Gehl Wheel Loader 418 Operator’s Manual(909877) – PDF DOWNLOAD

Gehl Wheel Loader 418 Operator’s Manual(909877) – PDF DOWNLOAD

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Gehl Wheel Loader 418 Operator’s Manual(909877) – PDF DOWNLOAD

Introduction
1.1 Notes on this operator’s manual

• This operator’s manual contains important information on how to work safely, correctly and economically with the model 418. Therefore, it aims not only at new operators, but is also a reference for experienced ones. It helps to avoid dangerous situations, and reduce repair costs and downtimes. Furthermore, the reliability and the service life of the machine will be increased by following the instructions in the operator’s manual. This is why the operator’s manual must always be kept in the machine.
• Your own safety, as well as the safety of others, depends to a great extent on how the machine is moved and operated. Therefore, carefully read and understand this operator’s manual prior to the first use. This operator’s manual will help to familiarize your more easily with the machine, thereby enabling you to use it more safely and efficiently.
• General safety instructions are given in Section 2 of this operator’s manual. Carefully read
  and understand them prior to the first use. As a rule, keep the following in mind:

Prudent and careful work is the best protection against accidents!

• Special safety instructions with direct reference to service, function and operation of the machine are given before the procedure to follow in the respective sections. These safety instructions must always be observed and followed.
• Operational safety and readiness of the machine do not only depend on your skill, but also 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 an expert with appropriate training. Insist on using original service parts when performing maintenance and repair work. This ensures operational safety and readiness of your machine, and maintains its value.
• Your dealer will be pleased to answer any further questions regarding the machine or the operator’s manual.
  TABLE OF CONTENTS:

