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5–34

AP0902

Maintenance

5.13.3

Instructions concerning specific components

Cables, bulbs and fuses

•

Defective components of the electrical system must always be replaced by authorized
technicians, except that bulbs and fuses may be changed by other persons

•

When carrying out maintenance work on the electrical system, pay particular attention
to ensuring good contact in connections and fuses

•

Blown fuses indicate overloading or short circuits. The electrical system must therefore
be checked before installing the new fuse

•

Only use fuses with the specified capacity (amperage) – see Electrical system on
page 7-5

Alternator

Always observe the following instructions:

•

Only test the engine with the battery connected

•

When connecting the battery, ensure that the poles are not reversed

•

Always disconnect the battery before carrying out welding work or connecting a quick
battery charger

•

Replace a defective charge warning light as quickly as possible

Battery

NOTE:

The battery is located in the engine compartment, on the left side.
Even so-called “maintenance-free” batteries must undergo maintenance, because
they too consume water.
Always follow the specific safety instructions!

☞

Observe the following instructions to ensure a long battery service life:

•

Keep the surface of the battery in clean and dry condition

•

Check the acid level at regular intervals and if necessary, fill up with demineralized or
distilled water. Never fill up with acid!
Check the regulator voltage of the machine in case of increased loss of water

•

Do not use so-called battery improving compounds

•

Check the battery charge condition by measuring the acid density.
(Exception: In the case of closed batteries by measuring the off-load voltage)

NOTE:

Recharge the disconnected battery if specific gravity is below 1.21. At this level the
battery will freeze only at temperatures below 5 °F ( –15 °C).

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Содержание 418T Wheel

Страница 1: ...OPERATOR S MANUAL Form No 418T Wheel Loader 909879...

Страница 2: ...OT INCLUDE 1 Transportation to selling dealer s business location or at the option of the Original Retail Purchaser the cost of a service call 2 Used equipment 3 Components covered by their own non Ge...

Страница 3: ...es of America All rights reserved No part of this publication may be reproduced translated or used in any form or by any means graphic electronic or mechanical including photocopying recording taping...

Страница 4: ...d consoles 3 4 Placing into service 3 5 Safety instructions 3 5 Placing the machine into service for the first time 3 5 Checklists 3 6 Driving the machine 3 8 Overview of controls 3 8 Warning Lights o...

Страница 5: ...fuel system 5 6 Engine lubrication system 5 7 Checking the engine oil level 5 7 Topping up the engine oil 5 7 Changing the engine oil 5 8 Changing the engine oil filter cartridge 5 9 Engine and hydra...

Страница 6: ...ing 5 36 Bolted connections 5 38 Pivots and hinges 5 38 Engine fluids and lubricants 5 39 Maintenance kits 5 40 Helpful information for using the service parts list Helpful information for using the s...

Страница 7: ...orques 7 9 Conversion tables 7 10 Conversion factors 7 10 Specific converted values 7 11 Annex Proofs of maintenance A 1 Maintenance plan model 418T overview A 3 Maintenance plan model 418T maintenanc...

Страница 8: ...escopic unit with the engine switched off 3 47 M Machine Brief description 1 3 Data 1 7 Fields of application 1 4 Overview 1 2 Machine inspections 1 5 Maintenance Air filter 5 13 Biodegradable oil 5 1...

Страница 9: ...7 2 Specific converted values 7 11 Steering 7 3 Telescopic unit 7 4 Tightening torques 7 9 Tires 7 7 Vibration 7 8 Weights 7 7 Work hydraulics 7 3 Starting with starting aid 3 24 Steering 3 21 Symbols...

Страница 10: ...Section 1 Introduction 1...

Страница 11: ......

Страница 12: ...y to avoid accidents Special safety instructions with direct reference to service function and operator s of the machine are given before the procedure to follow in the respective chapters These safet...

Страница 13: ...ve FOPS screen 9 Noise emission label 10 EC sign 11 Maximum driving speed label 12 Fuel filler inlet 13 Drawbar pin 14 Rear eye hooks lifting and strapping down the machine 15 Step 16 Working light op...

Страница 14: ...ic drive The diesel engine drives a hydraulic pump whose oil flow is sent to a hydraulic motor con nected to the rear axle The force of the hydraulic motor is transmitted to the rear axle via the tran...

Страница 15: ...table gives an overview of the possible attachments Description and Model Model No Use Standard bucket w teeth normal material 418T 810136 Loosening picking up transporting and loading loose or solid...

Страница 16: ...f your country Equipment The highway regulations of your state province may require you to equip your machine with Slow Moving Vehicle SMV emblem warning lights Become informed on and follow the local...

Страница 17: ...ine off the serial number plates and enter this data in the list They will immediately be at hand for all inquiries or service parts orders Machine model Date of registration Service hours kilometer r...

