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3640E/3840E/4240E Operator`s Manual

1. 917334 BP0310 Notes 4 917334 BP0310 CHAPTER 2 SAFETY This safety alert symbol means Attention Become alert Your safety is involved It stresses an attitude of Heads Up for Safety and can be found throughout this Operator s Manual and on the decals on the machine Before operating this machine read and study the following safety information For further reference on the safe operation of skid steer loaders Gehl Company suggests that equipment owners obtain the Gehl Skid Steer Loader Safety video which is available through Gehl dealers 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 thor oughly 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 insta bility 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 whe
2. 00 eee 67 SBOGITIGABOFIS 5 2 3 ous toot teen Go ana eere Pe diced 71 Table of Common Materials and Densities 76 Torque Specifications 5 issue Fae ee Peewee 79 nje s quce EE ee Sa ae 81 Loader Model Number Loader Serial Number Engine Serial Number All Tach and Hydraloc are trademarks of Gehl Company Gehl and Powerview are registered trademarks of Gehl Company 9 E HL EC DECLARATION OF CONFORMITY Manufacturer Gehl Company Address One Gehl Way West Bend WI 53095 U S A FAX 262 334 6687 Technical Construction File Location Attn Quality Manager 915 SW 7th St Madison SD 57042 U S A Authorized Representative Gehl Europe GmbH Address Burgsteinfurter Damm 89 D 48485 Neuenkirchen Rheine GERMANY We hereby declare that the model s listed below conforms to EC Directives 2004 108 EC EMC 97 23 EC Pressure Equipment 2006 42 EC Machinery and 2000 14 EC Noise Emission including all current amendments In accordance with EN ISO Standards EN ISO 3450 1996 ISO 6165 Category EARTH MOVING MACHINERY LOADERS COMPACT Model s 3840E 4240E 10 Directive Conformity Assessment Procedure Notified Body 2004 108 EC Type test Self certification 97 23 EC Self certification 2006 42 EC Self certification 2000 14 EC Annex VIII Full TUV Industrie Service Quality Assurance
3. 137683 Located on ROPS left panel AVOID INJURY OR DEATH C Maintain 3 point contact during entry and exit O Inspect work area avoid all hazards C Look in direction of travel Keep children and bystanders away LJ Start and operate machine only from seat A DANGER C Never carry riders Do not lift personnel in bucket C Operate only in well ventilated area AVOID OVERTURN C Keep away from electric AVOID INJURY OR DEATH power lines avoid contact C Keep hands feet and body inside cab when operating C Carry lead low Wear seatbelt C Keep cut from under Mt arm unless ER arm C Do not exceed Rated Operating Load C Do not wear loose clothing while C Avoid ste s ee ee operating or servicing machine is supported C Abways follow Mandatory Safety Shutdown Procedure C Travel up and down slopes with heavy end uphil C Wear any needed Personal Protective Equipment 137039 137647 Located on operator s lower left side 137639 Located on ROPS left panel 917334 BP0310 Safety Decals on the outside of the Skid Loader Hose removal or component failure can cause lift arm to drop Always use lift arm support device when leaving lift arm raised for service Be sure lock mechanism is securely engaged before working under ROPS FOPS Read instructions for use in Operator s Manual 184214 184214
4. 917334 BP0310 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 DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE LOADER TO TIP THROWING THE OPERATOR OUT OF THE SEAT OR LOADER RESULTING IN DEATH OR SERIOUS INJURY Therefore ALWAYS operate with the seatbelt fastened and the restraint bar lowered Do not exceed the machine s Rated Operating Load Carry the load low Move the controls smoothly and gradually and operate at speeds appro priate for the conditions When operating on inclines or ramps always travel with the heavier end of the loader toward the top of the incline for additional stability Do not raise or drop a loaded bucket or fork suddenly Abrupt movements under load can cause serious instability Never activate the float function with the bucket or attachment loaded or raised because this will cause the 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 oper atin
5. 6 Do not weld braze or otherwise attempt to repair and use a damaged rim 917334 BP0310 53 Checking Tire Pressure Inflation Pressure Tire Size psi kPa 10 x 16 5 8 ply Heavy Duty Flotation 60 414 27 x 8 5 15 8 ply Heavy Duty 60 414 27 x 10 5 15 8 ply Heavy Duty 60 414 6 5 x 16 5 50 Solid Rubber 7 00 15 SS Chevron Narrow 8 ply 60 414 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 When installing tires be sure they are the same size and style on each side of the loader Always replace tires with the same size as the original equipment Electrical System Circuit Breakers The circuit breakers for the loader are located on the right instrument panel There is also a 35 amp main circuit breaker located on the right side of the engine compartment directly behind the ROPS FOPS 54 917334 BP0310 Battery Before servicing the battery or electrical PN WARNING system be sure the battery disconnect switch if equipped is in the OFF position If not equipped with a discon nect switch disconnect the ground terminal from battery The battery on the loader is a 12 volt wet cell battery To access the battery open the rear door and lift the engine cover The battery top must be kept clean Clean it with an alkaline solution ammonia or b
6. GmbH T V SUD Group Westendst 199 D 80686 Munchen GERMANY CHAPTER 1 INTRODUCTION This Operator s Manual provides the owner operator information about main taining and servicing SL3640E SL3840E EU and SL4240E skid steer loader models More importantly this manual provides an operating plan for safe and proper use of the machine Major points of safe operation are detailed in the Safety chapter of this manual 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 those messages it will improve your operating and maintenance efficiency help avoid break downs 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 also available in Spanish 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 appli
7. Jerky lift arm and bucket action Seat or restraint bar switch malfunction Air in the hydraulic system Oil in hydraulic reservoir is low Check electrical connections to the switches Replace as needed Cycle lift tilt cylinders to maximum stroke and maintain pressure for short time to clear air from system Check and add oil Bucket drifts downward with tilt control in neutral No down pressure on the bucket Oil leaking past tilt cylinder seals internal or external Self leveling valve is malfunctioning Leaking hydraulic hoses tubes or fittings between control valve and cylinders Control valve in float position Tilt cylinders are malfunctioning Relief valve in control valve not functioning properly Squealing noise should be evident while operating Contact your dealer Contact your dealer Inspect hoses and tubes tighten fittings Replace hoses or tubes as needed Take control out of float position Contact your dealer Contact your dealer Bucket will not tilt lift arms work properly Tilt solenoid valve malfunctioning Tilt spool in control valve not actuated or leaking Check electrical connections to tilt solenoid and repair connections as needed If tilt solenoid valves are still not functioning properly contact your dealer Check valve control linkage and or tube connections to valve Slow or no response for bucket tilt lift wor
8. 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 can be obtained from your Gehl dealer New equipment must have all decals specified by the manufacturer affixed in their proper locations 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 align ment 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 locations Text decals begin on page 9 no text decals begin on page 12 8 917334 BP0310 Safety Decals inside the ROPS FOPS AVOID INJURY OR DEATH C Read Operator s Manual and all safety signs before using machine AVOID INJURY OR DEATH Always follow Mandatory Safety Shutdown Procedure C The owner is responsible to ensure all users are instructed on safe use and maintenance C Check machine before operating Service per Operators Manual LJ Contact dealer or manufacturer for information and service parts 137628 Located on manual box operator s right 1 Lower equipment to ground 2 Reduce throttle stop engine 3 Apply park brake remove key 4 Check safety interlocks
9. Check for low oil level in reservoir Add oil Contact your dealer Contact your dealer 60 917334 BP0310 Hydrostatic System Problem Possible Cause Remedy Hydrostatic drive is overheating Drive system overloaded continuously Lift tilt or auxiliary system overloaded continuously Drive motor s or hydrostatic pump s have internal damage or leakage Oil cooler fins plugged with debris Loader being operated in a high temperature area with no air circulation Improve efficiency of operation Improve efficiency of operation Contact your dealer Clean oil cooler fins Reduce duty cycle improve air circulation 917334 BP0310 61 Hydrostatic System Problem Possible Cause Remedy Hydrostatic drive system is noisy Right side doesn t drive in either direction Left side operates normally Hydraulic oil viscosity is too heavy Air in hydraulic system Drive motor s or hydrostatic pump s have internal damage or leakage Rear hydrostatic pump arm control shaft key missing Relief valves on rear hydrostatic pump malfunctioning Control rod linkage to rear hydrostatic pump disconnected Allow longer warm up or replace existing oil with the proper viscosity oil Cycle lift and tilt cylinders to maximum stroke and maintain pressure for a short time to clear air from system Also check for low oil
10. 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 917334 BP0310 1 Loader Identification 1 Upright 6 Lift Arm 2 Lift Cylinder 7 Auxiliary Hydraulic 3 Tires Couplers 4 Front Work Lights 8 Tilt Cylinders 5 Handholds 9 Attachment Bracket 1 Engine Cover 5 Roll Over Falling Object 2 Tail Lights Protective Structure 3 Rear Work Lights ROPS FOPS 4 Rear Door 6 Restraint Bar 2 917334 BP0310 Control Indicator Symbols 4 A Js Power Off Power On Engine Start Hazard Flasher Worklight tse L Worklight w Flasher Battery Charge Parking Brake Read Operator s Horn Manual Volume Full Volume Half Full Volume Empty Pre Heat Diesel Fuel Lift Point Neutral Safety Alert Chaincase Oil Seatbelt Lap Only oy Bi ho boa Engine Air Filter Engine Oil Engine Oil Filter Engine Oil Pressure Fuel Filter Oy o o L i E CA Engine Coolant Hydraulic System Hydraulic Oil Hydraulic Oil Filter Grease Lubrication Temperature Temperature Point roca rv I I I I I I A l I 1 I 1 Laud Land Tie Down Machine Travel Machine Travel Clockwise Rotation EUM Forward Reverse otation 48 NJ Fast Slow Bucket Lower Bucket Raise Bucket Float Wh Bucket Rollback p Bucket Dump
