Case 521D Operator Manual PDF

Form No.
909881
521 Wheel
Loader
OPERATOR’S MANUAL PRELIMINARY

1P0702
GEHL CONSTRUCTION
WARRANTY
GEHL CONSTRUCTION DIVISION of the GEHL COMPANY, hereinafter referred to as Gehl,

warrants new Gehl construction 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 CONSTRUCTION WARRANTY INCLUDES:

Genuine Gehl parts and labor costs required to repair or replace equipment at the selling
dealer’s 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.
GEHL WARRANTY SERVICE DOES NOT INCLUDE:

1. Transportation to selling dealer’s 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, 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 attachments; accident or other casualty.
6. Liability for incidental or consequential damages of any type, including, but not limited to lost profits
or 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. Any of these limitations excluded by local law shall be deemed deleted from this
warranty; all other terms will continue to apply.
Table of contents
Table of contents
I
Introduction
Introduction .................................................................................................................... 1-1
Notes on this operation manual ............................................................................... 1-1
Vehicle overview....................................................................................................... 1-2
Brief description ........................................................................................................ 1-3
Hydrostatic drive ............................................................................................. 1-3
Work hydraulics and hydrostatic four wheel steering ..................................... 1-3
Cooling system ............................................................................................... 1-3
Fields of application .................................................................................................. 1-4
Regulations............................................................................................................... 1-6
Vehicle data ............................................................................................................. 1-7
Vehicle model/version: ................................................................................. 1-7
Serial number: .............................................................................................. 1-7
Commissioning/date of registration: .......................................................... 1-7
Service hours/kilometre reading: ............................................................... 1-7
Cab number: ................................................................................................. 1-7
Engine number: .............................................................................................. 1-7
Hydraulic pump
Variable displacement pump model – identification number: ......................... 1-7
Hydraulic motor
variable displacement motor model – identification no.: ................................. 1-7
Front axle number: ......................................................................................... 1-7
Rear axle number: .......................................................................................... 1-7
Gearbox number: ........................................................................................... 1-7
Optional implements: ................................................................................... 1-7
Your local dealer ............................................................................................ 1-7
Page left intentionally blank .................................................................................. 1-8
Type labels and component numbers....................................................................... 1-9
Other Signs and symbols ....................................................................................... 1-10
... on the outside of the vehicle ..................................................................... 1-10
...inside the operator’s compartment ............................................................ 1-11
Notes: ........................................................................................................... 1-12
Safety instructions
Safety instructions .......................................................................................................... 2-1
Identification of warnings and dangers .................................................................... 2-1
Designated use and exemption from liability ............................................................ 2-2
General conduct and safety instructions................................................................... 2-3
Organizational measures ............................................................................... 2-3
Selection and qualification of personnel, basic responsibilities ...................... 2-5
Safety instructions regarding operation .................................................................... 2-6
Normal operation ............................................................................................ 2-6
Applications with lifting accessories ............................................................... 2-8
Trailers and implements ................................................................................. 2-9
Transport ........................................................................................................ 2-9
Safety instructions for maintenance........................................................................ 2-10
Warning of special hazards .................................................................................... 2-12
Electric energy .............................................................................................. 2-12
Gas, dust, steam, smoke .............................................................................. 2-12
Hydraulic equipment ..................................................................................... 2-13
Noise ............................................................................................................ 2-13
Oil, grease and other chemical substances ................................................. 2-13
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Table of contents
Battery .......................................................................................................... 2-13

