4640e Power2 5240e Power2 Operator's Manual PDF

SL4640E
SL4640E (EU)
Form No.
50950012/
AP0811
Power2
English
(SN 312901 and Up)
SL5240E
Operators Manual
SL5240E (EU)
Power2
(SN 432501 and Up)
Skid-Steer Loaders
Manitou Americas, Inc., in WRONG
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, Never use loader
you are reminded to BE ALERT! Your without ROPS/FOPS.
personal safety is involved! Never modify the
ROPS/FOPS
structure.
Operators must have instructions
before running the machine.
Untrained operators can cause
injury or death.
WRONG
CORRECT
Read Operators Manual Never use the loader

before using machine. to lift personnel.
CORRECT WRONG
Always fasten seatbelt Do not use loader

snugly. Always keep feet on around explosive dust
the floor/pedals when or gas, or where
operating loader. exhaust can contact
flammable material.
SL4640E, SL4640E (EU) and SL5240E, SL5240E (EU)
Power2 Skid-Steer Loader Operators Manual
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Controls and Safety Equipment . . . . . . . . . . . . . . . . . . . 19
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Loader Model Number
Loader Serial Number
Engine Serial Number
Hydraloc and Hydraglide are trademarks of Manitou Americas, Inc.

Gehl, All-Tach, Power-A-Tach and Powerview are registered trademarks of Manitou Americas, Inc.
EC DECLARATION OF CONFORMITY
1. Manufacturer: Manitou Americas, Inc.

2. Address: One Gehl Way
West Bend, WI 53095-0179 U.S.A.
3. Technical Construction File Location:

Manitou Interface and Logistics Europe SA/NV
Chausse de Wavre SN
1360 PERWEZ
Belgium
4. Authorized Representative:
5. Address:
6. 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), as
amended by 2005/88/EC.
7. In accordance with EN/ISO Standards:
EN ISO 3450:1996, ISO 6165
8. Category: EARTH-MOVING MACHINERY/
LOADERS/COMPACT
9. Model(s): 4640E Power2, 5240E Power2
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 TV Industrie Service
Quality Assurance GmbH TV SD Group
Westendst. 199, D-80686
Mnchen GERMANY
CHAPTER 1
INTRODUCTION
This Operators Manual provides the owner/operator with information for operat-
ing, maintaining and servicing Gehl SL4640E and 5240E Power2 skid-steer load-
ers. More important, 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 breakdowns
and damage, and extend your machines life.
A manual storage box in the operators compartment holds the Operators 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 rec-
ommend that these manuals be given to the new owner.
The attachments and equipment available for use with this machine have a wide
variety of potential applications. Read the manual provided with the attachment to
learn how to safely maintain and operate the equipment. Be sure the 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 Manitou Americas, 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 num-
bers in the space provided on the Table of Contents page, as a handy reference.
Manitou Americas 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.
50950012/AP0811 1
If this machine was purchased used, or if the owners address has changed,
please provide your Gehl dealer or Gehl Company Service Department with the
owners name and current address, along with the machine model and serial num-
ber. This will allow the registered owner information to be updated, so that the
owner can be notified directly in case of an important product issue, such as a
safety update program.
2 50950012/AP0811
Loader Identification
3 3 4
4 1
5
6
7 8
8
1. Lift Arm 5. Tilt Cylinders
2. Restraint Bar (Inside) 6. Bucket
3. Front Work Lights 7. Attachment Bracket
4. Handholds (hidden by bucket)
8. Tires
1
6
2
3
8
4
5
1. Engine Cover 6. Roll-Over/Falling Object
2. Rear Work Lights Protective Structure
3. Tail Lights (ROPS/FOPS)
4. Rear Grille 7. Lift Cylinder
5. Lift Arm Support Device 8. Fuel Filler Cap
50950012/AP0811 3
Control/Indicator Symbols
Power Off Power On Engine Start Battery Charge Electrical Power
Worklight w/Flasher Worklight Safety Alert Hazard Flasher Wear Seatbelt
Horn Read Operators Volume Full Volume Half Full Volume Empty
Manual
H-L N
High Low
F R
Neutral Forward Reverse Parking Brake
Engine Air Filter Engine Oil Engine Oil Filter Engine Oil Pressure Fuel Filter
Engine Temperature Hydraulic System Hydraulic Oil Hydraulic Oil Filter Grease Lubrication
Temperature Point
Glow Indicator Diesel Fuel Chaincase Oil Clockwise Rotation Counterclockwise

Lamp Rotation
Fast Speed Slow Speed Ride Control Power-A-Tach Bucket Float
Bucket Rollback Bucket Dump Lift Arm Lower Lift Arm Raise Service Hours
Lift Point Tie-Down Point Diesel Water Engine Malfunction

Separator Shutdown
4 50950012/AP0811
CHAPTER 2
SAFETY
This safety alert symbol means Attention! Become alert! Your safety is
involved! It stresses an attitude of safety awareness and can be found
throughout this Operators 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, Manitou Amer-
icas suggests that equipment owners obtain the Gehl Skid-Steer Loader Safety
DVD, 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
operators 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.
Manitou Americas ALWAYS considers the operators safety when designing its
machinery, and guards exposed moving parts for the operators protection. How-
ever, some areas cannot be guarded or shielded in order to assure proper opera-
tion. Furthermore, this Operators Manual and decals on the machine warn of
additional hazards and they should be read and observed closely.
Some photographs in this manual may show doors, guards and shields open or
removed for illustrative purposes only. Be sure that all doors, guards and shields
are in their proper operating positions before starting the engine to operate the
unit.
Different applications may require optional safety equipment, such as a back-up
alarm, mirror, strobe light or an impact-resistant front door. Be sure you know the
job site hazards and equip the machine as needed.
DANGER indicates an imminently haz-
DANGER ardous situation, which, if not avoided, will
result in death or serious injury.
WARNING indicates a potentially hazardous
WARNING situation, which, if not avoided, could result
in death or serious injury.
CAUTION indicates a potentially hazardous
CAUTION situation, which, if not avoided, may result in
minor or moderate injury. May also alert against unsafe practices.
50950012/AP0811 5
Mandatory Safety Shutdown Procedure
Before cleaning, adjusting, lubricating or servicing the unit, or leaving it
unattended:
1. Move the drive control handle(s) to the neutral position.
2. Lower the lift arm and attachment completely. If the lift arm must be left in the
raised position, BE SURE to properly engage the lift arm support device
(page 22).
3. Move the throttle to the low idle position, shut off the engine and remove the
key.
4. Before exiting, move the lift/tilt control(s) to verify that the controls do not
cause movement of the lift arm and hitch.
Safety Reminders
Before Starting
Do not modify the ROPS/FOPS unless instructed to do so in Manitou Amer-
icas-approved installation instructions. Modifications such as welding,
drilling or cutting can weaken the structure and reduce the protection it pro-
vides. 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. Manitou Americas 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.
6 50950012/AP0811
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 machines Rated Operating Capacity. Carry the
load low. Move the controls smoothly and gradually, and operate at speeds
appropriate 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 push the lift control into the float position with the bucket or attach-
ment loaded or raised, because this will cause the lift arm to lower rapidly.
Do not drive too close to an excavation or ditch; be sure that the surrounding
ground has adequate strength to support the weight of the loader and the load.
Never carry riders. Do not allow others to ride on the machine or attachments,
because they could fall or cause an accident.
Always look to the rear before backing up the skid-steer loader.
Operate the controls only from the operators seat.
Always keep hands and feet inside the operators compartment while oper-
ating 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.
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.
50950012/AP0811 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.
Do not smoke or have any spark-producing equipment in the area while filling
the fuel tank or while working on the fuel or hydraulic systems.
Potential Hazards
A skid-steer loader operator must ALWAYS be conscious of the working envi-
ronment. Operator actions, the environmental conditions and the job being per-
formed 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. It is not necessary to make
direct contact with a power line for power to ground through the structure of the
machine. Accidental contact or rupture can result in electrocution or an explo-
sion. Contact the North American One-Call Referral System at: 8-1-1 in the U.S.,
or 1-888-258-0808 in the U.S. and Canada for the local Diggers 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/m3 as a time-weighted average for up to a
10-hr workday during a 40-hr workweek. NIOSH also recommends substituting
less hazardous materials when feasible, using respiratory protection and regular
medical examinations for exposed workers.
Safety Decals
The skid-steer loader has decals that provide safety information and precautions
around the loader. These decals must be kept legible. If missing or illegible, they
must be replaced promptly. Replacements can be obtained from your Gehl dealer.
New equipment must have all decals specified by the manufacturer affixed in
their proper locations. If there is a decal on a part that is being replaced, be sure
that the decal is applied to the replacement part.
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 location. Text
decals begin on page 9; no-text decals begin on page 13.
8 50950012/AP0811
ANSI-Style Safety Decals inside the ROPS/FOPS
AVOID INJURY OR DEATH

Always follow "Mandatory
Safety Shutdown Procedure".
1 2
STOP
137628 Located on manual box, behind seat

3 4
P
1. Lower equipment to ground.
2. Reduce throttle, stop engine.
3. Apply park brake; remove key.
4. Check safety interlocks.

Maintain 3-point contact
during entry and exit.
Inspect work area,

avoid all hazards.
Look in direction of travel. Keep

children and bystanders away.
Start and operate machine

only from seat.
Never carry riders.

Do not lift personnel in bucket.
Operate only in well

ventilated area.
Keep away from electric

power lines, avoid contact.
Do not wear loose clothing

When operating or servicing
machine.
Wear any needed
Personal Protective Equipment.
194485 - Left Instrument

Panel
137647 Located on operators lower left side
50950012/AP0811 9
ANSI-Style Safety Decals on the outside of the Loader
137655 Located on front of loader
132166 Located on
rear window
emergency exit
137720 Located on hitch (manual hitch loaders only)
184481 Located on hitch (power hitch loaders only)
10 50950012/AP0811
ANSI-Style Safety Decals on the outside of the Loader
137637 Located on the left fender and left side of ROPS/FOPS
184214 Located under the ROPS/FOPS
50950012/AP0811 11
ANSI-Style Safety Decals in the Engine Compartment
137657 Located on the right riser
137658 Located on the fan shroud
12 50950012/AP0811
ISO-Style (used Internationally)
Safety Decals inside the ROPS/FOPS
Safety alert: Always follow

Mandatory Safety Shutdown
Procedure in Operators Manual.
1 Lower equipment to ground.
2 Reduce throttle, stop engine.
137842 Located on manual 3 Apply parking brake; remove
storage box, behind seat key.
4 Check safety interlocks.
Safety alert: Read Operators
Manual and all safety signs
before using machine. 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 Operators
Manual. Contact dealer (or
manufacturer) for information and
service parts.
A B B Maintain 3-point contact during
entry and exit.
C Inspect work area. Avoid all
C D hazards. Look in direction of travel.
Keep children and bystanders away.
D Start and operate machine only
E F from seat.
E Keep away from power lines;
avoid contact.
F Wear any needed Personal
137849 Part of Protective Equipment. Do not wear
left instrument loose clothing while operating or
panel servicing machine.
A B C D
137843 Located on operators 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.
50950012/AP0811 13
Safety Decals on the outside of the Loader
A B
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 platform.
132166 Located
on rear window
emergency exit
B
186743
186743 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 B Correct attachment engagement
A
B
139101 Located on hitch (power hitch loaders only)

Crush hazard: Before operating with attachment, check engagement of loader
attachment bracket locking pin to the attachment:
A Incorrect attachment engagement
B Correct attachment engagement
14 50950012/AP0811
Safety Decals on the outside of the Loader
Crush hazard:
Hose removal or
component failure
can cause lift arm
to drop. Always use
lift arm support
device when
137848
leaving lift arm
raised for service.
137848 Located on the left fender and
left side of ROPS/FOPS
184711 Located under

the ROPS/FOPS
Crush hazard: Be sure lock
mechanism is securely
engaged before working
under ROPS/FOPS. Read
instructions for use in
Operators Manual.
50950012/AP0811 15
Safety Decals in the Engine Compartment
A B C D E F
137845 Located on the right riser

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 Operators 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.
A B
137845 Located on the fan shroud

A Rotating fan: Keep hands out or stop engine.
B Hot surface: Do not touch hot engine or hydraulic system parts.
16 50950012/AP0811
Product and Component Plate Locations
1
6 7
Product and Component Plates

1. Operator protection system plate: with model, certification and operator protection
system serial number (located inside left ROPS/FOPS)
2. Skid-steer serial number imprint
3. Engine plate: with type designation, product and serial number
4. Product plate: with Product Identification Number and model/type designation
5. Seat plate according to ISO 7096 (located on seat)
6. Component, right and left drive motor: with product and serial number
7. Component, hydrostatic transmission: with product and serial number
50950012/AP0811 17
Notes
18 50950012/AP0811
CHAPTER 3
CONTROLS AND SAFETY EQUIPMENT
Become familiar with and know how to use all
WARNING 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 Manitou Americas-approved
referral attachment or accessory. Manitou Americas cannot be
responsible for operator safety if the loader is used with a non-
approved attachment.
Guards and Shields

Whenever possible and without affecting loader operation, guards and shields are
provided to protect against potentially hazardous areas. In many places, safety
decals are also provided to warn of potential hazards and/or to display special
operating procedures.
Read and thoroughly understand all safety
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 operators compartment. The restraint
bar is securely anchored to the ROPS/FOPS. The restraint bar switch and the seat
switch form an interlock for the lift arm, tilt, drive and starter circuits (refer to the
Safety Interlock System topic on page 20 for more information).
Never defeat the operator restraint bar or seat
WARNING switch electrically or mechanically. Always
wear the seatbelt.
50950012/AP0811 19
Operators Seat
The seat is mounted on rails for rearward or
forward repositioning. A spring-loaded
latch handle activates the seat position
adjustment mechanism.
1
Suspension seat (optional on all models):
A weight adjustment knob is provided 2
for individual operator adjustment.
4 3
Figure 1 Operators Seat

1. Restraint Bar
2. Seatbelt
3. Seat Position Adjustment Lever
4. Suspension Seat Weight
Adjustment Knob (optional)
Upper-Torso Restraint
Always wear the upper-torso restraint when

WARNING operating in high speed.
The seatbelt should always be fastened during operation.