11. Check electrical connections to solenoid Repair or replace as needed Lower restraint bar Check electrical connections to the switch Replace switch as needed 917334 BP0310 65 Notes 66 917334 BP0310 CHAPTER 7 MAINTENANCE SCHEDULE This Maintenance Interval Chart was developed to match the Service chapter of this manual Detailed information on each service procedure can be found in the Service chapter A Maintenance Log follows the chart for recording the mainte nance 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 10 Hours 500 Hours 250 Hours or Daily or Yearly Check Engine Air Cleaner Restriction Indicator e page 45 Check Engine Oil Level page 47 Check Hydraulic Oil Level page 50 Check Tire Pressures page 54 Grease Lift Arm Hitch and Cylinder Pivots page 44 Check Bucket Cutting Edge page 49 Check Seat and Restraint Bar Operation page 52 Check Coolant Level page 51 Clean Cooling System page 51 Check Wheel Nuts Torque page 53 Check Oil Level in Chaincases page 52 Clean Spark Arrestor Muffler page 49 Check Alternator Fan
12. The owner is responsible to ensure all users are instructed on safe use and maintenance 137847 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 137849 Part of left instrument panel 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 12 917334 BP0310 ISO Style used Internationally Safety Decals on the outside of the Skid Steer Loader 137844 Located on front of loader A Crush hazard Keep out from under work tool unless lift arm is supported B Fall hazard No riders Never use work tool as work pl
13. Under ROPS 44 DANGER AVOID INJURY OR DEATH C No riders Never use work tool as work platform 137655 Front of loader AVOID INJURY OR DEATH Before operating with attachment check engagement of loader attachment bracket locking pin to the attachment 137720 Front of loader 10 917334 BP0310 Safety Decals in the Engine Compartment AVOID INJURY OR DEATH LJ Keep safety devices working CO Keep guards screens and windows in place O Jump start per Operator s Manual procedure C Do not smoke while fueling or servicing machine O Clean debris from engine compartment daily to avoid fire Keep fire extinguisher nearby C Do not use hands to find hydraulic leaks Escaping oil under pressure can be invisible and penetrate skin O Allow radiator to cool before removing cap Loosen cap slowly to avoid burns 137657 137657 Right of hydraulic filter ROTATING FAN HOT SURFACE Keep hands out Do not touch hot engine or or stop engine hydraulic system parts 137658 On radiator 917334 BP0310 11 ISO Style used Internationally Safety Decals inside the ROPS FOPS Safety alert Always follow Mandatory Safety Shutdown Procedure in Operator s Manual 1 Lower equipment to ground 2 Reduce throttle stop engine 137842 Located on manual 3 Pd parking brake remove storage box ey Safety alert Read Operator s A Check safetyinterlocks Manual and all safety signs before using machine
14. be kept in proper operating condition at all times The following steps ensure correct usage The safest method of engaging the lift arm sup A WARNING port device requires two people one person inside the loader and another person to engage the support device Note With the keyswitch OFF and the solenoid valve working 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 and it begins to lower do not leave the operator s compart ment Instead have someone store the support device for you Then contact your Gehl dealer immediately to determine why the lift arm lowers while the keyswitch is OFF 20 917334 BP0310 Engagement Always engage the lift arm support device A WARNING before leaving the operator s compartment to work on the loader with the lift arm raised To engage the lift arm support device l 2 3 Lower the lift arm fully onto the loader frame Stop the engine Leave the operator s compartment Remove the lock pin holding the support device up against the lift arm Allow the support device to drop down into contact with the lift cylin der Return to the operator s compartment neue 4 Fro Em Sapper and start the engine evice Engage Raise the lift arm until the lift arm support device drops over the end of the lift cylinder and around the cylinder rod Slowly lower the lift arm until the support device contacts the top
15. end of the lift cylinder Be sure the support device is secure against the cylinder end Then stop the engine remove the key and leave the operator s compartment 917334 BP0310 21 Disengagement Never leave the operator s compartment to dis A WARNING engage the lift arm support device with the engine running To return the lift arm support device to its storage position 1 Raise the lift arm completely 2 Stop the engine remove the key and take it with you Figure 5 Lock Pin in storage Position Before testing the loader always clear people A WARNING from the area 3 Before leaving the operator s compartment be sure that the lift arm is being held in the raised position by the solenoid valve 4 To store the support device raise it up until it contacts the lift arm Slide the lock pin through the support device and catch under the lift arm Once the pin is secure flip the lock pin loop so that it locks the pin in Accessory Outlet The optional 12 volt accessory outlet is located at the bottom of the left instru ment panel 22 917334 BP0310 Engine 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 rear ward to decrease the engine speed T Bar Controls Only A right foot operated accelerator pedal is provided to control the engine speed The pedal linkage is spring loaded to return to
16. level in reservoir fill as needed Contact your dealer Contact your dealer Contact your dealer Attach control rod linkage Right side doesn t drive in forward direction Left side doesn t drive in either direction Right side operates normally Relief valve on rear hydrostatic pump is malfunctioning Rear hydrostatic pump malfunctioning Key missing on front hydrostatic pump arm control shaft Relief valves on front hydrostatic pump malfunctioning Control rod linkage to front hydrostatic pump disconnected Contact your dealer Contact your dealer Contact your dealer Contact your dealer Attach control rod linkage Left side doesn t drive in one direction Relief valve on front hydrostatic pump is malfunctioning Front hydrostatic pump malfunctioning Contact your dealer Contact your dealer 62 917334 BP0310 Hydraulic System Problem Possible Cause Remedy Lift Tilt controls fail to respond Auxiliary hydraulics do not function Hydraulic oil viscosity is too heavy Hydraulic oil level is low Solenoid valve s malfunctioning Restraint bar or seat switch malfunction Restraint bar is raised Lock solenoid malfunctioning Restraint bar switch malfunctioning Allow longer warm up or replace with proper viscosity oil Check oil level in reservoir If oil is low check for an external leak Rep
17. remove the oil filter Clean the filter sealing surface 4 Put clean oil on the new oil filter gasket Install the filter and tighten 3 4 of a turn past the point where the gas Figure 29 Rear Belly Pan ket contacts the filter head 5 Reinstall and tighten the drain plug 6 Remove the oil cap and add the recommended oil Refer to the Lubrication topic in this chapter for oil specifications 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 plug and remote oil drain hose Check the oil level Add oil if it is not at the top mark on the dipstick For a replacement element refer to the Replacement Parts topic page 43 Changing Fuel Filter The engine has a fuel filter located on the left side of the engine To change it 1 Shut off the fuel supply by turning the fuel shutoff valve on top of the water trap Shut off return line by turning valve on the fuel tank Remove the fuel filter element Lubricate new fuel filter element gasket with diesel fuel UV deco T9 Install and tighten the filter element one half turn past point the where the gasket contacts the filter head 6 Turn shutoff valve on water separator to ON 7 Turn on the fuel supply at fuel tank The engine is self priming To remove air before starting turn the ignition key to the ON position for 30 seconds For a replacement element refer to the R
18. special operating procedures Read and thoroughly understand all safety A WARNING decals on the loader before operating it Do not operate the loader unless all factory installed guards 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 is wired in series with the seat switch forming an interlock for the lift arm tilt drive and starter circuits refer to the Safety Interlock System topic on page 18 for more information Never defeat the operator restraint bar or seat A WARNING switch electrically or mechanically Always wear your seatbelt 917334 BP0310 17 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 Figure 1 Operator s Seat 1 Restraint Bar 2 Seatbelt 3 Seat Adjustment Level Upper Torso Restraint ALWAYS wear the upper torso restraint when PN WARNING operating skid steer The seat belt should always be fastened during operation Important Inspect the seat belt s for damage before use and replace if dam aged Keep seatbelt s clean Use only soap and water to wash seat belt s Cleaning solvents can cause damage to seatbelt s Safety Int
19. the adjusted hand operated throttle setting Figure 7 Foot Pedal T Bar 917334 BP0310 23 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 1 Hourmeter Displays the total operating hours on the loader 2 Fuel Level Gauge Displays the amount of fuel in the tank 3 Engine Coolant Temperature Gauge Indicates the engine coolant temperature Note Items 4 through 9 are indicator lamps which display the following 4 Fasten Seatbelt A momentary visual and audible indicator to remind the operator to fasten the seatbelt 5 Engine Oil Pressure Lights if the engine oil pressure drops too low warning the operator to immediately stop the engine and determine the cause for the pressure drop During normal operation this indicator should be OFF 6 Battery Lights if the charging voltage is too high or too low During normal opera tion this indicator should be OFF 7 Preheat Indicator Lamp Lights when the preheat switch is pressed During normal operation this indicator should be OFF 8 Engine Coolant Temperature Lights if the engine coolant becomes 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 o
20. 17334 BP0310 Dimensional Specifications P D V S L 3640 E amp 10 5 ft 0 3 m3 Bucket W 27 x 8 5 x 15 Tires SL3840E EU enr n A Overall Operation Height Fully Raised 139 6 3546 B Height to Hinge Pin Fully Raised 108 1 2746 C Overall Height to ROPS 70 3 1786 D Overall Length Bucket Down 114 0 2896 E Dump Angle at Full Height 429 F Dump Height 84 5 2146 G Dump Reach Bucket Full Height 22 8 579 J Rollback at Ground 290 M Rollback Angle at Full Height 990 O Seat to Ground Height 32 6 828 P Wheel Base Nominal 34 5 876 Q Overall Width Less Bucket 48 4 58 2 1229 1428 R Bucket Width Overall 55 3 1404 S Ground Clearance to Chassis Between Wheels 6 0 152 V Overall Length Less Bucket 88 9 2258 W Departure Angle 26 X Clearance Circle Front With Bucket 69 4 1763 Y Clearance Circle Front Less Bucket 44 1 1120 Z Clearance Circle Rear 54 1 1374 917334 BP0310 73 Dimensional Specifications SL4240E 11 7 ft 0 3 m3 Bucket w 10 x 16 5 Tires inches mm A Overall Operation Height Fully Raised 141 1 3584 B Height to Hinge Pin Fully Raised 110 0 2794 C Overall Height to ROPS 71 9 1826 D Overall Length Bucket Down 116 2 2952 E Dump Angle at Full Height 429 F Dump Height 84 5 2197