Tyres ............................................................................................................. 2-13
Operation
Operation ....................................................................................................................... 3-1
Overview of cab ........................................................................................................ 3-2
Overview: switches, levers and consoles ................................................................ 3-4
Taking into service .................................................................................................... 3-6
Safety instructions ............................................................................................. 3-6
Taking the vehicle into service for the first time ................................................. 3-6
Important information ...................................................................................... 3-6
Running-in period ........................................................................................... 3-6
Checklists ........................................................................................................... 3-7
Start-up checklist ............................................................................................ 3-7
Operation checklist ......................................................................................... 3-8
Parking checklist ............................................................................................. 3-8
Driving the vehicle..................................................................................................... 3-9
Overview of control elements ............................................................................ 3-9
Preheating start switch [76] ............................................................................ 3-9
Drive range selector [77] ............................................................................... 3-9
Driving direction tip switch [72/75] ................................................................ 3-10
Accelerator pedal [25] ................................................................................... 3-10
Manual throttle lever [71] (option) ................................................................. 3-11
Brake/inching pedal [27] ............................................................................... 3-11
Control lever [84] – low-speed control (option) ............................................. 3-12
Parking brake [24] ........................................................................................ 3-12
Multifunctional lever [26] ............................................................................... 3-13
Overview Telltales and warning lights ............................................................. 3-15
Before starting the engine ................................................................................ 3-18
Start the engine ............................................................................................... 3-18
General ......................................................................................................... 3-18
Procedure ..................................................................................................... 3-19
Starting at temperatures below 0 °C ............................................................. 3-19
When the engine has started ... .................................................................... 3-20
Connecting the oil preheater (option) ........................................................... 3-20
Fuel preheater (Not available) ...................................................................... 3-20
Jump-starting the vehicle.................................................................................. 3-21
Starting the engine with starting aid
(supply battery) ............................................................................................. 3-21
Before moving off.............................................................................................. 3-22
Special instructions for driving on public roads ............................................ 3-22
Preparing the vehicle for driving on public roads .......................................... 3-22
Before moving off: ........................................................................................ 3-23
Inspection of important functional units ........................................................ 3-24
Moving off ......................................................................................................... 3-26
Gear shift .......................................................................................................... 3-27
Selecting the drive range .............................................................................. 3-27
High speed (option) ...................................................................................... 3-28
Changing direction............................................................................................ 3-29
Backup warning system (option) .................................................................. 3-29
Load stabiliser................................................................................................... 3-30
Differential lock ................................................................................................. 3-31
Engaging differential lock ............................................................................. 3-31
Switching off the differential lock .................................................................. 3-31
Steering ............................................................................................................ 3-32
Synchronising the steering ........................................................................... 3-32
Changing steering mode in vehicles without high speed option ................... 3-33
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Table of contents
Changing steering mode in vehicles with high speed option ........................ 3-33
Stop the vehicle ................................................................................................ 3-34
Parking the vehicle .......................................................................................... 3-34
Light system ..................................................................................................... 3-35
Signalling system.............................................................................................. 3-37
Cabheating and ventilation ............................................................................... 3-38
Front window heater (option) ........................................................................ 3-39
Air conditioning (option) ................................................................................ 3-39
Auxiliary heating (option) .................................................................................. 3-40
Remedy for malfunction: .............................................................................. 3-40
Washer system................................................................................................. 3-41
Tank ............................................................................................................. 3-41
Seat adjustment................................................................................................ 3-42
Weight setting ............................................................................................... 3-42
Height setting ............................................................................................... 3-42
Armrest setting ............................................................................................. 3-43
Backrest setting ............................................................................................ 3-43
Longitudinal setting ...................................................................................... 3-43
Seat belt ........................................................................................................... 3-44
Vehicle doors.................................................................................................... 3-46
Other controls ................................................................................................... 3-47
Tank lock ...................................................................................................... 3-47
Engine cover ................................................................................................ 3-47
Battery master switch (option) ...................................................................... 3-47
Towing the vehicle............................................................................................ 3-48
Safety instructions ........................................................................................ 3-48
Towing .......................................................................................................... 3-48
Handling the vehicle with a crane..................................................................... 3-49
Crane handling ............................................................................................. 3-49
Loading and transporting the vehicle................................................................ 3-50
Loading the vehicle ...................................................................................... 3-50
Lashing down the vehicle ............................................................................. 3-51
Working with the vehicle ........................................................................................ 3-52
General safety instructions .............................................................................. 3-52
Load diagram ................................................................................................... 3-52
Control valve of the loader unit: overview......................................................... 3-53
Control lever for hydraulics of lift and tilt ram of loader unit ......................... 3-53
Tip switch on control lever ............................................................................ 3-53
Control lever for implements and 3rd control circuit ..................................... 3-54
Securing control levers for driving on public roads ....................................... 3-55
3rd electrically operated control
circuit (option) ............................................................................................... 3-56
Lowering the loader unit with the engine switched off ..................................... 3-57
Depressurising the quick couplers on the loader unit ...................................... 3-57
Connecting pressurised quick couplers............................................................ 3-58
Re-equipping the loader unit ............................................................................ 3-60
Fitting implements onto the quickhitch facility .............................................. 3-60
Taking an implement off the quickhitch facility ............................................. 3-63
Connection of electrically operated implements (option) ................................. 3-64
Operation of the restrictor unit on the tilt ram (option) ...................................... 3-66
Safety equipment "Hose burst valve" (option) .................................................. 3-67
Working with standard bucket and pallet forks ................................................. 3-69
Implements ................................................................................................... 3-69
Standard bucket ........................................................................................... 3-69
Working with pallet forks .............................................................................. 3-75

Table of contents
Troubleshooting
Troubleshooting ............................................................................................................. 4-1
Engine trouble........................................................................................................... 4-2
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
Changing the fuel filter........................................................................................ 5-4
Cleaning the screen filter of the fuel pump ......................................................... 5-5
Changing the leak oil line.................................................................................... 5-6
Engine lubrication system ......................................................................................... 5-7
Checking the oil level ......................................................................................... 5-7
Filling in engine oil .............................................................................................. 5-8
Changing the engine oil ...................................................................................... 5-9
Changing the engine oil filter cartridge ............................................................. 5-10
Engine and hydraulics cooling system.................................................................... 5-11
Specific safety instructions .............................................................................. 5-11
Engine oil cooler .............................................................................................. 5-11
Cleaning ....................................................................................................... 5-11
Hydraulic oil cooler ........................................................................................... 5-12
Cleaning ....................................................................................................... 5-12
Air filter ................................................................................................................... 5-13
Functional check of the dust valve ............................................................... 5-14
Replacing the filter cartridge ......................................................................... 5-15
V-belt....................................................................................................................... 5-16
Checking the V-belt tension .......................................................................... 5-16
Retightening the V-belt ................................................................................. 5-16
Hydraulic system..................................................................................................... 5-17
Hydraulic oil level.............................................................................................. 5-18
Checking the oil level .................................................................................... 5-18
Topping up hydraulic oil ................................................................................ 5-18
Changing the hydraulic oil ............................................................................ 5-19
Important information for the use of biodegradable oil ................................. 5-21
Hydraulic oil reflux filter..................................................................................... 5-22
Changing the filter insert ............................................................................... 5-22
Changing the breather filter ............................................................................. 5-23
Hydraulic pressure lines ................................................................................... 5-24
Specific safety instructions ........................................................................... 5-24
Gearboxes and axles ............................................................................................. 5-25
Rear axle gearbox ............................................................................................ 5-26
Checking/topping up the oil level in the rear axle gearbox ........................... 5-26
Changing the gearbox oil .............................................................................. 5-27
Rear axle differential......................................................................................... 5-28
Checking/topping up the oil level in the rear axle gearbox ........................... 5-28
Changing the oil ........................................................................................... 5-28
Front axle differential ........................................................................................ 5-29
Checking/topping up the oil level .................................................................. 5-29
Changing oil .................................................................................................. 5-29
Front and rear axle planetary drives ................................................................. 5-30

Table of contents
Checking/topping up the oil level .................................................................. 5-30