Important: Inspect the seatbelt(s) for damage before use, and replace if dam-
aged. Keep seatbelt(s) clean. Use only soap and water to wash seatbelt(s).
Cleaning solvents can cause damage to seatbelt(s).
Safety Interlock System
Hydraloc System
NEVER defeat the safety interlock system by
WARNING mechanically or electrically bypassing any
switches, relays or solenoid valves.
An interlock system is provided on the loader for operator safety. Together with
solenoid valves, switches and relays, the interlock system:
Prevents the engine from starting unless the operator is sitting on the seat and
the operator restraint bar is lowered.
20 50950012/AP0811
Disables the lift arm, auxiliary hydraulics, attachment tilt and wheel drives
whenever the operator leaves the seat, turns the keyswitch to Off or raises the
restraint bar.
Testing the Safety Interlock System

Before exiting the machine, check the safety interlock system for proper operation:
Restraint Bar
With the engine running, raise the restraint bar. Test each of the controls. There
should be no more than a slight movement of the lift arm, hitch and machine. If
there is any significant movement, troubleshoot and correct the problem immedi-
ately. Contact your dealer if necessary.
Seat Switch
With the engine off and the restraint bar lowered, unfasten the seatbelt, and lift
your weight off the seat. Try to start the engine. If the engine starts, turn off the
engine, troubleshoot and correct the problem. Contact your dealer if necessary.
ROPS/FOPS
The ROPS/FOPS (Roll-Over/Falling Object Protective Structure) is designed to
provide protection for the operator from falling objects and in case the loader tips
or rolls over, provided the operator is secured inside the ROPS/FOPS by the seat-
belt and restraint bar.
Never operate the loader with the ROPS/FOPS
WARNING removed or locked back.
Parking Brake
This skid-steer loader is equipped with a
spring-applied, hydraulic-released park-
ing brake. The parking brake engages
when the operator lifts the restraint bar,
exits the seat or shuts off the engine. The
brake can also be applied manually by
using the switch located on the left con-
trol panel of the ROPS/FOPS. A red indi-
cator lights on the left control panel when Figure 2 Parking Brake Switch
the parking brake is applied.
Horn
Pressing the button on the lower right portion of the control handle sounds the
horn (optional on all models).
50950012/AP0811 21
Rear Window Emergency Exit
The ROPS/FOPS rear window has three functions: noise reduction, flying
objects barrier and emergency exit.
To use the emergency exit, pull on the yellow warning tag at the top of the
window and remove the seal. Push or kick out the window and exit.
See your local automotive glass specialist to reinstall the window.
Lift Arm Support Device

The lift arm support device is used as a cylinder lock to prevent the raised lift arm
from lowering unexpectedly. Be sure to engage the support device when the lift
arm is raised for service. When the support device is not being used, return it to
its storage position. The support device is a safety device that must be kept in
proper operating condition at all times. The following steps ensure correct usage:
The safest method of engaging the lift arm
WARNING support device requires two people one
person inside the loader and another person outside the loader to
engage the support device.
Important: With the keyswitch OFF and the solenoid valve functioning properly,
the lift arm should stay raised if the lift control is moved to lower. If the sole-
noid valve does not hold the lift arm raised, lower the lift arm completely and
contact your Gehl dealer immediately to determine why the cause.
Engagement
To engage the lift arm support device:
1. Lower the lift arm fully.
2. Stop the engine.
3. Leave the operators compartment.
Press in and hold the lock pin button to
release its locking mechanism.
Remove the lock pin holding the sup-
port device up against the lift arm.
Allow the support device to come
down into contact with the lift cylinder. Figure 3 Lift Arm Support
Device Engaged
4. Return to operators compartment and
restart the engine.
5. Use the lift control to raise the lift arm
until the support device drops over the end of the lift cylinder and around the
cylinder rod. Slowly lower the lift arm until the free-end of the support device
contacts the top end of the lift cylinder.
6. Look to make sure the support device is secure against the cylinder end. Then,
stop the loader engine, remove the key and leave the operators compartment.
22 50950012/AP0811
Disengagement
To return the lift arm support device to its storage position:
1. Start the engine;
2. Raise the lift arm fully;
3. Stop the engine;
4. Before leaving the operators compartment, check to make sure that the lift arm
is being held in the raised position by the solenoid valve (See Note below).
Note: With the keyswitch OFF and the
solenoid valve working, the arm will stay
raised when the lift control is moved for-
ward. If the valve does NOT hold the lift
arm and it begins to lower, do NOT leave
the operators compartment. Instead, have
someone store the support device for you.
Then, contact your Gehl dealer to deter-
mine the reason why the lift arm lowers
while the keyswitch is in the OFF position.
5. To store the support device, raise it up
until it contacts the lift arm. Press in
and hold the lock pin button to release
its locking mechanism. Insert the lock
pin through the hole in left arm and
through the support device. Figure 4 Lift Arm Support
Device Storage Location
Accessory Plug
The accessory plug is located at the bottom of the left instrument panel.
Dome Light
The dome light is located on the right side of the ROPS/FOPS head liner. Push
the dome light to turn on the light.
Work Lights
Loaders have two sets of work lights. The front work lights are located at the top
of the ROPS/FOPS. The rear work lights are located in the rear grille.
50950012/AP0811 23
Heater (optional)
Loaders with the optional heater have a dial on the left instrument panel to con-
trol the fan speed.
Heater and Air Conditioner (optional)

Loaders with the combination heater/air
conditioner (HVAC) have two controls on
the left instrument panel: fan speed and
heater/air conditioner on/off, and temper- 1
ature.
1. Fan Speed: Controls the rate at
which air exits the vents.
2. Heater/Air Conditioner (HVAC)
Selector Switch: Turns on either the 2
heater or air conditioner. Center off
position allows fan-only operation for
air circulation. Figure 5 Heater/
Air Conditioner Controls
Note: The operator will feel cooler with
only the two front vents opened and
aimed at the upper body.
Tips For Improving Heater Performance

To maximize heater and combination heater/air conditioner (HVAC) performance,
the following steps are suggested.
1. Inside the engine compartment, close off the cold air intake on the heater box.
2. Inspect the cab recirculation air filter for excess dirt build-up.
3. Inspect the heater hoses for twists, kinks or pinched areas.
4. Ensure the heater valves are fully open. On heater-only units, the coolant is con-
trolled by a manual valve. On HVAC units, the coolant is controlled by an elec-
tric solenoid valve.
5. Run the engine at a mid-throttle position (see note). Running the engine at low
idle may not be enough load to bring the engine up to its full thermostat temper-
ature (188 F, or 87 C) depending upon ambient conditions.
Note: On a cold engine start-up, run the skid-steer loader at low idle for five
minutes before throttling up to a mid-throttle position.
24 50950012/AP0811
Engine Speed Control
An engine speed hand throttle (Figure 6)
is provided for setting the engine speed.
Move the control clockwise to increase
the engine speed, and counter-clockwise
to decrease the engine speed.
Figure 6 Hand Throttle
T-Bar, Dual-Hand, Dual Joystick and

T-Bar/Joystick Controls Only: A right-
foot-operated throttle pedal is provided to
control the engine speed (Figure 7). The
pedal linkage is spring-loaded to return to
the pre-set hand throttle setting.
Figure 7 Foot Throttle (T-Bar,

Dual-Hand, Dual Joystick & T-
Bar/Joystick control units)
50950012/AP0811 25
Two-Speed Transmission (optional)
Loaders with the optional two-speed transmission use the left button on the left
control handle for shifting between High (H) and Low (L). Shifting to High
allows the machine to exceed 8 mph (13 km/h), up to a maximum speed of
12.4 mph (20 km/h).
Hydraglide Ride Control System (optional)

Loaders with the optional ride control feature have a button on the right control
handle for shifting between normal mode and ride control mode. The ride control
system provides a smoother ride over uneven surfaces. Press the button once to acti-
vate the system and again to deactivate. The ride control system is automatically
deactivated when the machine is shut off.
When hydraglide is activated, the lift arm may
WARNING drop slightly without a load or several inches
with a heavy load.
Auto-Shutdown System
The auto-shutdown system will activate if the loader has an over-temperature sit-
uation or no oil pressure for more than 30 seconds. An audible alarm will sound
and the Engine Coolant Temperature light or Engine Oil Pressure light will turn
on and the loader will shut down after approximately 30 seconds.
26 50950012/AP0811
Attachment Mounting
The skid-steer loader is equipped with either the standard manual All-Tach
hitch or the optional Power-A-Tach hitch for mounting a bucket and other
attachments.
All-Tach Hitch
With the standard hitch mechanism, two
latch levers secure the attachment.
Rotate the levers until the handles are
horizontal to engage the lock pins.
Rotate the levers until the handles are
vertical to disengage the lock pins.
(Refer to page 46 for more information.)
Figure 8 All-Tach Hitch
To prevent unexpected release of the attach-

WARNING ment from the hitch, be sure to secure the
latch pins by rotating the levers all the way to the stops.
Power-A-Tach Hitch
With the optional hitch mechanism, a
switch on the left control panel activates
the latch pins. Metal flags on the pins
indicate their position: the pin flags
rotate to a horizontal position when
engaging the pins and a vertical position
when disengaging the pins. (Refer to
page 46 for more information.)
Figure 9 Power-A-Tach Hitch

WARNING ment from the hitch, be sure the latch pins are
secure by verifying that the pin flags have moved fully to the out-
side of the hitch.
50950012/AP0811 27
Instrument Panels
The instrument panels contain the switches and
indicator lights. Symbols on the indicator lights
are visible only when the indicator light are on.
Always follow "Mandatory
Safety Shutdown Procedure".
Left Panel 1 2
1. Two-Speed Transmission (optional) STOP
Lights when high speed is engaged. 3

P
4
2. Parking Brake Lights when the parking

1. Lower equipment to ground.
brake is applied. 2. Reduce throttle, stop engine.
3. Apply park brake; remove key.
3. Power-A-Tach Hitch (optional) Used to 4. Check safety interlocks.
operate the Power-A-Tach hitch.

4. Fan (optional) Used to control the fan AVOID INJURY OR DEATH
Maintain 3-point contact
speed for the air conditioner and heater. during entry and exit.
Inspect work area,
avoid all hazards.
5. Heater/Air Conditioner Selector Used to Look in direction of travel. Keep
children and bystanders away.
control the heater and air conditioner. Start and operate machine
only from seat.
Never carry riders.
6. Accessory Plug 12-volt DC power outlet. Do not lift personnel in bucket.
Operate only in well
7. Engine Malfunction Lights when the ventilated area.
Keep away from electric
power lines, avoid contact.
engine electronic control unit (ECU) has Do not wear loose clothing while
operating or servicing machine.
detected a failure warranting an automatic Wear any needed
Personal Protective Equipment.
shutdown. The indicator lamp also displays
error codes when the key switch is turned to
1 7
the on position. See Engine Diagnostics
chart on page 70. 2 8
8. Hydraglide Ride Control System
P 9
(optional) Lights when the ride control sys-
tem is activated. P
9. Float Indicator (T-Bar/Joystick and Dual
Joystick control options only) Lights 3 10
when float function is activated.
10. Parking Brake Switch Used to apply the P
parking brake. 4
Figure 10 Left Panel
28 50950012/AP0811
Right Panel
1. Hourmeter Displays the total operating
hours of the loader.
2. Fuel Level Gauge Displays the amount of
fuel in the tank.
3. Engine Coolant Temperature Gauge Dis-
plays the temperature of the engine coolant. 1
4. Engine Coolant Temperature Lights if the
engine coolant is too hot this warns the opera-
tor to stop the engine and determine and cor-
2
rect the cause for the high temperature.
During normal operation this indicator
should be OFF.
5. Hydraulic Oil Temperature Lights if the
3
hydraulic oil is too hot. This warns the opera-
tor to reduce the hydraulic load and deter-
mine the cause of the high temperature.
During normal operation this indicator
should be OFF. 14 10
6. Light Switch Controls all the lights on the
4 13
loader. Symbols denote the four positions of
the light switch. In a clockwise direction 15 11
these are:
Off 5 12
Flashers (optional)
Front Work Lights with Tail Lights
(position lights) 6
Both Front and Rear Work Lights
For the lights to function, the keyswitch
7
must be in the RUN position.
7. High-Flow Auxiliary Switch (optional)
Controls the direction of hydraulic oil flow.
Push the right side of the rocker switch for 8
forward flow, or the left side for reverse
flow. To disengage, push and release either
side of the switch or raise the restraint bar.
Turning the machine off and restarting the
engine will also reset the high-flow to neu- 9
tral.
Figure 11 Right Panel
50950012/AP0811 29
8. Keyswitch In a clockwise rotation, these positions are:
OFF Position With the key vertical, power from the battery is discon-
nected from the controls and instrument panel electrical circuits. This is
the only position the key can be inserted or removed from the keyswitch.
ON (or RUN) Position With the key turned one position clockwise from
vertical, power from the battery is supplied to all control and instrument
panel circuits.
START Position With the key turned fully clockwise, the electric
starter energizes, start the engine. Release the key to 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.
9. Engine Speed Control Controls the engine speed. Move the control clock-
wise to increase and counter-clockwise to decrease the engine speed.
10. Fasten Seatbelt A momentary visual (and audible) indicator to remind the
operator to fasten the seatbelt(s).
11. Battery Lights if the charging voltage is too high or too low. During normal
operation this indicator should be OFF.
12. Preheat Indicator Lamp Lights when the (automatic) preheat is active.
During normal operation this indicator should be OFF.
13. Engine Oil Pressure Lights if the engine oil pressure is too low. Warns the
operator to immediately stop the engine and determine the cause for the low
pressure. During normal operation this indicator should be OFF.
14. Engine Air Restriction Indicator (optional) - Lights when a restriction in
the engine air filter is detected. Warns the operator to immediately stop the
engine and clean or replace the element in the engine air cleaner. During nor-
mal operation this indicator should be OFF.
15. Hydraulic Oil Filter Indicator (optional) - Lights if the hydraulic oil filter
becomes restricted. Warns the operator to immediately stop the engine, allow
the engine to cool, and then change the oil and filter. During normal operation
this indicator should be OFF.
30 50950012/AP0811
T-Bar Controls
The loader may be equipped with the
Gehl T-Bar control option. The left T-Bar
controls the drive and the right T-Bar con-
trols the lift/tilt.
Drive Control 1 2
Forward, reverse, speed and turning