21. 2 kg Multiply the density of potash 1088 kg m by the capacity of the bucket 0 3 m to achieve the weight to be carried 1088 kg m x 0 3 m 326 4 kg This number is less than the machine rating allowing safe use of this bucket in this application 917334 BP0310 77 Notes 78 917334 BP0310 CHAPTER 9 TORQUE SPECIFICATIONS Use these torque values when tightening hardware excluding locknuts and self tapping thread forming and sheet metal screws unless otherwise specified UNIFIED GRADE 2 GRADE 5 GRADE 8 NATIONAL THREAD DRY LUBED DRY LUBED DRY LUBED 8 32 19 14 30 22 41 Sit 8 36 20 15 31 23 43 32 10 24 27 21 43 32 60 45 10 32 31 23 49 36 68 51 1 4 20 66 50 9 75 12 9 1 4 28 76 56 10 86 14 10 5 16 18 11 9 17 13 25 18 5 16 24 12 9 19 14 25 20 3 8 16 20 15 30 23 45 35 3 8 24 23 17 35 25 50 35 7 16 14 32 24 50 35 70 55 7 16 20 36 27 55 40 80 60 1 2 13 50 85 75 55 110 80 1 2 20 55 40 90 65 120 90 9 16 12 70 55 110 80 150 110 9 16 18 80 60 120 90 170 130 5 8 11 100 75 150 110 220 170 5 8 18 110 85 180 130 240 180 3 4 10 175 130 260 200 380 280 3 4 16 200 150 300 220 420 320 7 8 9 170 125 430 320 600 460 7 8 14 180 140 470 360 660 500 1 8 250 190 640 480 900 680 1 12 270 210 710 530 1000 740 METRIC GRADE 8 8 GRADE 10 9 GRADE 12 9 COARSE THREAD DRY LUBED DRY LUBED DRY LUBED M6 1 8 6 11 8 13 5 10 M8 1 25 19 1
22. 4 27 20 32 5 24 M10 1 5 37 5 28 53 39 64 47 M12 1 75 65 48 91 5 67 5 111 5 82 M14 2 103 5 76 5 145 5 108 176 5 131 M16 2 158 5 117 5 223 5 165 5 271 200 All Torque Values are in ft lbs except those marked with an which are in lbs For metric torque value N m multiply ft lbs value by 1 355 or the in lbs value by 0 113 917334 BP0310 79 GEHL COMPANY WARRANTY GEHL COMPANY hereinafter referred to as Gehl warrants new Gehl equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve 12 months from the Warranty Start Date GEHL WARRANTY SERVICE INCLUDES Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer s business location GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND EXPRESS OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL BE DEEMED DELETED FROM THIS WARRANTY STATEMENT ALL OTHER TERMS WILL CONTINUE TO APPLY SOME STATES DO NOT PERMIT THE EXCLUSION OF LIMITATION OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW GEHL WARRANTY DOES NOT INCLUDE 1 Transportation to selling dealer s business location or at the option of the Original Retail Purchaser the cost of a service call 2 Used equipment 3
23. Belt Tensions page 49 Change Engine Oil and Filter page 48 L1 Change Hydraulic Oil Filter page 50 L1 Check Battery page 55 Check Engine Mounting Hardware page 47 Change Fuel Filters page 48 Change Hydraulic Oil page 50 Change Chaincase Oil page 52 L1 Drain Flush Cooling System page 51 O gt 0 0o ojo Q Perform the initial procedure at 2 hours then at intervals O Perform the initial procedure at 50 hours then at 9 intervals Perform the maintenance at 1000 hours 917334 BP0310 67 Maintenance Log Date Hours Service Procedure 68 917334 BP0310 Maintenance Log Date Hours Service Procedure 917334 BP0310 69 Notes 70 917334 BP0310 CHAPTER 8 Loader Specifications Specification 3640E 3840E EU 4240E Operating Weight 4000 Ibs 1814 kg 4600 Ibs 2087 kg Shipping Weight 3515 Ibs 1594 kg 4065 Ibs 1844 kg Rated Operating Load capacity 1050 Ibs 476 kg 1350 Ibs 612 kg Engine Make Yanmar Yanmar Model 3TNV88 BKMS 4TNV88 BKMS Displacement Power net 100 in 1 64 L 85 hp 26 kW 133 in 2 19 L 46 hp 34 kW 2600 rpm 2600 rpm
24. Ciz HL 5L 3640E SL 3840E EU SL4240E SL4240E EU Skid Steer Loaders C 2 U han O 4 ha D Q O 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 Read Operator s Manual before using machine CORRECT Always fasten seatbelt snugly Always keep feet on the floor pedals when operating loader WRONG Never use loader without ROPS FOPS Never modify the ROPS FOPS structure Never use the loader to lift personnel WRONG Do not use loader around explosive dust or gas or where exhaust can contact flammable material SL3640E SL3840E EU and SL4240E Operator s Manual TABLE OF CONTENTS Introduction us cote Rm a hack ela e es 1 Sally dr dud eden iunc Belo tope dhs eared d e Sg 5 Controls and Safety Equipment 17 Operation 3 2 32 xe noon eX AE d QU RD Roa Moe dtd ES 31 SENICE su s dien esu Pd a Miba wc e n aan ak eee 41 Troubleshooting s set fe Rope dide CER P Crece s 57 Maintenance Schedule
25. Components covered by their own non Gehl warranties such as tires batteries trade accessories and engines 4 Normal maintenance service and expendable high wear items 5 Repairs or adjustments caused by improper use failure to fol low recommended maintenance procedures use of unautho rized parts or attachments accident or other casualty 6 Liability for incidental or consequential damages of any type including but not limited to lost profits and expenses of acquir ing replacement equipment No agent employee or representative of Gehl has any authority to bind Gehl to any warranty except as specifically set forth herein 80 204926 AP0407 INDEX A Cooling System Accessory Plug 22 Check Coolant Level Adjustments 43 Clean UD RE SS Control Handles 43 Pra USNs 25 8 Drive Chains 44 D Engine Speed Control 44 Dealer Services Fuel Sender 43 E Alternator Fan Belt 49 Emergency Exit Attachments 29 Engine Air Cleaner os Engine Mounting Hardware Auxiliary Hydraulic Controls 28 E g UU Engine Service Hand Foot Controlled 29 f T Bar Controlled 28 Change Fuel Filter B Change Oil and Filter Check Oil Battery 005 55 Engine Speed Control Jump Starting the Engine 32 G ingEdge Bucher Suning Ege d Guar
26. G Dump Reach Bucket Full Height 20 8 528 J Rollback at Ground 290 M Rollback Angle at Full Height 990 O Seat to Ground Height 33 6 853 P Wheel Base Nominal 36 7 932 Q Overall Width Less Bucket 52 5 58 4 1834 1483 R Bucket Width Overall 60 6 1539 S Ground Clearance to Chassis Between Wheels 8 3 211 V Overall Length Less Bucket 91 1 2314 W Departure Angle 29 X Clearance Circle Front With Bucket 69 2 1758 Y Clearance Circle Front Less Bucket 43 4 1102 Z Clearance Circle Rear 58 4 1484 74 917334 BP0310 Capacities and Ratings Note Use the Table of Common Materials and Densities page 76 for selecting the appropriate bucket Dirt Construction Buckets Rated Operating Capacity Description Weight SL3640E SL3840E EU 9L4240E 55 in 10 5 ft 1397 mm 0 30 m 235 Ibs 1095 Ibs 1383 Ibs 107 kg 497 kg 627 kg 60 in 10 0 ft 1524 mm 0 28 m3 252 Ibs 881 Ibs 1102 Ibs 114 kg 340 kg 500 kg 61 in 11 7 ft 1549 mm 0 33 m 253 Ibs 1082 Ibs 1370 lbs 115 kg 491 kg 621 kg Construction with High Back Buckets 55 5 in 9 5 ft 1410 mm 0 27 m 254 Ibs 1061 Ibs 1325 Ibs 115 kg 481 kg 601 kg 61 5 in 13 0 ft 1562 mm 0 37 m3 383 Ibs 975 lbs 1214 Ibs 174 kg 422 kg 551 kg Utility Buckets 55 5 in 13 5 ft 1410 mm 0 38 m 313 Ibs 1061 Ibs 1325 Ibs 142 kg 481 kg 601 kg 61 5 in 15 2 f
27. OPS FOPS Level Il Approved Overhead Guard Independent Hydraulic Reservoir and Hydraulic Oil Cooler Foot T Bar Only and Hand Throttle Operator Restraint Bar with Armrests Engine Intake Air Pre Heater Starting Assist Manual Optional Features YYY VVVV NN VNNN N N Audible Back Up Alarm Engine Block Heater Horn Suspension Seat Cab Door with Wiper and Dome Light Sliding Side Windows Heater Defroster Deluxe Sound Package 3 inch Wide Seatbelt When Required by Law Rear View Mirror Engine Auto Shutdown System Interior Dome Light VNN VVVV NN NN NN V VV VVVVVVVVVV VV Adjustable Seatbelt Lift Arm Support Device Hydraloc System Brakes and Interlock for Starter Lift Tilt Cylinders Auxiliary Hydraulics and Wheel Drives Dual Front and Rear Work Lights Removable Belly Plate and Access Cover Dual Element Air Cleaner with Visual Indicator Vandalism Lock Provisions Top and Rear Windows Spark Arrestor Muffler Headliner and Acoustical Interior Adjustable Seat Front Auxiliary Hydraulics with 3 4 inch Flat Faced Couplers Number 80K Drive Chain Powerview Lift Arm Visual Hydraulic Filter Indicator Power Plug 12 V Centrifugal Pre Cleaner Strobe Light Impact Resistant Door Single Point Lift Kit Four Point Lift Kit Rear Counterweight Battery Disconnect Switch Fenders Bucket Bolt On Cutting Edge Diesel Engine Exhaust Purifier Hydraulic Coupler Kit Self Leveling Lift Action 9
28. PS FOPS S SAFETY tarot ats noe Stes Safety Decals New Decal Application No Text Decals Safety Interlock System Testirig cet Safety Reminders Self Leveling SERVICE 05 Spark Arrestor Muffler SPECIFICATIONS Accessories Standard Features Starting the Engine Before Starting the Engine Stopping the Loader Switches Seat and Restraint Bar 82 67 31 17 18 31 32 52 T Table of Common Materials amp Densi HOS oce hte tases 76 Table of Common Materials and Densities 76 T Bar Controls 26 Drive Controls 26 Lift Tilt Controls 26 TItes che ee eae rege ees 53 Checking Tire Pressure 54 Mounting Tires 53 TORQUE SPECIFICATIONS 79 TROUBLESHOOTING 57 Electrical System 57 Engine 59 Hydraulic System 63 64 vicus ER 65 Hydrostatic System 60 62 W WARRANTY 80 Wheel Nuts 53 917334 BP0310 WRONG Never exceed rated Always carry attachment A operating load A as low as possible Do not travel or turn with the lift arm raised Load unload and turn on flat level surface Never carry riders Never modify equipment Keep bystanders away Use only attachments from work area app
29. Peak Torque 80 ft lbs 108 N m 103 ft Ibs 140 N m 1200 rpm 1200 rpm Hydraulic System theoretical Main Hydraulic System Pressure 2750 psi 190 bar 2750 psi 190 bar Standard Flow Rating 14 5 gpm 55 L min 16 5 gpm 62 L min Electrical Battery 12 Volt DC 675 CCA 12 Volt DC 675 CCA Starter 12 Volt DC 2 3 Kw 12 Volt DC 2 3 Kw Alternator 40 amperes 40 amperes Capacities Chaincase each 8 U S qts 7 6 L 8 0 U S qts 7 6 L Crankcase 7 6 U S qts 7 2 L 9 1 U S qts 8 6 L Fuel Tank 10 3 U S gal 39 L 12 4 U S gal 47 L Hydraulic Reservoir 8 U S gal 30 L 8 U S gal 30 L Sound with Deluxe Sound Kit Pressure Level Operator Ear 85 dB A 85 dB A Power Level Environmental 101 dB A 101 dB A 1 Operating load capacity rated for 3640E 3840E EU 55 in 1397 mm 10 5 ft8 0 3 m3 4240E 61 in 1550 mm 11 7 ft8 0 3 m3 dirt construction bucket in accordance with SAE J818 2 3640E 3840E EU shipped with 27 0 x 8 50 15 tires 4240E shipped with 10 00 x 16 5 tires 917334 BP0310 71 Standard Features Vv VV Vv VV VY VVVV VV WV Choice control types T Bar or Hand Foot Fuel Gauge All Tach Attachment System Universal Type Warning Lamps and Buzzer Engine and Hydraulic Oil Temperature Battery Charge Indicator Lamp Low Oil Pressure Light and Buzzer Seatbelt Indicator Lamp and Buzzer Coolant Temperature Gauge Hourmeter Manual Control Hydrostatic Drive R