Страница 18: ...mp The type label arrow Fig 5 is located on the pump below the air filter Hydraulic motor number The type label arrow Fig 6 is located on the lower side of the hydraulic motor above the cardan shaft F...

Страница 19: ...t of machine frame and at rear of machine Fig 8 3 Meaning Eye hooks limit Fig 10 stops on the machine The eye hooks are used for lifting or strap ping down the machine Location At the rear of the coun...

Страница 20: ...AP0902 1 9 Introduction Meaning Read and observe the operator s manual before carrying out maintenance work Location On the engine block Fig 12 Fig 12 Please refer to operator s manual...

Страница 21: ...10135 Off road application safety factor S 1 67 Distance of load to rear of fork arms 20 inches 500 mm Height of fork arm above tire contact area 61 inches 1 56 m Distance to tire front 132 inches 3 3...

Страница 22: ...Section 2 Safety instructions 2...

Страница 23: ......

Страница 24: ...or the operator or other persons Measures for avoiding danger IMPORTANT Failure to observe the instructions identified by this symbol may result in damage to the machine Measures for avoiding danger f...

Страница 25: ...ected by carrying out machine modifica tions without proper authority and by using spare parts equipment attachments and optional equipment which have not been checked and approved by the manufacturer...

Страница 26: ...rganization work sequences or the persons doing the work supplement the operator s manual by corresponding instructions including those relevant to supervising and reporting duties Persons who with wo...

Страница 27: ...age limits Employ only trained or instructed staff on the machine and set out clearly and unequiv ocally the individual responsibilities of the personnel for operation set up maintenance and repair D...

Страница 28: ...out start up and shut down procedures in accordance with the operator s manual and observe the warning lights Before putting the machine attachment into operation start up moving make sure nobody is...

Страница 29: ...the operator is responsible for third parties Caution when handling fuel increased danger of fire Make sure fuel does not come into contact with hot parts Stop the engine during refuel ling Do not sm...

Страница 30: ...ad hook Load diagrams The load must be secured so as to prevent it from falling or slipping Persons guiding the load or securing it must stay in visual contact with the machine operator The machine op...

Страница 31: ...f Relievepressure in the hydraulic system before connecting or disconnecting hydraulic lines Especially when driving or working with machines with a quick hitch facility for the attachments be sure th...

Страница 32: ...or to the control elements Remove the ignition key Perform service maintenance and repair work only if machine is positioned on firm and level ground Transmission control lever is in neutral position...

Страница 33: ...chafe marks and damage Any defects found must be corrected without delay Tighten any screw connections that have been loosened during maintenance and repair Any safety devices removed for set up main...

Страница 34: ...with the applicable electrical system repair procedures Inspect and check the electrical system of the machine at regular intervals Defects such as loose connections or burned cables must be corrected...

Страница 35: ...serve the product related safety regulations material safety data sheet MSDS Be careful when handling fluids because of the risk of burning or scalding Battery When handling the battery observe the sp...

Страница 36: ...Section 3 Operation...

Страница 37: ......

Страница 38: ...ent no 18 or position A in figure no 40 A figure carries no number when it is placed to the left of the text Unfold pages 3 2 and 3 4 for a better overview The symbols used in the description have the...

Страница 39: ...r wiper rocker switch 3 30 11 Hook 12 Door holder left and right 3 35 13 Drive electronics 3 9 14 Electronic load indicator 3 43 15 Front wiper 3 30 16 Side window locking 3 35 17 Control panel 3 4 3...

Страница 40: ...AP0902 3 3 Overview see overleaf Overview see overleaf...

Страница 41: ...ng brake 3 14 42 Warning Light green right left turn indicator 3 15 43 Warning Light blue high beam 3 15 44 Not assigned 45 Hour meter 3 15 46 Fuel level gauge 3 15 47 Rocker switch rotating beacon op...

Страница 42: ...condition in accordance with its designated use and the instructions set out in the operator s manual and only by persons who are fully aware of the risks involved in operating the machine Go through...

Страница 43: ...achine into service or starting the engine No Question 1 Sufficient fuel in the tank 5 1 2 Coolant level OK 5 10 3 Engine oil level in order 5 7 4 Oil level in hydraulic oil tank in order 5 16 5 Brake...

Страница 44: ...tor tested and OK 3 44 When travelling on public roads particular attention should be paid to the following points 7 Telescopic unit completely retracted 3 53 8 Bucket and attachments in transport pos...

Страница 45: ...y after releasing the parking brake 1 0 2 3 52 Fig 21 Preheating start switch P Position Function Power consumer P No function None 0 Inserting or removing ignition key None 1 ON drive position All fu...

Страница 46: ...with less hydraulic oil which means the entire engine output is available to the work hydraulics This allows the loader to raise more rapidly Braking Press the brake inching pedal 3 down with force In...

