Gehl All Wheel Steer Loader 680 Service Manual 918123A – PDF DOWNLOAD

Gehl All Wheel Steer Loader 680 Service Manual 918123A – PDF DOWNLOAD

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Gehl All Wheel Steer Loader 680 Service Manual 918123A – PDF DOWNLOAD

Language : English
Pages : 212
Downloadable : Yes
File Type : PDF
Size: 35.1 MB

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Gehl All Wheel Steer Loader 680 Service Manual 918123A – PDF DOWNLOAD

Beginning Serial Number: 343010001

Operation:
1. 1 Important information on this service manual:
Your decision to purchase this piece of Gehl equipment was a good one. We are sure that
your decision was carefully considered and that you are looking forward to many years of
reliable performance from this machine.
Gehl Company has invested much time and effort in developing its lines of equipment. The
equipment you have purchased is built with a great deal of pride, and designed to provide
long life, efficient operation, durability and dependability.
Modern machinery has become more sophisticated and, with that in mind, Gehl Company
asks that you read and COMPLETELY understand the contents of this manual and
become familiar with your new machine, BEFORE attempting to service it.
This manual was developed specifically for the machine you have purchased. The information
within is for your assistance in preparing, adjusting, maintaining and servicing your
machine. More importantly, this manual provides a service plan for safe and proper use of
your machine. Refer to the Table of Contents for an outline (by chapters) of this manual.
Use the Index, located at the back of this manual, for specific chapter and topic/page
number references.
If this machine is resold, Gehl Company recommends that this manual be given to the new
owner.
If this machine was purchased “used,” or if the owner’s address has changed, please provide
your Gehl dealer or Gehl Company with the owner’s name and current address, along
with the machine model and serial number. This will allow the registered owner information
to be updated, so that the owner can be notified directly in case of an important product
issue, such as a safety update program.
“Right” and “left” are determined from the position of sitting in the operator’s seat, facing
forward.
Gehl Company reserves the right to make changes or improvements in the design or construction
of any part without incurring the obligation to install such changes on any unit
previously delivered.
Throughout this manual information is provided that is introduced by the word NOTE or
IMPORTANT. Be sure to read carefully and comply with the message or directive given.
Following this information will improve your maintenance efficiency, help you to avoid
costly breakdowns or unnecessary damage and extend your machine’s life.
Operational safety and readiness of the machine depend partially on maintenance and
service of the machine. This is why regular maintenance and service work is absolutely
necessary. Extensive maintenance and repair work must always be carried out by a qualified
technician with appropriate training. Insist on using Gehl original service parts when
carrying out maintenance and repair work. This ensures operational safety and readiness
of your machine, and maintains its value.

TABLE OF CONTENTS:

Gehl All Wheel Steer Loader 680 Service Manual 918123A – PDF DOWNLOAD

Operation
Important information on this service manual …………………………………………………. 1-1
Serial plates and component numbers ………………………………………………………….. 1-2
Machine overview ………………………………………………………………………………………. 1-4
Inside of cab: overview ……………………………………………………………………………….. 1-5
Inside of cab: legend …………………………………………………………………………………… 1-6
Instrument panel, multifunctional lever and drive lever: overview ………………………. 1-7
Instrument panel, multifunctional lever and drive lever: legend …………………………. 1-8
Specifications
Frame ……………………………………………………………………………………………………….. 2-1
Engine ………………………………………………………………………………………………………. 2-1
Power train ………………………………………………………………………………………………… 2-2
Axles ………………………………………………………………………………………………………… 2-3
Brakes ………………………………………………………………………………………………………. 2-3
Steering …………………………………………………………………………………………………….. 2-3
Work hydraulics …………………………………………………………………………………………. 2-4
Pilot control ……………………………………………………………………………………………….. 2-4
Additional control circuit + high-flow control circuit (option) ………………………………. 2-4
Loader unit ………………………………………………………………………………………………… 2-5
Electrical system ………………………………………………………………………………………… 2-5
Tires …………………………………………………………………………………………………………. 2-8
Weights …………………………………………………………………………………………………….. 2-9
Sound levels …………………………………………………………………………………………….. 2-9
Vibration …………………………………………………………………………………………………… 2-9
Hardware torques …………………………………………………………………………………….. 2-10
Dimensions ……………………………………………………………………………………………… 2-11
Maintenance
Fluids and lubricants ………………………………………………………………………………….. 3-1
Maintenance decal ……………………………………………………………………………………… 3-2
Maintenance schedule Model 680 (overview) …………………………………………………. 3-4
Maintenance items ……………………………………………………………………………………… 3-7
Introduction ……………………………………………………………………………………………….. 3-7
Fuel system ……………………………………………………………………………………………….. 3-8
Engine lubrication system ………………………………………………………………………….. 3-11
Engine and hydraulics cooling system …………………………………………………………. 3-14
Air filter ……………………………………………………………………………………………………. 3-15
V-belt ………………………………………………………………………………………………………. 3-17
Gearboxes and axles ………………………………………………………………………………… 3-18
Hydraulic system ………………………………………………………………………………………. 3-24
Lubrication points ……………………………………………………………………………………… 3-28
Attachments …………………………………………………………………………………………….. 3-29
Brake system …………………………………………………………………………………………… 3-30
Tire care ………………………………………………………………………………………………….. 3-31
Changing wheels …………………………………………………………………………………….. 3-32
Electrical system ………………………………………………………………………………………. 3-33
General maintenance work ………………………………………………………………………… 3-36
Heating ……………………………………………………………………………………………………. 3-39
Engine
Engine BF4M 2011: overview ………………………………………………………………………. 4-1
Engine oil cooling ……………………………………………………………………………………….. 4-2
Fuel system ……………………………………………………………………………………………….. 4-3
Checking and adjusting valve tip clearance ……………………………………………………. 4-4
Replacing the fuel injection pump …………………………………………………………………. 4-5
Setting charge air pressure ………………………………………………………………………… 4-10
Removing/mounting the cylinder head …………………………………………………………. 4-12
Engine trouble ………………………………………………………………………………………….. 4-16
Table of contents
918123/AP0605 I-2
Table of contents
Power train
Variable displacement pump 12 – 25 mph (20 – 40 km/h) ……………………………….. 5-1
Hydraulic motor – control element 12 mph (20 km/h) ………………………………………. 5-2
Hydraulic motor – hydraulic connections 12 mph (20 km/h) ……………………………… 5-3
Power train diagram 12 mph (20 km/h) …………………………………………………………. 5-4
ECO-Speed – hydraulic motor 25 mph (40 km/h) ……………………………………………. 5-5
ECO speed power train (25 mph [40 km/h]): diagram ……………………………………… 5-7
Test report model ……………………………………………………………………………………….. 5-8
Towing and transporting the machine ……………………………………………………………. 5-9
Check and adjustment instructions ……………………………………………………………… 5-10
Drive electronics operator’s manual (SUSMIC) …………………………………………….. 5-17
Procedures (sensor) …………………………………………………………………………………. 5-18
Axles
Serial plate – axle ………………………………………………………………………………………. 6-1
Front axle screw connections ………………………………………………………………………. 6-2
Rear axle screw connections ……………………………………………………………………….. 6-3
Drain, fill and check plug – front axle …………………………………………………………….. 6-4
Drain, fill and check plug – rear axle ……………………………………………………………… 6-5
Tightening torques – front axle …………………………………………………………………….. 6-6
Tightening torques – rear axle ……………………………………………………………………… 6-7
Sealing work ……………………………………………………………………………………………… 6-8
Brakes
Brake circuit ………………………………………………………………………………………………. 7-1
Service brake …………………………………………………………………………………………….. 7-3
Steering
Steering circuit …………………………………………………………………………………………… 8-1
Steering circuit …………………………………………………………………………………………… 8-2
Hydraulic ports on servostat ………………………………………………………………………… 8-3
Pressure relief valve – servostat: settings ……………………………………………………… 8-3
Front/rear axle steering cylinder …………………………………………………………………… 8-4
Setting the steering sensors ………………………………………………………………………… 8-5
Hydraulic system
Test report ………………………………………………………………………………………………… 9-1
Control valve connections: overview …………………………………………………………….. 9-2
Control valve: design ………………………………………………………………………………….. 9-3
Pilot control unit: design ………………………………………………………………………………. 9-4
Valve block connections: overview ……………………………………………………………….. 9-5
Pilot control circuit ………………………………………………………………………………………. 9-6
Work hydraulics circuit ………………………………………………………………………………… 9-7
Load stabilizer circuit with hose burst valve ……………………………………………………. 9-8
Load stabilizer: circuit diagram …………………………………………………………………….. 9-9
Load stabilizer with hose burst valve: circuit diagram …………………………………….. 9-10
Hose burst valve with load stabilizer: connections ………………………………………… 9-11
Hose burst valve circuit ……………………………………………………………………………… 9-12
Hose burst valve circuit ……………………………………………………………………………… 9-13
4th control circuit (front/rear) ………………………………………………………………………. 9-14
4th control circuit (front/rear) circuit …………………………………………………………….. 9-15
Lift cylinder: sealing work …………………………………………………………………………… 9-16
Tilt cylinder: sealing work …………………………………………………………………………… 9-17
Control cylinder (quickhitch frame): sealing work ………………………………………….. 9-18
Work hydraulics diagram: legend ……………………………………………………………….. 9-20
Work hydraulics diagram …………………………………………………………………………… 9-21
I-3 918123/AP0605
Table of contents
Electrical system
Ohm’s Law (current, voltage, resistance generates power) …………………………….. 10-1
Measuring equipment and methods …………………………………………………………….. 10-1
Terminal description ………………………………………………………………………………….. 10-3
Cable color-coding ………………………………………………………………………………….. 10-10
Relays …………………………………………………………………………………………………… 10-11
Electrical units ………………………………………………………………………………………… 10-12
Fuse box on left and right of steering column ……………………………………………… 10-12
Main fuse box with relays …………………………………………………………………………. 10-13
Relays …………………………………………………………………………………………………… 10-14
Steering electronics ………………………………………………………………………………… 10-15
Instrument panel, fuse box, relays: overview ………………………………………………. 10-16
Legend for wiring diagram ………………………………………………………………………. 10-17
Wiring diagram ………………………………………………………………………………………. 10-18
Legend for wiring harness 207749: engine – frame …………………………………….. 10-19
Wiring harness: 207749: engine – frame …………………………………………………… 10-20
Legend for wiring harness 207750: cab ……………………………………………………… 10-21
Wiring harness 207750: cab ……………………………………………………………………. 10-22
Wiring harness 208562: control lever base (option) …………………………………….. 10-23
Wiring harness 207968: control lever base (standard) ………………………………… 10-24
Wiring harness 207810: steering-column control lever ………………………………… 10-25
Wiring harness 208111: additional control circuit ……………………………………….. 10-26
Wiring harness 208609 (joystick) ………………………………………………………………. 10-27
Electronics between joystick and wiring harness 208609 ……………………………… 10-27
Wiring harness 207539: rotating beacon (option) ……………………………………….. 10-28
Wiring harness 207539: front working light (option) …………………………………….. 10-29
Wiring harness 208589: load stabilizer (option) ………………………………………….. 10-30
Wiring harness 208676: solenoid valve – load stabilizer (option) ………………….. 10-31
Wiring harness 209185: inching sensor …………………………………………………….. 10-32
Wiring harness 209185: crawler gear – potentiometer …………………………………. 10-33
Wiring harness 208563: numberplate light (option) …………………………………….. 10-34
Wiring harness 208113: air-suspension operator’s seat (option) …………………… 10-35
Wiring harness: air conditioning (option) ……………………………………………………. 10-36
Plug – SUSMIC ………………………………………………………………………………………. 10-37
Relay assignment …………………………………………………………………………………… 10-38
Plug and socket connection: steering electronics – steering-column control lever ……..
10-39
Plug and socket connection: fuse box and relay (left) ………………………………….. 10-40
Plug and socket connection: fuse box and relay (right) ………………………………… 10-41
Plug and socket connection: cab ………………………………………………………………. 10-42
Plug and socket connection: instrument panel ……………………………………………. 10-42
Plug and socket connections: load stabilizer, speedometer 25 mph (40 km/h), front
socket ……………………………………………………………………………………………………. 10-43