30. Reinstall the anchor bolts washers and locknuts Never operate the loader with the ROPS FOPS PN WARNING removed or locked back Be sure the lock is securely engaged when the ROPS FOPS is tilted back Properly sup port the ROPS FOPS when unlatching the lock mechanism and low ering the ROPS FOPS Be sure to reinstall the anchor bolts washers and locknuts before resuming loader operation Figure 24 ROPS Lock Mechanism Loader Raising Procedure To raise the skid steer loader so all four tires are off the ground use the procedure below Do not rely on a jack or hoist to maintain the PN WARNING raised position without additional blocking and supports Serious personal injury could result from improperly raising or blocking the skid steer loader 1 Using a jack or hoist capable of lifting the fully equipped weight of the loader with all attached options lift the rear of the loader until the rear tires are off the ground 2 Stack wooden blocks under the flat part of the loader chassis They should run parallel with but not touch the rear tires Figure 25 3 Slowly lower the loader until its weight rests on the blocks If the tires still touch the ground raise the loader again add more blocks and lower again 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 a
31. With the bucket filled tilt the bucket back and back the loader away from the material Rest the lift arm against the Figure 17 Digging loader frame before proceeding to the dumping area Dumping the Load onto a Pile Carry a loaded bucket as low as possible until reaching the pile 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 Empty the bucket and back the loader away while tilting the bucket back and lowering the lift arm Never push the controls into the float position A WARNING with the bucket or attachment loaded or raised because this will cause the lift arm to lower rapidly 36 917334 BP0310 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 arm until the bucket clears the top of the box and move the loader ahead to position the bucket over the inside of the box slowly dump the bucket After the material is dumped back away from the box while tilting the bucket back and low ering the lift arm Figure 18 Dumping Into a Box Dumping the Load Over an Embankment Do not drive too close to an excavation or PN WARNING ditch Be sure the surrounding ground has ade
32. aced only when the restriction indicator turns red The inner element should be replaced every third time the outer element is replaced unless the 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 and clamps and the mounting bracket hardware to be sure they are properly tightened Access 1 Open the rear door and engine access cover 2 Unlatch the clamps on the air cleaner and remove the cover Clean out any dirt built up in the cover assembly 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 this step to prevent debris from entering the engine intake manifold 3 Replace the outer element Note Gehl does not recommend cleaning the outer element 4 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 Inner Element Note Replace the inner element only if it is dirty or if the outer element has been replaced three times 1 Before removing the inner element from the housing clean out any dirt built up in the housing Leave the inner element installed during this step to pre vent debris from entering the engine intake m
33. achment level while the lift arm is being raised Using a Bucket Always maintain a safe distance from electric PN WARNING power lines and avoid contact with any electri cally 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 up or down on an incline travel with the heavy end pointing uphill Try to avoid traveling on an incline but always travel with the bucket as possible to maintain stability 917334 BP0310 35 Loading a Bucket Approach the pile with the lift arm fully lowered and the bucket tilted slightly for ward 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 Figure 16 Loading Always carry the loaded bucket with the lift arm A WARNING resting on the loader frame For additional sta bility when operating on inclines always travel with the heavier end of the loader toward the top of the incline 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 Break the ground by driving for ward and gradually lowering the lift arm
34. air and add oil Check electrical connections to lift solenoid and repair Check switches Lower the restraint bar Check electrical connections to lock solenoid and repair connections as needed If lock solenoid is still not functioning properly contact your dealer Check electrical connections to restraint bar switch and repair connections as needed If switch is still not functioning properly contact your dealer Hydraulic cylinder action is slow for lift and or tilt functions Low engine speed Hydraulic oil viscosity is too heavy Control linkage is restricted Hydraulic oil leaking past cylinder piston seals Worn gear pump Solenoid valve s could be malfunctioning Relief valve in control valve not functioning correctly Squealing noise should be evident while operating Operate engine at higher speed Allow longer warm up or replace existing oil with proper viscosity oil Check for control linkage restriction and adjust Contact your dealer Contact your dealer Check electrical connections to lift solenoid and repair connections as needed If lift solenoid valve is still not functioning properly contact your dealer Contact your dealer 917334 BP0310 63 Hydraulic System Problem Possible Cause Remedy Bucket does not level on the lift cycle Self leveling valve misadjusted or malfunctioning Contact your dealer
35. aking soda and water After foaming has stopped flush the battery top with clean water If the terminals and cable connection clamps are corroded or have a build up disconnect the cables and clean the terminals and clamps with the same alkaline solution Explosive gas is produced while a battery is in PN WARNING use or being charged Keep flames or sparks away from the 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 contact with skin or fabrics If acid spills follow these first aid tips 1 Immediately remove any clothing on which acid spills 2 If acid contacts the skin rinse the affected area with running water for 10 to 15 minutes 3 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 kg of baking soda in 1 gallon 4 L of water b 1 pint 0 5 L of household ammonia in 1 gallon 4 L of water Whenever the battery is removed be sure to disconnect the nega tive battery terminal connection first 917334 BP0310 55 Notes 56 917334 BP0310 CHAPTER 6 TROUBLESHOOTING Electrical System Problem Possible Cause Remedy Entire electrical system
36. anifold 2 Remove the inner element 46 917334 BP0310 Reinstallation im P amp S 6 Check the inside of the housing for any damage that may interfere with the elements Be sure that the element sealing surfaces are clean Insert the element s making sure that they are seated properly Secure the cover to the housing with clamps Check the hose connections and be sure they are all clamped and tightened properly Reset the restriction indicator by pressing the reset button Engine Service Check Engine Mounting Hardware All bolts that secure the engine mounting brackets to the engine and the loader frame should be checked and re tightened as necessary Allow hot engine and hydraulic system compo PN WARNING nents to cool before servicing Checking Engine Oil Level Important For new units the initial oil change should be after the first 50 hours Open the rear door and engine access cover Pull out the dipstick and check the oil level Markings on the dipstick repre sent FULL and LOW add oil levels Refer to the Maintenance Interval Chart page 67 for the service interval for Figure 28 Oil Dipstick replacing the engine oil and filter and Fill Cap 1 Oil Dipstick 2 Oil Fill Cap 917334 BP0310 47 Changing Engine Oil and Filter 1 Run the engine until it is at operating temperature Stop the engine Remove the rear belly pan 2 Remove the drain plug 3 From the engine compartment
37. atform 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 arm raised for Service 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 917334 BP0310 13 ISO Style used Internationally Safety Decals in the Engine Compartment 137845 Located on cross member for frame 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 137845 Located on cross member for frame A Rotating fan Keep hands out or stop engine B Hot surface Do not to
38. cations Read the manual provided with the attachment to learn how to safely maintain and operate the equipment Be sure the machine is suitably equipped for the type of work to be performed Do not use this machine for any applications or purposes other than those described in this manual or those applicable for approved attachments If the machine is to be used with special attachments or equipment other than those 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 Provide complete information about the part and include the model and serial numbers of your machine Record these numbers in the space provided on the Table of Contents page as a handy refer ence Gehl Company strives to continuously improve its products and reserves the right to make changes and improvements in the design and construction of any part without incurring the obligation to install such changes on any previously deliv ered unit 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
39. cient time for the skid steer loader alternator to build up a charge in the battery before attempting to operate the loader or shut the engine off 917334 BP0310 33 Changing Attachments To prevent unexpected attachment release PN WARNING from the attachment bracket be sure to prop erly secure the latch pins by rotating the latch levers to a horizontal position The skid steer loader features a All Tach attaching mechanism for mounting a bucket or other attachment Two latch levers secure the attachment Connecting an Attachment 1 Rotate the latch levers to a vertical position to 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 back of the attachment 4 Tilt the attachment bracket forward a until the top edge of the bracket is Figure 15 Hitch disengaged below the flange on the back side of cee ao the attachment and centered between the vertical plates 5 Slowly drive the loader forward and at the same time tilt the attachment bracket back to engage the flange on the back side of the attachment 6 Stop forward travel when the flange is engaged but continue to tilt the attach ment bracket back to lift the attachment off the ground 7 Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE page 6 8 With the loader engine OFF leave the operator s compartment and rotate the latc
