Gehl AWS36 & AWS46 Wheel Steer Loader Service Manual 918265 – PDF DOWNLOAD

Gehl AWS36 & AWS46 Wheel Steer Loader Service Manual 918265 – PDF DOWNLOAD

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Gehl AWS36 & AWS46 Wheel Steer Loader Service Manual 918265 – PDF DOWNLOAD

Language : English
Pages : 208
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Gehl AWS36 & AWS46 Wheel Steer Loader Service Manual 918265 – PDF DOWNLOAD

Operation:
1.1 Important information about this 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 re-sold, 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’s 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.

TABLE OF CONTENTS:

Gehl AWS36 & AWS46 Wheel Steer Loader Service Manual 918265 – PDF DOWNLOAD

Operation 1
Important information about this manual ……………………………………………………….. 1-1
Abbreviations/symbols …………………………………………………………………………… 1-2
Brief description …………………………………………………………………………………………. 1-2
Hydrostatic drive …………………………………………………………………………………… 1-2
Work hydraulics and four-wheel steering …………………………………………………. 1-2
Cooling system …………………………………………………………………………………….. 1-2
Machine overview ………………………………………………………………………………………. 1-3
Serial plates and component numbers ………………………………………………………….. 1-4
Serial number ………………………………………………………………………………………. 1-4
Cab number …………………………………………………………………………………………. 1-4
Engine number …………………………………………………………………………………….. 1-4
Hydraulic pump number ………………………………………………………………………… 1-5
Hydraulic motor number ………………………………………………………………………… 1-5
Rear axle number …………………………………………………………………………………. 1-5
Front axle number ………………………………………………………………………………… 1-5
Safety decals …………………………………………………………………………………………….. 1-6
Fire extinguisher (option) …………………………………………………………………………….. 1-8
Cab overview …………………………………………………………………………………………….. 1-9
Instrument panel, multi-functional lever and switch panel: overview ………………… 1-10
Indicators and warning lights: overview ………………………………………………………. 1-11
Oil and fuel pre-heater (option) …………………………………………………………………… 1-12
Jump-starting the engine …………………………………………………………………………… 1-13
Backup warning system (option) …………………………………………………………………. 1-14
Manual throttle (option) ……………………………………………………………………………… 1-14
Low-speed control (option) ………………………………………………………………………… 1-15
Towing the machine ………………………………………………………………………………….. 1-16
Safety instructions for towing ………………………………………………………………… 1-16
Towing preparation ……………………………………………………………………………… 1-16
After towing ………………………………………………………………………………………… 1-17
Specifications 2
Frame ………………………………………………………………………………………………………. 2-0
Types and Models: overview ……………………………………………………………………….. 2-0
Engine ………………………………………………………………………………………………………. 2-0
Power train ………………………………………………………………………………………………… 2-1
Variable-displacement pump ………………………………………………………………….. 2-1
Boost pump …………………………………………………………………………………………. 2-1
Variable-displacement motor ………………………………………………………………….. 2-1
Axles ………………………………………………………………………………………………………… 2-2
Front axle …………………………………………………………………………………………….. 2-2
Rear axle …………………………………………………………………………………………….. 2-2
Brakes ………………………………………………………………………………………………………. 2-2
Steering system …………………………………………………………………………………………. 2-3
Work hydraulics …………………………………………………………………………………………. 2-3
Pilot control ……………………………………………………………………………………………….. 2-3
Loader unit with bucket — model AWS36 ……………………………………………………… 2-4
Loader unit with bucket — model AWS46 ……………………………………………………… 2-4
Loader unit with pallet forks — model AWS36 ……………………………………………….. 2-5
Loader unit with pallet forks — model AWS46 ……………………………………………….. 2-5
Alternator, starter, battery ……………………………………………………………………………. 2-5
Fuse box …………………………………………………………………………………………………… 2-6
Main fuse box — model AWS36 …………………………………………………………………… 2-7
Main fuse box — model AWS46 …………………………………………………………………… 2-7
Overview of switching relays ……………………………………………………………………….. 2-8
Table of contents
Table of contents
918265/AP1208 I-2 Printed in U.S.A
Tires for wheel loader — model AWS36 ………………………………………………………… 2-9
Tires for wheel loader — model AWS46 ………………………………………………………… 2-9
Weights …………………………………………………………………………………………………….. 2-9
Noise levels ……………………………………………………………………………………………….. 2-9
Vibration ………………………………………………………………………………………………….. 2-10
Hardware torques …………………………………………………………………………………….. 2-10
