dirt built up in the housing. Leave the inner element installed during thisstep to preventdebris from enteringthe engine intake manifold.

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

Note: Gehl does not recommend cleaning the outer element.

Inner Element

Note: Replace the inner elementonly if it isdirty or if theouter element has been replaced three times.

Before removing the inner element from the housing, clean out any dirt built up in the housing. Leave theinner element installedduring this step to prevent debris from enteringthe engine intake manifold. Removethe inner element.

Reinstallation

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

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

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

4. Secure the cover to the housing with the three clamps.

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

tightened properly.

6. Reset the indicator by pressing the reset button.

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Engine Service

Refer to the Maintenance IntervalChart (page 71)for change intervals.Refer to the “Replacement Parts” topic (page 45) for replacement part numbers.

Check Engine Mounting Hardware

All bolts that secure the engine mounting brackets to the engine and the loader frame should be checked and re-torqued as necessary. Refer to the Torque Specifications Chart (page 83) for torque information.

WARNING

Allow hot engine and hydraulic system

components to cool before servicing.

Fig. 41: Service Components

1. Air Cleaner 7. Muffler

2. Fuel Filter 8. Engine Oil Filter

3. Engine Oil Drain Valve 9. Engine Oil Dipstick

4. Engine Oil Fill Plug 10. Coolant Reservoir

5. Radiator/Cooler 11. Radiator Coolant Drain Valve

6. Engine Coolant Drain Valve 12. In-line Fuel Filter

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Check Oil Level

Open the rear door andengine cover (page47). Pull outthe dipstick andcheck the oil level. Markings on the dipstick represent

FULL and LOW (add oil)

levels.

Change Engine Oil and Filter

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

1. Run the engine until it is at operating temperature. Stop the engine.

2. Place a panunder the hose behind the left rear tire and then open the valve on the oil pan to drain the oil.

3. Remove the oil filter. Clean the filter sealing surface.

4. Put clean oil on the new oil filter gasket. Install and tighten the filter a ½ turn past the

Fig. 42: Remote Oil Drain

point where the gasket contacts the filter head.

5. Close the oil drain valve.

6. Remove the oil cap and add the recommended oil. Refer to the

“Lubrication” topic (page 49) for oil recommendations and capacities.

7. Start the engine and let it run for several minutes at low idle. Stop the engine. Check for leaks at the oil filter, drain valve and remote oil drain hose. Check theoil level. Addoil if itis not atthe top mark on the dipstick.

Change Spin-On Fuel Filter

1. Remove the filter element.

2. Lubricate the element gasket with diesel fuel.

3. Install and tighten the filter element a ½ turn past the point where the

gasket contacts the filter head.

The engine isself-priming, butif priming is needed, prime the filter assembly by loosening the bleed screw, and loosening and then stroking the lever until fuel runs out the bleed screw. Retighten the bleed screw and pump lever.

Change In-Line Fuel Filter

1. Loosen both clamps.

2. Replace the in-line filter.

3. Tighten clamps.

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Hydraulic System

Refer to the Maintenance IntervalChart (page 71)for service intervals.Refer to the “Replacement Parts” topic (page 45) for replacement part numbers.

WARNING

Before servicing the hydraulic system, be sure

the lift arm is lowered.

Check Filter Indicators

Hydraulic oil filter: An indicator on the instrument panel lights when the filter becomes restricted.

Hydrostatic oil filter: A visual indicator on the filter turns red if the filter becomes restricted.

Check Oil Level

The loader has asight gauge located on the left side of

the skid loader. Check the fluid level with the lift arm lowered and the attachment on the ground.

Add hydraulic fluid as required. Refer to the

“Lubrication” topic (page 49) for oil recommendations. Replace the cap.

Change Oil Filters

The loader has both a hydraulic oil filter and a hydrostatic oil filter.

Fig. 43

1. Sight Gauge

2. Oil Refill Location

1. Remove the right access panel (page 47). Unscrew the filters.

2. Clean the surface of thefilter housings where

the element seal contacts the housing. Put clean oil on the rubber gasket of the new filter element.

3. Install and tighten the filter element a ½ turn past the point where the gasket contacts the filter head.

Fig. 44: Oil Filters

1. Hydrostatic Oil Filter

2. Hydraulic Oil Filter

Change Oil

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

1. Unbolt the rear belly plate.

2. Install a catch pan of sufficient capacity under the oil reservoir

(15 gallons; 56,8 liters).