40. ckwise direction these are OFF Tail Lights ON Front Work Lights with Tail Lights ON both Front and Rear Work Lights For the lights to function the keyswitch must be in the RUN position 13 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 14 Accessory Outlet 12 volt DC power outlet 917334 BP0310 25 T Bar Controls The Gehl loader may be equipped with the T Bar control option The left T Bar controls the drive and the right T Bar con trols the lift tilt Drive Controls Forward reverse speed and turning maneuvers are controlled by movement of Figure the left T Bar To go forward push the 1 Drive Control control forward for reverse pull the con 2 Lift Tilt Control trol rearward To turn right twist the con trol clockwise to turn left twist the con trol counterclockwise For gradual turns twist the T Bar slightly clockwise or counterclockwise For sharp turns twist the control fully clockwise or counter clockwise Moving the T Bar farther from neutral increases the speed steadily to the max imum travel speed Tractive effort decreases as speed increases For maximum tractive effort move the T Bar only slightly from the neutral position The engine will stall if the control is moved too far
41. do not work Wiring to solenoids disconnected or faulty Faulty seat or restraint bar Switch Faulty solenoid valve coil Faulty hydraulic solenoid relay in instrument panel Troubleshoot circuit repair Contact your dealer Contact your dealer Contact your dealer 58 917334 BP0310 Engine Problem Possible Cause Remedy Engine turns over but will not start Engine cranking speed too slow Auxiliary valve engaged Fuel tank empty or faulty fuel gauge sender Glow plug module malfunctioning Fuel shut off solenoid not energizing Engine oil not warm enough Ambient temperature is too low Fuel pump not working Battery requires recharging or replacing or in cold temperatures pre warm the engine Return control valves to neutral Refill fuel tank Replace fuel gauge sender Check connection and voltage replace as needed Check electrical connections and voltage to shut off solenoid Install a pan heater Install a pan heater Contact your dealer Engine overheats 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 Air filter is restricted Add or remove oil as required With engine OFF remove blockage or restriction Contact your dealer Drain and replace wi
42. does not function Battery disconnect switch is OFF 15 ampere breakers tripped Main wiring harness connectors at rear of ROPS not properly plugged in Battery terminals or cables are loose or corroded Battery is faulty 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 Test battery and replace as needed No instrument panel lamps with keyswitch turned to ON 25 ampere breakers are tripped Battery terminals or cables are loose or corroded Check circuit and locate trouble before resetting breaker Clean battery terminals and cables and retighten them Seatbelt buzzer not sounding when key turned to ON indicator lamps work properly Buzzer is disconnected Faulty buzzer Reconnect wires to buzzer Replace buzzer Fuel gauge does not work Faulty fuel gauge sender Faulty fuel gauge Loose wiring terminal connections Replace fuel gauge sender Replace fuel gauge Verify wiring connections Engine temperature gauge does not work Faulty temperature sender Faulty temperature gauge Loose wiring terminal connections Replace temperature sender Replace temperature gauge Verify wiring connections Hourmeter does not work Loose wiring terminal connections Faulty alternator Faulty
43. ds and Shields Bucket Usage 35 H Digging with a Bucket 36 Driving on an Incline 35 SS oot Controls Driving over Rough Drive Controls Terrain 004 35 Lift Tilt Controls Dumping Into a Box 37 Highway Travel Dumping Onto a Pile 36 Hydraulic System Dumping the Load Over Change Oil AN EMOANKMENI rigen d Change Oil Filter Leveling the Ground 37 Check Oil Level Loading a Bucket 36 Scraping with a Bucket 37 C Instrument Panel i INTRODUCTION Capacities and Ratings 75 L Chaincases 52 Checking and Adding Oil 52 Lift Arm Support Device Draining Oil Ls 52 Loader Circuit Breakers 54 Lifting USO E SAE E EAEE Cold Starting Procedure 31 LOwETINg Pro edures dete Control Indicator Symbols 3 Raising Procedu Giss eet CONTROLS and SAFETY Storing ia paien EQUIPMENT 17 Transporting Lubrication 917334 BP0310 MAINTENANCE SCHEDULE Maintenance Log 69 Mandatory Safety Shutdown Procedure Model Identification OPERATION ss Operator Restraint Bar Operators Seat Parking Brake Parking the Loader Potential Hazards R Rear Window RO
44. e crushed 90 1440 Slag crushed 70 1120 Snow 15 50 240 800 Taconite 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 76 917334 BP0310 Bucket Selections 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 75 for a listing of attachments and their loader ratings Note Where the material density is listed as a range snow at 15 50 lbs ft for example always use the maximum density 50 lbs ft in this example for making calculations Also see the following examples Example 1 If snow density of 15 50 IbsJ ft is to be hauled using a 3640E 3840E model loader using Dirt Construction Bucket the bucket capacity is 10 5 ft and the loader rating is 1050 Ibs Multiply the density of snow 50 Ibs ft by the capacity of the bucket 10 5 ft to achieve the weight being car ried 50 Ibs ft3 x 10 5 ft 525 Ibs This number is less than the machine rating so you could safely use this bucket in this application Example 2 If potash density of 1088 kg m is to be hauled using a 3640E 3840E model loader using a 0 3 m Dirt Construction bucket the bucket capacity is 0 3 m and the loader rating is 61
45. eplacement Parts topic page 43 48 917334 BP0310 Servicing Water Separator Periodically check for water in water separator by checking level of float in water separator bowl If water is present 1 Shut off the fuel supply by turning the fuel shutoff valve on top of the water separator 2 Turn nut to release the bowl from the valve head Dispose remaining fuel and water 3 Clean bowl and filter element with warm water until all foreign material is removed Replace fuel filter if damaged Refer to Parts Manual for part num ber 4 Place element onto valve head Lubricate o ring on bowl with diesel fuel and place on valve head Turn nut to tighten 5 Turn on fuel supply Releasing Water from Separator 1 Check red float located in the water separator bowl If red float is raised open valve on the bottom of the bowl to drain water 2 Close valve quickly after float reaches the bottom of the bowl Spark Arrestor Muffler Important The loader is factory equipped with a spark arrestor type muffler Muffler maintenance is required to keep it in working condition Refer to local laws and regulations for spark arrestor requirements 1 Stop the engine open the rear door and engine cover Remove the plug from the bottom of the muffler Block the outlet of the muffler with a non combustible material Start the engine and run it for 10 15 seconds Stop the engine and remove the blockage Put anti seize coating on the p
46. erlock System NEVER defeat the safety interlock system by PN WARNING mechanically or electrically bypassing any switches relays or solenoid valves An interlock system is used on the loader for operator safety Together with solenoid valves switches and relays the interlock system gt Prevents the engine from starting unless the operator is sitting on the seat and the operator restraint bar is down gt Disables the lift arm attachment tilt and wheel drives when the operator leaves the seat turns the keyswitch to OFF or raises the restraint bar gt Disables auxiliary hydraulic system when the restraint bar is raised or the keyswitch is OFF Testing the Safety Interlock System Before leaving a parked machine check the safety interlock system for proper operation Restraint Bar 18 917334 BP0310 With the engine running raise the restraint bar Move each of the controls There should be not more than a slight movement of the lift arm attachment 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 the seatbelt Lift your weight up 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 ROPS FOPS The ROPS FOPS Roll Over Falling Object Protective Structure is des
47. fluid and the other is to check the fluid level Refer to the Maintenance Schedule chapter page 67 for change intervals Refer to the Lubrication topic page 44 for information on oil type and quantity Checking and Adding Oil 1 Park the loader on a level surface Stop the engine Figure 34 Drain Plugs 2 Remove the check plug from each chaincase housing If the oil can be reached with the tip of your finger the oil level is adequate 3 If the level is low add fluid through the check plug until the oil level reaches the edge of the hole Reinstall the check plug Draining Oil 1 Raise the rear of the machine to aid in draining the chaincases 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 check plugs Seat and Restraint Bar Switches Electrical switches in the seat and restraint bar must be closed operator sitting in the seat and restraint bar lowered to complete the circuit and start the engine 52 917334 BP0310 Bucket Cutting Edge The bucket cutting edge should be replaced when it is worn to within 1 in 25 mm of the bucket body Wheel Nuts Wheel nut torque must be checked before initial operation and every two hours thereafter until the wheel mounting hardware torque stabilizes at the recommended setting of 120 130 ft Ibs 161 175 N m When tires are removed and replaced this procedu
48. forward when loading the bucket Be sure the controls are in neutral before PN WARNING starting the engine Operate the controls grad ually and smoothly Excessive speed and quick control movements without regard for conditions and circumstances are hazardous and could cause an accident 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 down ward 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 speed To place the lift arm into the detent float position push the right T Bar all the way forward into the detent This position allows the lowered lift arm to float while traveling over changing ground conditions Never push the lift tilt T Bar control into the A WARNING float position with the attachment loaded or raised because this will cause the lift arm to lower rapidly 26 917334 BP0310 Hand Foot Controls The Gehl loader may be equipped with the hand foot control option The handles control the drive and the foot pedals control the lift tilt Drive Controls Forward reverse speed and turning maneuvers are controlled by movement of the control handles To g