Gehl Wheel Loader 418 Operator’s Manual(909877) – PDF DOWNLOAD

Introduction
Introduction …………………………………………………………………………………………………….. 1-1
Notes on this operator’s manual …………………………………………………………………… 1-1
Machine overview ……………………………………………………………………………………….. 1-2
Brief description ………………………………………………………………………………………….. 1-3
Hydrostatic drive ………………………………………………………………………………… 1-3
Work hydraulics and hydrostatic fourwheel steering ……………………………….. 1-3
Cooling system ………………………………………………………………………………….. 1-3
Applications ………………………………………………………………………………………………. 1-4
Regulations………………………………………………………………………………………………… 1-5
Machine data …………………………………………………………………………………………….. 1-6
Machine model: …………………………………………………………………………………. 1-6
Serial number: …………………………………………………………………………………… 1-6
Date of registration: ……………………………………………………………………………. 1-6
Cab number: ……………………………………………………………………………………… 1-6
Engine number: …………………………………………………………………………………. 1-6
Hydraulic pump
Variable displacement pump model – identification number: ……………………. 1-6
Hydraulic motor
Variable displacement motor model – identification number: ……………………. 1-6
Front axle number: …………………………………………………………………………….. 1-6
Rear axle number: ……………………………………………………………………………… 1-6
Gearbox number: ………………………………………………………………………………. 1-6
Optional attachments: ………………………………………………………………………… 1-6
Your local dealer ……………………………………………………………………………….. 1-6
Serial numbers and type labels …………………………………………………………………….. 1-7
Safety signs and symbols ……………………………………………………………………………. 1-8
…on the outside of the machine …………………………………………………………… 1-8
…inside the operator’s compartment …………………………………………………… 1-10
Safety instructions
Safety instructions ……………………………………………………………………………………………. 2-1
Identification of warnings and dangers ………………………………………………………….. 2-1
Designated uses…………………………………………………………………………………………. 2-2
General conduct and safety instructions…………………………………………………………. 2-3
Organizational measures ……………………………………………………………………. 2-3
Selection and qualification of personnel, basic responsibilities …………………. 2-4
Safety instructions regarding operation ………………………………………………………….. 2-5
Normal operation ……………………………………………………………………………….. 2-5
Applications with lifting accessories ……………………………………………………… 2-7
Trailers and attachments …………………………………………………………………….. 2-8
Transport ………………………………………………………………………………………….. 2-8
Safety instructions for maintenance……………………………………………………………….. 2-9
Warning of special hazards ………………………………………………………………………… 2-11
Electrical hazards …………………………………………………………………………….. 2-11
Gas, dust, steam, smoke …………………………………………………………………… 2-11
Hydraulic equipment …………………………………………………………………………. 2-12
Noise ……………………………………………………………………………………………… 2-12
Oil, grease and other chemical substances …………………………………………. 2-12
Battery ……………………………………………………………………………………………. 2-12
Tires ………………………………………………………………………………………………. 2-12
Operation ……………………………………………………………………………………………………….. 3-1
Overview of cab ………………………………………………………………………………………….. 3-2
Overview: Multifunctional lever and consoles ………………………………………………… 3-4
Placing into service …………………………………………………………………………………….. 3-5
Safety instructions ………………………………………………………………………………… 3-5
Placing the machine into service for the first time ……………………………………… 3-5
Important information ………………………………………………………………………….. 3-5
Running-in period ………………………………………………………………………………. 3-5
Checklists …………………………………………………………………………………………….. 3-6
Start-up checklist ……………………………………………………………………………….. 3-6
Operation checklist …………………………………………………………………………….. 3-7
Parking checklist ………………………………………………………………………………… 3-7
Overview of controls …………………………………………………………………………….. 3-8
Preheating/start switch [52] …………………………………………………………………. 3-8
Driving direction tip switch / …………………………………………………………………. 3-8
Drive range selector [58] ……………………………………………………………………. 3-9
Accelerator pedal [6] …………………………………………………………………………… 3-9
Brake/inching pedal [3] ……………………………………………………………………….. 3-9
Parking brake [24] ……………………………………………………………………………. 3-10
Multi functional lever [7] …………………………………………………………………….. 3-11
Warning lights: overview……………………………………………………………………….. 3-13
Before starting the engine …………………………………………………………………….. 3-16
Start the engine ………………………………………………………………………………….. 3-16
General …………………………………………………………………………………………… 3-16
Procedure ……………………………………………………………………………………….. 3-16
Starting at temperatures below
32 °F (0 °C) ……………………………………………………………………………………… 3-17
Engine preheater (option) ………………………………………………………………….. 3-18
Fuel preheater (option) ……………………………………………………………………… 3-18
Jump-starting the engine …………………………………………………………………… 3-19
Before moving the machine …………………………………………………………………… 3-20
Inspection of important functional units ……………………………………………….. 3-22
Driving ……………………………………………………………………………………………….. 3-23
Drive ranges ……………………………………………………………………………………….. 3-24
Selecting the drive range …………………………………………………………………… 3-24
Changing direction ……………………………………………………………………………. 3-25
Backup alarm (option) ………………………………………………………………………. 3-25
Load stabilizer (option) …………………………………………………………………………. 3-26
Differential lock ……………………………………………………………………………………. 3-27
Stopping the machine ………………………………………………………………………….. 3-27
Parking the machine ……………………………………………………………………………. 3-27
Light system ……………………………………………………………………………………….. 3-28
Signalling system ………………………………………………………………………………… 3-29
Cab heating and ventilation …………………………………………………………………… 3-30
Washer system ……………………………………………………………………………………. 3-31
Seat adjustment…………………………………………………………………………………… 3-32
Weight adjustment ……………………………………………………………………………. 3-32
Height setting …………………………………………………………………………………… 3-32