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3. Remove the drain plug located on the bottom left of the oil reservoir. Early Units:To drain the oil in earlier units, remove the belly plate and

disconnect the lowest fitting from the front of the hydraulic tank.

4. Change the oil filters.

5. Reinstall the drain plug (or fitting).

6. Refill the reservoir. Refer to the “Lubrication” topic (page 49) for oil

recommendations.

7. Start the engine and operate the hydraulic controls.

8. Stop the engineand check forleaks at thefilters and reservoirdrain plug.

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

10. Reinstall the rear belly plate.

Bucket Cutting Edge

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

Alternator/Fan Belt

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

Wheel Nuts

Wheel nut torque must be checked before initial operation and every two hours thereafter until the wheel mounting hardware torque setting stabilizes at the recommended setting 180 ft-lbs (244 N·m). When wheels are removed and replaced, this procedure must be repeated.

Lift Arm Pivots

The lift arm pivot points should be torqued to 240 ft-lbs (325 N·m). Refer to the Maintenance Interval Chart (page 71) for the service interval for the lift arm pivots.

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Cooling System

Important: Check the cooling system every day to prevent overheating, loss of performance and engine damage.

Refer to theMaintenance Interval Chart (page 71)for other serviceintervals.

Check Coolant Level

1. Remove the left access panel (page 47). Check that the coolant recovery tank is 1/3 to 1/2 full with a cold engine and 2/3 to 3/4 full with a hot engine.

2. Allow the coolant to cool. Do not remove the cap when the coolant is hot. Serious burns may occur.

3. Add premixed coolant, 50% water and 50% ethylene glycol, to the recovery tank if the coolant level is low.

Clean Cooling System

1. Park the loader on a level surface, lower the lift arm and stop the engine. Allow the machine to cool.

2. Open the rear door and engine cover (page 47).

3. Clean the radiator and oil cooler by blowing compressed air through the

fins.

Drain/Flush Cooling System

Note: Coolant must be drained from the radiator and the engine.

1. Open the rear door and engine cover. Remove the left access panel

(page 47).

2. Radiator - Openthe drain valve located onthe left sideof the radiatorand drain the coolant into a suitable container.

Engine - Open the drain valve located underneath the engine oil filter. The coolant will drain through a hose located behind the left rear tire. Drain the coolant into a suitable container.

3. Close the drain valves.

Note: Protect the cooling system by adding premixed 50% water and 50%

ethylene glycol to the system. This mixture will protect the cooling system to

-34°F (-36°C).

4. Fill the radiator fully and the recovery tank half full with the premixed coolant.

5. Reinstall the radiator cap.

6. Run the engine until it is at operating temperature. Stop the engine and let

it cool. Check the coolant level. Add more fluid if required.

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Tires

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

It is important to keep the same size tire on each side of the loader to prevent excessive wear on tires, chain and chaincase, or other damage. If different sizes are used, each tire will be turning at different speeds, causing excessive wear.

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

Mounting Tires

WARNING

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

Check Tire Pressure

Tire Size

14 x 17.5 12-ply Heavy Duty Flotation 50 345

Inflation Pressure

PSI kPa

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

Heater Filters

Loaders with the optional heater or heater/air conditioner include two filters: fresh air intake and recirculation air . Refer to the “Replacement Parts” topic (page 45) forreplacement part numbers. Filters shouldbe replaced asneeded.

Fresh Air Intake Filter: Located on the right side of the main unit. Tilt the ROPS back for access (page 47) and slide the filter out.

Recirculation Air Filter: Located on the front of the ROPS rear deck panel. Remove four screws and pull the filter out.

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Electrical System

Circuit Breakers

The circuit breakersfor the loader are locatedon the rightinstrument panel.

Battery

WARNING

system, be surethe battery disconnectswitch isin the

Before servicing the battery or electrical

OFF position.

The battery on the loader is a 12 volt, wet-cell battery, located under the operator’s seat. To access the battery, remove the two cover plates (refer to Figs. 45, 46). Remote battery terminals andthe battery disconnect switchare located at the rear of the loader.

Fig. 45: T-bar and Dual Hand Battery Cover Plates

Fig. 46: Hand/Foot Battery Cover Plates

The battery top must be kept clean. Clean it with an alkaline solution (ammonia or baking soda and water). After foaming has stopped, flush the battery top with clean water. Ifthe terminals and cable connection clamps are corroded or have a build-up, disconnect the cables and clean the terminals and clamps with the same alkaline solution.