49. g the machine 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 Always wear safety goggles ear and head protection while operating the machine Operator must wear protective clothing when appropriate Exhaust fumes can kill Do not operate this machine in an enclosed area unless there is adequate ventilation 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 procedure detailed in the Operation chapter of this 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 917334 BP0310 7 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 gt Do n
50. h levers to a horizontal position to fully engage the latch pins Important To check that the attachment is properly installed apply down pres sure to the attachment prior to operating Connecting Auxiliary Hydraulic Couplings Note With the engine OFF key in the ON position and the restraint bar down the auxiliary hydraulic control can be moved to relieve any pressure in the hydraulic system The hydraulic couplers are located on the left lift arm A port is pressure B port is return when the auxiliary control is in the detent position 34 917334 BP0310 Removing Attachments Tilt the attachment bracket 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 switch but do not start the engine b With the restraint bar down move the auxiliary hydraulic control back and forth This will relieve the pressure in the hydraulic system 4 With the engine OFF leave the operator s compartment disconnect the auxil iary hydraulic hoses and rotate the latch levers completely vertical to fully retract the latch pins 5 Start the engine and be sure that the lift arm is fully lowered and in contact with the loader frame 6 Tilt forward and slowly back the loader until the attachment is free from the loader Self Leveling optional The feature is designed to keep the att
51. he accelerator pedal for hands only controlled machines 4 Turn the keyswitch to the OFF position to shut off the engine 5 Raise the restraint bar unfasten the seatbelt and grasp the hand holds while climbing out of the operator s compartment Note The skid steer 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 Parking the Loader Park the loader on level ground away from traffic If this is not possible park the loader across the incline and block the tires to prevent movement Jump Starting the Engine 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 loader engine The ONLY safe method for jump starting with A WARNING 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 start the engine from any position other than on 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 p
52. hour meter Verify wiring connections Repair the alternator Replace hour meter 917334 BP0310 57 Electrical System Problem Possible Cause Remedy Starter will not engage when key is turned to START Work lights not functioning properly 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 Single light doesn t work Light bulb burned out faulty wiring No lights at all 25 ampere breaker tripped Faulty light switch or poor ground Replace switches as needed If engine still doesn t start contact your dealer Verify relay connections Clean terminals cables and retighten Contact your dealer Recharge or replace battery Troubleshoot circuit Replace the starter solenoid Check wiring for poor connections broken leads repair wiring or connection Remove starter repair replace as needed 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 Lift Tilt and or drive lock solenoids
53. igned 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 Never operate the loader with the ROPS FOPS A WARNING removed or locked back Parking Brake This skid steer 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 right control panel of the ROPS The red indi cator on the switch lights when the parking brake is applied Figure 2 Parking Brake Switch 917334 BP0310 19 Rear Window Emergency Exit The ROPS rear window has three func tions noise reduction flying objects bar rier and emergency exit To use the emergency exit pull on the yellow warning tag at the bottom of the window and remove the seal Push out the window and exit Figure 3 Rear Window Emergency Exit 1 Pull Tag Lift Arm Support Device Eie as ee The lift arm support device on the left lift cylinder 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 store it under the lift arm using the lock pin The support device is a safety device that must
54. inated after major repairs and after 1000 hours or one year of use Remove the oil filler cap Install a catch pan of sufficient capacity under the oil reservoir 8 gallons 30 liters Remove the drain plug located on the bottom left of the oil reservoir Remove and replace the hydraulic oil filter Reinstall the drain plug Refill the reservoir until the oil is between the two lines on the dipstick gauge Start the engine and operate the hydraulic controls 917334 BP0310 8 Stop the engine and check for leaks at the filter and reservoir drain plug 9 Check the fluid level and add fluid if needed Cooling Systems Important Check the cooling system every day to prevent overheating loss of performance or engine damage Checking Coolant Level 1 Open the rear door Check the coolant level in the coolant recovery tank on the inside of the rear door The coolant recovery tank must be 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 5096 water and 50 ethylene glycol to the recovery tank if the coolant level is low Figure 32 Cooling System 1 Recovery Tank 1 Park the loader on a level surface 2 Radiator Cooler lower the lift arm and stop the engine 3 Drain Plug Allow the engine to cool Cleaning Cooling System 2 Open the rear door Lift the e
55. ks properly Hand Foot units only Pilot control lines have air in them Low charge pressure Linkage misadjusted between right foot pedal and pilot valve Bleed the pilot control line from the main control valve Contact your dealer Readjust for full travel without restriction 64 917334 BP0310 Hydraulic System Problem Possible Cause Remedy Lift arm does not raise bucket tilt works properly Lift solenoid valve could be malfunctioning Lift spool in control valve not actuated or leaking Check electrical connections to lift solenoid and repair connections as needed If lift solenoid valve is still not functioning properly contact your dealer Contact your dealer Lift arm doesn t maintain raised position with lift control in NEUTRAL Lift arm will not lower or raise Oil leading past lift cylinder seals internal or external Oil leaking past lift spool in control valve Self leveling valve malfunctioning Leaking hydraulic hoses tubes or fittings between control valve and cylinders Lift arm support device engaged Lift solenoid valve malfunctioning Restraint bar not lowered Seat or restraint bar switch malfunction Contact your dealer Contact your dealer Contact your dealer Inspect hoses and tubes tighten fittings as needed Replace as needed Raise lift arm and disengage support device
56. lug Se BOS JP Reinstall and tighten the plug 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 by following the proce dure in the separate engine manual 917334 BP0310 49 Hydraulic System Checking Hydraulic Oil Level The loader has a dipstick located in the engine compartment Check the fluid level with the lift arm lowered and the attachment on the ground When hydraulic fluid is required allow the system to cool Slowly remove the oil fill cap allowing the pressure to dispel before removing the cap completely Add hydraulic fluid as required Refer to the Lubrication topic page 44 for oil recommendations Replace the cap Figure 30 Hydraulic Oil Service Changing Hydraulic Oil Filter Before servicing the hydraulic filter be sure A WARNING the lift arm is lowered l 2 Open the rear door and engine cover to access the filter Unscrew the filter Clean the surface of the filter housing where the element seal contacts the housing Put clean oil on the rubber gasket of the new filter element Install and tighten the filter element 3 4 of a turn past the point where the gasket contacts the filter head For a replacement element refer to the Figure 31 Drain Plug Replacement Parts topic page 43 Changing Hydraulic Oil The hydraulic oil must be replaced if it becomes contam
57. n designing its machinery and guards exposed moving parts for the operator s protection However some areas cannot be guarded or shielded in order to assure proper operation Further more this Operator s Manual and decals on the machine warn of additional haz ards 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 mirror strobe light or an impact resistant front door Be sure you know the job site hazards and equip your machine as needed DANGER indicates an imminently haz PN DANGER ardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous PN WARNING situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous A CAUTION situation which if not avoided may result in minor or moderate injury May also alert against unsafe practices 917334 BP0310 5 Mandatory Safety Shutdown Procedure Before cleaning adjusting lubricating servicing the unit or leaving it unattended 1 2 Move the drive control handle s to the neutral position Lower the lift arm and attachment comple
58. nd rear of the hauling vehicle s tires 2 If the loader has an attachment lift it Figure 21 Front Tie slightly off the ground Down Retrieval point 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 vehi cle 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 vehi Figure 22 Rear Tie Down cle Retrieval point 917334 BP0310 39 Notes 40 917334 BP0310 CHAPTER 5 SERVICE Before servicing the machine unless expressly PN WARNING instructed to the contrary exercise the MAN DATORY SAFETY SHUTDOWN PROCEDURE 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 in the Troubleshooting and Maintenance Schedule Schedule chapters of this manual Refer to the separate engine manual provided for engine related adjustments lubrication and servicing procedures Note All service procedures except those described under the Dealer Services topic are owner operator responsibilities Important More frequent service than
59. nding on loader model and attachment single point lift only 2 Center the hoist over the ROPS FOPS To prevent shock loading of the equip ment and excessive swinging slowly lift the loader off the ground Perform all movements slowly and gradually As needed use a tag line to help position the loader 38 917334 BP0310 Storing the Loader If your skid steer loader is to be stored for a long period of time the following procedure is suggested Fully inflate the tires Lubricate all grease zerks Check all fluid levels and replenish as necessary Add stabilizer to the fuel per the fuel supplier s recommendations Remove the battery charge fully and store in a cool dry location AEE a SE Protect against extreme weather conditions such as moisture sunlight and temperature Transporting the Loader Park the truck or trailer on a level surface Be A WARNING sure the vehicle and its ramps have the weight capacity to support the loader Make sure the vehicle surface and its ramps are clear of debris and slippery material that may reduce trac tion Move the loader on and off the vehicle ramp slowly and care fully Failure to follow these instructions could result in an overturn accident Observe all local regulations governing the loading and transporting of equip ment Ensure that the hauling vehicle meets all safety requirements before loading the skid steer loader NT GEHL 1 Place blocks at the front a