maneuvers are accomplished by move-
ment of the left T-Bar. To go forward,
push the control forward; for reverse,
pull the control rearward. To turn right,
turn the control clockwise; to turn left, Figure 12 T-Bar Controls
turn the control counterclockwise. For 1. Lift/Tilt Control
gradual turns, move the T-Bar slightly for- 2. Drive Control
ward or rearward. For sharp turns, turn the
control clockwise or counterclockwise.
Moving the T-Bar farther from neutral increases the speed steadily to the max-
imum travel speed. Tractive effort decreases as speed increases. To get maximum
tractive effort, move the T-Bar only slightly away from the neutral position. The
engine will stall if the control is moved too far forward when loading the bucket.
Be sure the T-Bar controls are in neutral
WARNING before starting the engine. Operate the con-
trols gradually and smoothly. Excessive speed and quick control
movements without regard for conditions and circumstances are
hazardous and could cause an accident.
50950012/AP0811 31
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 forward
and down, twist the control clockwise; to tilt the attachment up and 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. 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
WARNING float position with the attachment loaded or
raised, because this will cause the lift arm to lower very rapidly.
32 50950012/AP0811
T-Bar/Joystick Controls
Gehl T-Bar/Joystick control option. The
left T-Bar controls the drive and the right
joystick controls the lift/tilt.
Drive Control
maneuvers are accomplished by move- 1 2
ment of the left T-Bar. To go forward,
push the control forward; for reverse,
pull the control rearward. To turn right, Figure 13 T-Bar/Joystick
Controls
turn the control clockwise; to turn left,
1. Lift/Tilt Control
turn the control counterclockwise. For
2. Drive Control
gradual turns, move the T-Bar forward or
rearward and turn slightly. For sharp turns,
turn the control clockwise or counterclockwise.
Moving the T-Bar farther from neutral increases the speed steadily to the max-
tractive effort, move the T-Bar only slightly away from the neutral position. The
engine will stall if the control is moved too far forward when loading the bucket.
Be sure the T-Bar controls are in neutral
50950012/AP0811 33
Lift/Tilt Control
the right joystick. To raise the lift arm, pull the control straight rearward; to
lower the lift arm, push the control straight forward. To tilt the attachment for-
ward and down, move the control to the right; to tilt the attachment up and
back, move the control to the left.
joystick movement and engine speed.
To place the lift arm into the detent (float) position, push and hold the left
button on the right joystick. This mode allows the lowered lift arm to move up
and down without moving the T-Bar while traveling over changing ground condi-
tions. An indicator light in the left instrument panel will blink when float is acti-
vated.
Never push the float control button with the
WARNING attachment loaded or raised, because this will
cause the lift arm to lower very rapidly.
Releasing the float button will cancel the float mode if the button was pressed
less than five seconds. If the float mode button is pressed longer than five sec-
onds, the float feature will stay on and the float indicator lamp will light continu-
ously until the button is pressed again.
34 50950012/AP0811
Dual Joystick Controls
The loader may be equipped with the dual
joystick control option. The left joystick
controls the drive and the right joystick
controls the lift/tilt.
Drive Control
maneuvers are accomplished by move- 1 2
ment of the left joystick. To go forward,
push the control forward; for reverse, pull
the control rearward. To turn right, push Figure 14 Joystick Controls
the control right; to turn left, push the 1. Lift/Tilt Control
control left. To go forward and left, 2. Drive Control
move the control forward and left. To go
forward and right, move the control forward and right. To go back and left,
move the control back and to the right. To go back and right, move the control
back and to the left.
Be sure the joystick controls are in neutral
Moving the joystick farther from neutral increases the speed steadily to the max-
tractive effort, move the joystick only slightly away from the neutral position.
The engine will stall if the control is moved too far forward when loading the
bucket.
50950012/AP0811 35
Lift/Tilt Control
the right joystick. To raise the lift arm, pull the control straight rearward; to
lower the lift arm, push the control straight forward. To tilt the attachment for-
ward and downward, move the control to the right; to tilt the attachment up
and back, move the control to the left.
joystick movement and engine speed.
To place the lift arm into the float position, push and hold the left button on the
right joystick. This mode allows the lowered lift arm to follow the ground con-
tour while traveling over changing ground conditions. An indicator light in the
left instrument panel will blink when the float is activated.
Never push the float control button with the
WARNING attachment loaded or raised, because this will
cause the lift arm to lower very rapidly.
Releasing the float button will cancel the float mode if the button was pressed
less than five seconds. If the float mode button is pressed longer than five sec-
onds, the float feature will stay on and the float indicator will light continuously
until the button is pressed again.
36 50950012/AP0811
Hand/Foot Controls
hand/foot control option. The handles
control the drive and the foot pedals con-
trol the lift/tilt. 3 4
Drive Controls
maneuvers are accomplished by move- 1
2
ment of the control handles. To go for-
ward, push both handles forward; for
reverse, pull both handles rearward. For Figure 15 Hand/Foot Controls
1. Left Drive Control Handle
turning, move one handle farther forward
or rearward than the other handle. Turn 2. Right Drive Control Handle
3. Lift Control Pedal
direction is determined by which handle
4. Tilt Control Pedal
is moved farther forward; to turn left,
move the right handle farther forward
than the left handle; to turn right, move
the left handle farther forward than the right handle. For sharp turns, move the
handles in opposite directions.
Moving the handles farther from neutral increases the speed steadily to the max-
tractive effort, move the handles only slightly away from the neutral positions. The
engine will stall if the handles are moved too far forward when loading the bucket.
Be sure the controls are in neutral before
WARNING starting the engine. Operate the controls
gradually and smoothly. Excessive speed and quick control move-
ments without regard for conditions and circumstances are haz-
ardous and could cause an accident.
50950012/AP0811 37
Lift/Tilt Controls
the foot pedals. The left pedal raises and lowers the lift arm; the right pedal tilts
the attachment. To raise the lift arm, push down on the back of the left pedal with
your left heel; to lower the lift arm, push down on the front of the left pedal with
the toes of your left foot. To tilt the attachment forward and downward, push
down on the front of the right pedal with the toes of your right foot; to tilt the
attachment up and back, push down on the back of the right pedal with your
right heel.
pedal movement and engine speed.
To place the lift arm into the detent (float) position, use the toes of your left
foot to push the front of the left pedal all the way down. This position allows the
lowered lift arm to follow the ground contour while traveling over changing
ground conditions.
Never push the left pedal into the float posi-
WARNING tion with the attachment loaded or raised,
because this will cause the lift arm to lower very rapidly.
38 50950012/AP0811
Dual-Hand Controls
dual-hand control option. The left handle
controls the left side drive and the lift.
The right handle controls the right side
drive and the tilt.
Drive Controls
1
2
maneuvers are accomplished by pushing
and pulling the handles. To go forward,
Figure 16 Dual-Hand Controls
push both handles forward; for reverse,
1. Left Drive Control Handle
pull both handles rearward. For turning,
2. Right Drive Control Handle
move one handle farther forward or rear-
ward than the other handle. Turn direction
is determined by which handle is moved farther forward. To turn left, move the
right handle farther forward than the left handle; to turn right, move the left
handle farther forward than the right handle. For sharp turns, move the handles in
opposite directions.
Moving the handles farther from neutral increases the speed steadily to the max-
tractive effort, move the handles only slightly away from the neutral position.
The engine will stall if the handles are moved too far forward when loading the
bucket.
Be sure the controls are in neutral before
WARNING starting the engine. Operate the controls
gradually and smoothly. Excessive speed and quick control move-
ments without regard for conditions and circumstances are haz-
ardous and could cause an accident.
Lift/Tilt Controls
Moving the lift arm and tilting the attachment are accomplished by rotating the
control handles. To raise the lift arm, rotate the left handle outward (to the left);
to lower the lift arm, rotate the left handle inward (to the right). To tilt the
attachment forward and downward, rotate the right handle; to tilt the attach-
ment up and back, rotate the right handle inward.
control movement and engine speed.
To place the lift arm into the detent (float) position, push the left (lift) handle
all the way inward. This position allows the lowered lift arm to follow the ground
contour while traveling over changing ground conditions.
Never put the lift control into the float posi-
WARNING tion with the attachment loaded or raised,
because this will cause the lift arm to lower very rapidly.
50950012/AP0811 39
Auxiliary Hydraulic Controls
Auxiliary hydraulics are used with attachments that have a mechanism requiring
hydraulic power.
Always be sure the auxiliary hydraulic control
WARNING is in neutral before starting the loader or dis-
connecting the auxiliary hydraulic couplers.
Standard-Flow Auxiliary Hydraulic Control

Loaders are equipped with a standard-flow
auxiliary hydraulic system with flat-face
couplers. The couplers are located under
the lift arm on the left side.
Note: A second set of hydraulic couplers
can be added to the front of the lift arm by
ordering a field installation kit. This
second set of couplers is for use with spe-
cial attachments such as grapple forks,
etc. Figure 17 T-Bar and Dual-Hand
Auxiliary Hydraulic
T-Bar and Dual-Hand Control Loaders: A Control
foot pedal is used to control the direction
of oil flow. A latch is provided to lock the
foot pedal for continuous operation (Figure 17).
T-Bar/Joystick and Dual Joystick Control
Loaders equipped with Electric Control:
The yellow switch located on the right con-
trol handle controls the direction and flow of
oil. The farther the switch is moved from the
center, the higher the flow in the auxiliary
circuit. The direction of flow is reversed
when the switch is moved in the opposite
direction from the center. For continuous
operation, move the switch fully in either
direction and press the red trigger button,
located on the front of the grip, and release.
To cancel continuous operation, press the red Figure 18 T-Bar/Joystick and
trigger button again or move the yellow Dual Joystick Electric
Auxiliary Control
switch in either direction.
40 50950012/AP0811
Hand/Foot Control Loaders: The right
handle controls the direction of oil flow. A
locking pin locks it in the up position for
continuous operation (Figure 19).
Figure 19 Hand/Foot
Auxiliary Control
High-Flow Auxiliary Hydraulic Control (optional)

In addition to a standard-flow auxiliary
hydraulic system, some loaders are
equipped with a reversible high-flow aux-
iliary hydraulic system. The couplers are
located on the right lift arm. A high-flow
auxiliary hydraulic system is used for
operating certain hydraulic attachments
(e.g., cold planer, snowblower) that
require higher flows.
The high-flow auxiliary switch controls
the direction of hydraulic oil flow. The
switch is located on the right instrument
panel. Push the right side of the rocker Figure 20 High-Flow Auxiliary
Switch
switch for forward flow, or the left side
for reverse flow. To disengage, push and
release either side of the switch. Turning off the machine, raising the restraint bar,
or restarting the engine will also reset the high-flow to neutral. A small light on
either side of the switch will illuminate when the high-flow auxiliary hydraulic
system is engaged.
50950012/AP0811 41
Notes
42 50950012/AP0811
CHAPTER 4
OPERATION
Before starting the engine and operating the
WARNING loader, review and comply with all safety rec-
ommendations 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(s) 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
handholds to get into the operators compartment.
2. Fasten the seatbelt(s) and lower the restraint bar.
3. Verify the following:
the lift/tilt, drive and auxiliary hydraulic controls are in their neutral
positions,
the parking brake switch is on.
4. Push the throttle lever forward to approximately 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 key to the start position.
Note: If temperature is below 32F (0C), see Cold-Starting Procedure, on
page 44.
Important: Do not engage the starter for longer than 15 seconds at a time. Lon-
ger use can overheat and damage the starter. If the engine fails to start within 15
seconds, return the key to the off position. Allow the starter to cool for
20 seconds and repeat Step 5.
After the engine starts, allow a sufficient warm-up time before attempting to
operate the controls.
Important: If the indicator warning lights do not go off, stop the engine and
investigate the cause.
50950012/AP0811 43
Cold-Starting
If the temperature is below 32F (0C), try the following to make starting the
engine easier:
Replace the engine oil with SAE approved oil; (see page 63)
Make sure the battery is fully charged;
Install an engine block heater.
A block heater is recommended for starting in temperatures of 20F (-7C) or
lower. See your dealer for heater options.
Let the engine run for a minimum of five minutes to warm the engine and
hydraulic fluid before operating the loader.
Cold-Starting Procedure
Do not use starting fluid (ether) with preheat

WARNING systems. An explosion can result, which can
cause engine damage, injury or death.
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 the
throttle pedal for hands-only control machines);
4. Turn the keyswitch to the off position and remove the key; and
5. Raise the restraint bar, unfasten the seatbelt(s). Verify that movement of the
controls does not cause machine movement and then grasp the handholds while
climbing out of the operators compartment.
Note: The skid-steer loader is equipped with a spring-applied automatic parking
brake. The parking brake is applied when the operator lifts the restraint bar,
leaves the operators seat, shuts off the engine or actuates the parking brake
switch.
Parking the Loader

Park the loader away from traffic on level ground. If this is not possible, park the
loader across the incline and block the tires to prevent movement.
44 50950012/AP0811
Jump-starting
If the battery becomes discharged or does not have enough power to start the
engine, use jumper cables and the following procedure to jump-start the loader
engine.
The ONLY safe method for jump-starting a
WARNING 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
operators 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 operators seat and then ONLY after being sure ALL controls
are in neutral.
Closely follow the procedure, in order, to avoid personal injury. In
addition, wear safety glasses to protect your eyes 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.
Note: BE SURE the jumper battery is a 12-volt D.C. battery.
1. Turn the keyswitches of both vehicles to OFF, be sure the vehicles are in
neutral and NOT touching each other.
2. 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 (+) battery terminals.
3. Connect the other end of the positive jumper cable to the jumper vehicles bat-
tery positive (+) terminal.
4. Connect the negative (-) jumper cable to the jumper vehicles battery negative
(-) terminal.
5. Make the final negative (-) jumper cable connection to the disabled loaders
engine block or loader frame (ground) NOT to the disabled batterys negative
post. If connected to the engine, keep the jumper clamp away from the battery,
fuel lines and moving parts.
6. Start the loader. If it does not start at once, start the jumper vehicle engine to
avoid excessive drain on the booster battery.
7. After the disabled loader is started and running smoothly, have the second per-
son remove the jumper cables (negative [-] jumper cable first) from the jumper
vehicles battery and then from the disabled loader while being sure NOT to
short the two cables together.
Allow sufficient 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.
50950012/AP0811 45
Changing Attachments

WARNING ment from the hitch, be sure to properly
secure the hitch latch pins by rotating the latch levers
fully(manual All-Tach hitch) or by ensuring that the pin flags are
all the way to the outside (Power-A-Tach hitch).
The skid-steer loader features either a manual or a power hitch for mounting a
bucket or other attachment conforming to SAE Standard J2513.
On a manual All-Tach hitch (Figure 21), two latch levers engage the latch pins
to secure the attachment. On a Power-A-Tach hitch (Figure 22), a switch on the
left instrument panel (page 28) activates the latch pins to secure the attachment.
Connecting Attachments
1. Manual hitch: Rotate the latch levers
until the handles are vertical to retract
the lock pins.
1 1
2 2
Figure 21 Manual Hitch

disengaged
1. Latch Levers
2. Latch Pins
2. Power hitch: Activate the switch to 1
unlock the hitch and fully retract the
latch pins.
3. Start the loader engine. Be sure the lift 2 1 1 2
arm is lowered and in contact with the
loader frame.
4. Align the loader squarely with the back
of the attachment.
5. Tilt the hitch forward until the top edge
of the hitch is below the flange on the Figure 22 Power Hitch
back side of the attachment and cen- disengaged
tered between the vertical plates. 1. Pin Flags
2. Latch Pins
6. Slowly drive the loader forward and, at
the same time, tilt the hitch back to
engage the flange on the back side of the attachment.
7. Stop forward travel when the flange is engaged, but continue to tilt the hitch
back to lift the attachment off the ground.
46 50950012/AP0811
8. Manual hitch: Exercise the MANDATORY SAFETY SHUTDOWN PRO-
CEDURE (page 6). Exit the operators compartment and rotate the latch levers
to the horizontal position to fully engage the latch pins.
9. Power hitch: Activate the switch to lock the hitch and fully engage the latch
pins.
Important: To check that the attachment is properly installed, apply downward
pressure to the attachment prior to operating.
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.
Standard-Flow Auxiliary Hydraulics

Coupler hookup is located on the left lift arm. When the auxiliary control is in the
detent position, the top coupler is pressure, and the bottom coupler is return.
High-Flow Auxiliary Hydraulics

Coupler hookup is located on the right lift arm. When the auxiliary control is in
the detent position, the top coupler is pressure, and the middle coupler is
return. The smaller bottom coupler is for the case drain.
Only connect high-flow attachment couplers
WARNING to the high-flow auxiliary couplers.
Removing Attachments
1. Tilt the hitch back until the attachment is off the ground.
2. Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 6).
3. Relieve any hydraulic pressure in the auxiliary and attachment lines:
a. Turn the key on (do not start the engine).
b. With the restraint bar down, move the auxiliary hydraulic control back and
forth. This will relieve the pressure in the hydraulic system.
4. With the engine off, leave the operators compartment and disconnect the auxil-
iary hydraulic hoses.
5. Manual hitch: Rotate the hitch latch levers to the vertical position to fully
retract the latch pins.
Power hitch: Turn the key ON (do not start the engine) and activate the
switch to unlock the hitch and fully retract the latch pins.
6. Start the engine and be sure that the lift arm is fully lowered and in contact with
the loader frame.
7. Tilt the hitch forward and slowly back the loader away until the attachment is
free from the loader.
50950012/AP0811 47
Self-Leveling
The feature is intended to automatically keep the attachment level while the lift
arm is being raised.
Using a Bucket
Always maintain a safe distance from electric

WARNING power lines and avoid contact with any elec-
trically charged conductor or gas line. Accidental contact or rup-
ture can result in electrocution or an explosion. Contact the
Diggers Hotline or proper local authorities for utility line loca-
tions before starting to dig.
Driving over Rough Terrain