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WARNING

Explosive gas is produced while a battery is in use orbeing charged. Keep flames or sparks away fromthe battery area. ALWAYS charge the battery in a well-ventilated area.

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

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

1. Immediately remove any clothing on which acid spills.

2. If acid contacts the skin, rinse the affected area with running

water for 10 to 15 minutes.

3. If acid contacts the eyes, flood the eyes with running water for

10 to 15 minutes. See a doctor at once. Never use any medication or eye drops unless prescribed by the doctor.

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

mixtures: a. 1 pound (0,5 kilogram) ofbaking soda in 1 gallon(4 liters)

of water

b. 1 pint (0,5 liters) of household ammonia in 1 gallon

(4 liters) of water

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

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TROUBLESHOOTING

Electrical System

Problem Possible Cause Remedy

Battery disconnect switch is

OFF.

20 ampere breakers are tripped.

Entire electrical system does not function.

No instrument panel lamps with keyswitch turned to “ON.”

Fuel gauge does not work.

Engine temperature gauge does not work.

Hourmeter does not work.

Starter will not engage when key is turned to

63 908274/BP1202

START.

Main wiring harness connectors at rear of ROPS not properly plugged in.

Battery terminals or cables are loose or corroded.

Battery is faulty. Test battery and replace as

20 ampere breaker tripped. Check circuit and locate

Battery terminals or cables are loose or corroded.

Faulty fuel gauge sender. Replace fuel gauge sender. Faulty fuel gauge. Replace fuel gauge. Loose wiring/terminal

connections. Faulty temperature sender. Replace temperature sender. Faulty temperature gauge. Replace temperature gauge. Loose wiring/terminal

connections. Loose wiring/terminal

connections. Faulty alternator. Repair the alternator. Faulty hour meter. Replace hour meter. Seat or restraint bar switch

malfunctioning or not activated.

Poor connections to starter relay in instrument panel.

Battery terminals or cables loose or corroded.

Faulty starter relay in instrument panel.

Battery discharged or defective.

Starter solenoid not functioning.

Ignition wiring, seat switch, restraint bar switch, etc. loose or disconnected.

Starter or pinion faulty. Remove starter;

Turn battery disconnect switch to ON.

Check circuit and locate trouble before resetting breaker.

Check main harness connectors.

Clean battery terminals and cables and retighten them.

needed.

trouble before resetting breaker.

Clean battery terminals and cables and retighten them.

Verify wiring connections.

Contact your dealer.

Verify relay connections.

Clean terminals, cables and retighten.

Contact your dealer.

Recharge or replace battery.

Contact your dealer.

Check wiring for poor connections, broken leads; repair wiring or connection.

repair/replace as needed.

Page 67

Electrical System

Problem Possible Cause Remedy

Work lights not functioning properly.

Lift/Tilt and/or drive lock solenoids do not work.

Single light doesn’t work: Light bulb burned out, faulty wiring.

No lights at all; 20 ampere breaker tripped.

Faulty light switch or poor ground.

Wiring to solenoids disconnected or faulty.

Restraint bar or seat switch malfunction.

Faulty solenoid valve coil. Contact your dealer. Faulty hydraulic solenoid

relay in instrument panel.

Check and replace light bulb as needed. Check wiring connection to light.

Check circuit and locate trouble before replacing fuse.

Replace light switch. Check ground wire connections.

Troubleshoot circuit, repair.

Contact your dealer.

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Engine

Problem Possible Cause Remedy

Engine turns over but will not start.

Engine overheats.

Engine cranking speed too slow.

Auxiliary valve engaged. Return the control valves to

Fuel tank empty. Refill fuel tank. Glow plug module

malfunctioning. Fuel shut-off solenoid not

energizing.

Engine oil not warm enough. Install a block heater. Ambient temperature is too

low. Fuel filter(s) plugged. Replace the filter(s) Fuel pump not working. Contact your dealer. Crankcase oil level too low or

too high. Fan air circulation blocked or

restricted. Fan shroud improperly

positioned. Grade of oil improper or

excessively dirty. Exhaust restricted. Allow exhaust to cool,

Air filter is restricted. Replace the filter(s). Low coolant level. Add coolant. Fan belt loose. Tighten fan belt.

Battery requires recharging or replacing, or, in cold temperatures, pre-warm the engine.

neutral.

Check connection and voltage, replace as needed.

Check electrical connections and voltage to shut-off solenoid.