Armrest setting ………………………………………………………………………………… 3-33
Backrest adjustment …………………………………………………………………………. 3-33
Fore-and-aft setting ………………………………………………………………………….. 3-33
Seat belt……………………………………………………………………………………………… 3-34
Driver’s door and side window……………………………………………………………….. 3-36
Driver’s door ……………………………………………………………………………………. 3-36
Side window ……………………………………………………………………………………. 3-37
AP0802 I-3
Table of contents
Emergency exit ………………………………………………………………………………… 3-38
Other controls……………………………………………………………………………………… 3-39
Fuel tank …………………………………………………………………………………………. 3-39
Engine cover …………………………………………………………………………………… 3-39
Towing the machine …………………………………………………………………………….. 3-40
Safety instructions ……………………………………………………………………………. 3-40
Towing ……………………………………………………………………………………………. 3-40
Lifting the machine with a crane…………………………………………………………….. 3-41
Safety instructions ……………………………………………………………………………. 3-41
Crane handling ………………………………………………………………………………… 3-41
Machine loading & transporting ……………………………………………………………… 3-42
Safety instructions ……………………………………………………………………………. 3-42
Loading the machine ………………………………………………………………………… 3-42
Tying down the machine …………………………………………………………………… 3-43
Working with the machine ………………………………………………………………………….. 3-44
General safety instructions …………………………………………………………………… 3-44
Load diagram ……………………………………………………………………………………… 3-44
Control valve of the loader unit: overview………………………………………………… 3-45
Control lever for hydraulics of lift and tilt ram of loader unit ……………………. 3-45
Electrically operated float position
(only with hose burst valve (option) …………………………………………………….. 3-46
Lock for driving on public roads ………………………………………………………….. 3-46
Control lever for implements and 3rd control circuit ………………………………. 3-47
3rd electrically operated control circuit (option) …………………………………….. 3-49
Lowering the loader unit with the engine switched off ……………………………….. 3-50
Depressurising the quick couplers on the loader unit ……………………………….. 3-50
Re-equipping the loader ……………………………………………………………………….. 3-51
Fitting implements onto the quick hitch facility ……………………………………… 3-51
Connection of electrically operated implements (option) ………………………… 3-52
Taking an implement off the quick hitch facility …………………………………….. 3-53
Connecting pressurized quick couplers…………………………………………………… 3-54
Operation of restrictor unit on tilt ram (option) ………………………………………….. 3-56
Safety equipment “Hose burst valve” (option) ………………………………………….. 3-57
Emergency lowering …………………………………………………………………………. 3-58
Working with the standard bucket ………………………………………………………….. 3-59
Checking the tilt position of the bucket ………………………………………………… 3-59
Checking the transport position of the bucket ………………………………………. 3-59
Transporting with a full bucket ……………………………………………………………. 3-60
Loading loose material ……………………………………………………………………… 3-60
Working with pallet forks ………………………………………………………………………. 3-65
Safety instructions ……………………………………………………………………………. 3-65
Troubleshooting
Troubleshooting ………………………………………………………………………………………………. 4-1
Engine trouble…………………………………………………………………………………………….. 4-2
Possible causes for malfunctions …………………………………………………………….. 4-3
Maintenance
Maintenance …………………………………………………………………………………………………… 5-1
Introduction ……………………………………………………………………………………………….. 5-1
Fuel system ………………………………………………………………………………………………. 5-1
Specific safety instructions …………………………………………………………………….. 5-1
Refuelling……………………………………………………………………………………………… 5-2
Stationary fuel pumps …………………………………………………………………………. 5-2
Specification for diesel fuel ………………………………………………………………….. 5-3
Cleaning the fuel tank ……………………………………………………………………………. 5-3
I-4 AP0802
Table of contents
Changing the fuel filter……………………………………………………………………………. 5-4
Cleaning the fuel/water separator…………………………………………………………….. 5-5
Bleed the fuel system …………………………………………………………………………….. 5-6
Engine lubrication system …………………………………………………………………………….. 5-7
Checking the oil level …………………………………………………………………………….. 5-7
Filling in engine oil ………………………………………………………………………………… 5-7
Changing the engine oil ………………………………………………………………………….. 5-8
Changing the engine oil filter cartridge ……………………………………………………… 5-9
Engine and hydraulics cooling system………………………………………………………….. 5-10
Specific safety instructions …………………………………………………………………… 5-10
Checking the coolant level/Topping up the coolant …………………………………… 5-11
Checking the coolant level …………………………………………………………………. 5-11
Topping up the coolant ……………………………………………………………………… 5-12
Cleaning the cooling ribs ……………………………………………………………………… 5-12
Air filter ……………………………………………………………………………………………………. 5-13
Functional check of the dust valve, every week ……………………………………. 5-14
Replacing the filter cartridge ………………………………………………………………. 5-14
V-belt……………………………………………………………………………………………………….. 5-15
Checking the V-belt tension ………………………………………………………………….. 5-15
Retightening the V-belt ………………………………………………………………………… 5-15
Hydraulic system……………………………………………………………………………………….. 5-16
Specific safety instructions …………………………………………………………………… 5-16
Checking the hydraulic oil level …………………………………………………………….. 5-16
Top up the hydraulic oil…………………………………………………………………………. 5-17
Changing the hydraulic oil ……………………………………………………………………. 5-17
Important information for the use of biodegradable oil ………………………….. 5-19
Hydraulic oil return filter…………………………………………………………………………. 5-20
Changing the filter insert ……………………………………………………………………. 5-20
Changing the breather filter …………………………………………………………………… 5-21
Hydraulic pressure lines ………………………………………………………………………. 5-21
Specific safety instructions ………………………………………………………………… 5-21