Changing the oil .......................................................................................... 5-30
Lubricating planetary drive bearings ................................................................ 5-31
Lubricating the rear axle oscillation-type bearing ............................................ 5-31
Loader unit.............................................................................................................. 5-32
Lubricating the pivots on the loader unit .......................................................... 5-32
Tyre care................................................................................................................. 5-33
Inspection work ................................................................................................ 5-33
Daily checks ................................................................................................. 5-33
Checks every week ...................................................................................... 5-33
Wheel change................................................................................................... 5-34
Removing the wheels ................................................................................... 5-34
Fitting the wheels ......................................................................................... 5-34
Heating ................................................................................................................... 5-35
Cleaning the dust filter of the heating system .................................................. 5-35
Electrical system..................................................................................................... 5-36
Service and maintenance work at regular intervals.......................................... 5-37
Instructions concerning specific components .................................................. 5-37
Cables, bulbs and fuses ............................................................................... 5-37
Alternator ...................................................................................................... 5-37
Battery .......................................................................................................... 5-38
General maintenance work..................................................................................... 5-39
Cleaning .......................................................................................................... 5-39
General instructions for all areas of the vehicle ........................................... 5-39
Inside of operator compartment ................................................................... 5-40
Exterior of the vehicle ................................................................................... 5-40
Engine compartment .................................................................................... 5-40
Screw connections ........................................................................................... 5-41
Pivots and hinges ............................................................................................ 5-41
Engine fluids and lubricants .................................................................................. 5-42
Service kits ............................................................................................................ 5-43
Proofs of maintenance ........................................................................................... 5-44
Proofs of maintenance ................................................................................. 5-44
Maintenance plan (overview) ................................................................................. 5-48
Maintenance label .................................................................................................. 5-52
valid for model 521 ........................................................................................ 5-52
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

Table of contents
Specifications
Specifications ................................................................................................................. 7-1
Frame ....................................................................................................................... 7-1
Engine ...................................................................................................................... 7-1
Power train................................................................................................................ 7-2
Axles ........................................................................................................................ 7-3
Brakes ..................................................................................................................... 7-3
Steering ................................................................................................................... 7-4
Work hydraulics ....................................................................................................... 7-4
Pilot control ............................................................................................................. 7-4
Loader unit ............................................................................................................... 7-5
Weights .................................................................................................................... 7-5
Electrical system ...................................................................................................... 7-6
Noise levels .............................................................................................................. 7-9
Vibration ................................................................................................................... 7-9
Tyres ....................................................................................................................... 7-10
Dimensions ........................................................................................................... 7-11
Coolant compound table ........................................................................................ 7-11
Tightening torques ................................................................................................. 7-12
General tightening torques .............................................................................. 7-12
Specific tightening torques .............................................................................. 7-12
Annex
Hydraulics diagram (options) ........................................................................................ A-1
Hydraulics diagram ....................................................................................................... A-2
valid for model 521 ........................................................................................ A-2
Legend – wiring diagram ............................................................................................... A-4
Wiring diagram .............................................................................................................. A-7
Wiring diagram legend – options ................................................................................... A-8
Wiring diagram – option ................................................................................................ A-8

Index
I
Index
Numerisch Loader unit
3rd electrically operated control circuit (option) ...................................3-56 Checking the tilt position of the bucket ......................................... 3-69
Checking the transport position of the bucket .............................. 3-69
A Depressurising quick couplers ..................................................... 3-57
Abbreviations .........................................................................................1-1 Lowering with the engine switched off .......................................... 3-57
Air filter cartridge ........................................................................ 5-13, 5-15 Lubricating .................................................................................... 5-32
Auxiliary heating (option) .....................................................................3-40 Re-equipping ................................................................................ 3-60
B Loading vehicles .................................................................................. 3-75
Locking control levers for road travel .................................................. 3-23
Backup warning system (option) ..........................................................3-29
Low speed control (option) .................................................................. 3-12
Battery master switch (option) .............................................................3-47
Lowering the loader unit with the engine switched off ......................... 3-57
Biodegradable oil .................................................................................5-21
Lubricants ............................................................................................ 5-42
Brake/inching pedal ................................................................... 3-11, 3-12
M
C
Maintenance
Capacities ............................................................................................5-42
Air filter ......................................................................................... 5-13
CE mark ...............................................................................................1-11
Biodegradable oil .......................................................................... 5-21
Checklists ..............................................................................................3-7
Changing the engine oil .................................................................. 5-9
Control lever
Changing the engine oil filter cartridge ......................................... 5-10
Continuous operation of implements ............................................3-54
Changing the filler and breather filter on the hydraulic oil tank .... 5-23
For implements and 3rd control circuit ..........................................3-54
Changing the fuel filter ................................................................... 5-4
For lift and tilt ram .........................................................................3-53
Changing the hydraulic oil ............................................................ 5-19
Securing for driving on public roads ..............................................3-55
Checking the engine oil level .......................................................... 5-7
Controls .................................................................................................3-9
Checking the hydraulic oil level .................................................... 5-18
D Cleaning ....................................................................................... 5-39
Designated use and exemption from liability .........................................2-2 Cleaning the engine oil cooler ...................................................... 5-11
Differential lock ....................................................................................3-31 Cleaning the fuel tank ..................................................................... 5-3
Documents .............................................................................................1-6 Cleaning the hydraulic oil cooler .................................................. 5-12
Doors ...................................................................................................3-46 Cleaning the screen filter of the fuel pump ..................................... 5-5
Drive pedal ...........................................................................................3-10 Electrical diagram (options) ............................................................A-8
Driving licence .......................................................................................1-6 Electrical system .......................................................................... 5-36
Driving on public roads ........................................................................3-22 Engine and hydraulics cooling system ......................................... 5-11
Driving the vehicle .................................................................................3-9 Engine lubrication system .............................................................. 5-7
Dust filter ..............................................................................................5-35 Filling in engine oil .......................................................................... 5-8
Front axle differential .................................................................... 5-29
E Fuel system .................................................................................... 5-1
Electrical diagram ..........................................................................A-7, A-8 Gearboxes and axles ................................................................... 5-25
Engine fluids ........................................................................................5-42 General maintenance work .......................................................... 5-39
F Heating ......................................................................................... 5-35
Hydraulic oil reflux filter ................................................................ 5-22
Fields of application
Hydraulic pressure lines ............................................................... 5-24
Possible implements .......................................................................1-4
Hydraulic system .......................................................................... 5-17
Fine dust filter (option) .........................................................................5-35
Instructions concerning specific components ............................... 5-37
Front window heater (option) ...............................................................3-39
Lubricating the loader unit ............................................................ 5-32
Fuel level indicator ...............................................................................3-17
Lubricating the oscillation-type bearing ........................................ 5-31
Fuel preheater (option) ........................................................................3-20
Maintenance plan ......................................................................... 5-48
Fuel system
Pivots and hinges ......................................................................... 5-41
Cleaning the screen filter of the fuel pump .....................................5-6
Planetary drives ............................................................................ 5-30
G Proofs of maintenance ................................................................. 5-44
General conduct ....................................................................................2-3 Rear axle differential .................................................................... 5-28
Rear axle gearbox ........................................................................ 5-26
H
Screw connections ....................................................................... 5-41
Hazard warning system .......................................................................3-37 Service and maintenance work at regular intervals ...................... 5-37
Heating ................................................................................................3-38 Topping up hydraulic oil ............................................................... 5-18
L Tyre care ...................................................................................... 5-33
Legal regulations ...................................................................................1-6 V-belt ............................................................................................ 5-16
Light system .........................................................................................3-35 Wheel change .............................................................................. 5-34
Load diagram .......................................................................................3-52 Manual throttle (option) ..............................................................3-11, 3-23
Load stabiliser ......................................................................................3-30 Maximum speed .................................................................................. 1-11
Multifunctional lever ............................................................................. 3-13
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Index
N Specifications ........................................................................................ 7-1