Install a block heater.

Add or remove oil as required.

With engine OFF, remove blockage or restriction.

Contact your dealer.

Drain and replace with proper grade new oil.

remove restriction.

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Hydrostatic System

Problem Possible Cause Remedy

Hydrostatic (drive) system is noisy.

Left side doesn’t drive in either direction. Right side operates normally.

Left side doesn’t drive in forward direction.

Right side doesn’t drive in either direction. Left side operates normally.

Right side doesn’t drive in one direction.

Hydraulic oil viscosity is too heavy.

Air in hydraulic system. Cycle lift and tilt cylinders to

Drive motor(s) or hydrostatic pump(s) have internal damage or leakage.

Rear hydrostatic pump arm control lever loose.

Relief valves on rear hydrostatic pump malfunctioning.

Control rod linkage to rear hydrostatic pump disconnected.

Relief valve on rear hydrostatic pump is malfunctioning.

Rear hydrostatic pump malfunctioning.

Front hydrostatic pump arm control lever loose.

Relief valves on front hydrostatic pump malfunctioning.

Control rod linkage to front hydrostatic pump disconnected.

Relief valve on front hydrostatic pump is malfunctioning.

Front hydrostatic pump malfunctioning.

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

maximum stroke and maintain pressure for a short time to clear air from system. Also check for low oil level in reservoir, fill as needed.

Contact your dealer.

Tighten.

Contact your dealer.

Attach control rod linkage.

Contact your dealer.

Tighten.

Contact your dealer.

Attach control rod linkage.

Contact your dealer.

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Page 72

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Hydraulic System

Problem Possible Cause Remedy

Restraint bar is raised. Lower the restraint bar.

Auxiliary hydraulics do not function.

High flow auxiliary functions slowly.

High flow auxiliary does not function

Spool lock solenoid malfunctioning

Restraint bar or seat switch malfunctioning.

Load sense signal line loose or broken.

Load sense compensator not functioning.

High pressure compensator on pump not functioning.

Control linkage misadjusted. Check linkage, readjust for

Low engine speed. Operate engine at higher

Hydraulic oil level low. Add oil. Hydraulic oil viscosity is too

heavy. Restraint bar is raised. Lower the restraint bar. Spool lock solenoid

malfunctioning.

Restraint bar or seat switch malfunction.

Load sense signal line loose or broken.

Load sense compensation not functioning.

High pressure compensation on pump not functioning.

Check electrical connections to lock solenoid and repair connections as needed. If still not functioning properly, contact your dealer.

Contact your dealer.

Check line; tighten or replace if necessary.

Contact your dealer.

full spool travel.

speed.

Allow longer warming.

Check electrical connections to lock solenoid and repair connections as needed. If still not functioning properly, contact your dealer.

Contact your dealer.

Check line; tighten or replace if necessary.

Contact your dealer.

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Page 74

MAINTENANCE SCHEDULE

This Maintenance Interval Chart was developed to match the Service chapter of this manual. Detailed information on each service procedure may befound in the Service chapter. A Maintenance Log follows thechart forrecording the maintenance performed. Recording the 10 hour (or daily) service intervals would be impractical and is therefore not recommended.

Important: Under severe operating conditions more frequent service than the recommended intervals may be required. You must decide, based on your use, if your operation requires more frequent service.

Maintenance Interval Chart

Maximum Interval

Service Procedure

Foreign Material Removal (p48) l

Check Engine Air Cleaner Restriction Indicator

Check Engine Oil Level (p56) l Check Hydraulic Oil Level (p57) l Check Tire Pressures (p60) l

Grease Lift Arm, Hitch, Cylinder Pivots and Latch Pins

Check Bucket Cutting Edge (p58) l Test Safety Interlock System (p16) l Check Coolant Level (p59) l Clean Cooling System (p59) l Check Drive Chain Tension (p52) l Check Wheel Nuts Torque (p58) ml Check Lift Arm Torque (p58) l Check Oil Level in Chaincases (p51) l Check Alternator/Fan Belt Tensions (p58) l Change Engine Oil and Filter (p56) ov l Change Hydrostatic Oil Filter (p57) ol Change Hydraulic Oil Filter (p57) l Check Battery (p61) l Check Engine Mounting Hardware (p55) l Change Fuel Filters (p56) l Change Hydraulic Oil (p57) t Change Chaincase Oil (p51) ot Drain/Flush Cooling System (p59) l

(p53)

(p49)

10 Hours (or Daily)

250

Hours

500 Hours

(or Yearly)

m Perform the initial procedure at 2 hours then at “l” intervals. o Perform the initial procedure at 50 hours then at “l”or“t” intervals. v Severe operating conditions. t Perform the procedure at 1000 hours.