60. ngine cover 3 Clean the radiator and oil cooler by blowing through the fins with high pres sure water or air Note The radiator can be tipped out for cleaning by loosening and rotating the over center links on each side This will also help in cleaning the oil cooler Draining Flushing Cooling System 1 Open the rear door Lift the engine cover 2 Slowly remove the radiator cap allowing pressure to dispel before removing completely Liquid cooling systems build up pressure as the PN WARNING engine becomes hot Before removing the radi ator cap stop the engine and let the system cool Remove the radiator cap only after the coolant has cooled Remove the cap slowly or severe burns may result 3 Remove the drain plug and drain the coolant into a suitable container 4 Replace the drain plug 917334 BP0310 51 Note Protect the cooling system by adding premixed 50 water and 50 ethy lene glycol to the system This mixture will protect the cooling system to 34 F 36 C 5 Fill the radiator fully and the recovery tank half full with the premixed coolant 6 Reinstall the radiator cap 7 Run the engine until it is at operating temperature Stop the engine and let it cool Check the coolant level Add more coolant if required Chaincases Figure 33 Check Plug The chaincase contains the drive pra gt gt al sprockets and drive chains There are two 3 GEHL S plugs in each chaincase One is to drain the
61. ns Wipe dirt from the fit tings before greasing them to prevent contamination Replace any missing or damaged fittings To minimize dirt build up avoid excessive greasing 44 917334 BP0310 l Figure 26 Grease Every 10 Hours or daily 1 Lift arm pivots 2 2 Lift cylinder pivots 4 3 Tilt cylinder pivots 2 4 Attachment Bracket pivots 2 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 ele ments is located on the right side of the front of the air cleaner If the air filter becomes restricted this indi cator will turn red to warn the operator that the element s require service Push the reset button located on the end of the indicator after fitting a clean element For replacement elements refer to the Replacement Parts topic page 43 917334 BP0310 Figure 27 Dual Element Air Cleaner 1 Restriction Indicator 2 Element Housing 3 Inner Filter Element 4 Outer Filter Element 5 Element Cover 45 Note Before replacing the filter element s push the reset button on the indi cator 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 repl
62. o forward push Figure 10 Hand Foot Controls both handles forward for reverse pull 1 Left Drive Control Handle both handles rearward For turning move 2 Right Drive Control Handle one handle farther forward or rearward 3 Tilt Control Foot Pedal than the other handle Turn direction is 4 Lift Control Foot Pedal determined by which handle is moved the farthest 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 For maximum tractive effort move the handles only slightly from the neutral position The engine will stall if the controls are moved too far forward when loading the bucket Be sure the controls are in neutral before PN WARNING starting the engine Operate the controls grad ually and smoothly Excessive speed and quick control movements without regard for conditions and circumstances are hazardous and could cause an accident Lift Tilt Controls Moving the lift arm and tilting the attachment are accomplished by movement of the foot pedals The left 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 the left pedal to lower the lift arm use your toes to push down on the left pedal To tilt the attachment downwa
63. obstacles Always look in the direction of travel 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 the back of the loader For highway operation obtain and install dual amber flashers or a strobe light Check state and local laws and regulations Lifting the Loader The loader can be lifted using a single point or four point lift kit which is avail able from your Gehl dealer WARNING Before lifting check the lift kit for proper installation e Never allow riders in the operator s compartment 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 attach ments other than those stated Lift equipment used and its installation is the responsibility of the party con ducting the lift All rigging MUST comply with applicable regulations and guidelines 1 Using suitable lift equipment hook into the lift eyes 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 FOPS Four point lift only Note The loader my be slightly off level 10 degrees max when lifted depe
64. ot smoke or have any spark producing equipment in the area while filling the fuel tank or while working on the fuel or hydraulic systems Potential Hazards A skid steer loader operator must ALWAYS be conscious of the working envi ronment Operator actions environmental conditions and the job being done require the full attention of the operator so that safety precautions can be taken 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 North American One Call Referral System at 1 888 258 0808 for the 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 and often fatal lung disease A Hazard Review Pub No 2002 129 by the U S National Institute for Occupational Safety and Health NIOSH indicates a significant risk of chronic silicosis for workers exposed to inhaled crystalline silica over a working lifetime NIOSH recom mends 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
65. peration this indicator should be OFF 9 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 opera tion this indicator should be OFF 24 11 13 lt 14 Ce pr C D 5 l 4 5 ET 7 oO e mit f Figure 8 Instrument Panel 917334 BP0310 10 Keyswitch In a clockwise rotation these positions are OFF Position With the key vertical power from the battery is disconnected to the controls and instrument panel electrical circuits This is the only posi tion the key can be inserted or removed from the keyswitch ON or Run Position With the key turned one position clockwise from vertical power from the battery is supplied to all control and instrument panel electrical circuits START Position With the key turned fully clockwise the electric starter energizes start the engine Release the key to the RUN position after the engine starts Note The engine cannot be started unless the operator is sitting in the seat and the restraint bar is lowered 11 Parking Brake Switch Used to manually apply the parking brake The red indicator on the switch lights when the parking brake is applied 12 Light Switch Controls all the lights on the loader Symbols denote the four positions of the light switch In a clo
66. quate 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 embank ment Tilt the bucket forward and raise the lift arm to dump the material After the material is dumped back away from the embankment while tilting the bucket back and lowering the lift arm 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 to be 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 to be leveled Then place the lift arm into the float position and drive the loader rear ward dragging the dirt and at the same time leveling it 917334 BP0310 Figure 20 Leveling the Ground 37 Note The float detent position for T Bar 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 Check that the work area is clear of people and PN WARNING
67. rd use your toes to push down on the right pedal to tilt the attachment up or back use your heel to push down on the right pedal Note The speed of the lift tilt motion is directly proportional to the amount of pedal movement and engine speed To place the lift arm in the detent float position use your toes to push the left pedal all the way down into the detent This position allows the lowered lift arm to float while traveling over changing ground conditions Never push the left pedal into the float position PN WARNING with the attachment loaded or raised because this will cause the lift arm to lower rapidly 917334 BP0310 27 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 auxil iary hydraulic couplers Couplers are 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 34 T Bar Controlled Loaders A foot pedal is used to control the direc tion of oil flow 28 Figure 12 T Bar Auxiliary Control 917334 BP0310 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 p Figure 13 Hand Foot Auxiliary Control At
68. re complete the skid steer loader can be taken down from the raised position To lower the loader onto its tires 42 917334 BP0310 1 Using a jack or hoist raise the front 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 When the procedure is finished all four tires will be on the Figure 25 Blocked Loader ground and the blocks removed from under the loader Replacement Parts Part Description Gehl Part No Air Cleaner Element Primary 188814 Air Cleaner Element Secondary 188817 Hydraulic Oil Filter Element 074830 Engine Oil Filter Element 137500 Fuel Filter Cartridge 182130 Note Part numbers may change Your Gehl dealer will always have the latest part numbers 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 in the fuel tank sends a signal to the fuel gauge indi cating the amount of fuel left 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 replacement is required apply an RTV or gasket sealant around the gasket when res
69. re must be repeated 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 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 Inflating or servicing tires can be dangerous PN WARNING When possible trained personnel should service and mount tires To avoid possible death or serious injury follow the safety precautions below 1 Be sure the rim is clean and free of rust 2 Lubricate the tire beads and rim flanges with a soap solution Do not use oil or grease 3 Use a clip on tire chuck with remote hose and gauge allowing you to stand clear while inflating the tire Do not place your fingers on the tire bead or rim during inflation 4 Never inflate beyond 35 psi 240 kPa to seat the beads If the beads have not seated by the time the pressure reaches 35 psi 240 kPa deflate the assembly reposition the tire on the rim lubricate both parts and re inflate Inflation pressure beyond 35 psi 240 kPa with unseated beads may break the bead or rim with explosive force sufficient to cause death or serious injury 5 After seating the beads adjust the inflation pressure to the recommended operating pressure