Noise level ................................................................................... 1-11, 7-9 Axles ............................................................................................... 7-3
Brakes ............................................................................................ 7-3
O Coolant compound table .............................................................. 7-11
Oil preheating (option) .........................................................................3-20 Dimensions ................................................................................... 7-11
Operation ...............................................................................................3-1 Electrical system ............................................................................ 7-6
Backup warning system (option) ...................................................3-29 Engine ............................................................................................ 7-1
Before moving off ..........................................................................3-22 Frame ............................................................................................. 7-1
Before starting the engine .............................................................3-18 Loader unit ..................................................................................... 7-5
Changing direction ........................................................................3-29 Noise levels .................................................................................... 7-9
Drive ranges .................................................................................3-27 Pilot control ..................................................................................... 7-4
Moving off .....................................................................................3-26 Power train ..................................................................................... 7-2
Overview of cab ..............................................................................3-2 Steering .......................................................................................... 7-4
Overview of control elements .........................................................3-9 Tightening torques ........................................................................ 7-12
Overview of instrument panel, multifunctional lever and drive switch .. Tyres ............................................................................................ 7-10
3-4 Vibration ......................................................................................... 7-9
Parking the vehicle .......................................................................3-34 Weights .......................................................................................... 7-5
Restrictor unit ................................................................................3-66 Work hydraulics .............................................................................. 7-4
Restrictor unit on tilt ram (option) ........................................ 3-66, 3-67 Standard electrical diagram ..................................................................A-7
Selecting the drive range ..............................................................3-27 Starting aid .......................................................................................... 3-21
Start the engine ............................................................................3-18 Starting with starting aid ...................................................................... 3-29
Stop the vehicle ............................................................................3-34 Steering ............................................................................................... 3-24
To fasten seat belt ........................................................................3-44 Steering angle limit ....................................................................... 7-10
Operation manual Steering-column control lever ............................................................... 3-9
Notes ..............................................................................................1-1 Symbols ................................................................................................ 1-1
P Synchronous wheel position ............................................................... 3-24
Pallet forks ...........................................................................................3-75 T
Safety instructions ........................................................................3-75 Taking into service ................................................................................ 3-6
Parking brake .......................................................................................3-12 Checklists ....................................................................................... 3-7
Picking up an implement ......................................................................3-60 Safety instructions .......................................................................... 3-6
PME fuel ................................................................................................5-3 Taking the vehicle into service for the first time ............................. 3-6
Preheating start switch ..........................................................................3-9 Telltales ............................................................................................... 3-15
R To fasten seat belt ............................................................................... 3-44
Towing the vehicle .............................................................................. 3-48
Re-equipping the loader unit ................................................................3-60
Transport ............................................................................................. 3-70
Refuelling ...............................................................................................5-2
Transport position ............................................................................... 3-22
Restrictor unit on tilt ram (option) .........................................................3-66
Turn indicators .................................................................................... 3-37
Road travel ..........................................................................................3-22
Type labels and component numbers ................................................... 1-9
Rotating beacon (option) .....................................................................3-37
Tyre care ............................................................................................. 5-33
Running-in period ..................................................................................3-6
V
S
Vehicle
Safety instructions .................................................................................2-1
Brief description .............................................................................. 1-3
Identification ....................................................................................2-1
Crane handling ............................................................................. 3-49
Operating ........................................................................................2-6
Data ................................................................................................ 1-7
Special hazards ............................................................................2-12
Fields of application ........................................................................ 1-4
Seat adjustment ...................................................................................3-42
Loading and transporting .............................................................. 3-50
Armrest setting ..............................................................................3-43
Overview ........................................................................................ 1-2
Backrest setting ............................................................................3-43
Vehicle equipment ................................................................................. 1-6
Height setting ................................................................................3-42
Vehicle inspections ............................................................................... 1-6
Longitudinal setting .......................................................................3-43
Ventilation ........................................................................................... 3-38
Weight setting ...............................................................................3-42
Ventilation, fresh air ...................................................................... 3-38
Service brake .......................................................................................3-25
Service kits ..........................................................................................5-43 W
Signalling system .................................................................................3-37 Warning identification ............................................................................ 1-7
Signs and symbols ...............................................................................1-10 Washer pump ...................................................................................... 3-41
Washer system ................................................................................... 3-41
Tank ............................................................................................. 3-41
Wheel change ..................................................................................... 5-34
Window wiper ...................................................................................... 3-41
Wiring diagram ......................................................................................A-7
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Index
Working
... with pallet forks .........................................................................3-75
... with standard bucket .................................................................3-69
... with the vehicle .........................................................................3-52
Freeing the vehicle ........................................................................3-75
General safety instructions ...........................................................3-52
Loading heaped material ..............................................................3-74
Loading loose material ..................................................................3-70
Planieren .......................................................................................3-74
Practical hints ................................................................................3-75
Removing material/digging in hard soil .........................................3-73
Removing material/digging in soft soil ..........................................3-72
Restrictor unit on tilt ram (option) ..................................................3-66
Safety equipment "Hose burst valve" (option) ..............................3-67
BA 302 01 US-Gehl - Edition 1.0 * 30201busg10SIX.fm I-9