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Maintenance Log

Date Hours Service Procedure

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Maintenance Log

Date Hours Service Procedure

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Maintenance Log

Date Hours Service Procedure

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Page 78

SPECIFICATIONS

Loader Specifications

Operating Weight

7600 9745 lb (4420 kg) 7800 9955 lb (4515 kg)

Shipping Weight

7600 8040 lb (3650 kg) 7800 8175 lb (3710 kg)

SAE Rated Operating Load

7600 3150 lb (1429 kg) 7800 3600 lb (1633 kg)

Engine

Make Yanmar Model

7600 4TNE106

7800 4TNE106T Displacement 269 in Power (net) @ 2500 rpm

4TNE106 90 hp (67 kW)

4TNE106T 110 hp (82 kW) Peak Torque @ 1600 rpm

4TNE106 240 lb-ft (325 N·m)

4TNE106T 301 lb-ft (408 N·m)

Hydraulic System (theoretical)

Main Hydraulic System Pressure 3300 psi (228 bar) Standard Flow Rating 40 gpm (151 L/min)

Electrical

Battery 12 Volt DC with 950 CCA min. Starter 12 Volt DC (3 kW) Alternator 60 amperes

Capacities

Chaincase (each) 3 U.S. gal (11,4 L) Engine Oil 14.8 U.S. qts (14 L) Fuel Tank 29.5 U.S. gal (112 L) Hydraulic Reservoir 15 U.S. gal (56,8 L)

Sound Levels (with Deluxe Sound Kit)

Pressure Level (Operator Ear) 92 dB(A) Power Level (Environmental) 106 dB(A)

Operating load rated with an 82” (2083 mm) (7600 - 21 ft3;7800-27ft3) dirt/construction bucket in

accordance with SAE J818.

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Page 79

Standard Features

Fuel Gauge

Engine Coolant Temperature Gauge

and Light

Hourmeter

Oil Pressure, Battery Charge

Indicator

Seatbelt Indicator Light and Buzzer

Choice of three control types:

T-Bar, Hand & Foot or Dual Hand

Foot Throttle (T-Bar and Dual Hand only)

Acoustical Material, Floor Mat and

Headliner

Adjustable Operator Restraint Bar

with Armrests

Hydraulic Lift ROPS

Fixed-Top Window and Opening

Rear Window

Full Suspension Adjustable Seat

(7800 only)

ROPS-FOPS ISO Level II

Number 100HK Drive Chain

Ü Ü

Skid Plate for Clean Out

Hydraulic Oil Filter Indicator Light

Horn

Interior Dome Light

Hydraloc™ System – Brakes and

Interlock for Starter, Lift Cylinders, Tilt Cylinders, Wheel Drives, Auxiliary and High Flow Hydraulics

Dual Element Air Cleaner with Visual

Indicator Anti-Vandalism Tailgate/Step for

Service Access Glow Plug Starting Assist

Servo-Controlled Hydrostatic Drive

Lift Arm Support Device

Self-Leveling Lift Action

Independent Steel Hydraulic

Reservoir Dual Front & Rear Halogen Work

Lights and Dual Tail Lights Bi-directional Adjustable Flow

Auxiliary Hydraulics with Flush-Faced Couplers

Powerview® Vertical Path Lift Arm

Choice of All-Tach™Attachment

Mounting System: Single Lever (Manual) or Power

Bi-directional High Flow Auxiliary Hydraulics with Flush-Faced Couplers

(7800 only)

Remote Battery Jump Terminals

Battery Disconnect Switch

Engine Auto-Shutdown System

Accessories

3-inch Wide Seatbelt –

When Required by Law

Sliding Side Windows

Deluxe Sound Package

Rear View Mirror

Suspension Seat (option on 7600)

Impact-Resistant Front Door

Front Door with Wiper

Operator’s Compartment

Heater/Defroster/Air Conditioner

Audible Back-Up Alarm

908274/BP1202 76

Strobe Light

Dual Flasher Kit

Bucket Bolt-On Cutting Edge Kits

Four-Point Lift Kit

Single-Point Lift Kit

Hydraulic Couplers Kit

Centrifugal Pre-Cleaner

Engine Block Heater

2-Speed Transmission

(option on 7600)