When traveling over rough terrain, drive slowly with the bucket lowered.
Driving on an Incline
When traveling on an incline, travel with the heavy end pointing uphill.
Digging with a Bucket

Approach the digging site with the lift
arm slightly raised and the bucket tilted
forward until the edge contacts the
ground. Dig into the ground by driving
forward and gradually lowering the lift
arm (Figure 23).
Figure 23 Digging
When the bucket is filled, tilt the bucket
back, and back the loader away from the
material. Rest the lift arm against the
loader frame before proceeding to the
dumping area.
Always carry the loaded bucket with the lift
WARNING arm resting on the loader frame. For addi-
tional stability when operating on inclines, always travel with the
heavier end of the loader toward the top of the incline.
48 50950012/AP0811
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 24).
Figure 24 Loading
Dumping the Load Onto a Pile

Carry a loaded bucket as low as possible until the pile is reached. Gradually stop
forward motion and raise the lift arm high enough so that the bucket clears the
top of the pile. Then, slowly move the loader ahead to position the bucket to
dump the material on top of the pile. Dump the material and then back the loader
away while tilting the bucket back and lowering the lift arm.
Never push the float button with the bucket
WARNING or attachment loaded or raised, because this
will cause the lift arm to lowering rapidly.
Dumping the Load into a Truck or Hopper

Carry the loaded bucket low and approach
the vehicle or bin. Stop your approach as
close to the side of the truck or hopper 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 truck or hopper and move Figure 25 Dumping into a Truck
the loader ahead to position the bucket or Hopper
over the inside of the truck or hopper.
Dump the material and then back away
while tilting the bucket back and lowering the lift arm (Figure 25).
Dumping the Load Over an Embankment

Do not drive too close to an excavation or
WARNING ditch. Be sure the surrounding ground has ade-
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. Dump
the material, and then back away from the embankment while tilting the bucket
back and lowering the lift arm.
50950012/AP0811 49
Scraping with a Bucket
For scraping, the loader should be operated
in the forward direction. Position the lift
arm down against the loader frame. Tilt the
bucket cutting edge forward at a slight
angle to the surface being scraped. While
traveling slowly forward with the bucket in
this position, material can flow over the Figure 26 Scraping
cutting edge and collect inside the bucket
(Figure 26).
Leveling the Ground

Drive the loader to the far edge of the area
to be leveled. Tilt the bucket forward to
place the bucket cutting edge at a 30 to
45 degree angle to the surface being lev-
eled. Then place the lift arm into the float
position and drive the loader rearward,
dragging the dirt and, at the same time, Figure 27 Leveling the Ground
leveling it (Figure 27).
Note: The float (detent) position for T-Bar loaders is reached by pushing the
right handle all the way forward, and for dual-hand control loaders by rotating
the left handle all the way outward. For hand/foot control loaders, use the toes of
the left foot to push the front of the left pedal all the way down. For T-Bar/Joy-
stick control loaders press float button the right grip. Pressing button for more
than 5 seconds will allow the machine to go into detent (float) mode. Press
again to cancel detent.
Check that the work area is clear of people
WARNING and obstacles. Always look in the direction of
travel.
50 50950012/AP0811
Vibration Information
Compact construction equipment is generally used in harsh environments. This
type of usage can expose an operator to uncomfortable levels of vibration. It is
useful to understand exposure to vibration levels when operating compact equip-
ment and what can be done to reduce vibration exposure. As a result, equipment
operation can be more efficient, productive and safe.
An operators exposure to vibration occurs in two ways:
Whole-Body Vibration (WBV)
Hand-Arm Vibration (HAV)
This section will cover primarily WBV issues, because evaluations have shown
that operation of mobile compact construction equipment on jobsites typically
results in HAV levels less than the allowed exposure limit of 2.5 m/s2.
Member States of the European Union must comply with the Physical Agents
(vibration) Directive, 2002/44/EC.
Effective control of vibration exposure for an operator involves more than just
vibration levels on the machine. The job site, how the machine is used, and
proper training all play important roles in reducing vibration exposure.
Vibration exposure results from:
worksite conditions
how the machine is operated
the machine characteristics
Common causes of high WBV vibration levels:

Using a machine that is improper for the task
Work site with potholes, ruts and debris
Improper operating techniques, such as driving too fast
Incorrect adjustment of the seat and controls
Other physical activities while using the machine
Vibration Measurement and Actions

The vibration directive places the responsibility for compliance on employers.
Actions that should be followed by employers include:
Assess the levels of vibration exposure.
Determine from this assessment if operators will be exposed to vibration
levels above the limits stated in the directive.
Take appropriate actions to reduce operators exposure to vibration.
Provide operators with information and training to reduce their exposure to
vibration.
Keep good records and update operations and training on a regular basis.
50950012/AP0811 51
If the assessment concludes that vibration level exposure is too high, one or more
of the following actions may be necessary:
1. Train operators
Perform operations (accelerating, steering, braking, etc.) in a smooth
manner.
Adjust machine speed appropriately.
Adjust the controls, mirrors and seat suspension for comfortable operation.
Travel across the smoothest parts of the work site and avoid ruts and pot-
holes.
2. Choose proper equipment for the job
Use machines with the proper power and capacity.
Select machines with good suspension seats.
Look for controls that are easy to use.
Ensure good visibility from the operators position.
3. Maintain the work site
Smooth ruts and fill potholes in traffic areas whenever possible.
Clean up debris frequently.
Vary traffic patterns to avoid exposure to rough terrain.
4. Maintain the equipment
Ensure correct tire pressures.
Check that seat suspension and all controls work smoothly and properly.
52 50950012/AP0811
Vibration Levels
The following table shows typical Whole-Body
Vibration levels for Gehl skid-steer loaders.
Figure 28 - Vibration
measurement axes
Typical Whole-Body Vibration Levels*

Vibration Levels
Range of x-axis y-axis z-axis
Activity
Readings meter/ meter/ meter/
second2 second2 second2
V-Pattern Highest 0.53 0.50 1.03
Loading Lowest 0.28 0.24 0.34
Load & Carry Highest 0.37 0.36 0.83
Motion Lowest 0.25 0.28 0.36
Highest 0.42 0.43 0.73
Roading
Lowest 0.28 0.29 0.30
*Vibration levels were recorded using a range of skid-steer loader models driven by
an experienced operator on flat conditioned soil and handling gravel in the
activities indicated. For additional vibration data, refer to ISO TR 25398.
The data above indicates that Gehl skid-steer loaders, when used in a similar
manner as described above, do not exceed the limit value for Whole-Body Vibra-
tions, and can therefore be operated by one operator for at least 8 hours per day.
Note: When the skid-steer loader is operated in accordance with the instructions
in the operators manual, the hand-arm vibration levels are below the exposure
action value of 2.5 m/s2.
50950012/AP0811 53
Highway Travel
If it becomes necessary to move the loader a long distance, use a properly rated
trailer. (See Transporting the Loader on page 55.) For short distance highway
travel, attach an SMV (Slow-Moving Vehicle) emblem (purchased locally) to the
back of the loader. For highway operation, install the optional strobe light. Check
state and local laws and regulations.
Storing the Loader

If the skid-steer loader is to be stored for a long period, in excess of two months,
the following procedures are suggested:
1. Fully inflate the tires.
2. Lubricate all grease zerks.
3. Check all fluid levels and replenish as necessary.
4. Add stabilizer to the fuel per the fuel suppliers recommendations.
5. Remove the battery, charge fully and store in a cool, dry location.
6. Protect against extreme weather conditions such as moisture, sunlight and tem-
perature.
Removing Loader from Storage

1. Check the tire air pressure and inflate the tires if they are low.
2. Connect the battery.
3. Check the fan belt tension.
4. Check all fluid levels (engine oil, transmission/hydraulic oil, engine coolant
and any attached implements).
5. Start the engine. Observe all gauges. If all gauges are functioning properly
and reading normal, move the machine outside.
6. Once outside, park the machine and let the engine idle for at least five min-
utes.
7. Shut the engine off and walk around machine. Make a visual inspection look-
ing for evidence of leaks.
54 50950012/AP0811
Transporting the Loader
Park the truck or trailer on a level surface. Be

WARNING sure the vehicle and its ramps have the
weight capacity to support the loader. Be sure the vehicle surface
and its ramps are clear of debris and slippery material that may
reduce traction. Move the loader on and off the vehicle ramp
slowly and carefully. Failure to follow these instructions could
result in an overturn accident.
Observe all local regulations governing the loading and transporting of equip-
ment (Reference: U.S. Federal Motor Carrier Safety Regulations, Section 392).
Ensure that the hauling vehicle meets all safety requirements before loading the
skid-steer loader.
1. Place blocks at the front and rear of
the hauling vehicles tires.
2. If the loader has an attachment, lift it
slightly off the ground.
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 Figure 29 Front Tie-Downs/
remove the key. Retrieval Points
5. Fasten the loader to the hauling vehicle
at the points indicated by the tie-down
decals (Figure 29 and Figure 30).
6. Measure the clearance height of the
loader and hauling vehicle. Post the
clearance height in the cab of the
vehicle.
Figure 30 Rear Tie-Down/

Retrieval Points
50950012/AP0811 55
Lifting the Loader
The loader can be lifted using a single-point or a four-point lift kit, which are
available from your Gehl dealer.
WARNING
Before lifting, check the lift kit for proper installation.
Never allow riders in the operators 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 conducting
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.
Figure 31 Single-Point
Lift Eye
Note: The loader my be slightly off level
(10 degrees max.) when lifted.
Figure 32 Front
Four-Point Lift Eyes
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 posi-
tion the loader and keep it from swing-
ing.
Figure 33 Right Rear
Four-Point Lift Eye
(Left same)
56 50950012/AP0811
CHAPTER 5
SERVICE
Before servicing the machine, unless
WARNING expressly instructed to the contrary, exercise
the MANDATORY 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
operation.
This Service chapter details procedures for performing routine maintenance
checks, adjustments and replacements. Most procedures are referred to in the
Troubleshooting and Maintenance chapters of this manual. Refer to the Mainte-
nance Interval Chart (page 91) for service intervals. Refer to the separate engine
manual for engine-related adjustments, lubrication and service procedures.
Note: All service procedures, except those described under the Dealer Services
topic are owner-operator responsibilities.
Important: Always dispose of waste lubricating oils and hydraulic fluids accord-
ing 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 drive components,
hydraulic system pumps, valves, hydraulic cylinders, electrical components
(other than battery, fuses).
50950012/AP0811 57
Replacement Parts
Part Description Gehl Part No.

Air Cleaner Element, Primary 184146
Air Cleaner Element, Secondary 184195
Hydraulic Oil Filter Element 074830
Engine Oil Filter Element 195568
Main Fuel Filter Cartridge 193024
Small Fuel Filter Cartridge 245005
Fresh Air Intake Filter (heater option) 184708
Recirculation Air Filter (heater option) 184709
Note: Part numbers may change. Your Gehl dealer will always have the latest
part numbers.
Important: To ensure continued warranty coverage, only genuine Gehl replace-
ment filters are to be used.
58 50950012/AP0811
Loader Raising Procedure
To raise the skid-steer loader so all four tires ARE NOT contacting the ground,
use the procedure below:
Do not rely on a jack or hoist to maintain the
WARNING raised position without additional blocking
and supports. Serious personal injury could result from improp-
erly raising or blocking the loader.
1. To block the loader, obtain enough solid wooden or metal blocks, so that
when stacked, all of the tires are raised off the ground.
Figure 34 Loader Properly Blocked

(Tires and wheels removed to show blocks)
2. Using a jack or hoist capable of lifting at 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.
3. Stack wooden blocks under the flat part of the loader chassis. They should run
parallel with, but not touch, the rear tires.
4. 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.
5. Repeat Steps 2 through 4 for the front end. When the procedure is finished, all
four tires are off the ground so they could be removed.
50950012/AP0811 59
Loader Lowering Procedure
When service or adjustment procedures are complete, the loader can be lowered
from the raised position. To lower the loader onto its tires:
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 fin-
ished, all four tires will be on the ground and the blocks removed from under
the loader.
Engine Compartment Access

To open the engine compart-
ment, lift the engine cover. Then
pull the rear grille latch and
carefully swing open the rear
grille.
Figure 35 Engine Compartment

Access Doors
60 50950012/AP0811
Tilting Back the ROPS/FOPS
The ROPS/FOPS is designed to protect the
operator from flying objects and provide
protection if the loader tips or rolls over,
provided the operator is secured inside the
ROPS/FOPS by the seat belt and restraint
bar.
For service, unbolt the ROPS/FOPS and
tilt it back slowly, moving the control han-
dles out of the way. Two gas-charged
springs help tilt it back. A self-actuating
lock mechanism will engage to lock when
the ROPS/FOPS in a rolled-back position.
To lower the ROPS/FOPS apply upward
force on it while pushing the lock mecha-
nism handle toward the rear of the loader.
Lower the ROPS/FOPS slowly onto the
chassis, moving the control handles out of Figure 36 ROPS/FOPS Lock
the way. Reinstall the anchor bolts, Mechanism Engaged
washers and locknuts.
Never operate
WARNING the loader with the ROPS/FOPS removed or
tilted back. Be sure the lock mechanism is securely engaged when
the ROPS/FOPS is tilted back. Be sure to reinstall the anchor
bolts, washers and locknuts before resuming operation.
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 gauge sender, located on the fuel tank, sends a signal to the fuel gauge to
indicate the amount of fuel in the fuel tank.
Check the fuel gauge sender periodically to ensure that the mounting screws are
tight and that there is no fuel around the gasket. If service is required, apply an
RTV or gasket sealant around the gasket when restoring the sender.
50950012/AP0811 61
Foreign Material Removal
The loader should be cleared daily of dirt and other foreign materials in the fol-
lowing areas:
around the lift cylinders
at the front of the loader
on the hitch, especially around tilt cylinder
around the hydraulic oil reservoir breather
in the engine compartment
in the operators compartment
engine side screen covers (attached at back of the ROPS/FOPS)
Important: Build up of foreign materials in these areas can interfere with the
operation of the loader, cause component damage or become a fire hazard.
Lubrication
Listed on page 63 are the temperature ranges and types of lubricants for this
machine. Refer to the separate engine manual for more information regarding
engine lubricants, quantities and grades required.
Note: Refer to the specific service sections for detailed information on periodic
checking and replenishing of lubricants.
Refer to Figure 37 for grease fitting locations. Wipe dirt from the fittings before
greasing them to prevent contamination. Replace any missing or damaged fit-
tings. To minimize dirt build-up, avoid excessive greasing.
Important: Always dispose of waste lubricating oils and hydraulic fluids accord-
ing to local regulations or take to a recycling center for disposal. Do not pour
onto the ground or down the drain.
62 50950012/AP0811
System Lubricant
Use Petro Canada HVI60, Mobil DTE 15M or equivalent, that
Hydraulic contains anti-rust, anti-foam and anti-oxidation additives, and
System Oil conforms to ISO VG46.
Capacity: 15 U.S. gallons (57 L)
Use hydraulic system oil or SAE grade 15W40 motor oil.
Chaincase Oil
Capacity (each side): 8 U.S. quarts (7.5 L)
Grease Fittings Use lithium-based grease.
Below 32F (0C) Use SAE Grade* 10W or 10W-30

Above 32F (0C) Use SAE Grade* 15W-40
*Service Classification: API CH-4
1Capacity: without filter: 9.0 U.S. quarts (8,5 L)
Engine Oil with new filter: 9.5 U.S. quarts (9,0 L)
1Approximate value can vary depending on oil tray or cooler
version (external cooling system). Use mark on dipstick to

determine FULL oil level.
Power-A-Tach Use Mobil ATF Dexron III
Reservoir Capacity: 0.8 U.S. quarts (0,75 L)
50950012/AP0811 63
10
500
500
50/250
5240/
2056
4640
Figure 37 Service Locations
10 Hours 500 Hours

Lubrication Procedure 250 Hours
(or Daily) (or Yearly)
Check Engine Oil Level (page 69)
Check Hydraulic Oil Level (page 74)
Grease Lift Arm, Hitch, Cylinder Pivots and

Latch Pins
Check Oil Level in Chaincases (page 65)
Change Engine Oil and Filter (page 69)
Change Hydraulic Oil Filter (page 74)
Change Hydraulic Oil (page 75)
Change Chaincase Oil (page 65)
Check and Drain Water Separator
Perform the initial procedure at 50 hours, then at or intervals.