Index
I-10 BA 302 01 US-Gehl - Edition 1.0 * 30201busg10SIX.fm

Section 1
Introduction
Introduction
Introduction
1 Introduction 1
1.1 Notes on this operation manual

This operation manual contains important information on how to work safely, correctly and
economically with the wheel loader model 521. Therefore, it aims not only at new oper-
ators, 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 vehicle will be increased by following the instructions in the operation manual. This is
why the operation manual must always be kept at hand in the vehicle.
Your own safety, as well as the safety of others, depends to a great extent on how the
vehicle is moved and operated. Therefore, carefully read and understand this operation
manual prior to the first drive. This operation manual will help to familiarise yourself more
easily with the vehicle, thereby enabling you to use it more safely and efficiently.
General safety instructions are given in Section 2 of this operation manual. The owner and
the operators of the vehicle must know and follow them at all times. As a rule, keep the fol-
lowing 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
vehicle are given right before the procedure to follow in the respective sections. This is to
make sure that these safety instructions are read and followed when needed.
Operational safety and readiness of the vehicle do not only depend on your skill, but also
on maintenance and service of the vehicle. This is why regular maintenance and service
work is absolutely necessary. Extensive maintenance and repair work must always be car-
ried out by an expert with appropriate training. Insist on using original spare parts when
carrying out maintenance and repair work. This ensures operational safety and readiness
of your vehicle, and maintains its value.
Your dealer will be pleased to answer any further questions regarding the vehicle or the
operation manual.
Abbreviations/Symbols
• This symbol stands for an enumeration
• Subdivision within lists or an activity. If possible, follow the order recommended
☞ This symbol requires you to carry out the activity described
➥ This symbol marks the passages in the text describing the effects or results of an
activity
n. s. = not shown
SO = option
Stated whenever controls or other components of the vehicle are installed as an option.
This symbol shows the direction of travel – for better orientation in figures and
graphics.
BA 302 01 US-Gehl – Edition 1.0 * 30101b0110.fm 1-1

Introduction
1.2 Vehicle overview

4 5 6 7 8 9 10 11
12
2
15
1
20
17
30 16 30300b0324.eps
18
29 29 24
19
19
28
20
7 7 8
20 21
27 27 20
13
26 13
25 22
2
21
15
23
23
3
14
30300b03025.eps 30101b01000.eps
1 Tooth guard for bucket for long-haul travel 18 Signalling device – backup warning system (option)
2 Danger label 19 Rearview mirror
3 Front eye hooks – lifting and strapping down the vehicle 20 Brake light, rear light and turn indicator
4 Horn 21 Label – Do not touch any moving or turning parts!
5 Mark – loader unit position for long-haul travel Do not open engine cover before engine is at a standstill!
6 Wheel chock 22 Engine cover lock
7 Access handle 23 Reflectors
8 Maximum driving speed label 24 Working light (option)
9 EC mark 25 Fuel filler inlet
10 Noise emission label 26 Front registration number (possibly necessary depending on
11 Door arrester the legal regulations of your country)
12 Upper foothold 27 Turn indicators, clearance lights
13 Extra clearance light (option) 28 Possible installation of fire extinguisher
14 Rear eye hooks – lifting and strapping down the vehicle 29 Headlights
15 Tow away facility 30 Protective FOPS screen (option)
16 Lower foothold
17 Rear registration number (possibly necessary depending on
the legal regulations of your country) Fig. 1: Vehicle outside views
1-2 BA 302 01 US-Gehl – Edition 1.0 * 30101b0110.fm

Introduction
1.3 Brief description

The wheel loader model 521 is a self-propelled work machine.
This vehicle is a versatile and powerful helper for moving earth, gravel and debris on con-
struction sites and elsewhere. The wide range of implements accounts for the numerous
applications of the vehicle: as a fork lift, a snow plough, a spreader for grit, salt etc., a
sweeper or a tree replanter. See part 1.4 Fields of application for further applications. Ret-
rofit the vehicle with the respective safety devices when using it as a lifting accessory, see
Section “Applications with lifting accessories” on page 2-8.
The main components of the vehicle model 521 are:
• ROPS-tested operator's cab with comfort seat, protective FOPS screen (option),
adjustable steering column, emergency seat upon request
• Oil-to-air cooled, sound-insulated 4-cylinder Deutz diesel engine
• Sturdy, U-section frame in torsion-resistant box-type design, cab and engine rubber
mounted
• Hydrostatic drive with axle transfer gearbox and 2 drive ranges, inching function;
20 kph max. speed, 40 kph max. speed as high speed option or 30 kph max. speed as
restricted high speed option
• Hydrostatic four-wheel steering with emergency steering features, automatic steering
synchronisation by pressing a button
• Front and rear planetary steering and drive axles, rear axle with oscillation
• Service brake designed as inner multi-disc brake, secondary and parking brake
designed as disc brake on front axle
Hydrostatic drive The diesel engine permanently drives a hydraulic pump, whose oil flow is sent to a hydrau-
lic motor flanged onto the rear axle. The force of the hydraulic motor is transmitted to the
rear axle via the transfer gearbox. At the same time, the front axle is driven by the cardan
shaft, ensuring permanent four wheel drive.
Work hydraulics and hydrostatic four The diesel engine also drives the joint gear pump for work hydraulics and hydrostatic four
wheel steering wheel steering. The oil flow of this pump depends on the diesel engine revs only.
When the vehicle is in operation, the entire diesel engine output can be transmitted to the
gear pump for work hydraulics and steering. This is made possible by the so-called inching
which responds as soon as the inching brake is used, reducing or cutting off power input of
the drive. Therefore, engine output is fully available for the loader unit by pressing the
accelerator pedal and the inching brake pedal at the same time.
Cooling system An oil cooler is located at the rear of the vehicle for hydraulic oil cooling. The engine oil is
cooled by a separate oil cooler mounted on the engine. The telltales in the instrument
panel ensure constant monitoring of the coolant and hydraulic oil temperature.