Diesel Engine Exhaust Purifier

Hydraglide™ Ride Control System

Page 80

Dimensional Specifications

R Q

Overall Operation Height - Fully Raised

Height to Hinge Pin - Fully Raised

Overall Height - Top of ROPS

Ground Clearance - to Chassis (Between Wheels)

Overall Length - Bucket Down

Overall Length (Less Bucket)

Wheel Base - Nominal

Dump Reach - Bucket Full Height

Rollback at Ground

Dump Angle at Full Height

Overall Width - Less Bucket

Bucket Width - Overall

Clearance Circle - Rear

Clearance Circle - Front (Less Bucket)

Clearance Circle - Front (With Bucket)

Seat to Ground Height

Rollback Angle at Full Height

Dump Height

Departure Angle

Reach Maximum (Bucket Flat)

Maximum Back Grading Angle

3/4 Yd3Bucket

w/14 X 17.5 Tires

1Yd3Bucket

w/14 X 17.5 Tires

inches (mm) inches (mm)

185.8 (4719) 189.3 (4808)

142.0 (3607) 142.0 (3607)

81.1 (2060) 81.1 (2060)

9.1 (231) 9.1 (231)

155.8 (3957) 159.3 (4046)

117.5 (2985) 117.5 (2985)

54.3 (1379) 54.3 (1379)

33.0 (838) 36 (914)

28° 28°

40° 40°

80.3 (2040) 80.3 (2040)

84.0 (2134) 84.0 (2134)

72.0 (1829) 72.0 (1829)

58.3 (1481) 58.3 (1481)

98.1 (2492) 101.3 (2573)

40.5 (1029) 40.5 (1029)

97° 97°

108.0 (2743) 105.7 (2685)

30° 30°

48.5 (1232) 52.0 (1321)

86° 86°

77 908274/BP1202

Page 81

Capacities and Ratings

Note: Use theTable of Common Materials andDensities (page 79) for selecting the appropriate bucket.

Dirt / Construction Buckets

Description

82/84” 21 ft

82/84” 27 ft

(2083/2121 mm 0.6 m3)

(2083/2121 mm 0.8 m3)

Weight 7600 Rating 7800 Rating

660 lb

(300 kg)

700 lb

(318 kg)

3150 lb

(1430 kg)

3050 lb

(1383 kg)

3700 lb

(1678 kg)

3600

(1633 kg)

Pallet Forks @ 24” (1610 mm) Load Center

Description Weight 7600 Rating 7800 Rating

48" (1219 mm) Forks with Backrest

inner/outer dimensions give

450 lb

(204 kg)

2270 lb

(1030 kg)

2680 lb

(1216 kg)

908274/BP1202 78

Page 82

Table of Common Materials and Densities

Material

Ashes

Brick-common

Cement

Charcoal

Clay, Wet-Dry

Coal

Concrete

Cinders

Coal-anthracite

Coke

Earth-dry loam

Earth-wet loam

Granite

Gravel-dry

Gravel-wet

Gypsum-crushed

Iron Ore

Lime

Lime Stone

Manure-liquid

Manure-solid

Peat-solid

Phosphate-granular

Potash

Quartz-granular

Salt-dry

Salt-Rock-solid

Sand-dry

Sand-wet

Sand-foundry

Shale-crushed

Slag-crushed

Snow

Taconite

(lb/ft

35-50 560-800

112 1792 110 1760

23 368

80-100 1280-1600

53-63 848-1008

115 1840

50 800 94 1504 30 480

70-90 1121-1442 80-100 1281-1602 93-111 1488-1776

100 1602 120 1922 115 1840 145 2320

60 960 90 1440 65 1040 45 720 47 752 90 1440

68 1088 110 1760 100 1602 135 2160 108 1728 125 2000

95 1520

90 1440

70 1120

15-50 240-800

107 1712

Note: The densities listed are average values and intended only as a guide for bucket selection. For a material that is not in the table, obtain its density value before selecting the appropriate bucket.

Density

) (kg/m3)

79 908274/BP1202

Page 83

To use the table, find the material name and see what its maximum density is. Then, multiply the loader rating of the attachment by the material density to determine if the attachment can safely be used. See page 78 for a listing of attachments and their loader ratings.

Note: Where the material density is listed as a range (clay at 80-100 lb/ft example), always use the maximum density (100 lb/ft

in this example) for

, for

making calculations. Also, see the following examples.