Страница 47: ...ng away Emergency brake in case of service brake breakdown WARNING Use the parking brake 25 instead of the service brake only in an emergency i e in case of a breakdown of the service brake The brake...

Страница 48: ...on and off with rotary switch 32 Switch on front window washer pump with tip switch 33 Sound horn with tip switch 34 Switches on high beam and headlight flasher with lever 31 Turn indication with leve...

Страница 49: ...tip switch 33 Sound horn with tip switch 34 Fig 31 Actuating the washer pump 33 Tip switch 33 Effect Slide to the left and hold Washer pump ON Release Washer pump OFF Fig 32 Actuating the horn 34 Tip...

Страница 50: ...on if coolant temperature is too high A buzzer sounds at the same time The warn ing light and the buzzer go out as soon as the coolant temperature is back in the accept able range WARNING Never open t...

Страница 51: ...Warning Light red hydraulic oil filter Indicates an unacceptably high pressure in the hydraulic return line to the tank In this case Replace the hydraulic oil return filter page 5 20 In cold weather w...

Страница 52: ...Flashes intermittently when the turn indicators are used lever 17 31 43 Warning Light blue high beam Comes on if high beam is switched on or during headlight flashing 44 Not assigned 45 Hourmeter Coun...

Страница 53: ...e is off Procedure After you have completed the starting preparations in accordance with 3 4 3 Before starting the engine Insert the ignition key into the preheating start switch 33 52 Turn the igniti...

Страница 54: ...n general a battery delivers less energy in cold conditions As a result you must be sure the battery is always well charged for a cold start at outside temperatures below 32 F 0 C Let the engine run a...

Страница 55: ...ises and is replaced by cold fluid The coolant or the oil can only be thoroughly warmed up to service temperature if the engine preheater is connected over a longer period of time preferably over nigh...

Страница 56: ...Drive the jump starting machine close enough to the machine so that the jumper cables can reach to connect the two batteries Start the engine of the jump starting machine First connect one end of the...

Страница 57: ...mm 36 C with standard bucket and standard tires 12 5 20 Secure the control lever for the telescopic unit 21 against unintentional operation To do this Push control lever 21 down in neutral position T...

Страница 58: ...ing behavior Use a towing rod Functional check Move the steering wheel to the left and right Wheel synchronization position Important Important Important Important Carefully steering the front and rea...

Страница 59: ...e service brake action as follows Before driving machine press down the brake inching pedal 16 3 to check whether After a maximum of half the pedal travel there is a firm resistance to be felt Brake l...

Страница 60: ...eed Machine drive system also may be damaged Switch drive ranges with the machine driving at low speed only Fig 40 Selection of drive range with rocker switch 58 B A Drive range Rocker switch 58 Recom...

Страница 61: ...ke Backup alarm option DANGER When backing up with the machine Accident hazard Make sure that nobody is within the area of danger of the machine when changing the driving direction Do not rely exclusi...

Страница 62: ...re locked automatically The differential lock cannot be engaged or disengaged by the operator If a wheel loses contact with the ground the differential lock on the respective axle is no longer effecti...

Страница 63: ...e both LEDs 61 and 62 go out Apply the parking brake permanently see Section 3 4 9 Stopping the machine Retract the telescopic unit To do this Press tip switch 64 until the telescopic unit is complete...

Страница 64: ...y switch 32 to position II Warning Light 19 43 comes on with high beam switched on OFF Turn rotary switch 32 to position 0 High beam and warning light 19 43 go out 31 Fig 46 Switching on high beam and...

Страница 65: ...downwards in A down Warning Light in rocker switch 53 flashes OFF Press rocker switch 53 downwards in B above Warning Light in rocker switch 53 goes out Fig 49 Turn indicators 31 L R Turn indicators...

Страница 66: ...partment via a foot vent 16 19 The foot vent can be closed and directed separately Fig 51 Fan switch A B 56 Ventilation fresh air 1st fan level Press rocker switch 56 down in A below by one step 2nd f...

Страница 67: ...ich give information about concentrations A B 55 Fig 53 Front wiper switch Front wiper ON Press rocker switch 55 in A below OFF Press rocker switch 55 in B above 33 Fig 54 Washer pump tip switch A B W...

Страница 68: ...t Important Adjust the seat suspension correctly to ensure comfort Use lever a to adjust the seat suspension to the operator s weight The weight indicator b shows the set operator weight in kg Sit dow...

Страница 69: ...quired Backrest setting Sit down on the operator s seat Pull lever e upwards and at the same time Lean back to push the backrest into the required position Let lever e lock into place Fore and aft set...

Страница 70: ...ed otherwise the buckle latch can not lock into place WARNING After an accident the belt strap may be stretched and is no longer serviceable In an accident the seat belt will not provide adequate prot...