Gearboxes and axles ………………………………………………………………………………… 5-22
Rear axle transfer gearbox …………………………………………………………………… 5-22
Checking/topping up the oil level ………………………………………………………… 5-22
Changing the oil ………………………………………………………………………………. 5-23
Front and rear axle differentials ……………………………………………………………… 5-24
Checking/topping up the oil level ………………………………………………………… 5-24
Changing the oil ………………………………………………………………………………. 5-24
Front and rear axle planetary drives ……………………………………………………….. 5-25
Checking/topping up the oil level ………………………………………………………… 5-25
Changing the oil ………………………………………………………………………………. 5-25
Lubricating the rear axle oscillation-type bearing ……………………………………… 5-26
Lubricating planetary drive bearings ………………………………………………………. 5-26
Maintenance of the brake system ………………………………………………………………… 5-27
Specific safety instructions …………………………………………………………………… 5-27
Check/top up the brake fluid …………………………………………………………………. 5-27
Loader unit ……………………………………………………………………………………………….. 5-28
Lubricating the pivots on the loader unit …………………………………………………. 5-28
Tyre care………………………………………………………………………………………………….. 5-30
Inspection work …………………………………………………………………………………… 5-30
Daily checks ……………………………………………………………………………………. 5-30
Checks every week ………………………………………………………………………….. 5-30
Wheel change……………………………………………………………………………………… 5-31
Removing the wheels ……………………………………………………………………….. 5-31
Fitting the wheels ……………………………………………………………………………… 5-31
Heating…………………………………………………………………………………………………….. 5-32
Cleaning the dust filter of the heating system ………………………………………….. 5-32
Electrical system ………………………………………………………………………………………. 5-33
Specific safety instructions …………………………………………………………………… 5-33
Service and maintenance work at regular intervals ………………………………….. 5-33
Before driving the vehicle ………………………………………………………………….. 5-33
Every week ……………………………………………………………………………………… 5-33
Instructions concerning specific components…………………………………………… 5-34
Cables, bulbs and fuses ……………………………………………………………………. 5-34
Alternator ………………………………………………………………………………………… 5-34
Battery ……………………………………………………………………………………………. 5-34
Drive electronics ………………………………………………………………………………. 5-35
General maintenance work…………………………………………………………………………. 5-36
Cleaning ……………………………………………………………………………………………. 5-36
General instructions for all areas of the vehicle ……………………………………. 5-36
Inside of operator compartment …………………………………………………………. 5-37
Exterior of the vehicle ……………………………………………………………………….. 5-37
Engine compartment ………………………………………………………………………… 5-37
Screw connections ………………………………………………………………………………. 5-38
Pivots and hinges ……………………………………………………………………………….. 5-38
Engine fluids and lubricants ………………………………………………………………………. 5-39
Service kits ………………………………………………………………………………………………. 5-40
Helpful information for using the spare parts list
Helpful information for using the spare parts list …………………………………………………… 6-1
Introduction ……………………………………………………………………………………………….. 6-1
Composition of spare parts list …………………………………………………………………….. 6-1
Groups ………………………………………………………………………………………………… 6-1
Group overview …………………………………………………………………………………….. 6-2
Figures…………………………………………………………………………………………………. 6-3
Number index ………………………………………………………………………………………. 6-3
Symbols and abbreviations ………………………………………………………………………….. 6-4
Description of symbols ………………………………………………………………………….. 6-4
Abbreviations………………………………………………………………………………………… 6-6
Indication of position …………………………………………………………………………… 6-6
Use ………………………………………………………………………………………………….. 6-6
Language codes ………………………………………………………………………………… 6-6
Colour codes …………………………………………………………………………………….. 6-7
Vehicle data ………………………………………………………………………………………………. 6-7
Helpful information for ordering spare parts …………………………………………………… 6-7
Order information…………………………………………………………………………………… 6-8
Address for your spare part order ……………………………………………………………. 6-8
Specifications
Specifications ………………………………………………………………………………………………….. 7-1
Frame ………………………………………………………………………………………………………. 7-1
Engine ………………………………………………………………………………………………………. 7-1
Power train…………………………………………………………………………………………………. 7-2
Axles ……………………………………………………………………………………………………….. 7-2
Brakes………………………………………………………………………………………………………. 7-3
Steering …………………………………………………………………………………………………… 7-3
Work hydraulics …………………………………………………………………………………………. 7-3
Loader unit ……………………………………………………………………………………………….. 7-4
Electrical system…………………………………………………………………………………………. 7-5
Fuse boxes in side console ……………………………………………………………………. 7-5
Main fuses in engine compartment ………………………………………………………….. 7-6
Relays …………………………………………………………………………………………………. 7-6
Tires …………………………………………………………………………………………………………. 7-7
Weights …………………………………………………………………………………………………….. 7-7
Noise levels ……………………………………………………………………………………………….. 7-7
Vibration ……………………………………………………………………………………………………. 7-8
Dimensions ……………………………………………………………………………………………….. 7-8
Coolant compound table ………………………………………………………………………………. 7-9
Tightening moments …………………………………………………………………………………… 7-9
General tightening torques …………………………………………………………………….. 7-9
Specific tightening torques …………………………………………………………………….. 7-9
Annex
Proofs of maintenance …………………………………………………………………………………….. A-1
Maintenance plan model 418 (overview) ……………………………………………………………. A-3
Maintenance plan model 418 (maintenance label) ………………………………………………. A-5
Hydraulics diagram model 418 ………………………………………………………………………….. A-7
Legend – wiring diagram ………………………………………………………………………………….. A-8
Wiring diagram model 418 ……………………………………………………………………………….. A-9
Legend – wiring diagram ………………………………………………………………………………… A-10
Wiring diagram – option …………………………………………………………………………………. A-10