Example 1: If clay (density of 80-100 lb/ft model loader using a 27 ft

27 ft

and the loader rating is 3600lb. Multiply the density ofclay (100 lb/ft3)

Dirt/Construction Bucket, the bucket capacity is

by the capacity of the bucket (27 ft (100 lb/ft

x27ft3= 2700 lb). This number is less than the machine rating so

) is to be hauled using an SL7800

) to achieve the weight being carried

you could safely use this bucket in this application.

Example 2: If granite (density of 1488-1776 kg/m SL7600 model loader using a 21 ft capacity is 0.6 m granite (1776 kg/m

and the loader rating is 1430 kg. Multiply the density of

) by the capacity of the bucket (0.6 m3) to achieve the

weight being carried (1776 kg/m

Dirt/Construction Bucket, the bucket

x 0.6 m3= 1066 kg). This number is less

) is to be hauled using an

than the machinerating so you could safelyuse this bucketin this application.

908274/BP1202 80

Page 84

INDEX

Accessory Plug .................19

Adjustments ....................48

Control Handles ..............48

Engine Speed Control .........48

Fuel Sender .................48

Air Conditioner

See Heater

Alternator/Fan Belt ...............58

Attachments .................21,37

Capacities and Ratings ........78

Auxiliary Hydraulic Controls

High Flow ..................32

Standard Flow ...............31

Battery ........................61

Disconnect Switch ............16

Jump-starting ................36

Bucket Cutting Edge .............58

Bucket, Usage ..................39

Digging with a Bucket..........39

Driving on an Incline...........39

Driving over Rough Terrain .....39

Dumping Into a Box ...........40

Dumping Onto a Pile ..........40

Dumping Over an Embankment. . 40

Leveling the Ground...........41

Loading a Bucket .............40

Scraping with a Bucket.........41

Cooling System .................59

Check Coolant Level ..........59

Clean ......................59

Drain/Flush..................59

Dealer Services .................45

Drive Chains

Adjust Chain Tension ..........52

Check Chain Tension..........52

Dual Hand Controls ..............29

Auxiliary Hydraulic Controls .....31

Drive Control ................29

Lift/Tilt Control ...............30

Emergency Exit .................17

Engine Air Cleaner...............53

Engine Compartment Access ......47

Engine Mounting Hardware ........55

Engine Service

Change Fuel Filters ...........56

Change Oil and Filter ..........56

Check Oil Level ..............56

Foreign Material Removal .........48

Guards and Shields ..............15

Chaincases ....................51

Checking and Adding Oil .......51

Draining Oil .................51

Circuit Breakers .................61

Cold Starting Procedure...........35

Control/Indicator Symbols ..........4

CONTROLS AND SAFETY EQUIPMENT 15

81 908274/BP1202

Hand/Foot Controls ..............27

Auxiliary Hydraulic Controls .....31

Drive Controls ...............27

Lift/Tilt Controls ..............28

Heater

Filter Service ................60

Operation ...................19

Heater and Air Conditioner

See Heater

Highway Travel .................42

Page 85

Horn ..........................17

Hydraulic System ................57

Change Oil ..................57

Change Oil Filters ............57

Check Filter Indicators .........57

Check Oil Level ..............57

Instrument Panel................22

INTRODUCTION ..................1

Lift Arm Pivots ..................58

Lift Arm Support Device ...........17

Loader

Lifting ......................44

Lowering Procedure ...........46

Raising Procedure ............46

Storing .....................42

Towing .....................42

Transporting ................43

Lubrication .....................49

ROPS/FOPS ...................17

Tilting Back..................47

Safety Decals....................8

New Decal Application ..........8

No-Text Decals ..............12

Text Decals ..................9

Safety Interlock System ...........16

Testing .....................16

Safety Reminders ................6

Self-Leveling ...................38

SERVICE .......................45

SPECIFICATIONS ................75

Accessories .................76

Dimensional Specifications .....77

Loader Specifications..........75

Standard Features ............76

Speed Control ..................20

Starting the Engine ..............34

Before Starting the Engine ......34

Stopping the Loader..............35

MAINTENANCE SCHEDULE

Maintenance Interval Chart .....71

Maintenance Log ........72,73,74

Mandatory Safety Shutdown

Procedure ......................6

Model Identification ...............3

OPERATION ....................34