Introduction
1.4 Fields of application

The implements will decide in the first place how the vehicle can be used (see table below).
Note that not all implements listed below comply with local traffic regulations. The imple-
ments complying with local traffic regulations and the applicable provisions are listed in the
vehicle documentation!
The authorities of your country may require specific permits, certifications, registrations
etc. for the use of implements not authorised or listed in the vehicle documentation!
Get informed on and follow the legal regulations of your country.
The following table provides an overview of possible implements
Description of implement Vehicle model Model Use
Loosening, picking up, transporting and loading loose or solid

Standard bucket – normal material 521 810137 material (material density £ 1.8 kg/dm³)
Pallet forks 521 810138 Only with load diagram 0004353146

Introduction

Introduction
1.5 Regulations
Driving licence
Earth moving machinery may be driven on public roads only if the driver has a driving
licence for the vehicle, as defined by national traffic regulations. German traffic regulations
require the following driving licences for driving the vehicle:
In normal version (20 kph): Driving licence category L (European Union)
With high speed (40 kph): Driving licence category C1 (European Union)
Equipment
German traffic regulations require to equip the vehicle with e.g.:
• 1 warning triangle with design certification
• 1 warning light with design certification
• 1 first-aid kit in accordance with the legal regulations in your country
We recommend to equip the vehicle with a fire extinguisher. The fire extinguisher can be
mounted on the right B pillar in the operator's cab
(see graphic “Vehicle overview” on page 1-2).
Vehicle inspections
Accident prevention regulations must be followed when operating earth moving machinery
in Germany.
All employer's liability insurance associations in Germany require your vehicle to be
checked for technical safety according to VBG 40 §50 which must be carried out at least
once a year by an expert (test report).
Provide for a label on the vehicle stating the inspection intervals (fig. 17 on page 1-11).
Vehicles with high speed option:
• Your vehicle may possibly be subject to registration
• Your vehicle must possibly undergo main inspections/brake checks at regular intervals
Documents
German traffic regulations require to have the following documentation on board, e.g.:
• General certification
• Driving licence
• Inspection report as per VBG 40 §50

Introduction
Vehicle warning identification

Vehicles used on public roads for
• Road building
• Road maintenance
• Road or park cleaning
must under all circumstances be equipped according to German traffic regulations as
of 01 October 1998, with the red and white identification according to DIN 30 710 in con-
nection with the yellow rotating beacon (option).
1.6 Vehicle data

The following data provide a detailed description of your vehicle. Please supply your
dealer with these data for all correspondence or telephone inquiries.
Please read the data valid for your vehicle/implement off the type labels, and enter these
data in the list. They will immediately be at hand for all inquiries or spare parts orders
( section 6 "Helpful information for using the spare parts list" on page 6-1).
Vehicle model/version: ......................................................................................................................................
Serial number: ......................................................................................................................................
Commissioning/date of registration: ......................................................................................................................................
Service hours/kilometre reading: ......................................................................................................................................
Cab number: ......................................................................................................................................
Engine number: ......................................................................................................................................
Hydraulic pump ......................................................................................................................................

Variable displacement pump model –
identification number:
Hydraulic motor ......................................................................................................................................

variable displacement motor model –
identification no.:
Front axle number: ......................................................................................................................................
Rear axle number: ......................................................................................................................................
Gearbox number: ......................................................................................................................................
Optional implements: ......................................................................................................................................
......................................................................................................................................
Your local dealer • Address:
• Telephone:

Introduction
1.7 Page left intentionally blank

Introduction
1.8 Type labels and component numbers

Type label
The type label (Fig. 3) is located at the front right of the vehicle frame (Fig. 2/A).
A Serial number
B The serial number is stamped on the vehicle frame (Fig. 2/B). It is also located on the type
label (Fig. 3).
20 Type label information

Fig. 2: Type label: location 39
Example for vehicle model 521:
Vehicle model: 521
Version 521
00 435 12 21
Serial number: 521 0100

Fhzg-Typ
Model
Zul. Achslast vorn
Front GAWR [ kg ]
Year of construction: 2002
Modèle PNBE AV
Typ / Ausf.
Version
Zul. Achslast hinten
Rear GAWR [ kg ]
Gross front axle weight rating: 4000 kg
Version PNBE AR
Fg.-Nr.
Serial no.
No. de série
Zul. Ges. Gew.
GWR
PTAC
[ kg ] Gross rear axle weight rating: 4000 kg
Baujahr Leistung
Model year
Année fabr.
Output
Performance
[ kW ]
Gross weight rating: 6000 kg
30300b0010.eps
Fig. 3: Type label

Output: 48,5 kW
Check your vehicle's type label or the "Specifications" section for vehicle data.
Cab number
The type label of the vehicle cab is located at the upper left, on the B pillar of the vehicle
cab.
Fig. 4: Cab type label
Engine number
The engine number is located on the type label on top of the engine block (Fig. 5).
Example:
BF4L 1011FT 00411134
Fig. 5: Diesel engine number
Hydraulic pump number

The type label (arrow, Fig. 6) is located at the front, on the hydraulic pump housing.
Fig. 6: Hydraulic pump type label

Introduction
Hydraulic motor number

The type label (arrow) is located on the lower side of the hydraulic motor, above the
cardan shaft.
Fig. 7: Hydraulic motor: type label
Rear axle and gearbox number

The axle number is located on the type label, on the inside of the axle tube, on the left in
driving direction (arrow).
The gearbox number is located on the type label, close to the cardan shaft flange, on the
left in driving direction (arrow)
Fig. 8: Rear axle and gearbox: type label
Front axle number

The axle number is located on the type label, on the inside of the axle tube, on the right in
driving direction (arrow).
Fig. 9: Front axle: type label
1.9 Other Signs and symbols

The following states signs and symbols which are not unequivocally comprehensible. They
do not contain explanatory text and are not explained in the following sections.
... on the outside of the vehicle
A
C
B
Fig. 10: Labels at the vehicle rear end
Meaning
General indication of danger:
This sign warns persons standing or working near the vehicle of an existing danger within
the area of increased danger around the vehicle.
308b0360.eps Location:
Fig. 11: Danger sign Front left and right of the vehicle frame, and at the vehicle rear end (Fig. 10/A).