Страница 71: ...the buckle latch at a right angle to the seat belt and pull the seat belt to the required length see Fig 65 To shorten the lap belt just pull on the free end D of the belt see Fig 65 NOTE When pulled...

Страница 72: ...y b in door lock to the right Unlock door Turn ignition key b in door lock to the left Opening from inside Pull lever 1 up Driver s door in open position with the door arrester Press the operator s do...

Страница 73: ...llows Pull the end of lever a to the rear out of guide b Side window in open position with door holder 16 12 Open the side window completely and push against door holder 16 12 until the door locks int...

Страница 74: ...ds or handles that ensure a safe access exit Moreover the side window cannot be held in open position if locking lever 69 16 is lifted out of guide 69 b Danger of personal injury Do not use the side w...

Страница 75: ...ing Turn the key to the left Engine cover The engine cover can only be opened by key Unlocking Turn the key to the right Pull the engine cover upwards Closing Press the engine cover firmly down Turn t...

Страница 76: ...y only be towed with a cable if the service brakes and steering are fully operational When loading and transporting the machine The transport machine must be of adequate size refer to section Specific...

Страница 77: ...below Do not tow the machine for more than 100 yards 100 meters and do not tow it faster than 2 3 mph 3 4 km h Tow the machine as follows Move drive lever to neutral see Driving direction selector sw...

Страница 78: ...he ramps Carefully drive the wheel loader onto the transport machine Move drive lever to neutral see Driving direction selector switch on page 3 8 Apply the parking brake of the wheel loader Lower the...

Страница 79: ...ks comply with the load diagrams for this machine The hydraulic system of the machine remains pressurized even when the engine is not running Relieve the pressure in the sections of the system and hyd...

Страница 80: ...ic unit Your machine is equipped with an electronic load indicator 14 which continuously monitors the weight variations on the rear axle during operation Visible and audible signals warn the operator...

Страница 81: ...safe work load The complete indicator is flashing the acoustic signal is given although the TEST tip switch has not been activated The load indicator is defective Have it immediately checked and repa...

Страница 82: ...lever for driving on public roads To engage Follow the instructions given in Section 3 4 5 Before driving the machine Push control lever 21 down in neutral position The control lever is locked in thi...

Страница 83: ...backward To open briefly Pull lock sleeve 23 up to the limit and hold it in this position As long as lock sleeve 23 is being pulled upward lever 22 can be moved 22 Fig 78 Control lever for attachments...

Страница 84: ...even when the engine is not running The hydraulic quick couplers can be released however they cannot be re attached because the pressure in the hydraulic lines is too high Therefore Depressurize sect...

Страница 85: ...e that the attachment is securely locked onto the quick hitch facility by means of the lock cylinder You must be able to see the lock pins on both sides of the mounting holes Proceed as follows Drive...

Страница 86: ...c and if used electrical connections for the attachment in accor dance with its operator s manual Connection of electrically operated attachments option The machine can be equipped with a 4 pole front...

Страница 87: ...lever 21 forward C Attachments with hydraulic function Switch off the engine Change round the hydraulic connections figure 89 from the attachment to the lock cylinder in accordance with the operator s...

Страница 88: ...facility is exposed to the sun for a long period of time without being connected to the machine This pres sure cannot be lowered by means of depressurization as described in section 3 Relieving press...

Страница 89: ...aulic line A to blue plug D of the quick hitch facility on the right Connect hydraulic line B to red plug C of the quick hitch facility on the left Release lock of lever 22 Return lever 22 back to neu...

Страница 90: ...dible signal warn of loads exceeding 100 The operator must reduce the load below the 100 limit by retracting the telescopic unit Lift Proceed as follows Raise the retracted telescopic unit to the requ...

Страница 91: ...the telescopic unit To do this Press tip switch 64 until the telescopic unit is completely retracted Lower the retracted telescopic unit To do this Push lever 21 forward C 1 Fig 99 Retract the telesc...

Страница 92: ...ose burst valve only in an emer gency Have damage to the hydraulic system and to the hose burst valve immedi ately repaired and checked by trained personnel In the event of damage to the hydraulic sys...

Страница 93: ...pic unit to transport position Tighten screw B again countering it with locknut A Drive the machine out of the hazard zone with the bucket lowered Have the setting of the hose burst valve checked by a...

Страница 94: ...fully extend the push out cylinder until the bore on the left side of the telescopic unit can be accessed Carefully turn out screw A by about 1 2 turn until the attachment starts dumping Retighten scr...

Страница 95: ...A on top of the bucket is the same as the angle of the cutting blade B Checking the transport position of the bucket NOTE The bucket is in transport position when the Telescopic unit is fully retracte...

Страница 96: ...The lower the bucket and the center of gravity the less chance there is of tipping over To avoid accidents Completely retract the telescopic unit Roll back the bucket all the way Raise the bucket to...

Страница 97: ...ly retract the telescopic unit Select low drive range Align the blade parallel with the ground A see also Checking the tilt position of the bucket Lower the bucket to the ground B To do this Push leve...

Страница 98: ...Move lever 21 to the left and right A and B Ending loading Proceed as follows Roll back in bucket C To do this Push lever 21 to the left A Reduce engine speed Reverse out of the material A Raise the...

Страница 99: ...do this Push lever 21 forward C Set digging angle 113 1 To do this Push lever 21 to the right B Drive the machine forward 114 1 Once the bucket has penetrated the soil Set digging angle slightly flatt...

Страница 100: ...ard 115 3 and Press the bucket downward slightly To do this Push lever 21 slightly forward C Once the bucket has penetrated the soil Set digging angle slightly flatter 116 1 To do this Push lever 21 t...

Страница 101: ...pic unit Keep the bucket level When the telescopic unit stops raising Roll back the bucket 118 1 Raise the telescopic unit 118 2 Reverse away from the heaped material 118 3 Lower the telescopic unit t...

Страница 102: ...lope Loading machines When loading machines we recommend to take into account the following Select low drive range If possible the lorry and the working direction of the machine should form an angle o...

Страница 103: ...ient bearing capacity for a fully loaded machine Never lift the load with only one fork arm Keep a minimum distance of 6 m between telescopic unit load and tower lines Before commencing work make sure...

Страница 104: ...escopic unit slowly and make sure that the limits of load diagram and safe load indicator are not exceeded In case of doubt or danger lower the load immediately Tilt the fork frame backwards 1 Complet...

Страница 105: ...ork arms level again 3 Lower the telescopic unit slowly 4 making sure that the preset limits of load diagram and safe load indicator are not exceeded In case of doubt or danger stop stacking immediate...

Страница 106: ...Section 4 Troubleshooting...

Страница 107: ......

Страница 108: ...personnel when carrying out repair work It allows for fast and reliable detection of errors and malfunctions so that appropriate measures can be taken for troubleshooting The detailed description of...

Страница 109: ...11 13 15 17 18 19 21 22 34 36 37 38 39 40 42 43 44 63 Black smoke 11 13 15 17 19 21 22 34 36 37 38 39 40 42 43 44 63 Blue or white smoke 4 15 21 23 36 37 38 39 42 44 45 52 58 62 Oil pressure too low 4...

Страница 110: ...ing 29 Engine oil level too high 30 Limited circulation of air or coolant through radiator 31 Breather line constricted 32 Coolant level too low 33 Vacuum line leaks or defective vacuum pump 34 Defect...

Страница 111: ...4 4 AP0902 Troubleshooting Notes...

Страница 112: ...Section 5 Maintenance 5...

Страница 113: ......

Страница 114: ...ervals for the maintenance work described below are listed in the maintenance plans in the annex 5 2 Fuel system 5 2 1 Specific safety instructions Extreme caution is essential when handling fuel beca...

Страница 115: ...possible only refuel from stationary fuel tanks Fuel from barrels or cans is usually con taminated Even the smallest particles of dirt can cause Increased engine wear Malfunctions in the fuel system...

Страница 116: ...el tank when the fuel level in the tank is as low as possible Clean the fuel tank as follows Place a drip tray under fuel tank A Unscrew return connection piece B Flush out the fuel tank with fuel sev...

Страница 117: ...old lower cover 133 6 of the filter and unscrew screw 133 1 on the filter head Pull lower cover 133 6 of the filter downward Remove and dispose of filter 133 4 Clean the inside of the filter head and...

Страница 118: ...stem there is an increased risk of fire Never clean the fuel water separator if the engine is hot Proceed as follows Place a drip tray under the fuel water separator Unscrew the drain plug on the lowe...

Страница 119: ...eriod of time Bleed the fuel system as follows Fill the fuel tank Unscrew the vent screw 135 1 on the side of the fuel injection pump Actuate the hand pump lever on the fuel supply pump 135 2until the...

Страница 120: ...in engine damage For this reason Do not add engine oil above the MAX mark 136 2 of the oil dipstick Use only the specified engine oil see section 5 15 Engine fluids and lubri cants on page 5 39 Envir...

Страница 121: ...a capacity of about 8 quarts 8 liters under the opening Unscrew filler cap C of oil drain valve E Unscrew oil drain coupling D with a sufficiently long hose making sure the end of the hose is in the...

Страница 122: ...e the thread adapter 140 1 is correctly placed in the filter head Clean the inside of the filter head Apply a thin coat of fresh engine oil to the rubber seal 140 2 of the new oil filter cartridge Tig...

Страница 123: ...d to engine damage Therefore Check the coolant level at regular intervals Refer to the maintenance plan in the Annex for the intervals If coolant must be added frequently check the cooling system for...

Страница 124: ...s under high pressure and there is a risk of burns Wait at least 10 minutes after switching off the engine Wear protective gloves and clothing Always start by actuating the safety valve in the cap of...

Страница 125: ...Reduce the overpressure in expansion tank A To do this Open filler cap D by half a revolution After releasing the pressure Open filler cap D completely Fill up coolant up to MAX mark C Close filler ca...

Страница 126: ...ry year NOTE The air filter can be fitted with an optional safety cartridge for applications in especially dusty environment It is not possible to clean the safety cartridge Replace the safety cartrid...

Страница 127: ...engine cover Open the three bow clips 145 B on the lower housing section 145 C Remove the lower housing section 145 C Remove filter cartridge 146 E with a slight turning movement Additionally after e...

Страница 128: ...ddle of the longest section between two pulleys figure 148 to check whether the V belt can be deflected by no more than about 0 4 in 10 mm Re tension the V belt if necessary see Section 5 6 2 Re tensi...

Страница 129: ...system This may cause damage to the hydraulic pump Contact your dealer immediately Insufficient or incorrect hydraulic oil will result in damage to the hydraulic system For this reason Only use author...

Страница 130: ...il Check the hydraulic oil level on oil level sight glass A Top up the hydraulic oil if necessary and check again 5 7 4 Changing the hydraulic oil WARNING Draining hot hydraulic oil and removing the f...

Страница 131: ...ace the hydraulic oil return filter see Hydraulic oil return filter on page 5 20 Check the whether the filling screen is intact Important If the hydraulic oil is contaminated there is a risk of severe...

Страница 132: ...of the oil analysis Drain the condensation water in the hydraulic oil tank every 600 service hours and in any case before the cold season The water content should not exceed 0 1 by weight The instruc...

Страница 133: ...Open breather A on the hydraulic oil tank Unscrew caps F and 154 1 of the filter by about 2 turns and wait for the oil level in the filter housing to fall to the level in the tank Completely unscrew a...

Страница 134: ...ctions could set in Never search for leaks with your bare hands but wear protective gloves Use paper or wood to check for minor leaks Never use an unprotected light or naked flame Always observe the f...

Страница 135: ...nsfer gearbox B If the oil level is below the opening or if the oil level cannot be seen at all Top up with oil see section 5 15 Engine fluids and lubricants on page 5 39 If the oil level is correct T...

Страница 136: ...ansfer gearbox to collect the oil Clean and unscrew plug A on transfer gearbox B Unscrew plug C on transfer gearbox B Completely drain the old gearbox oil Tighten plug C with a new sealing ring to ens...

Страница 137: ...n level ground Clean and unscrew plug 158 A Fill with oil until it runs out of the filler opening see section 5 15 Engine fluids and lubricants on page 5 39 Tighten plug 158 A with a new sealing ring...

Страница 138: ...ug 159 A Fill with fresh oil up to the oil level mark 159 2 overflow see section 5 15 Engine fluids and lubricants on page 5 39 Tighten plug 159 A with a new sealing ring 159 D to ensure an oil tight...

Страница 139: ...n bearing uses Longlife lubrication Lubricate the bearing every 1200 service hours maintenance plan C Grease oscillation type bearing A on grease nipple B with lithium based multipurpose grease see se...

Страница 140: ...run in the brake pads brake the machine more frequently than usual using the service brakes but avoid full braking Replace damaged brake lines or hoses immediately because of the risk of accidents 5...

Страница 141: ...3 every 50 service hours or once a week with grease 5 10 2 Lubricating the telescopic unit Lubricate the pad tracks at regular intervals Recommended lubricant see section 5 15 Engine fluids and lubric...

Страница 142: ...t the wear pads as follows Extend the telescopic unit by about 20 cm so that the front wear pads can be easily accessed Switch off the engine Prop the telescopic unit securely Loosen the locknuts at s...

Страница 143: ...Specifications on page 7 7 for the authorized tire types and the correct tire pressures This table is also on the label on the front win dow 5 11 1 Inspection work Daily checks Carry out the followin...

Страница 144: ...ng the wheels Proceed as follows Park the machine on level and firm ground and prevent it from rolling away Slightly loosen the wheel nuts of the tire you want to remove Place a jack under the axle be...

Страница 145: ...air taken in by the heater Blow compressed air through the filter as often as necessary but at least once a year The volume of warm air flowing out of the air vents decreases as filter contamination i...

Страница 146: ...attery may rupture or explode Avoid sparks and unprotected light sources and refrain from smoking in the vicinity of opened battery cells because the gas produced during normal battery operation may i...

Страница 147: ...out welding work or connecting a quick battery charger Replace a defective charge warning light as quickly as possible Battery NOTE The battery is located in the engine compartment on the left side Ev...

Страница 148: ...th of the amp hour capacity e g 80 Ah 8 A charging current Charge closed batteries with regulated battery chargers only Make sure acid temperature does not exceed 120 F 55 C during recharging Stop rec...

Страница 149: ...ch as gasoline or diesel fuel Compressed air Work carefully Wear goggles and protective clothing Do not aim the compressed air at the skin or at other people Do not use compressed air for cleaning you...

Страница 150: ...ne only with a mild soap solution do not use chemical agents because they may destroy the fabric WARNING For automatic seat belts option soiled belts may impair winding and thereby affect safety Only...

Страница 151: ...n the mainte nance schedules Tighten loose connections immediately Tightening torques can be found in section Specifications 5 14 3 Pivots and hinges All mechanical pivot points on the machine e g doo...

Страница 152: ...AE 90 LS 3 9 quarts 3 7 litres each SAE 80W 90 LS concentrate7 7 Necessary addition of Fuchs LS concentrate 20 gr ltr Hydraulic oil tank Engine oil2 SAE 5 W 303 4 F to 95 F 20 C to 35 C About 52 8 qua...

Страница 153: ...0160030030 Maintenance kit 1 Maintenance kit for Maintenance plan B 0160030130 Maintenance kit 1 Maintenance kit for Maintenance plan C 0160030230 Maintenance kit 1 Additional parts for maintenance k...

Страница 154: ...Section 6 Helpful information for using the service parts list...

Страница 155: ......

Страница 156: ...machine Please read this section carefully It will make it easier for you to carry out your work and find service parts The illustrations in the service parts list are not binding for design Subject...

Страница 157: ...uel system 10 Air filter 15 Cooling system 17 Speed regulation 20 Machine frame 22 Hydrostatic drive 23 Front axle 24 Brake system 26 Rear axle 27 Steering 29 Operator s seat 30 Sheet metal parts 31 W...

Страница 158: ...eference numbers in the figures Part numbers are listed in the order of figures and of reference number 01 58 20 19 17 18 21 22 21 19 Figure number Fig 168 Example for figure Reference numbers 01 7 1...

Страница 159: ...cled number identifies an assembly which may consist of several component parts Assemblies are delivered as finished assemblies or preassembled with all necessary component parts Component parts can b...

Страница 160: ...e standard torques if no specific torque is stated see section 7 16 1 General tightening torques on page 7 9 and section 7 Specific tightening torques on page 7 9 Safety part For reasons of safety par...

Страница 161: ...machine 6 4 Machine data Always include the exact machine data in your orders to ensure correct delivery of service parts required See section 1 Machine data on page 1 6 and Type labels and component...

Страница 162: ...delivery of service parts Customer and address e g Jason Miller High Street 40 Leighton Buzzard LU5 8RT Delivery address if not identical with customer s address e g Construction site Jeff Mason Churc...

Страница 163: ...AP0902 Helpful information for using the service parts list 6 5 2 Address for your service part order Gehl Company 143 Water Street West Bend WI 53095 0179 U S A Telephone 262 334 9461 Fax 262 338 75...

Страница 164: ...Section 7 Specifications 7...

Страница 165: ......

Страница 166: ...3 1 kW at 2400 rpm Max torque 154 9 lb ft 210 Nm at 1600 min 1 Specific minimum fuel consumption 288 g hp hr 215 g kWh Fuel injection system Direct fuel injection Firing order 1 3 4 2 Starting aid Glo...

Страница 167: ...ly potentiometer Variable displacement motor Design Axial piston motor swash plate design Capacity 0 9 3 7 in rev 16 60 cm rev Drive speed 0 12 mi h 0 20 km h forward and reverse Max traction force 85...

Страница 168: ...ump steering unit with flanged priority valve steering cylinder automatic synchroniza tion in left and right hand final positions Max pressure of hydraulic lines 2611 lb in2 180 bar Hydraulic pump Gea...

Страница 169: ...hitch facility 185 in 4690 mm Dumping reach Extended 47in 1205 mm Scraping depth about 2 in 50 mm Tilt back angle 40 Dump out angle 40 Breakout force lift cylinder 6744 lbf 30 0 kN Breakout force tilt...

Страница 170: ...F5 A 10 A Front wiper F6 A 10 A Cigarette lighter F7 A 7 5 A Interior lighting Hazard warning system F8 A 7 5 A Switch lights Turn indicators F9 B 10 A Drive switch Drive electronics F10 B 15 A Lights...

Страница 171: ...cab in the side console Fig 171 Main fuses in engine compartment D F24 F23 Fuse Rated current A Protected circuit F23 100 A Main fuse F24 100 A Main fuse 0160081701 eps Fig 172 Relay assignment K2 K1...

Страница 172: ...mm 14 5 20 MPT 10PR 29 lb in2 2 0 bar 25 lb in2 1 7 bar 375 75 R 20 136G 36 lb in2 2 5 bar 29 lb in2 2 0 bar 405 70 R 18 141B 2 2 Overall width of machine larger than standard bucket when equipped wi...

Страница 173: ...h a 217 in 5500 mm Overall height b With FOPS screen With FOPS screen and rotating beacon option 100 in 2530 mm 103 in 2610 mm Overall width c 71 in 1800 mm Ground clearance d under rear axle gearbox...

Страница 174: ...3 0 4 3 7 5 M5 4 1 5 5 5 9 8 7 4 10 M6 7 4 10 10 3 14 11 8 16 M8 17 0 23 25 0 34 29 5 40 M10 33 9 46 49 4 67 58 3 79 M12 58 3 79 84 8 115 99 6 135 M14 92 2 125 136 4 185 162 2 220 M16 143 8 195 213 9...

Страница 175: ...Imperial gallons Imp gal litres ltr 4 546 15 59 US gallons US gal litres ltr 3 785 20 68 Miles per hour mph kilometres per hour km hr 1 6093 30 86 Long tons kilograms kg 1016 05 40 104 Long tons tonn...

Страница 176: ...4 in 2974 kg 6556 4 lb 1750 mm 68 9 in 3150 kg 6994 4 lb 1910 mm 75 2 in 3750 kg 8267 lb 2530 mm 99 6 in Mass Length 4950 kg 10 913 lb 3360 mm 132 3 in 5500 kg 12 125 lb 3950 mm 155 5 in 4690 mm 184 7...

Страница 177: ...7 12 AP0902 Specifications Notes...

Страница 178: ...Annex...

Страница 179: ......

Страница 180: ...50 A 1200 C 1250 A 1300 A 1350 A 1400 A 1450 A 1500 A 1550 A 1600 A 1650 A 1700 A 1750 A 1800 B 1850 A 1900 A 1950 A 2000 A 2050 A Proofs of maintenance After service hours Maintenance plan Date Servi...

Страница 181: ...00 A 4350 A 4400 A 4450 A 4500 A 4550 A 4600 A 4650 A 4700 A 4750 A 4800 C 4850 A 4900 A 4950 A 5000 A 5050 A 5100 A 5150 A 5200 A Proofs of maintenance After service hours Maintenance plan Date Servi...

Страница 182: ...late the crankcase 9 Check glow plugs Replace if necessary Check the fuel water separator Drain water if necessary Check valve tip clearance engine timing Set if necessary Battery Check electrolyte le...

Страница 183: ...place at least every 12 months or 1200 service hours When working in an acidic environment replace the filter every 300 service hours 4 When using biodegradable oil Drain the condensation water in the...

Страница 184: ...nctional check of the steering synchronise the steering Carry out a functional check of the brake system Check brake fluid level Top up if necessary Check hydraulic oil level Top up if necessary Check...

Страница 185: ...bar 12 Temperature switch 212 F 100 C 3 13 Return suction filter initial stress 7 3lb in2 0 5 bar 14 Hydraulic oil tank Hydraulic oil tank Vtotal 15 9 gal 60 l Voil level 13 2 gal 50 l 15 Pressure sw...

Страница 186: ...P2 P1 A P 1 P X C V P T B4 A4 X B3 A3 A2 B2 A1 B1 P T X C V X 0260010325 eps A1 A2 V1 V2 C1 C2 M B1 B2 R L P T LS A EF LS 0 5 0 5 1 7 8 6 9 10 11 12 13 14 16 17 24 22 18 3 4 Hydraulics diagram model 4...

Страница 187: ...h hydraulic oil 2 S12 Temperature switch coolant 2 S13 Pressure switch air filter 2 S14 Pressure switch oil return filter 2 S15 Oil pressure switch engine 2 S16 Multifunctional lever on steering colum...

Страница 188: ...S4 S6 S2 S8 F4 F22 F21 F19 F2 F8 F7 F10 F3 F6 F1 F20 R3 M4 S14 S15 S1 X10 J X X X K X V17 V16 V15 B3 H15 H16 H14 H12 H13 H10 H9 H8 E11 P1 P2 H17 V14 S22 S21 X2 R2 R4 R1 K2 R5 X7 R6 R7 Y2 Y1 B4 X11 X1...

Страница 189: ...Annex A 10 AP0902 Notes...

Страница 190: ......

Страница 191: ...16 3 8 24 20 23 15 17 30 35 23 25 45 50 35 7 16 14 32 24 50 35 70 55 7 16 14 7 16 20 32 36 24 27 50 55 35 40 70 80 55 60 1 2 13 50 35 75 55 110 80 1 2 13 1 2 20 50 55 35 40 75 90 55 65 110 120 80 90 9...

Страница 192: ...the contents of this manual Failure to follow safety operating and maintenance instructions could result in serious injury to the operator or bystanders poor operation and costly breakdowns If you hav...

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