70. rotect your eyes and avoid leaning over the batteries while jump starting DO NOT jump start the battery if it is frozen because it may rupture or explode 32 917334 BP0310 Note BE SURE the jumper battery is a 12 volt D C battery 1 2 Turn the keyswitches of both vehicles to OFF be sure the vehicles are in neutral and NOT touching each other Connect the positive jumper cable to the positive battery terminal on the disabled loader first DO NOT allow the positive clamps to touch any metal other than the positive 4 battery terminals Connect the other end of the positive jumper cable to the jumper vehicle s bat tery positive terminal Connect the negative jumper cable to the jumper vehicle s battery negative terminal Make the final negative jumper cable connection to the disabled loader s engine block or loader frame ground NOT to the disabled battery s negative post If connected to the engine keep the jumper clamp away from the battery fuel lines and moving parts Start the loader If it does not start at once start the jumper vehicle engine to avoid excessive drain on the booster battery After the disabled loader is started and running smoothly have the second person remove the jumper cables negative jumper cable first from the jumper vehicle s battery and then from the disabled loader while being sure NOT to short the two cables together Allow suffi
71. roved for the loader WRONG Never leave loader with A engine running or with lift arm up To park engage parking brake and put attachment flat on the ground 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 care fully read and thoroughly understand the contents of this Operator s Manual Failure to follow safety operating and maintenance instruc tions can result in serious injury to the operator or bystand ers 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 or other reproductive harm Wash hands after handling battery Cuz HL Gehl Company One Gehl Way P O Box 179 West Bend WI 53095 0179 U S A www gehl com 2010 GEHL COMPANY 917334 BP0310 All Rights Reserved PRINTED IN U S A
72. t 1562 mm 0 43 m3 335 Ibs 826 lbs 1064 Ibs 152 kg 375 kg 483 kg 67 in 18 4 ft3 1701 mm 0 52 m3 395 Ibs 795 Ibs 1000 Ibs 179 kg 361 kg 454 kg Earth and Foundry Bucket 61 5 in 10 9 ft 1562 mm 0 31 m3 331 Ibs 1228 lbs 1469 Ibs 150 kg 557 kg 666 kg Pallet Forks 15 75 in 400 mm Forks with 470 Ibs 662 Ibs 838 Ibs Backrest Rating per EN474 3 213 kg 300 kg 380 kg 19 68 in 500 mm Forks with 470 lbs 616 lbs 775 lbs Backrest Rating per EN474 3 213 kg 279 kg 352 kg 24 in 670 mm Forks with 470 Ibs 575 lbs 526 lbs Backrest Rating per SAE J1197 213 kg 261 kg 239 kg 917334 BP0310 75 Table of Common Materials and Densities Density Material Ibs ft kg m Ashes 35 50 560 800 Brick common 112 1792 Cement 110 1760 Charcoal 23 368 Clay wet dry 80 100 1280 1600 Coal 53 63 848 1008 Concrete 115 1840 Cinders 50 800 Coal anthracite 94 1504 Coke 30 480 Earth dry loam 70 90 1121 1442 Earth wet loam 80 100 1281 1602 Granite 93 111 1488 1776 Gravel dry 100 1602 Gravel wet 120 1922 Gypsum crushed 115 1840 Iron ore 145 2320 Lime 60 960 Lime stone 90 1440 Manure liquid 65 1040 Manure solid 45 720 Peat solid 47 752 Phosphate granular 90 1440 Potash 68 1088 Quartz granular 110 1760 Salt dry 100 1602 Salt Rock solid 135 2160 Sand dry 108 1728 Sand wet 125 2000 Sand foundry 95 1520 Shal
73. t tilt drive and auxiliary controls are in their neutral positions the brake is on 4 Push the throttle 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 START position Important Do not engage the starter for longer than 15 seconds at a time Longer use can overheat and damage the starter 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 Cold Starting Procedure Do not use starting fluid ether with preheat PN WARNING systems An explosion can result which can cause engine damage injury or death 917334 BP0310 31 1 Turn the key to the run position If the preheat light on the right instrument panel comes on wait until it goes out 2 Turn the key switch to the start position 3 Repeat if engine does not start Stopping the Loader The following procedure is the recommended sequence for stopping the loader 1 Check that the drive control handle s is are in neutral position 2 Lower the lift arm and rest the attachment on the ground 3 Pull the throttle lever back to the low idle position and or take your foot off t
74. tachment Mounting The Gehl loader is equipped with a two pin All Tach attachment bracket for mounting a bucket or other attach ment Two latch levers secure the attach ment Rotate the levers until they are hori zontal to engage the latch pins Rotate the levers until they are vertical to disengage the latch pins Figure 14 All Tach Attaching Mechanism Hitch To prevent unexpected attachment release PN WARNING from the hitch be sure to secure the lock pins by rotating the levers downward into a horizontal position 917334 BP0310 29 Notes 30 917334 BP0310 CHAPTER 4 OPERATION Before starting the engine and operating the PN WARNING 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 prop erly 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 yourself with 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 handholds to get into the operator s compartment 2 Fasten the seatbelt and lower the restraint bar 3 Verify the following gt the lif
75. tely If the lift arm must be left in the raised position BE SURE to properly engage the lift arm support device page 20 Move the throttle to the low idle position shut off the engine and remove the key Before exiting move the lift tilt control s to verify that the controls do not cause movement of the lift arm or attachment Safety Reminders Before Starting gt v Vv VV V WV Do not modify the ROPS FOPS unless instructed to do so in installation instructions Modifications such as welding drilling or cutting can weaken the structure and reduce the protection it provides A damaged ROPS FOPS cannot be repaired it must be replaced To ensure safe operation replace damaged or worn out parts with genuine Gehl service parts Gehl skid steer loaders are designed and intended to be used only with Gehl attachments or approved referral attachments Gehl cannot be responsible for operator safety if the loader is used with a non approved attachment Remove all trash and debris from the machine each day especially in the engine compartment to minimize the risk of fire Always face the loader and use the handholds 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 all nearby 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
76. th proper grade new oil Allow exhaust to cool remove restriction Replace the filter s 917334 BP0310 59 Hydrostatic System Problem Possible Cause Remedy No response from either hydrostatic drive or the lift tilt systems Hydraulic oil viscosity is too heavy Hydraulic oil supply is too low Drive coupling failure Allow longer warm up or replace existing oil with the proper viscosity oil Check for low oil level in reservoir Add oil Replace the coupling Traction drive will not operate in either direction Parking brake is engaged Hydraulic oil supply is low Control rod linkage disconnected Low or no charge pressure Hydrostatic pump s relief valves are malfunctioning Disengage parking brake Check for low oil level in reservoir Add oil Check linkage connection at control levers and neutral centering mechanisms Reconnect linkage Contact your dealer Contact your dealer Sluggish response to acceleration Air in hydraulic system Automatic parking brake partially engaged Hydraulic oil supply is too low Low hydrostatic system charge pressure Drive motor s or hydrostatic pump s have internal damage or leakage Cycle lift and tilt cylinders to maximum stroke and maintain pressure for a short time to clear air from system Also check for low oil level in reservoir fill as needed Contact your dealer
77. the recommended intervals may be required under severe operating conditions You must decide if your operation requires more service 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 loader dealer hydrostatic components hydraulic system gear pump valves cylinders electrical components other than the battery circuit breakers Figure 23 Engine Compartment Air Cleaner Muffler Radiator Cooler Coolant Recovery Tank Hydraulic Oil Filter Engine Oil Dipstick Engine Oil Fill Cap Engine Oil Filter Fuel Filter 10 Fuel Pump 11 Water Trap OANDARWND 917334 BP0310 41 Tilting Back the ROPS FOPS For service unbolt the two anchor bolts at the front of the ROPS FOPS and tilt it back slowly moving the control handles out of the way A gas charged spring helps tilt it back A self actuating lock mechanism engages to lock the ROPS FOPS in a rolled back position To lower the ROPS FOPS apply upward force on it while pulling the lock mecha nism handle toward the front of the loader Lower the ROPS slowly onto the chassis moving the control handles out of the way
78. toring the fuel sender 917334 BP0310 43 Engine Speed Control The throttle cable does not require routine adjustment Refer to the Service Manual for the initial setup procedure Besides throttle cable adjustment the throttle lever friction pad pressure can be readjusted 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 Drive Chains The drive chains do not require routine adjustment Refer to the Service Manual for the initial setup procedure Lubrication Listed below are the locations temperature ranges and types of recommended lubricants to be used when servicing this machine Refer to the separate engine manual for more information regarding recommended engine lubricants quanti ties required and grades Use Mobil DTE 15M or equivalent that contains anti rust Hydraulic System anti foam and anti oxidation additives and conforms to ISO VG46 Capacity 8 U S gallons 30 0 liters Use SAE15W 40 motor oil Chaincases Capacity each side 8 U S quarts 7 6 liters Grease Fittings 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 Engine Service Classification API CH 4 CI 4 Capacity 3 cylinder 7 6 U S quarts 7 2 liters 4 cylinder 9 0 U S quarts 8 6 liters Refer to the following figure for grease fitting locatio
79. uch hot engine or hydraulic System parts 14 917334 BP0310 Product and Component Plate Locations Product and Component Plates Engine plate with e g type designation product and serial number Operator protective system plate with e g model certification and operator protection System serial number Product plate with Product Identification Number and e g model type designation Seat plate according to ISO 7096 Component plate rear drive axle with e g product and serial number Component plate front drive axle with e g product and serial number Component plate transmission with e g product and serial number Ny NOOR OO 917334 BP0310 15 Notes 16 917334 BP0310 CHAPTER 3 CONTROLS AND SAFETY EQUIPMENT Become familiar with and know how to use all PN CAUTION 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

3640E/3840E/4240E Operator`s Manual

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