Severe operating conditions.
Perform the procedure at 1000 hours.
64 50950012/AP0811
Chaincases
There is a chaincase on each side of the loader. Refer to the Maintenance Interval
Chart (page 91) for change intervals. Refer to the Lubrication chart (page 64).
Checking and Adding Oil

1. Park the loader on a level surface. Stop the
engine.
2. Remove the fill and check plug (Figure 38)
from each chaincase cover. The oil level
should be at the plug level or no more than
1/4 in. (6 mm) below the plug.
3. If the level is low, add fluid through the fill Figure 38 Fill and Check
and check plug; (Figure 38) until the oil Plug Location
level reaches the check plug hole. Reinstall
the plug.
Draining Oil
1. Park the loader on a level surface, or on a
sloping surface with the loader facing
downhill and the tires blocked.
2. Remove the drain plug on each chaincase
and drain the oil (Figure 39) into a suitable
container.
3. Reinstall and tighten the drain plugs.
4. Refill the chaincases at the fill plugs. Figure 39 Drain Plug
Drive Chains
Drive chains are located in the chaincase on each side of the machine. Refer to
the Maintenance Interval Chart (page 91) for tension check interval.
Checking Chain Tension

1. Raise the loader following the Loader Raising Procedure (page 59).
2. Rotate each tire by hand. The proper amount of chain defection should be 1/8
in. to 1 in. (3 to 25 mm) forward and rearward. If the chain defection is more
than 1 in. (25 mm) or less than 1/8 in. (3 mm) in either direction, the chains
should be adjusted.
Adjusting Chain Tension

1. Raise the loader following the Loader Raising Procedure (page 59).
2. Remove the tire from the axle to be adjusted.
3. Loosen (but DO NOT remove) the bolts holding the axle to the chaincase.
50950012/AP0811 65
4. Front Chain Tension To tighten the front chain, move the front axle assem-
bly toward the front of the loader. To loosen the chain, move the front axle
assembly toward the rear of the loader.
Rear Chain Tension To tighten the rear chain, move the rear axle assembly
rearward. To loosen the chain, move the rear axle assembly toward the front
of the loader.
5. After proper tension is achieved, retighten the bolts.
Important: Be careful not to over-tighten the drive chains. Over-tightening will
cause premature drive chain and axle sprocket wear.
6. Reinstall the tire.
7. Repeat Steps 2 through 6 for any other axle requiring adjustment.
8. Lower the loader following the Loader Lowering Procedure (page 60).
66 50950012/AP0811
Engine Air Cleaner
Important: Failure to follow proper filter servicing instructions could result in

catastrophic engine damage.
The air cleaner assembly consists of an outer (primary) filter element and an
inner (secondary) filter element. An air filter restriction indicator for monitoring
the condition of the elements is located on the front of the air cleaner. If the air
filter becomes restricted, this indicator turns red to warn the operator that the air
cleaner requires service. Push the reset button located at the end of the indicator
after fitting a clean element. For replacement elements, refer to the Replacement
Parts chart (page 58).
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 replaced 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 visibly
dirty.
Along with a daily check of the restriction indicator, check that the air cleaner
intake hose and clamps, and the mounting bracket hardware are properly secure.
2
1
5 6
4
3
Figure 40 Dual-Element Air Cleaner

1. Restriction Indicator 4. Outer Filter Element
2. Element Housing 5. Element Cover
3. Inner Filter Element 6. Dust Ejector
Changing the Air Cleaner Elements

1. Open the engine cover and then the rear grille (page 60).
2. Unlatch the three latches on the air cleaner and remove the cover. Clean out any
dirt built up in the cover assembly.
50950012/AP0811 67
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 dur-
ing this step to prevent debris from entering the engine intake manifold.
3. Use a trouble light inside the outer element to inspect for bad spots, pinholes or
ruptures. Replace the outer element if any damage is noted. The outer element
must be replaced if it is oil- or soot-laden.
Note: Cleaning the outer element is not recommend.
Inner Element
Note: Replace the inner element only if it is visibly dirty or if the outer element
has been replaced three times.
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 prevent
debris from entering the engine intake manifold. Remove the inner element.
Reinstallation
1. Check the inside of the housing for any damage that may interfere with the
elements.
2. Be sure that the element sealing surfaces are clean.
3. Insert the element(s), making sure that they are seated properly.
4. Secure the cover to the housing with the three clamps.
5. Check the hose connections and make sure they are all clamped and tightened
properly.
6. Reset the indicator by pressing the reset button.
Note: Periodically inspect intake system tubes, rubber elbows and connections.
Inspect for cracks, loose fits and loose clamps. Tighten or replace as needed.
Intake system must be air tight.
Engine Service
Refer to the Maintenance Interval chart (page 91) for change intervals. Refer to
the Replacement Parts chart (page 58) for filter part numbers.
Checking Engine Mounting Hardware

All bolts that secure the engine mounting brackets to the engine and the loader
frame should be checked and re-torqued as necessary. Refer to the Torque Speci-
fications chart (page 103) for torque information.
Allow hot engine and hydraulic system com-
WARNING ponents to cool before servicing.
68 50950012/AP0811
Checking Engine Oil Level
Open engine cover (page 60), pull out the dipstick and check the oil level. Mark-
ings on the dipstick represent FULL and LOW (add oil) levels.
1 3 4 6
2 5
7 9
8
Figure 41 Engine Service Components
1. Radiator/Cooler 6. Air Cleaner
2. Remote Engine Oil Filter 7. Fuel Filter
3. Muffler 8. Remote Engine Oil Drain
4. Engine Oil Fill Cap 9. Water Separator
5. Engine Oil Dipstick
Changing Engine Oil and Filter

Note: For new units, the initial oil change should be after the first 50 hours.
Important: Always dispose of waste
lubricating oil according to local regula-
tions or take to a recycling center for dis-
posal; do not pour onto the ground or
down the drain.
The loader has a remote engine oil filter
located behind the engine, beside the radi-
ator/cooler. Raise the engine access cover
and lock open the rear grille to access the
oil filter.
Note: Before removing the oil filter, place Remote Engine Oil Drain
a shop rag or small catch pan under the
filter to contain any oil drip.
Access for draining the engine oil is located behind the left rear tire.
50950012/AP0811 69
To add new oil, open the engine access cover. Remove the oil fill cap and add the
recommended type and quantity of oil. Refer to the Lubrication chart, page 63.
Visually inspect the remote oil drain hose for damage or leaks.
Changing Main Fuel Filter

The 5240E loader has a remote fuel filter bolted to the chassis, located near the
left side of the radiator/cooler. Turn two fuel line petcocks (red levers) to stop
fuel flow BEFORE replacing the filter. Remove the spin-on filter cartridge.
Install the new cartridge, return the fuel line petcocks to their open positions,
start the engine and check for leaks. These same instructions apply for changing
the fuel filter at the water separator.
The 4640E loader has a fuel filter located on the left side of the engine. Follow
the ROPS/FOPS and Lock Mechanism procedure (page 61) to lift up the ROPS/
FOPS and access the filter. Turn two fuel line petcocks (red levers) to stop fuel
flow BEFORE replacing the filter. Remove the spin-on filter cartridge. Install the
new cartridge, return the fuel line petcocks to their open positions, start the
engine and check for leaks. These same instructions apply for changing the fuel
filter at the water separator.
Engine Diagnostic Chart

When detecting failures, the engine electronic control unit (ECU) flashes the
failure lamp to alert the operator to the occurrence of the failure conditions. The
failure lamp will light for two seconds when the engine electronic control unit is
power on. This allows checking if the engine electronic control unit is supplied
with power normally. (The failure lamp is an essential way for checking or diag-
nosing the engine electronic control unit.)
Flashing patterns of the failure lamp are showing in Figure 42. When accelerator
sensor failure (flashing 5 times) and Exhaust Gas Recirculation valve failure
(flashing 1-3 times) occurs, the failure lamp flashes as shown in Figure 42. When
two or more failures have occurred simultaneously, the failure lamp indicates all
the failures in order of increasing number of flashes cyclically.
Figure 42 Flashing Patterns of the Failure Lamp
70 50950012/AP0811
Engine Diagnostic Chart (continued)
Action/ Number
Failure detection
No. Item Operation when failure occurs condition for Category of
conditions
recovery flashes
1 Coolant tempera- Sensor voltage is Engine runs with a coolant temperature of Correct failure. Always 4
ture sensor failure 4.8 V or more, or 30C. enable
0.2 V or less.
2 Accelerator sensor Sensor voltage is [Without optional backup accelerator sensor] Correct failure. Default to 5
failure 4.6 V or more, or Engine runs at 1500 min-1. (Option can disable
0.2 V or less. change)
[With optional backup accelerator sensor]
Select backup accelerator sensor: No
limitation
Backup accelerator sensor failure: Engine
runs at 1500 min-1.(Option can change)
3 Speed sensor Engine start signal [With optional backup speed sensor] Turn key off. Always 6
failure (E8) is on, but the Backup speed sensor becomes active; enable
engine speed is speed is limited to 1800 min -1.(Option can
zero. change)
Engine speed Backup speed sensor failed: Engine stops.
decreases by 480 [Without optional backup speed sensor]
-1 or more in 40 Engine stops.
min
ms.
4 Rack position Correlation Engine runs with limited output and speed. Turn key off. Always 7
sensor failure between rack actu- (Rack position control is inactive and speed enable
ator output and rack control is active).
position exceeds
threshold upper
limit by 0.32 sec. or
more.
Correlation
between rack actu-
ator output and rack
position exceeds
threshold lower limit
by 0.16 sec. or
more.
5 Rack actuator Rack actuator cur- Engine stops. Turn key off. Always 8
failure rent is too high. enable
Rack actuator cur-
rent is too low.
Engine accelerates
with minimum rack
actuator output.
Engine stalls while
rack position sensor
is failed.
6 Overspeed Idling engine speed Engine stops. Turn key off. Always 9
exceeds high idling enable
speed plus 600 min .-1
50950012/AP0811 71
Action/ Number
Failure detection
conditions
recovery flashes
7 Backup speed Engine start signal Engine continues to run while main speed Turn key off. Default to 1-1
sensor failure (E8) is on, but the sensor is used. disable
engine speed is Backup speed sensor failed: Engine stops.
zero.
Engine speed
decreases by 480
min-1 or more in 40
ms.
8 CAN communica- CAN communica- Last value is retained. Backup sensor Correct failure. Default to 1-2
tion failure tion packets cannot becomes active. enable
be received.
9 EGR valve failure Low status is Engine runs with limited output(92%) and Turn key off. Default to 1-3
detected even speed(1800min-1). disable
through port is off.
High status is
detected even
through port is on.
10 CSD solenoid valve High status is Engine continues to run with port being off. Turn key off. Always 1-4
failure detected even enable
Low status is
detected even
through port is on.
11 Air heater relay High status is Engine runs with air heater relay being off. Turn key off. Default to 1-5
Low status is
detected even
through port is on.
12 Main relay failure Power is not shut off Engine runs normally. Correct fail- Default to 1-6
even though main ure.Or turn key disable
relay is off. off.
13 Rack actuator relay Low status is Engine stops. Turn key off. Always 1-7
High status is
detected even
through port is on.
14 Backup accelerator Sensor voltage is Engine continues to run while main acceler- Correct failure. Default to 1-8
sensor failure 4.6 V or more, or ator sensor is used. enable
0.2 V or less. Main accelerator sensor failure: Engine runs
at 1500 min-1.(Option can change)
15 Atmospheric pres- Atmospheric pressure compensation is Turn key off. Default to 1-9
sure sensor failure canceled. enable
16 Oil pressure switch Oil pressure switch Engine runs normally.(Option can change) Turn key off. Default to 2-1
failure fails to turn on when enable
engine is off.
17 Charge switch Charge switch fails Engine runs normally. Turn key off. Default to 2-2
failure to turn on when enable
engine is off.
18 Power supply volt- E-ECU supply volt- Engine runs normally. Correct failure. Always 2-3
age abnormal age exceeds 10.0 V. enable
E-ECU supply volt-
age exceeds 16.0 V.
72 50950012/AP0811
Action/ Number
Failure detection
conditions
recovery flashes
19 Sensor 5V failure Monitoring voltage Engine runs normally. Turn key off. Always 2-4
is approx. 0 V. enable
Monitoring voltage
is 4.5 V or less.
Monitoring voltage
is 5.5 V or more.
20 E-ECU overheat E-ECU temperature Engine runs normally.(Option can change) Correct failure. Default to 2.5
alarm exceeds 105C. enable
Alarm is canceled
when E-ECU tem-
perature decreases
to 100C.
(Option can change)
21 Oil pressure low Oil pressure switch Engine runs normally.(Option can change) Correct failure. Default to 3-1
fails to turn off when enable
engine is running.
22 Charge failure Charge switch fails Engine runs normally. Turn key off. Default to 3-2
to turn off when enable
engine is running.
23 Coolant tempera- Coolant tempera- Engine runs normally.(Option can change) Turn key off. Default to 3-3
ture abnormal ture switch turns on. enable
24 Air cleaner block- Air cleaner switch Engine runs normally.(Option can change) Turn key off. Default to 3-4
age alarm turns on. enable
25 Oily water separa- Oily water separa- Engine runs normally.(Option can change) Turn key off. Default to 3-5
tor alarm tor switch turns on. enable
26 Coolant tempera- Coolant tempera- Engine runs normally. Correct failure. Default to 3-6
ture high alarm ture is 115C or enable
higher.
Alarm is canceled
when Coolant tem-
perature decreases
to 110C.
(Option can change)
27 E-ECU failure FlashROM suffers Engine stops. Turn key off. Always 4-1
[ROM error] checksum error. enable
28 E-ECU failure Reading/Writing Engine runs normally. Turn key off. Always 4-1
[EEPROM error] fails. enable
EEPROM suffers
checksum error.
29 E-ECU failure E-ECU fails to com- Engine runs normally. Turn key off. Always 4-1
[Sub CPU failure] municate with sub enable
CPU.
30 E-ECU failure Map format is Engine stops. Turn key off. Always 4-1
[Mapping error] invalid. enable
31 E-ECU failure Sensor voltage is Engine runs normally. Correct failure. Always 4-1
[E-ECU tempera- 4.6 V or more, or enable
ture sensor failure] 1.0 V or less.
50950012/AP0811 73
Hydraulic System
Refer to the Maintenance Interval chart (page 91) for service intervals. Refer to
the Replacement Parts chart (page 58) for filter part numbers.
Before servicing the hydraulic system, be
WARNING sure the lift arm is lowered.
Checking Hydraulic Oil Level

The loader has a sight gauge located at the
right rear of the skid-steer loader inside
the engine compartment (Figure 43).
Check the fluid level with the lift arm
lowered and the attachment on the
ground.
Add hydraulic oil as required. Refer to the
Lubrication chart (page 63). Replace the
fill cap.
Figure 43 Sight Gauge

and Fill Tube
Changing Hydraulic Oil Filter
To check the hydraulic filter element, run
the engine at full throttle and normal
operating temperature. Lift the engine
access cover. Observe the hydraulic filter
indicator located on the filter head
(Figure 44). If the indicator is green, the
filter does not need replacing. If the indi-
cator is red, replace the filter following
the instructions below.
1. Turn off the engine.
2. Open the reservoir drain plug located Figure 44 Hydraulic Oil Filter
on the inside bottom of the right riser. and Indicator
3. Drain the oil out to a level below the
point where the filter attaches to the reservoir.
4. Replace the reservoir drain plug.
5. Spin off the old hydraulic filter element and spin on the new filter element.
6. Refill the hydraulic oil reservoir with oil. Refer to the Lubrication chart
(page 63).
74 50950012/AP0811
Changing Hydraulic Oil
The hydraulic oil must be replaced if it becomes contaminated, after major
repairs and after 1000 hours or one year of use.
1. Place a catch pan of sufficient capacity under the oil reservoir, see page 62.
2. Remove the drain plug located on the bottom front of the oil reservoir, behind
the right rear tire. Allow the oil to drain.
3. Reinstall the drain plug.
4. Change the oil filter.
5. Refill the reservoir. Refer to the Lubrication topic (page 62).
6. Start the engine and operate the hydraulic controls.
7. Stop the engine and check for leaks at the filter and reservoir drain plug.
8. Check the fluid level and add fluid if needed.
Bucket Cutting Edge

The bucket cutting edge should be replaced when it is worn to within 1 in.
(25 mm) of the bucket body.
Alternator/Fan Belt
Refer to the separate engine manual for checking and adjusting proper belt ten-
sion. If the belt is worn, cracked or otherwise deteriorated, replace the belt fol-
lowing the procedure in the engine manual.
Wheel Nuts
Wheel nut torque must be checked before initial operation and every two hours
thereafter until the wheel mounting hardware torque remains at 180 ft.-lbs.
(244 Nm). Whenever wheels are removed and reinstalled this procedure must be
repeated.
Lift Arm Pivots

The All-Tach pivots should be torqued periodically to 240 ft.-lbs. (325 Nm).
Refer to the Maintenance Interval chart (page 91).
50950012/AP0811 75
Cooling System
Important: Check the cooling system daily to prevent overheating, loss of perfor-
mance and engine damage.
Cleaning the Cooling System

Allow sufficient time for the radiator to cool
WARNING before working on or near it. Parts get
extremely hot during operation and can burn you.
The oil cooler assembly is mounted between the engine and the hinged rear grille.
When operating correctly, air is blown through the openings between the fins by the
engine fan. During operation dust and debris can build up on the engine side of the
oil cooler and restrict air flow through the fins. To remove this restriction, use com-
pressed air or a water hose and direct the flow through the fins from the rear of the
cooler towards the engine.
Tires
Inflating or servicing tires can be dangerous.

WARNING When possible, trained personnel should ser-
vice and mount tires. To avoid possible death or serious injury,
follow the safety precautions below.
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, chains, or other damage. If different sizes are used, tires
will be turning at different speeds, causing excessive wear.
Note: The tread bar of all tires should face the same direction.
BE SURE the rim is clean and free of rust.
Lubricate the tire beads and rim flanges with a soap solution. Do NOT use oil
or grease.
Use a clip-on tire chuck with remote hose and gauge, allowing you to stand
clear while inflating the tire.
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 as-
sembly, reposition the tire on the rim, lubricate both parts and re-inflate. In-
flation 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.
After seating the beads, adjust the inflation pressure to the recommended
operating pressure.
Do NOT weld, braze or otherwise attempt to repair and use a damaged rim.
76 50950012/AP0811
Checking Tire Pressure
Correct tire pressure should be maintained for all tires to enhance operating sta-
bility and extend tire life. Refer to the charts below for proper inflation pressures.
Inflation Pressure
4640E/5240E Tire
psi kPa
10 x 16.5 8-ply
60 415
Heavy-Duty Flotation
12 x 16.5 10-ply
65 450
Heavy-Duty Flotation
10 x 16.5 10-ply
65 450
Severe-Duty
33 x 15.5 x 16.5
60 415
Extra Wide Flotation
Heater Filters
Loaders with the optional heater or heater/air conditioner include two filters:
fresh air intake and recirculation air.
Refer to the Replacement Parts topic (page 58) for filter part numbers. Filters
should be replaced as needed.
Fresh Air Intake Filter: Located on the backside of the main unit. Tilt back
the ROPS/FOPS for access and slide out the filter.
Recirculation Air Filter: Located on the front of the ROPS/FOPS rear deck
panel. Remove four screws and pull out the filter.
Note: Keeping the cab clean will reduce need for service and help ensure proper
air conditioner and heater operation. Failure to do so can cause evaporator and
heater core plugging, fan noise, vibration and failure.
50950012/AP0811 77
Electrical System
Fuse Panel
The main fuse panel is located behind the latched cover in the operators com-
partment above the chaincase on the left side of the operators foot area. The
loader also has three distribution panels located on the left side in the rear engine
compartment.
INTER FRONT ACCESS RADIO

WASH AL ARM
SOL. ACCESS
HEAT
BACK
AC
GLOW
SAFETY
START
HORN
60 20 5 10 20
POWER RELAY 1 POWER RELAY 3
HORN
WIPE
START
L/P
SOLENOID
60 10 15 20 15
LIGHTS
LOCK/
PILOT
TAIL
STROBE 2-SPEED
LOCK LIGHTS
AUX. GAUGES
P-A-T
DOME RIDE/
KEY POWER FUSE 1 POWER FUSE 3
20 60 60 7.5 10 20 10
CNTRL
PUMP
CONTROL
AUXILIARY
FUEL
REAR LIGHTS POWER FUSE 2
LIGHTS
WORK
EMPTY
REAR
20 60 10 5 10 10
EMPTY
ECU
EMPTY
AC POWER
KEY
30 10 10
EMPTY POWER RELAY 2
EMPTY
EMPTY
DIODE
EMPTY
EMPTY
EMPTY
HEATER POWER
30
REAR ELECTRICAL PANELS FRONT ELECTRICAL PANELS

(ORIENTATION MAY VARY)
78 50950012/AP0811
Battery
Before servicing the battery or electrical
WARNING system, be sure the battery disconnect switch
(optional) is in the OFF position. If not equipped with an electrical
disconnect switch, remove the negative ( - ) battery cable from the
battery post.
The battery on the loader is a 12-volt, wet-cell battery. To access the battery on a
4640E loader, open the engine access cover, unlatch and open the rear grille. To
access the battery on a 5240E loader, follow the ROPS/FOPS and Lock Mecha-
nism procedure (page 61) to lift up the ROPS/FOPS and access the battery.
The 4640E and 5240E loaders have remote battery terminals as standard equip-
ment installed.
The battery top must be kept clean. Clean it with an alkaline solution (ammonia
or baking soda and water). After foaming has stopped, flush the battery top with
clean water. 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 when a battery is
WARNING in 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 mix-
tures:
a. 1 pound (0.5 kg) of baking soda in 1 gallon (4 L) of water, or
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
50950012/AP0811 79
Notes
80 50950012/AP0811
CHAPTER 6
TROUBLESHOOTING
Electrical System
Problem Possible Cause Remedy
Battery disconnect switch in Turn battery disconnect
OFF position. switch to ON.
Main wiring harness Check main harness
Entire electrical connectors at rear of ROPS connectors.
system does not not properly plugged in.
function. Battery terminals or cables Clean battery terminals and
loose or corroded. cables and retighten them.
Battery is faulty. Test battery, replace as
needed.
No instrument panel Battery terminals or cables Clean battery terminals and
lamps with keyswitch are loose or corroded. cables and retighten them.
turned to ON.
Faulty fuel gauge sender. Replace fuel gauge sender.
Fuel gauge does not Faulty fuel gauge. Replace fuel gauge.
work.
Loose wiring/terminal Verify wiring connections.
connections.
Faulty temperature sender. Replace temperature sender.
Engine temperature Faulty temperature gauge. Replace temperature gauge.
gauge does not work. Loose wiring/terminal Verify wiring connections.
connections.
Loose wiring/terminal Verify wiring connections.
connections.
Hourmeter does not
work. Faulty alternator. Repair alternator.
Faulty hourmeter. Replace hourmeter.
50950012/AP0811 81
Electrical System
Seat or restraint bar switch Contact your dealer.
malfunctioning or not
actuated.
Poor connections to starter Verify relay connections.
relay in instrument panel.
Battery terminal or cables Clean terminal, cables and
loose or corroded. retighten.
Faulty starter relay in Contact your dealer.
instrument panel.
Starter will not
Battery discharged or Recharge or replace battery.
engage when key is
defective.
turned to START.
Starter solenoid not Contact your dealer.
functioning.
Ignition wiring, seat switch, Check wiring for poor
restraint bar switch, etc. connections, broken leads;
loose or disconnected. repair wiring or connection.
Starter relay malfunctioning. Verify relay is working
properly, replace.
Starter or pinion faulty. Remove starter; repair/
replace as needed.
Single light not working; light Check and replace light bulb
bulb burned out, faulty as needed. Check wiring
wiring. connection to light.
Work lights not No lights; 30 ampere light Check circuit and locate
functioning properly. fuse blown. trouble before replacing fuse.
Faulty light switch or poor Check ground wire
ground. connections. Replace light
switch.
Wiring to solenoids Troubleshoot circuit, repair.
disconnected or faulty.
Restraint bar or seat switch Contact your dealer.
malfunction.
Lift/Tilt and/or drive
lock solenoids do not Faulty solenoid valve coil. Contact your dealer.
work.
Solenoid relay Verify relay is working
malfunctioning. properly, replace.
Faulty hydraulic solenoid Contact your dealer.
relay in instrument panel.
82 50950012/AP0811
Engine
Engine cranking speed too Battery requires recharging
slow. or replacing, or, in cold
temperatures, pre-warm the
engine.
Auxiliary valve engaged. Return control valves to
neutral.
Fuel tank empty. Refill fuel tank.
Glow plug module Check connection and
Engine turns over
malfunctioning. voltage, replace as needed.
but will not start.
Fuel shut-off solenoid not Check electrical connections
energizing. and voltage to shut-off
solenoid.
Engine not warm enough. Install block heater.
Ambient temperature too low. Install block heater.
Fuel filter plugged. Replace filter.
Fuel pump not working. Contact your dealer.
Crankcase oil level too low or Add or remove oil as
too high. required.
Fan air circulation blocked or With engine off, remove
restricted. blockage or restriction.
Fan shroud improperly Contact your dealer.
positioned.
Engine overheats. Grade of oil improper or Drain and replace with

excessively dirty. proper grade new oil.
Exhaust restricted. Allow exhaust to cool,
remove restriction.
Air filter restricted. Replace filter(s).
Low coolant level. Add coolant.
Fan belt loose. Tighten fan belt.
50950012/AP0811 83
Hydrostatic Drive System
Hydraulic oil viscosity too Allow longer warm-up or
heavy. replace oil with proper
No response from
viscosity oil.
either hydrostatic
drive or the lift/tilt Hydraulic oil too low. Check for low oil level in
systems. reservoir, add oil.
Drive coupling failure. Replace coupling.
Parking brake is engaged. Disengage parking brake.
Hydraulic oil level low. Check for low oil level in
reservoir, add oil.
Control rod linkage Check linkage connection at
Traction drive will not
disconnected. control levers and neutral
operate in either
centering mechanisms,
direction.
reconnect linkage.
Low or no charge pressure. Contact your dealer.
Hydrostatic pump(s) relief Contact your dealer.
valves malfunctioning.
Air in hydraulic system. Cycle lift and tilt cylinders to
maximum stroke and
maintain pressure for short
time to clear air from system.
Also check for low oil level in
reservoir, fill as needed.
Sluggish Hydraulic oil level too low. Check for low oil level in
acceleration. reservoir, add oil.
Hydrostatic system charge Contact your dealer.
pressure low.
Drive motor(s) or hydrostatic Contact your dealer.
pump(s) have internal
damage or leakage.
84 50950012/AP0811
Hydrostatic Drive System
Drive system overloaded Improve efficiency of
continuously. operation.
Lift/tilt or auxiliary system Improve efficiency of
overloaded continuously. operation.
Hydrostatic drive damage or leakage.
overheating. Oil cooler fins plugged with Clean oil cooler fins.
debris.
Hydraulic oil filter plugged or Replace filter.
restricted.
Loader being operated in Reduce duty cycle; improve
high temperatures with no air air circulation.
circulation.
50950012/AP0811 85
Hydraulic System
viscosity oil.
Air in hydraulic system. Cycle lift and tilt cylinders to
maximum stroke and
Hydrostatic (drive) maintain pressure for short
system is noisy. time to clear air from system.
Also check for low oil level in
reservoir, fill as needed.
damage or leakage.
Rear hydrostatic pump arm Tighten.
control lever loose.
Left side doesnt Relief valves on rear Contact your dealer.
drive in either hydrostatic pump
direction. Right side malfunctioning.
operates normally.
Control rod linkage to rear Attach control rod linkage.
hydrostatic pump
disconnected.
Relief valve on rear Contact your dealer.
Left side doesnt hydrostatic pump
drive in one malfunctioning.
direction. Rear hydrostatic pump Contact your dealer.
malfunctioning.
Front hydrostatic pump arm Tighten.
control level loose.
Right side doesnt Relief valves on front Contact your dealer.
drive in either hydrostatic pump
direction. Left side malfunctioning.
operates normally.
Control rod linkage to front Attach control rod linkage.
hydrostatic pump
disconnected.
Relief valve on front Contact your dealer.
Right side doesnt hydrostatic pump
drive in one malfunctioning.
direction. Front hydrostatic pump Contact your dealer.
malfunctioning.
86 50950012/AP0811
Hydraulic System
Restraint bar raised. Lower restraint bar.
heavy. replace with proper viscosity
oil.
Hydraulic oil level low. Check oil level in reservoir. If
Lift/Tilt controls fail
oil is low, check for external
to respond.
leak, repair and add oil.
Solenoid valve(s) Check electrical connections
malfunctioning. to lift solenoid and repair.
Restraint bar or seat switch Contact your dealer.
malfunctioning.
Low engine speed. Operate engine at higher
speed.
heavy. replace with proper viscosity
oil.
Hydraulic oil level low. Check oil level in reservoir. If
oil is low, check for an
external leak. Repair and add
oil.
Hydraulic cylinder
Control linkage restricted. Check control linkage,
action is slow for lift
readjust for full spool travel.
and/or tilt functions.
Hydraulic oil leaking past Contact your dealer.
cylinder piston seals.
Worn pump. Contact your dealer.
Solenoid valve(s) Check electrical connections
malfunctioning or one of the to lift solenoid and repair
two cartridges on solenoid connections as needed. If
valve is malfunctioning. solenoid valve is still not
functioning properly, contact
your dealer.
Self-leveling valve Contact your dealer.
Bucket does not level
misadjusted or
on the lift cycle.
malfunctioning.
malfunctioning.
Air in hydraulic system. Cycle/lift and tilt cylinders to
Jerky lift arm and
maximum stroke and
bucket action.
maintain pressure for short
time to clear air from system.
Oil in hydraulic reservoir low. Check and add oil.
50950012/AP0811 87
Hydraulic System
Control valve in float Take control out of float
No down pressure on position. position.
the bucket.
Tilt cylinders malfunctioning. Contact your dealer.
Oil leaking past tilt cylinder Contact your dealer.
seals (internal or external).
Bucket drifts down Self-leveling valve is Contact your dealer.
with tilt control in malfunctioning.
neutral.
Leaking hydraulic hoses, Check oil level in reservoir. If
tubes or fittings between oil is low, check for external
control valve and cylinders. leaks, repair and add oil.
Tilt solenoid valve Check electrical connections
malfunctioning. to tilt solenoid and repair
connections as needed. If
Bucket will not tilt, lift still not functioning properly,
arm works properly. contact your dealer.
Tilt spool in control valve not Check valve control linkage
actuated or leaking. and/or tube connections to
valve.
Lift solenoid valve could be Check electrical connections
malfunctioning. to lift solenoid and repair
Lift arm does not still not functioning properly,
raise, bucket tilt contact your dealer.
works properly.
Lift spool in control valve not Check valve control linkage
actuated or leaking. and/or tube connections to
valve.
Oil leading past lift cylinder Contact your dealer.
seals (internal or external).
Oil leaking past lift spool in Contact your dealer.
Lift arm does not control valve.
maintain raise
position with left Self-leveling valve Contact your dealer.
control in NEUTRAL. malfunctioning.
Leaking hydraulic hoses, Inspect hoses and tubes,
tubes or fittings between tighten fittings as needed.
control valve and cylinders. Replace as needed.
88 50950012/AP0811
Hydraulic System
Lift arm support device Raise lift arm and remove
engaged. support device.
Restraint bar not lowered. Check electrical connections
to solenoid. Repair or replace
Lift arm will not lower as needed.
or raise.
Lift solenoid valve Lower restraint bar.
malfunctioning.
malfunction.
Restraint bar raised. Lower the restraint bar.
Spool lock solenoid Check electrical connections
malfunctioning. to lift solenoid and repair
still not functioning properly,
Auxiliary hydraulics contact your dealer.
do not function. Restraint bar or seat switch Contact your dealer.
malfunctioning.
Low engine speed. Operate engine at higher

speed.
High-flow auxiliary
Hydraulic oil level low. Add oil.
functions slowly.
Hydraulic oil viscosity too Allow longer warm-up, or
viscosity oil.
Restraint bar raised. Lower the restraint bar.
Spool lock solenoid Check electrical connections
malfunctioning. to solenoid, repair
still not functioning properly,
High-flow auxiliary contact your dealer.
does not function. Restraint bar or switch Contact your dealer.
malfunctioning.
50950012/AP0811 89
Notes
90 50950012/AP0811
CHAPTER 7
MAINTENANCE
This Maintenance Interval chart was developed to match the Service chapter of this
manual. Detailed information on each service procedure may be found in the Ser-
vice chapter. A Maintenance Log follows this chart for recording the maintenance
performed. Recording the 10-hour (or daily) service intervals would be impractical
and is therefore not recommended.
Important: Under severe operating conditions, more frequent service than the
recommended intervals may be required. You must decide, based on your use, if
your operation requires more frequent service.
Maximum Interval
Service Procedure 10 Hours 500 Hours
250 Hours
(or Daily) (or Annually)
Foreign Material Removal (page 62)
Check Engine Air Cleaner Restriction Indicator
(page 67)

Check Engine Oil Level (page 69)
Check Hydraulic Oil Level (page 74)
Check Tire Pressures (page 77)
Grease Lift Arm, Hitch, Cylinder Pivots and
Latch Pins (page 62)

Check Bucket Cutting Edge (page 75)
Test Safety Interlock System (page 20)
Check Coolant Level (page 76)
Clean Cooling System (page 76)
Check Drive Chain Tension (page 65)
Check Wheel Nuts Torque (page 75)
Check All-Tach Pivot Torque (page 75)
Check Oil Level in Chaincases (page 65)
Check Alternator/Fan Belt Tensions (page 75)
Change Engine Oil and Filter (page 69)
Change Hydraulic Oil Filter (page 74)
Check Battery (page 79)
Check Engine Mounting Hardware (page 68)
Change Fuel Filters (page 70)
Change Hydraulic Oil (page 75)
Change Chaincase Oil (page 65)
Perform the initial procedure at 2 hours then at intervals.
Perform the initial procedure at 50 hours then at or intervals.
Severe operating conditions.
Perform the procedure at 1000 hours.
50950012/AP0811 91
Maintenance Log
Date Hours Service Procedure
92 50950012/AP0811
Maintenance Log
50950012/AP0811 93
Maintenance Log
94 50950012/AP0811
CHAPTER 8
SPECIFICATIONS
Loader Specifications
Specification 4640E
Operating Weight 6300 lbs. (2858 kg)

Shipping Weight 5700 lbs. (2585 kg)
Rated Operating Capacity1 1650 lbs. (748 kg)
Engine
Make Yanmar (water cooled)
Model 4TNV98
Displacement 202 cu. in. (3,31 L)
Power (net) 68 hp (51 kW)
@ 2500 rpm
Peak Torque 180 ft.-lb. (244 Nm)
@ 1600 rpm
Hydraulic System (theoretical)
Main Hydraulic System Pressure 2750 psi (190 bar)
Standard-Flow Rating 19.0 gpm (72 L/min)
High-Flow Rating 30.0 gpm (114 L/min)
Electrical
Battery 12-Volt DC, 950 CCA
Starter 12-Volt DC (3,0 kW)
Alternator 95 amperes
Capacities
Chaincase (each) 8 U.S. qts. (7.5 L)
Engine Oil2 without filter: 9.0 U.S. qts. (8,5 L)
with new filter: 9.5 U.S. qts. (9,0 L)
Fuel Tank 14 U.S. gal. (53 L)
Hydraulic Reservoir 15 U.S. gal. (57 L)
Coolant Reservoir 9.7 U.S. qts. (9,18 L)
Sound (with Deluxe Sound Kit)
Pressure Level (Operator Ear) 83 dB(A)
Power Level (Environmental) 101 dB(A)
1. Operating capacity rated with an 66 in. (1676 mm) 15.1 ft.3 (0.43 m3) dirt/con-
struction bucket in accordance with SAE J818 and ISO14397.
2. Approximate value can vary depending on oil tray or cooler version (external
cooling system). Use mark on dipstick to determine FULL oil level.
50950012/AP0811 95
Specification 5240E
Operating Weight 6900 lbs (3130 kg)

Shipping Weight 6300 lbs (2858 kg)
Rated Operating Load1 (capacity) 1900 lbs (862 kg)
Engine
Make Yanmar (water cooled)
Model 4TNV98
Displacement 202 cu. in. (3,31 L)
Power (net) 68 hp (51 kW)
@ 2500 rpm
Peak Torque 180 ft-lb (244 Nm)
@ 1600 rpm
Hydraulic System (theoretical)
Main Hydraulic System Pressure 2750 psi (190 bar)
Standard-Flow Rating 19 gpm (72 L/min)
High-Flow Rating 30 gpm (114 L/min)
Electrical
Battery 12-Volt DC, 950 CCA
Starter 12-Volt DC (3,0 kW)
Alternator 95 amperes
Capacities
Chaincase (each) 8.0 U.S. qts (7.5 L)
Engine Oil2 without filter: 9.0 U.S. qts. (8,5 L)
with new filter: 9.5 U.S. qts. (9 L)
Fuel Tank 16 U.S. gal (60 L)
Hydraulic Reservoir 15 U.S. gal (57 L)
Coolant Reservoir 9.7 U.S. qts. (9,18 L)
Sound (with Deluxe Sound Kit)
Pressure Level (Operator Ear) 83 dB(A)
Power Level (Environmental) 101 dB(A)
1. Operating capacity rated with an 66 in. (1676 mm) 15.1 ft.3 (0.43 m3) dirt/con-
struction bucket in accordance with SAE J818 and ISO14397.
2. Approximate value can vary depending on oil tray or cooler version (external
cooling system). Use mark on dipstick to determine FULL oil level.
96 50950012/AP0811
Standard Features
Fuel Level Gauge Hydraloc System Brakes and
Engine Coolant Temperature Interlock for Starter, Lift Cylinders,
Gauge and Indicator Lamp Tilt Cylinders, Wheel Drives,
Hourmeter Dual-Element Air Cleaner with
Oil Pressure Indicator Lamp Visual Restriction Indicator
Battery Charge Indicator Lamp Anti-Vandalism Rear Grille
Seatbelt Indicator Lamp and Pre-Heat Starting Assist
Buzzer Servo-Controlled Hydrostatic Drive
Choice of five control types: T-Bar, Lift Arm Support Device
Hand/Foot, Dual-Hand, Dual Joy- Self-Leveling Lift Action
stick or T-Bar/Joystick Dual Front and Rear Halogen
Foot Throttle (T-Bar, Dual Joystick, T- Work Lights and Dual Tail Lights
Bar/Joystick and Dual-Hand only) Bi-directional Auxiliary Hydraulics
Acoustical Material and Head liner with Flat-Faced Couplers
Adjustable Operator Restraint Bar Powerview Lift Arm
with Armrests Hydraglide Ride Control Sys-
ROPS/FOPS ISO Level II tem (Dual Joystick only)
Skid Plate for Clean Out All-Tach Attachment Mounting
Interior Dome Light System: Two Lever (Manual)
Engine Auto-Shutdown System
Optional Features
2-Speed Transmission Four-Point Lift Kit
Upper-torso Restraint (required Single-Point Lift Kit
with 2-speed transmission) Hydraulic Couplers Kit
3-inch Wide Seatbelt - (where Centrifugal Pre-Cleaner
required by law) Engine Block Heater
Sliding Side Windows Hydraglide Ride Control Sys-
Rear-View Mirror tem (Hand/Foot, T-Bar/Joystick and Dual-
Adjustable Suspension Seat Hand)
Impact-Resistant Front Door Bi-directional High-Flow Auxiliary
Front Door with Wiper Hydraulics with Flat-Faced Cou-
Operators Compartment Heater/ plers
Defroster/Air Conditioner with Power-A-Tach Attachment
Filters (5240E only) Mounting System
Audible Back-Up Alarm Hydraulic Oil Filter Indicator Lamp
Strobe Light Horn
Bucket Bolt-On Cutting Edge Kits Spark Arresting Muffler
50950012/AP0811 97
Dimensional Specifications
15.1 ft.3 (0.43 m3)

Bucket w/10 x 16.5
SL4640E Tires
inches mm
A Overall Operation Height Fully Raised 152.5 3873,5
B Height to Hinge Pin Fully Raised 115.5 2933,7
C Overall Height Top of ROPS 78.5 1994
D Overall Length Bucket Down 122 3099
E Dump Angle at Full Height 43.5 0
F Dump Height 84.5 2146,3

G Dump Reach Full Height 26.5 673
I Rollback at Ground 23 0
M Rollback Angle at Full Height 88.50

O Seat to Ground Height 37.5 952,5
P Wheel Base Nominal 38 965
Q Overall Width Less Bucket1 63 1600
R Bucket Width Overall 60-70 1524-1778
S Ground Clearance to Chassis (Between Wheels) 6.5 165
U Maximum Grading Angle 89 0
V Overall Length (Less Bucket) 91 2311

W Departure Angle 210
X Clearance Circle Front (With Bucket) 77 1956
Y Clearance Circle Front (Less Bucket) 45 1143
Z Clearance Circle Rear 52.5 1333,5
1. Overall width (Q) is dependent upon the amount of wheel offset.
98 50950012/AP0811
15.1 ft.3 (0.43 m3)
Bucket w/12 x 16.5
SL5240E Tires
inches mm
A Overall Operation Height Fully Raised 153.5 3899
B Height to Hinge Pin Raised 121 3073,4
C Overall Height Top of ROPS 79.4 2016,7
D Overall Length Bucket Down 126.3 3208
E Dump Angle at Full Height 430
F Dump Height 91.75 2330,5
G Dump Reach Full Height 22.75 578
I Rollback at Ground 240
M Rollback Angle at Full Height 880
O Seat to Ground Height 37.5 952,5
P Wheel Base Nominal 42 1067
Q Overall Width Less Bucket1 63.5 1613
R Bucket Width Overall 60-70 1524-1778
S Ground Clearance to Chassis (Between Wheels) 7.5 190,5
U Maximum Grading Angle 880
V Overall Length (Less Bucket) 95 2413
W Departure Angle 230
X Clearance Circle (With Bucket) 79.5 2019,3
Y Clearance Circle Front (Less Bucket) 43.75 1111,3
Z Clearance Circle Rear 57.25 1454,2
1. Overall width (Q) is dependent upon the amount of wheel offset.
50950012/AP0811 99
Capacities and Ratings
SL4640E/5240E Models
Note: Use the Common Materials and Densities table (page 101) for selecting
the appropriate bucket.
Description SL4640E SL5240E

Weight
Rating Rating
Dirt/Construction Buckets
60.0 in./11.0 ft.3 (1524 mm/0.31 m3) 304 lbs. 1596 lbs. 1885 lbs.
(138 kg) (724 kg) (855 kg)
(139 kg) (723 kg) (854 kg)
66 in./15.1 ft.3 (1676 mm/0.43 m3) 411 lbs. 1477 lbs. 1754 lbs.
(186 kg) (670 kg) (796 kg)
(198 kg) (665 kg) (790 kg)
Dirt/Construction with Spill Guard Buckets
(154 kg) (801 kg) (948 kg)
(200 kg) (747 kg) (889 kg)
Low Profile/Grading Bucket
(239 kg) (590 kg) (706 kg)
Utility Buckets
(195 kg) (661 kg) (786 kg)
(216 kg) (640 kg) (763 kg)
(229 kg) (634 kg) (757 kg)
Pallet Forks
15.75 in. (400 mm) Forks with Backrest 500 lbs. 1070 lbs. 1450 lbs.
Rating per EN474-3 (227 kg) (485 kg) (658 kg)
19.68 in. (500 mm) Forks with Backrest 500 lbs. 1020 lbs. 1375 lbs.
Rating per EN474-3 (227 kg) (463 kg) (624 kg)
24 in. (610 mm) Forks with Backrest 500 lbs. 970 lbs. 1300 lbs.
Rating per SAE J1197 (227 kg) (440 kg) (590 kg)
100 50950012/AP0811
Common Materials and Densities
Density
Material
lbs./ft.3 kg/m3
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
Shale-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.
50950012/AP0811 101
Bucket Selection
To use the table, find the material to be loaded and read its maximum density.
Then multiply the volumetric rating of the attachment by the material density to
determine if the attachment can safely be used. See page 100 for a listing of
attachments and their capacity ratings.
Note: Where the material density is listed as a range (clay at 80-100 lbs./ft.3, for
example), always use the maximum density (100 lbs./ft.3 in this example) for
making calculations. Also, see the following examples.
Example 1: If clay (density of 80-100 lbs./ft.3) is to be hauled using a SL4640E
model loader using a 15.1 ft.3 Dirt/Construction bucket, the bucket capacity is
15.1 ft.3 and the loader rating is 1650 lbs. Multiply the density of clay (100 lbs/
ft.3) by the capacity of the bucket (15.1 ft.3) to determine the weight to be carried
(100 lbs./ft.3 x 15.1 ft.3 = 1510 lbs.). This number is less than the machine rating,
allowing safe use of this bucket in this application.
Example 2: If dry sand (density of 1728 kg/m3) is to be hauled using a SL4640E
model loader using a 0.43 m3 Dirt/Construction bucket, the bucket capacity is
0.43 m3 and the loader rating is 748 kg. Multiply the density of dry sand (1728
kg/m3) by the capacity of the bucket (0.43 m3) to determine the weight to be car-
ried (1728 kg/m3 x 0.43 m3 = 743 kg). This number is less than the machine
rating, allowing safe use of this bucket in this application.
102 50950012/AP0811
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
DRY LUBED DRY LUBED DRY LUBED
THREAD
8-32 19* 14* 30* 22* 41* 31*
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
-13 50 35 75 55 110 80
-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
DRY LUBED DRY LUBED DRY LUBED
THREAD
M6-1 8 6 11 8 13.5 10
M8-1.25 19 14 27 20 32.5 24
M10-1.5 37.5 28 53 39 64 47
M12-1.75 65 48 91.5 67.5 111.5 82
M14-2 103.5 76.5 145.5 108 176.5 131
M16-2 158.5 117.5 223.5 165.5 271 200
*All torque values are in ft-lbs., except those marked with an * which are in lbs.
For metric torque value (Nm), multiply the ft-lbs value by 1.355 or the in-lbs value
by 0.113.
50950012/AP0811 103
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 dealers business location.
GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF

ANY KIND, EXPRESS OR IMPLIED (INCLUDING THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED
IN THIS WARRANTY STATEMENT.
ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW
SHALL BE DEEMED DELETED FROM THIS WARRANTY; ALL
OTHER TERMS WILL CONTINUE TO APPLY.
SOME STATES DO NOT PERMIT THE EXCLUSION OR
LIMITATION OF THESE WARRANTIES AND YOU HAVE
GREATER RIGHTS UNDER THE STATE LAW.
GEHL WARRANTY DOES NOT INCLUDE:

1. Transportation to selling dealers business location or, at the
option of the Original Retail Purchaser, the cost of a service call.
2. Used equipment.
3. Components covered by their own non-Gehl warranties, such
as tires, batteries, trade accessories and engines.
4. Normal maintenance service and expendable, high-wear items.
5. Repairs or adjustments caused by: improper use; failure to follow
recommended maintenance procedures; use of unauthorized
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 acquiring
replacement equipment.
No agent, employee or representative of Gehl has any authority to
bind Gehl to any warranty except as specifically set forth herein.
104 50950012/AP0811
INDEX
A C
Accessory Plug . . . . . . . . . . . . . 23 Chaincases . . . . . . . . . . . . . . . . . 65
Adjustments. . . . . . . . . . . . . . . . 61 Checking and
Control Handles. . . . . . . . . . 61 Adding Oil. . . . . . . . . . . . . . 65
Fuel Sender . . . . . . . . . . . . . 61 Draining Oil . . . . . . . . . . . . . . 65
Air Conditioner Changing Attachments
Operation. . . . . . . . . . . . . . . 24 Connecting Attachments . . . . 46
Alternator/Fan Belt . . . . . . . . . . 75 Removing Attachments . . . . . 47
Attachment Mounting . . . . . . . . 27 Changing Hydraulic Oil . . . . . . . . 75
All-Tach Hitch . . . . . . . . . . 27 Changing Hydraulic
Oil Filter . . . . . . . . . . . . . . . . . . 74
Power-A-Tach Hitch . . . . . 27
Chart, Diagnostic
Attachments, Changing . . . . . . . 46
Engine . . . . . . . . . . . . . . . . . . 70
Auto-Shutdown . . . . . . . . . . . . . 26
Checking and Adding Oil . . . . . . 65
Auxiliary Hydraulic Controls
Checking Hydraulic
High-Flow . . . . . . . . . . . . . . 41 Oil Level . . . . . . . . . . . . . . . . . . 74
Standard Flow . . . . . . . . . . . 40 Checking Tire Pressure . . . . . . . 77
Cleaning the Cooling
B System . . . . . . . . . . . . . . . . . . 76
Battery . . . . . . . . . . . . . . . . . . . . 79 Cold Starting Procedure 44
Jump-starting. . . . . . . . . . . . 45 Common Materials and
Before Starting the Engine Densities . . . . . . . . . . . . . . . . 101
Cold-Starting . . . . . . . . . . . . . 44 Connecting Auxiliary
Hydraulic Couplings . . . . . . . . . 47
Cold-Starting Procedure . . . 44
Control/Indicator Symbols. . . . . . . 4
Bucket Cutting Edge . . . . . . . . . 75
Controls and Safety
Bucket Selection . . . . . . . . . . . 102
Equipment Chapter . . . . . . . . . 19
Bucket, Usage . . . . . . . . . . . . . . 48
Cooling System. . . . . . . . . . . . . . 76
Digging with a Bucket . . . . . 48
Cleaning . . . . . . . . . . . . . . . . 76
Driving on an Incline . . . . . . 48
Driving over Rough
Terrain . . . . . . . . . . . . . . . 48 D
Dealer Services. . . . . . . . . . . . . . 57
Dumping into a
Truck or Hopper . . . . . . . . 49 Dimensional Specifications . . . . . 98
Dumping Onto a Pile . . . . . . 49 Dome Light . . . . . . . . . . . . . . . . . 23
Dumping Over Draining Oil . . . . . . . . . . . . . . . . . 65
an Embankment . . . . . . . . 49 Drive Chains
Leveling the Ground . . . . . . 50 Adjusting Chain Tension . . . . 65
Loading a Bucket. . . . . . . . . 49 Checking Chain Tension . . . . 65
Scraping with a Bucket . . . . 50 Dual Hand Controls. . . . . . . . . . . 39
Auxiliary Hydraulic
50950012/AP0811 105
Controls . . . . . . . . . . . . . . . 40 Operation . . . . . . . . . . . . . . . 24
Drive Control . . . . . . . . . . . . . 39 Heater and Air Conditioner
Lift/Tilt Control . . . . . . . . . . . . 39 Operation . . . . . . . . . . . . . . . 24
Dual Joystick Controls . . . . . . . . 35 Heater Filters . . . . . . . . . . . . . . . 77
Drive Controls . . . . . . . . . . . . 35 Highway Travel. . . . . . . . . . . . . . 54
Lift/Tilt Controls . . . . . . . . . . . 36 Horn . . . . . . . . . . . . . . . . . . . . . . 21
Hydraglide Ride
E Control System . . . . . . . . . . . . 26
Electrical System . . . . . . . . . . . . 78 Hydraloc System. . . . . . . . . . . 20
Fuse Panel . . . . . . . . . . . . . . 78 Hydraulic System . . . . . . . . . . . . 74
Emergency Exit. . . . . . . . . . . . . . 22 Changing Hydraulic Oil . . . . . 75
Engine Air Cleaner . . . . . . . . . . . 67 Changing Hydraulic
Oil Filter . . . . . . . . . . . . . . 74
Changing Air Cleaner
Elements . . . . . . . . . . . . . . 67 Checking Oil Level . . . . . . . . 74
Engine Auto-Shutdown . . . . . . . . 26
Engine Compartment I
Access . . . . . . . . . . . . . . . . . . . 60 Instrument Panel . . . . . . . . . . . . 28
Engine Diagnostic Chart . . . . . . . 70 Instrument Panels . . . . . . . . . . . 28
Engine Service Left Instrument Panel . . . . . . 28
Changing Engine Oil Right Instrument Panel . . . . . 29
and Filter . . . . . . . . . . . . . . 69 Introduction. . . . . . . . . . . . . . . . . . 1
Changing Main Fuel Filter . . . 70
Checking Engine L
Mounting Hardware . . . . . . 68
Lift Arm Pivots . . . . . . . . . . . . . . 75
Checking Oil Level . . . . . . . . 69
Lift Arm Support Device . . . . . . . 22
Engine Speed Control. . . . . . . . . 25
Disengagement . . . . . . . . . . 23
Engagement . . . . . . . . . . . . . 22
F Lifting the Loader . . . . . . . . . . . . 56
Foreign Material Removal. . . . . . 62
Loader
Fuse Panel . . . . . . . . . . . . . . . . . 78
Lifting . . . . . . . . . . . . . . . . . . 56
Lowering Procedure . . . . . . . 60
G Raising Procedure . . . . . . . . 59
Guards and Shields . . . . . . . . . . 19
Removing from Storage . . . . 54
Storing . . . . . . . . . . . . . . . . . 54
H Transporting . . . . . . . . . . . . . 55
Hand/Foot Controls. . . . . . . . . . . 37
Loader Identification . . . . . . . . . . . 3
Auxiliary Hydraulic
Controls . . . . . . . . . . . . . . . 40 Loader Specifications . . . . . . . . . 95
Drive Controls . . . . . . . . . . . . 37 Lubrication . . . . . . . . . . . . . . . . . 62
Lift/Tilt Controls . . . . . . . . . . 38
Heater
Filter Service . . . . . . . . . . . . . 77
106 50950012/AP0811
M Before Starting . . . . . . . . . . . . 6
Maintenance Chapter . . . . . . . . 91 During Operation. . . . . . . . . . . 7
Maintenance Schedule Maintenance . . . . . . . . . . . . . . 7
Maintenance Interval Seatbelt
Chart . . . . . . . . . . . . . . . . . 91 Upper-Torso Restraint. . . . . . 20
Maintenance Log . . . . . . . . . 92 Self-Leveling . . . . . . . . . . . . . . . . 48
Mandatory Safety Shutdown Service Chapter . . . . . . . . . . . . . 57
Procedure. . . . . . . . . . . . . . . . . 6
Specifications
Dimensional Specifications . . 98
O Loader Specifications . . . . . . 95
Operation
Optional Features . . . . . . . . . 97
Jump-Starting . . . . . . . . . . . 45
Standard Features . . . . . . . . 97
Parking the Loader . . . . . . . 44
Specifications Chapter . . . . . . . . 95
Stopping the Loader . . . . . . 44
Speed Control . . . . . . . . . . . . . . . 25
Operation Chapter. . . . . . . . . . . 43
Standard Features . . . . . . . . . . . 97
Operator Restraint Bar . . . . . . . 19
Starting the Engine . . . . . . . . . . . 43
Operators Seat . . . . . . . . . . . . . 20
Before Starting the Engine . . 43
Optional Features . . . . . . . . . . . 97
Stopping the Loader . . . . . . . . . . 44
Storing the Loader . . . . . . . . . . . 54
P
Parking Brake . . . . . . . . . . . . . . 21
T
Parking the Loader . . . . . . . . . . 44
T-Bar Controls. . . . . . . . . . . . . . . 31
Potential Hazards . . . . . . . . . . . . 8
Auxiliary Hydraulic
Product and Component Controls . . . . . . . . . . . . . . . 40
Plate Locations . . . . . . . . . . . . 17
Drive Controls . . . . . . . . . . . 31
Lift/Tilt Controls . . . . . . . . . . . 32
R T-Bar/Joystick Controls. . . . . . . . 33
Removing Loader from Storage 54
Drive Controls . . . . . . . . . . . 33
Replacement Parts . . . . . . . . . . 58
Lift/Tilt Controls . . . . . . . . . . . 34
Ride Control System . . . . . . . . . 26
Tips For Improving Heater Perfor-
ROPS/FOPS . . . . . . . . . . . . . . . 21 mance . . . . . . . . . . . . . . . . . . . 24
Tilting Back . . . . . . . . . . . . . 61 Tires . . . . . . . . . . . . . . . . . . . . . . 76
Checking Tire Pressure. . . . . 77
S Torque Specifications . . . . . . . . 103
Safety Chapter . . . . . . . . . . . . . . 5 Troubleshooting
Safety Decals . . . . . . . . . . . . . . . 8 Electrical . . . . . . . . . . . . . . . . 81
New Decal Application. . . . . . 8 Engine . . . . . . . . . . . . . . . . . . 83
No-Text Decals . . . . . . . . . . 13 Hydraulic System . . . . . . . . . 86
Text Decals . . . . . . . . . . . . . . 9 Hydrostatic Drive System . . . 84
Safety Interlock System Troubleshooting Chapter . . . . . . 81
Testing. . . . . . . . . . . . . . . . . 20 Two-Speed Transmission . . . . . . 26
Safety Reminders . . . . . . . . . . . . 6
50950012/AP0811 107
V
Vibration Information. . . . . . . . . . 51
Vibration Levels . . . . . . . . . . . . . 53
Vibration Measurement and
Actions . . . . . . . . . . . . . . . . . . . 51
W
WARRANTY . . . . . . . . . . . . . . . 104
Wheel Nuts . . . . . . . . . . . . . . . . . 75
Work Lights . . . . . . . . . . . . . . . . 23
108 50950012/AP0811
WRONG WRONG
Never exceed rated Always carry attachment

operating load. as low as possible. Do
not travel or turn with
the lift arm raised. Load,
unload and turn on flat
level surface.
WRONG WRONG
Never carry riders. Never modify equipment.
Keep bystanders away Use only attachments

from work area. approved for model
loader.
WRONG
Never leave loader with

engine running or with
lift arm up. To park,
engage parking brake
and put attachment flat
on the ground.
WARNING
THIS OPERATORS 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
Operators 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
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.
Manitou Americas, Inc., P.O. Box 179, West Bend, WI 53095-0179 U.S.A.
www.gehl.com
2011 MANITOU AMERICAS, INC.

50950012/AP0811 All Rights Reserved. PRINTED IN U.S.A.

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SL4640E

(SN 312901 and Up)

Read Operators Manual Never use the loader

Always fasten seatbelt Do not use loader

Loader Model Number

Loader Serial Number

Engine Serial Number

Hydraloc and Hydraglide are trademarks of Manitou Americas, Inc.

1. Manufacturer: Manitou Americas, Inc.

3. Technical Construction File Location:

6. We hereby declare that the model(s) listed below

2004/108/EC Type-test Self-certification

Power Off Power On Engine Start Battery Charge Electrical Power

Worklight w/Flasher Worklight Safety Alert Hazard Flasher Wear Seatbelt

Glow Indicator Diesel Fuel Chaincase Oil Clockwise Rotation Counterclockwise

Fast Speed Slow Speed Ride Control Power-A-Tach Bucket Float

Lift Point Tie-Down Point Diesel Water Engine Malfunction

New Decal Application

AVOID INJURY OR DEATH

137628 Located on manual box, behind seat

1. Lower equipment to ground.

2. Reduce throttle, stop engine.

3. Apply park brake; remove key.

4. Check safety interlocks.

AVOID INJURY OR DEATH

Inspect work area,

Look in direction of travel. Keep

Start and operate machine

Never carry riders.

Operate only in well

Keep away from electric

Do not wear loose clothing

194485 - Left Instrument

137647 Located on operators lower left side

137655 Located on front of loader

137720 Located on hitch (manual hitch loaders only)

184481 Located on hitch (power hitch loaders only)

137637 Located on the left fender and left side of ROPS/FOPS

184214 Located under the ROPS/FOPS

137657 Located on the right riser

137658 Located on the fan shroud

Safety alert: Always follow

137843 Located on operators lower left side

137844 Located on front of loader

186743 Located on hitch (manual hitch loaders only)

139101 Located on hitch (power hitch loaders only)

184711 Located under

137845 Located on the right riser

137845 Located on the fan shroud

Product and Component Plates

Guards and Shields

Operator Restraint Bar

Figure 1 Operators Seat

Always wear the upper-torso restraint when

The seatbelt should always be fastened during operation.

Safety Interlock System

Testing the Safety Interlock System

Lift Arm Support Device

Heater and Air Conditioner (optional)