Operator Restraint Bar............15

Operator’s Seat .................15

Parking Brake ..................17

Parking the Loader...............35

Potential Hazards.................8

Table of Common Materials & Densities 79

T-Bar Controls ..................25

Auxiliary Hydraulic Controls .....31

Drive Control ................25

Lift/Tilt Control ...............26

Tires .........................60

Check Tire Pressure ..........60

Mounting Tires ...............60

TORQUE SPECIFICATIONS .........83

TROUBLESHOOTING

Electrical System .............63

Engine .....................65

Hydraulic System .............68

Hydrostatic System ...........66

Two-Speed Transmission .........20

Replacement Parts ..............45

Ride Control System .............20

908274/BP1202 82

WARRANTY.....................84

Wheel Nuts ....................58

Page 86

TORQUE SPECIFICATIONS

Use these torque values when tightening hardware (excluding: locknuts, and self-tapping, thread forming, and sheet metal screws) unless otherwise specified.

UNIFIED

NATIONAL

THREAD

8-32

8-36 10-24 10-32

GRADE 2 GRADE 5 GRADE 8

DRY LUBED DRY LUBED DRY LUBED

19* 20* 27* 31*

14* 15* 21* 23*

30* 31* 43* 49*

22* 23* 32* 36*

41* 43* 60* 68*

31* 32* 45* 51*

1/4-20

1/4-28 5/16-18 5/16-24

3/8-16

3/8-24 7/16-14 7/16-20

1/2-13

1/2-20 9/16-12 9/16-18

5/8-11

5/8-18

3/4-10

3/4-16

7/8-9

7/8-14

1-8

1-12

METRIC COARSE THREAD

M6-1 M8-1.25 M10-1.5

66* 76*

11 12

20 23 32 36

50 55 70 80

100 110 175 200

170 180 250 270

GRADE 8.8 GRADE 10.9 GRADE 12.9

DRY LUBED DRY LUBED DRY LUBED

37.5

50* 56*

15 17 24 27

35 40 55 60

85 130 150

125 140 190 210

6 14 28

9 9

10 17 19

30 35 50 55

90 110 120

150 180 260 300

430 470 640 710

11 27 53

75* 86*

13 14

23 25 35 40

55 65 80 90

110 130 200 220

320 360 480 530

8 20 39

12 14 25 25

45 50 70 80

110 120 150 170

220 240 380 420

600 660 900

1000

13.5

32.5 64

9 10 18 20

35 35 55 60

80 90

110 130

170 180 280 320

460 500 680 740

10 24 47

M12-1.75

M14-2 M16-2

*All Torque Values are in ft-lbs except those marked with an * which are in in-lbs.

For metric torque value (N·m) multiply ft-lbs value by 1.355 or the in-lbs value by 0.113.

83 908274/BP1202

103.5

158.5

76.5

117.5

91.5

145.5

223.5

67.5 108

165.5

111.5

176.5 271

82 131 200

Page 87

GEHL CONSTRUCTION

WARRANTY

GEHL CONSTRUCTION DIVISION of the GEHL COMPANY, hereinafter

referred to as Gehl, warrants new Gehl construction equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months from the Warranty Start Date, except as set forth below.

GEHL CONSTRUCTION WARRANTY SERVICE INCLUDES:

Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer’s business location.

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

GEHL WARRANTY SERVICE DOES NOT INCLUDE:

1. Transportation to selling dealer’s business location or, at the

option of the Original Retail Purchaser,the costof aservice call.

2. Used equipment.

3. Components covered by their own non-Gehl warranties, such as

tires, trade accessories and engines.

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

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

recommended maintenance procedures; use of unauthorized parts or attachments; accident or other casualty.

6. Liability for incidental or consequential damages of any type,

including, but not limited to lost profits or expenses of acquiring replacement equipment.

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

Page 88

Page 89

WRONG

Never exceed rated operating load.

WRONG

Never carry riders.

Keep bystanders away from work area.

WRONG

Always carry attachments as low as possible. Do not travel or turn with the lift arms raised. Load, unload and turn on flat level

WRONG

Never modify equipment.

Use only attachments approved for this model loader.

Never leave loader with engine running or with lift arm up. To park, engage parking brake and put attachment flat on the ground.

Page 90

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 carefully read and thoroughly understand the contents of this Operator’s Manual.

Failure to follow safety, operating and maintenance instructions can result in serious injury to the operator or bystanders, poor operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or maintenance of 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 or other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects orother reproductive harm.Wash hands afterhandling battery.

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

www.gehl.com

Gehl SL7600, SL7800 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual