Gehl SL4640 User manual

SL4640
SL4840
SL5640
SL6640
Skid-Steer
Loaders
Operator’s Manual
Form No.
917001/
CP0905
English
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Gehl Company, in cooperation
with the American Society of
Agricultural Engineers and the
Society of Automotive Engineers, has
adopted this Safety Alert Symbol to
pinpoint precautions which, if not
properly followed, can create a safety
hazard. When you seethis symbol in this
manual or on the machine itself, you are
reminded to BE ALERT! Your personal
safety is involved!
Operators must have instructions
before running the machine.
Untrained operators can cause
injury or death.
Read Operator’s Manual
before using machine.
CORRECT
Always fasten seatbelt
snugly. Always keep feet on
the floor/pedals when
operating loader.
CORRECT
Never use loader
without ROPS/FOPS.
Never modify the
ROPS/FOPS
structure.
WRONG
Never use the loader
to lift personnel.
WRONG
Do not use loader
aroundexplosivedust
or gas, or where
exhaust can contact
flammable material.
WRONG
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Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Controls and Safety Equipment . . . . . . . . . . . . . . . . . . . 17
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
SL4640, SL4840, SL5640 and SL6640
Skid-Steer Loader
TABLE OF CONTENTS
All-Tach, Hydraloc and Hydraglide are trademarks of Gehl Company.
Gehl and Powerview are registered trademarks of Gehl Company.
Loader Model Number
Loader Serial Number
Engine Serial Number
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Notes
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917001/CP0905 1
CHAPTER 1
INTRODUCTION
This Operator’s Manual provides the owner/operator with information for operat-
ing, maintaining and servicing SL4640, SL4840, SL5640 and SL6640 skid-steer
loader models. More importantly, this manual provides an operating plan for safe
and proper use of the machine. Major points of safe operation are detailed in the
Safety chapter of this manual.
We ask that you read and understand the contents of this manual completely and
become familiar with your new machine before operating it. See your authorized
Gehl dealer if you have any questions concerning information in the manual,
require extra manuals or for information concerning the availability of manuals
in other languages.
Throughout this manual, information is provided set in italic type and introduced
by the word Note or Important. Read carefully and comply with those messages
– it will improve your operating and maintenance efficiency, help avoid break-
downs and damage, and extend your machine’s life.
A manual storage box in the operator’s compartment holds the Operator’s Manual
and AEM Safety Manual (also available in Spanish). Please return the manuals to
this box and keep them with the unit at all times. If this machine is resold, we 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 Gehl Company, consult your Gehl dealer. Any person using non-
approved attachments or making unauthorized modifications is responsible for
the consequences.
The Gehl dealership network stands ready to provide you with any assistance you
may require, including providing genuine Gehl service parts. All service parts
should be obtained from your Gehl dealer. Provide complete information about
the part and include the model and serial numbers of your machine. Record these
numbers in the space provided on the Table of Contents page, as a handy refer-
ence.
Please be aware that Gehl strives to continuously improve its products and
reserves the right to make changes and improvements in the design and construc-
tion of any part without incurring the obligation to install such changes on any
previously delivered unit.
If this machine was purchased “used”, or if the owner’s address has changed,
please provide your Gehl dealer or Gehl Company Service Department with the
owner’s name and current address, along with the machine model and serial num-
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2917001/CP0905
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.
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917001/CP0905 3
Loader Identification
1. Front Work Lights
2. Handholds
3. Tilt Cylinders
4. Hitch
5. Restraint Bar
6. Lift Arm
7. Lift Cylinder
8. Tires
1
2
3
4
5
6
7
8
1. Engine Cover
2. Rear Work Lights
3. Tail Lights
4. Rear Door
5. Roll-Over/Falling Object
Protective Structure
(ROPS/FOPS)
3
3
4
1
2
5
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4917001/CP0905
Control/Indicator Symbols
Power Off Power On Engine Start Battery Charge Electrical Power
Worklight w/Flasher Worklight Safety Alert Hazard Flasher Seatbelt
Horn Read Operator’s
Manual Volume – Full Volume – Half Full Volume – Empty
H-L
High – Low N
Neutral F Forward R Reverse Parking Brake
Engine Air Filter Engine Oil Engine Oil Filter Engine Oil Pressure Fuel Filter
Engine Temperature Hydraulic System Hydraulic Oil
Temperature Hydraulic Oil Filter Grease Lubrication Point
Glow Indicator
Lamp Diesel Fuel Chaincase Oil Clockwise Rotation Counterclockwise Rotation
Fast Slow Ride Control Power Hitch Bucket – Float
Bucket – Rollback Bucket – Dump Lift Arm – Lower Lift Arm – Raise Service Hours
Lift Point Tie-Down Diesel Water
Separator Engine Malfunction Shutdown
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917001/CP0905 5
CHAPTER 2
SAFETY
This safety alert symbol means Attention! Become alert! Your safety is
involved! It stresses an attitude of “Heads Up for Safety” and can be
found throughout this Operator’s Manual and on the decals on the machine.
Before operating this machine, read and study the following safety information.
For further reference on the safe operation of skid-steer loaders, Gehl Company
suggests that equipment owners obtain the Gehl “Skid-Steer Loader Safety”
video, which is available through Gehl dealers. In addition, be sure that everyone
who operates or works with this machine, whether family member or employee,
is familiar with these safety precautions. It is essential to have competent and
careful operators, who are not physically or mentally impaired, and who are thor-
oughly trained in the safe operation of the machine and the handling of loads. It is
recommended that the operator be capable of obtaining a valid motor vehicle
operator’s license.
The use of skid-steer loaders is subject to certain hazards that cannot be eliminated
by mechanical means, but only by exercising intelligence, care and common sense.
Such hazards include, but are not limited to, hillside operation, overloading, insta-
bility of the load, poor maintenance and using the equipment for a purpose for
which it is not intended or designed.
Gehl ALWAYS considers the operator’s safety when designing its machinery, and
guards exposed moving parts for the operator’s protection. However, some areas
cannot be guarded or shielded in order to assure proper operation. Furthermore,
this Operator’s 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 your machine as needed.
“DANGER” indicates an imminently haz-
ardous situation which, if not avoided, will
result in death or serious injury.
“WARNING” indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
“CAUTION” indicates a potentially hazardous
situation which, if not avoided may result in
minor or moderate injury. May also alert against unsafe practices.
DANGER
WARNING
CAUTION
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6917001/CP0905
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 20).
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
¾Do not modify the ROPS/FOPS unless instructed to do so in installation
instructions. Modifications such as welding, drilling or cutting can weaken
the structure and reduce the protection it provides. A damaged ROPS/FOPS
cannot be repaired – it must be replaced.
¾To ensure safe operation, replace damaged or worn-out parts with genuine
Gehl service parts.
¾Gehl skid-steer loaders are designed and intended to be used only with Gehl
attachments or approved referral attachments. Gehl cannot be responsible for
operator safety if the loader is used with a non-approved attachment.
¾Remove all trash and debris from the machine each day, especially in the
engine compartment, to minimize the risk of fire.
¾Always face the loader and use the handholds and steps when getting on and
off the loader. Do not jump off the loader.
¾Never use starting fluid (ether).
¾Walk around the machine and warn all nearby personnel before starting the
machine.
¾Always perform a daily inspection of the machine before using it. Look for
damage, loose or missing parts, leaks, etc.
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917001/CP0905 7
During Operation
¾Machine stability is affected by: the load being carried, the height of the load,
machine speed, abrupt control movements and driving over uneven terrain.
DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE
LOADER TO TIP, THROWING THE OPERATOR OUT OF THE
SEAT OR LOADER, RESULTING IN DEATH OR SERIOUS INJURY.
Therefore: ALWAYS operate with the seatbelt fastened and the restraint bar
lowered. Do not exceed the machine’s Rated Operating Load. Carry the load
low. Move the controls smoothly and gradually, and operate at speeds appro-
priate for the conditions.
¾When operating on inclines or ramps, always travel with the heavier end of
the loader toward the top of the incline for additional stability.
¾Do not raise or drop a loaded bucket or fork suddenly. Abrupt movements
under load can cause serious instability.
¾Never 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.
¾Do 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.
¾Never carry riders. Do not allow others to ride on the machine or attachments,
because they could fall or cause an accident.
¾Always look to the rear before backing up the skid-steer loader.
¾Operate the controls only from the operator’s seat.
¾Always keep hands and feet inside the operator’s compartment while oper-
ating the machine.
¾New 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.
¾Exhaust fumes can kill. Do not operate this machine in an enclosed area
unless there is adequate ventilation.
¾When 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
¾Never attempt to by-pass the keyswitch to start the engine. Use only the jump
starting procedure detailed in the Operation chapter of this manual.
¾Never 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.
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8917001/CP0905
¾Always 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.
¾Do 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 environ-
ment. Operator actions, the environmental conditions and the job at hand require
the full attention of the operator so that safety precautions can be taken.
ALWAYS maintain a safe distance from electric power lines and avoid contact
with any electrically charged conductor or gas line. Accidental contact or rupture
can result in electrocution or an explosion. Contact the North American One-Call
Referral System at: 1-888-258-0808 for the local “Digger's Hotline” number or
the proper local authorities for utility line locations BEFORE starting to dig!
Exposure to crystalline silica (found in sand, soil and rocks) has been associated
with silicosis, a debilitating and often fatal lung disease. A Hazard Review
(Pub. No. 2002-129) by the U.S. National Institute for Occupational Safety and
Health (NIOSH) indicates a significant risk of chronic silicosis for workers
exposed to inhaled crystalline silica over a working lifetime. NIOSH recom-
mends an exposure limit of 0.05 mg/m3as 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.
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.
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917001/CP0905 9
ANSI-Style Safety Decals inside the ROPS/FOPS
1
37628 – Located on manual box, behind seat
Left Instrument Panel
1
37647 – Located on operator’s lower left side
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10 917001/CP0905
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)
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917001/CP0905 11
ANSI-Style Safety Decals on the outside of the Loader
137647 – Located on the left fender and left side of ROPS/FOPS
184214 – Located under the ROPS/FOPS
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12 917001/CP0905
ANSI-Style Safety Decals in the Engine Compartment
1
37657 – Located on radiator
1
37658 – Located on radiator
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917001/CP0905 13
ISO-Style (used Internationally)
Safety Decals inside the ROPS/FOPS
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.
Safety alert: Read Operator’s
Manual and all safety signs
before using machine. The
owner is responsible to ensure
all users are instructed on safe
use and maintenance.
137842 – Located on manual
storage box, behind seat
137847 – Part of left
instrument panel
Safety alert: Always follow
“Mandatory Safety Shutdown
Procedure” in Operator’s Manual.
1– Lower equipment to ground.
2– Reduce throttle, stop engine.
3– Apply parking brake; remove
key.
4– Check safety interlocks.
137847 – Part of
left instrument
panel
Safety alert:
A– Check machine before
operating; Service per Operator’s
Manual. Contact dealer (or
manufacturer) for information and
service parts.
B– Maintain 3-point contact during
entry and exit.
C– Inspect work area. Avoid all
hazards. Look in direction of travel.
Keep children and bystanders away.
D– Start and operate machine only
from seat.
E– Keep away from power lines;
avoid contact.
F– Wear any needed Personal
Protective Equipment. Do not wear
loose clothing while operating or
servicing machine.
AB
CD
EF
137843 – Located on operator’s lower left side
ABCD
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14 917001/CP0905
ISO-Style (used Internationally)
Safety Decals on the outside of the Loader
137844 – Located on front of loader
132166 – Located
on rear window
emergency exit
37852 – Located on hitch (manual hitch loaders only)
139101 – Located on hitch (power hitch loaders only)
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.
Crush hazard: Before operating with attachment, check engagement of hitch
locking pin to the attachment:
A– Incorrect attachment engagement C– Lock hitch lever
B– Correct attachment engagement D– Unlock hitch lever
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
AB
A
B
A
B
C
D
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917001/CP0905 15
ISO-Style (used Internationally)
Safety Decals on the outside of the Loader
137848 – Located on the left fender and
left side of ROPS/FOPS
Crush hazard:
Hose removal or
component failure
can cause lift arm
to drop. Always use
lift arm support
device when
leaving lift arm
raised for service.
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
Operator’s Manual.
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16 917001/CP0905
ISO-Style (used Internationally)
Safety Decals in the Engine Compartment
137845 – Located on radiator
A– Safety alert: Keep safety devices in place and in working order. Keep guards, screens
and windows in place.
B– Fire hazard: Do not smoke while fueling or servicing machine. Clean debris from
engine compartment daily to avoid fire. Keep fire extinguisher nearby.
C– Run-over hazard: Jump-start per Operator’s Manual procedure.
D– Oil injection hazard: Do not use hands to find hydraulic leaks. Escaping oil under
pressure can be invisible and penetrate skin. Use a piece of cardboard to find leaks.
E– Burn hazard: Allow radiator to cool before removing cap. Loosen cap slowly to avoid
burns.
F– Suffocation hazard: Operate only in a well-ventilated area.
ABCDEF
137845 – Located on radiator
A– Rotating fan: Keep hands out or stop engine.
B– Hot surface: Do not touch hot engine or hydraulic system parts.
AB
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