General torques ………………………………………………………………………………….. 2-10
Specific torques …………………………………………………………………………………. 2-10
Dimensions — model AWS36 …………………………………………………………………….. 2-11
Dimensions — model AWS46 …………………………………………………………………….. 2-12
Maintenance 3
Introduction ……………………………………………………………………………………………….. 3-0
Important information on maintenance and service work ……………………………. 3-0
Fluids and lubricants ………………………………………………………………………………….. 3-1
Index to component maintenance …………………………………………………………………. 3-2
Explanation of symbols on maintenance label ………………………………………………… 3-3
Maintenance label ………………………………………………………………………………………. 3-4
Maintenance schedule ………………………………………………………………………………… 3-5
Maintenance of the fuel system ……………………………………………………………………. 3-8
Specific safety instructions …………………………………………………………………….. 3-8
Refueling ……………………………………………………………………………………………… 3-8
Stationary fuel pumps ……………………………………………………………………………. 3-8
Diesel fuel specification …………………………………………………………………………. 3-8
Replacing the fuel filter ……………………………………………………………………………….. 3-9
Cleaning the fuel pump screen filter ……………………………………………………………. 3-10
Bleeding the fuel system ……………………………………………………………………………. 3-10
Checking/adding engine oil ………………………………………………………………………… 3-11
Changing engine oil ………………………………………………………………………………….. 3-12
Changing the engine oil filter cartridge ………………………………………………………… 3-13
Engine and hydraulics cooling system …………………………………………………………. 3-14
Specific safety instructions …………………………………………………………………… 3-14
Cleaning the oil cooler ………………………………………………………………………………. 3-14
Hydraulic system ………………………………………………………………………………………. 3-15
Specific safety instructions …………………………………………………………………… 3-15
Checking hydraulic pressure lines ………………………………………………………………. 3-16
Specific safety instructions …………………………………………………………………… 3-16
Monitoring the hydraulic oil return filter ………………………………………………………… 3-17
Important information for the use of biodegradable oil ……………………………… 3-17
Hydraulic oil return filter …………………………………………………………………………….. 3-18
Changing the filter insert ………………………………………………………………………. 3-18
Checking the hydraulic oil level …………………………………………………………………… 3-19
Adding hydraulic oil …………………………………………………………………………………… 3-19
Changing the hydraulic oil ………………………………………………………………………….. 3-20
Rear axle transfer gearbox oil levels ……………………………………………………………. 3-21
Front and rear axle differential oil levels ………………………………………………………. 3-22
Front and rear axle planetary drive oil levels ………………………………………………… 3-23
Air filter maintenance ………………………………………………………………………………… 3-24
Check: air filter contamination ………………………………………………………………. 3-24
Replacing the air filter cartridge ………………………………………………………………….. 3-25
V-belt ………………………………………………………………………………………………………. 3-26
Checking V-belt tension ……………………………………………………………………….. 3-26
Tensioning the V-belt …………………………………………………………………………… 3-26
Lubrication points ……………………………………………………………………………………… 3-27
Lubricating the rear axle oscillation-type bearing …………………………………….. 3-27
Lubricating the front and rear axle planetary drive bearings ………………………. 3-27
Lubricating the loader unit ………………………………………………………………………….. 3-28
Table of contents
Printed in U.S.A I-3 918265/AP1208
Attachment maintenance …………………………………………………………………………… 3-28
Brake system …………………………………………………………………………………………… 3-29
Specific safety instructions …………………………………………………………………… 3-29
Checking/adding brake fluid …………………………………………………………………. 3-29
Repair work on the brake system ………………………………………………………….. 3-29
Tire care ………………………………………………………………………………………………….. 3-30
Daily tire check …………………………………………………………………………………… 3-30
Weekly check …………………………………………………………………………………….. 3-30
Changing wheels ……………………………………………………………………………………… 3-31
Heating …………………………………………………………………………………………………… 3-32
Cleaning the dust filter of the heating system ………………………………………….. 3-32
Electric system …………………………………………………………………………………………. 3-33
Safety instructions ………………………………………………………………………………. 3-33
Service and maintenance work at regular intervals ………………………………….. 3-34
Cables, bulbs and fuses ………………………………………………………………………. 3-34
Alternator …………………………………………………………………………………………… 3-34
Battery maintenance …………………………………………………………………………………. 3-35
General maintenance work ………………………………………………………………………… 3-36
Cleaning ……………………………………………………………………………………………. 3-36
When using washing solvents ………………………………………………………………. 3-36
When using compressed air …………………………………………………………………. 3-36
When using a high-pressure or steam jet cleaner ……………………………………. 3-36
When using volatile and flammable anti-corrosion agents and sprays ………… 3-36
Cleaning inside the cab …………………………………………………………………………….. 3-37
Cleaning the seat belt ……………………………………………………………………………….. 3-37
Machine exterior ………………………………………………………………………………………. 3-37
Engine compartment …………………………………………………………………………………. 3-38
Bolted connections, hinges ………………………………………………………………………… 3-38
Engine 4
F4M 2011/BF4M 2011 engine: overview ……………………………………………………….. 4-0
Engine oil cooling ……………………………………………………………………………………….. 4-1
Fuel system ………………………………………………………………………………………………. 4-2
Checking and adjusting valve clearance ……………………………………………………….. 4-3
Replacing the fuel injection pump …………………………………………………………………. 4-4
Setting the charge-air pressure — model AWS46 …………………………………………… 4-9
Charge-pressure dependent full-load stop — model AWS46 ………………………….. 4-10
Turning off minus compensation …………………………………………………………………. 4-10
Minus compensation — function …………………………………………………………… 4-10
Switching off minus compensation — model AWS36 …………………………………….. 4-11
Heating connection …………………………………………………………………………………… 4-11
Removing/mounting the cylinder head ………………………………………………………… 4-12
Sealing the bleeder valve ………………………………………………………………………….. 4-16
Intake/exhaust manifold ……………………………………………………………………….. 4-16
Engine trouble …………………………………………………………………………………………. 4-17
Power train 5
Variable-displacement pump test ports — model AWS36 ………………………………… 5-0
Variable-displacement pump — model AWS36 ………………………………………………. 5-1
Variable-displacement pump test ports, 12 mph (20 kph) — model AWS46 ……….. 5-2
Variable-displacement pump, 12 mph (20 kph) — model AWS46 …………………….. 5-3
Variable-displacement motor, 12 mph (20 kph) — all models …………………………… 5-4
………………………………………………………………………………………………………………… 5-4
Variable-displacement pump test po …………………………………………………………….. 5-4
Inching valve overview ………………………………………………………………………………… 5-5
Inching valve circuit, 12 mph (20 kph) …………………………………………………………… 5-6
Drive circuit, 12 mph (20 kph) — model AWS36 …………………………………………….. 5-7
Drive, 12 mph (20 kph): wiring diagram …………………………………………………………. 5-8
Table of contents
918265/AP1208 I-4 Printed in U.S.A
Towing and transporting the machine ……………………………………………………………. 5-9
Transporting …………………………………………………………………………………………. 5-9
Towing ………………………………………………………………………………………………… 5-9
Test report — model AWS36 ……………………………………………………………………… 5-10
Test report — model AWS46 ……………………………………………………………………… 5-11
Power train adjustment ……………………………………………………………………………… 5-12
Tools required …………………………………………………………………………………….. 5-12
Adjusting boost pressure …………………………………………………………………………… 5-12
Adjusting starting speed …………………………………………………………………………….. 5-12
Setting high pressure/drive pressure …………………………………………………………… 5-13
Setting the secondary valves for forward/reverse driving ……………………………….. 5-14
Setting the pump hydraulic resistance (characteristic curve) …………………………… 5-14
Setting engine droop …………………………………………………………………………………. 5-15
Setting control initiation on the hydraulic motor …………………………………………….. 5-15
Setting the wheel speed …………………………………………………………………………….. 5-16
Tools required …………………………………………………………………………………….. 5-16
Axles 6
Axle overview …………………………………………………………………………………………….. 6-0
Sealing service (joint housing/axle carrier) …………………………………………………….. 6-1
Bevel gear shaft seals ……………………………………………………………………………….. 6-12
Differential cage/differential lock screw connections ……………………………………… 6-13
Overview of differential lock and differential cage ………………………………………….. 6-14
Removing the differential cage with the differential lock …………………………………. 6-15
Removing the differential lock …………………………………………………………………….. 6-16
Assembling the differential lock ………………………………………………………………….. 6-17
Removing the gearbox ………………………………………………………………………………. 6-18
Input shaft version 1 sealing: overview ………………………………………………………… 6-24
Assembling the gearbox ……………………………………………………………………………. 6-25
Brakes 7
Brake circuit ………………………………………………………………………………………………. 7-0
Brake diagram ……………………………………………………………………………………………. 7-1
Handbrake circuit ……………………………………………………………………………………….. 7-2
Inching valve circuit, 12 mph (20 kph) …………………………………………………………… 7-3
Service brake …………………………………………………………………………………………….. 7-4
Brake caliper maintenance …………………………………………………………………….. 7-4
Steering 8
Steering circuit for model AWS36 …………………………………………………………………. 8-0
Steering diagram for model AWS36 ……………………………………………………………… 8-1
Steering circuit for model AWS46 …………………………………………………………………. 8-2
Steering diagram for model AWS46 ……………………………………………………………… 8-3
Steering system adjustment …………………………………………………………………………. 8-4
Function ………………………………………………………………………………………………. 8-4
Checking a steering cylinder …………………………………………………………………… 8-4
Checking the check block ………………………………………………………………………. 8-4
Hydraulic ports on servostat ………………………………………………………………………… 8-5
Pressure relief valve: adjustment ………………………………………………………………….. 8-5
Steering cylinder: seals ……………………………………………………………………………….. 8-6
Overview of steering cylinder adjustment ………………………………………………………. 8-7
Necessary tools ……………………………………………………………………………………. 8-7
How to adjust the steering cylinders ……………………………………………………………… 8-8
Checking the track setting ……………………………………………………………………………. 8-9
Correcting the track setting ………………………………………………………………………….. 8-9
Setting the steering limit …………………………………………………………………………….. 8-10
Checking steering synchronization ……………………………………………………………… 8-11
Checking the bypass …………………………………………………………………………… 8-11
Bleeding the steering cylinders ……………………………………………………………… 8-12
Table of contents
Printed in U.S.A I-5 918265/AP1208
Setting steering synchronization …………………………………………………………………. 8-13
Final check/test run …………………………………………………………………………….. 8-13
Hydraulic system 9
Test report for model AWS36 ………………………………………………………………………. 9-0
Test report for model AWS46 ………………………………………………………………………. 9-1
Work hydraulics oil supply …………………………………………………………………………… 9-2
Control valve ports ……………………………………………………………………………………… 9-3
Priority valve ports ……………………………………………………………………………………… 9-3
Priority valve diagram …………………………………………………………………………………. 9-4
Load stabilizer ports ……………………………………………………………………………………. 9-4
Load stabilizer circuit ………………………………………………………………………………….. 9-5
Load stabilizer diagram ……………………………………………………………………………….. 9-5
Lift cylinder: seals ………………………………………………………………………………………. 9-6
Tilt cylinder: seals ………………………………………………………………………………………. 9-7
Control cylinder (quick-hitch frame): seals ……………………………………………………… 9-8
Work hydraulics diagram …………………………………………………………………………… 9-10
Electrical system 10
Ohm’s Law ………………………………………………………………………………………………. 10-0
Measuring equipment and methods ……………………………………………………………. 10-0
Terminal description …………………………………………………………………………………. 10-2
Cable color coding ……………………………………………………………………………………. 10-6
Other color codes ……………………………………………………………………………….. 10-8
Relays …………………………………………………………………………………………………….. 10-8
Use, mode of function ………………………………………………………………………….. 10-8
Terminal description on relay ………………………………………………………………. 10-8
Starter, battery, alternator …………………………………………………………………………. 10-9
Fuse box …………………………………………………………………………………………………. 10-9
Main fuse box with relays for model AWS36 ………………………………………………. 10-10
Main fuse box with relays for model AWS46 ………………………………………………. 10-10
Switching relays ……………………………………………………………………………………… 10-11
Description of blocking diodes ………………………………………………………………….. 10-12
Blocking diodes V8, V9 ………………………………………………………………………. 10-12
Blocking diode V10 ……………………………………………………………………………. 10-12
Blocking diode V11 ……………………………………………………………………………. 10-12
Blocking diodes V16, V17 …………………………………………………………………… 10-12
Blocking diodes V20, V21 …………………………………………………………………… 10-12
Overview of switch assignment ………………………………………………………………… 10-13
Installing a rotating beacon ………………………………………………………………………. 10-14
Installing the backup warning system ………………………………………………………… 10-14
Installing two front work lights …………………………………………………………………… 10-15
Installing two front work lights and one rear work light …………………………………. 10-15
Electric diagram (sheet 1) for model AWS36 ………………………………………………. 10-17
Electric diagram (sheet 2) for model AWS36 ………………………………………………. 10-18
Legend: electric diagram for model AWS46 ……………………………………………….. 10-19
Electric diagram (sheet 1) for model AWS46 ………………………………………………. 10-20
Electric diagram (sheet 2) for model AWS46 ………………………………………………. 10-21