Introduction
Meaning
Indicates eye hooks on the vehicle. The eye hooks are used for lifting or strapping down
the vehicle.
Location:
At the rear on the counterweight (Fig. 10/B), and at the
308b0680.eps
front over the front axle, to the left and right of the vehicle frame.
Fig. 12: Label: eye hooks
Meaning
1 Do not open engine cover before engine is at a standstill!
2 Do not touch any moving or turning parts!
Location:
At the rear on the engine cover of the vehicle (Fig. 10/C), and on the engine block
Fig. 13: Prohibitory sign
Meaning
ε L pA
Indication of Noise levels produced by the vehicle
LWA = sound power level
LPA = noise level inside the cab
XX XX Further indications – see section 7.12 Noise levels on page 7-9
Fig. 14: Labels: noise levels Location:
On rear left window
Meaning
Design-specific max. vehicle speed in kph
20 Location:
Left and right of counterweight and on rear window
Fig. 15: Speed label
Meaning
The CE mark means that the vehicle meets the requirements of the EC Machine Directive
and that the conformity procedure has been carried out. The vehicle meets all health and
safety requirements of the EC Machine Directive.
ce.ai Location:
Fig. 16: CE mark On rear left window
...inside the operator’s compartment

Meaning
Certification of inspection by UVV (German regulations for accident prevention) as per
Sicherheitstechnische Überprüfung
nach VBG 40 § 50 VBG 40 §50 (brochure of the German employer's liability insurance association for con-
struction engineering), by means of an expert
Location:
In the cab on the left B pillar
Fig. 17: UVV inspection label

Introduction
Load diagram (Fig. 18)

... for operation of pallet forks with fork arms:
The framed numbers indicate the maximum authorized load on the fork arms for industrial
and off-road applications respectively. The maximum load varies according to the distance
from the load centre.
Reading example for implement no. 810138, model 521:
Off-road operation ➝ Safety factor S=1.67
Load distance = 600 mm
1440 The maximum load amounts to e.g. 1580 kg!
Tyre inflation pressure table (fig. 18)

...List of authorised types of tyres with prescribed tyre inflation pressures
Further indications – see section 7.14 Tyres on page 7-10
Location:
Inside the cab, on left side of front window
Important!
The load diagrams shown on the front window are valid only for applications with
pallet forks. Observe the specific load diagrams of other implements used, e.g.
rotary crane jib!
Typ
model
modèle
521
30100b1370.eps
Fig. 18: Load diagram/tyre table for model 521
Notes:

Section 2
Safety instructions
Safety instructions
Safety instructions
2 Safety instructions2
2.1 Identification of warnings and dangers
Important indications regarding the safety of the operating personnel and the vehicle are
indicated in this operation manual with the following terms and symbols:
Danger!
Failure to observe the instructions identified by this symbol may result in

personal injury or death for the operator or other persons.
☞ Measures for avoiding danger
Caution!
Failure to observe the instructions identified by this symbol may result in

damage to the vehicle.
☞ Measures for avoiding danger for the vehicle
Important!
This symbol identifies instructions for a more efficient and economical use of the
vehicle.
Environment!
Failure to observe the instructions identified by this symbol may result in damage to the
environment.
The environment is in danger if environmentally hazardous material (e.g. waste oil) is not
subject to proper use or disposal.

Safety instructions
2.2 Designated use and exemption from liability

• The vehicle is intended for:
• Moving earth, gravel, coarse gravel or ballast and rubble as well as
• Working with the implements stated in the present operation manual
Every other application is regarded as not designated for the use of the vehicle. Pro-
ducer will not be liable for damage resulting from this. The user alone will bear the risk.
Designated use also includes observing the instructions in the operation manual and
observing the conditions of maintenance and service.
• Observe the pertinent regulations relevant to accident prevention, other generally
acknowledged regulations regarding safety and occupational medicine, as well as the
regulations and standards relevant to motor vehicles and traffic which are valid in your
country. Producer will not be liable for damage resulting from the failure to observe
these regulations.
• The safety of the vehicle can be negatively affected by carrying out vehicle modifica-
tions without proper authority and by using spare parts, equipment, implements and
optional equipment which have not been checked and released by producer. Producer
will not be liable for damage resulting from this.
• Producer will not be liable for personal injury and/or damage to property caused by
failure to observe the safety instructions and the operation manual, and by the negli-
gence of the duty to exercise due care when:
• Handling
• Operating
• Servicing and carrying out maintenance work or
• Repairing
the vehicle. This is also applicable in those cases in which special attention has not
been drawn to the duty to exercise due care, in the safety instructions as well as in the
operation and maintenance manuals (vehicle/engine).
Read and understand the operation manual before starting up, servicing or repairing
the vehicle. Observe the safety instructions!
• The vehicle may not be used for transport jobs on public roads.
• In applications with lifting accessories, the vehicle is used according to its designated
use only if the prescribed safety devices are installed and functional.

Safety instructions
2.3 General conduct and safety instructions

Organizational measures • The vehicle has been designed and built in accordance with state-of-the-art standards
and the recognised safety regulations. Nevertheless, its use may constitute a risk to life
and limb of the user or of third parties, or cause damage to the vehicle and to other
material property.
• The vehicle must only be used in technically perfect condition in accordance with its
designated use and the instructions set out in the operation manual, and only by safety-
conscious persons who are fully aware of the risks involved in operating the vehicle.
Any functional disorders, especially those affecting the safety of the vehicle, must
therefore be rectified immediately!
Basic rule:
Before starting up the vehicle, inspect the vehicle for safety in work and road operation!
• Careful and prudent working is the best way to avoid accidents!
• The operating instructions must always be at hand at the place of use of the vehicle,
and must therefore be kept in the storage compartment provided for in the cab.
Immediately complete or replace an incomplete or illegible operation manual.
• In addition to the operating instructions, observe and instruct the operator in all other
generally applicable legal and other mandatory regulations relevant to accident
prevention and environmental protection.
These compulsory regulations may also deal with the handling of hazardous
substances, issuing and/or wearing of personal protective equipment, or traffic regula-
tions.
• With regard to specific operational features, e.g. those relevant to job organisation,
work sequences or the persons entrusted with the work, supplement the operation
manual by corresponding instructions, including those relevant to supervising and
reporting duties.
• Persons entrusted with work on the vehicle must have read and understood the
operation manual and in particular, Section 2 “Safety Instructions” before beginning
work. This applies especially to persons working only occasionally on the vehicle,
e.g. set-up or maintenance.
• The user/owner must check – at least from time to time – whether the persons
entrusted with operation or maintenance of the vehicle are working in compliance with
the operation manual and are aware of risks and safety factors.
• The user/owner commits himself to operate and keep the vehicle in a perfect condition,
and, if necessary or required by law, to require the operating or servicing persons to
wear protective clothing etc.
• In the event of safety-relevant modifications or changes on the vehicle or of its
behaviour, stop the vehicle immediately and report the malfunction to the competent
authority/person.
Safety-relevant damage or malfunctions of the vehicle must be rectified immediately.

Safety instructions
• Never make any modifications, additions or conversions to the vehicle and its super-
structures (cab, loader unit etc.), as well as to the implements, which might affect safety
without the approval of producer! This also applies to the installation and the
adjustment of safety devices and valves, as well as to welding work on load-bearing
elements.
• Spare parts must comply with the technical requirements specified by producer.
Original spare parts from producer can be relied to do so.
• Replace hydraulic hoses within stipulated and appropriate intervals even if no safety-
relevant defects have been detected.
• Before working on or with the vehicle, take off jewellery, such as rings, wristwatches,
bracelets etc., and tie back long hair and do not wear loose-fitting garments, such as
unbuttoned or unzipped jackets, ties or scarves.
Injury may result from being caught up in the machinery or from rings catching on
moving parts!
• Keep the vehicle clean. This reduces
• Fire hazard, e.g. due to oil-soaked rags lying around
• Danger of injury, e.g. due to dirt or debris on the footholds, and
• Danger of accident e.g. due to dirt or debris on the brake or accelerator pedal!
• Observe all safety, warning and information signs and labels on the vehicle.
• Adhere to prescribed intervals or those specified in the operation manual for routine
checks/inspections and maintenance work!
• For service, inspection, maintenance or repair work, tools and workshop equipment
adapted to the task on hand are absolutely indispensable.

Safety instructions
Selection and qualification of person- • Any work on or with the vehicle must be carried out by reliable personnel only. Do not
nel, basic responsibilities let unauthorised persons drive or work with the vehicle! Observe statutory minimum
age limits!
• Employ only trained or instructed staff on the vehicle, and set out clearly and unequivo-
cally the individual responsibilities of the personnel for operation, set-up, maintenance
and repair!
• Define the vehicle operator's responsibilities – also with regard to observing traffic
regulations. Give the operator the authority to refuse instructions by third parties that
are contrary to safety.
• Do not allow persons to be trained or instructed or persons taking part in a general
training course to work on or with the vehicle without being permanently supervised by
an experienced person!
• Work on the electrical system and equipment, on the chassis and the steering and
brake systems may be carried out only by skilled personnel which has been specially
trained for such work.
Work on the hydraulic system of the vehicle must be carried out only by personnel with
special knowledge and experience of hydraulic equipment!
• Seal off the area of danger should it not be possible to keep a safe distance.
Stop work if persons do not leave the area of danger in spite of warning! Keep out of
the area of danger!
Area of danger:
The area of danger is the area in which persons are in danger due to the movements of
the
• Vehicle
• Work equipment
• Additional equipment or
• Material
This also includes the area affected by falling material, equipment or by parts which are
thrown out.
The danger area must be extended by 1 ft 7 in (0.5 m) in the immediate vicinity of
• Buildings
• Scaffolds or
• Other elements of construction

Safety instructions
2.4 Safety instructions regarding operation

Normal operation • Before beginning work, familiarise yourself with the surroundings and circumstances of
the work site. These are e.g. obstacles in the working and travelling area, the soil
bearing capacity and any necessary barriers separating the work site from public roads.
• Take the necessary precautions to ensure that the vehicle is used only when in a safe
and reliable state!
Operate the vehicle only if all protective and safety-oriented devices, e.g. removable
safety-devices, soundproofing elements and exhausters etc., are in place and fully
functional!
• Check the vehicle at least once daily/per work shift for visible damage and defects.
Report any changes (incl. changes in the vehicle’s working behaviour) to the competent
organization/person immediately! If necessary, stop the vehicle immediately and lock it!
• In the event of malfunctions, stop the vehicle immediately and lock it! Have any defects
rectified immediately!
• Start and operate the vehicle from the operator seat only!
• Carry out start-up and shut-down procedures in accordance with the operation manual,
and observe the telltales!
• Before putting the vehicle/implement into operation (start-up/moving), make sure
nobody is at risk by putting the vehicle/implement into operation!
• Before driving with the vehicle, and also after interrupting work, check whether the
brakes, the steering, signalling and light systems are functional!
• Before moving the vehicle always check whether the supplementary equipment and the
implements have been safely stowed away or mounted!
• When driving on public roads, ways and places, observe the valid traffic regulations
and, if necessary, make sure beforehand that the vehicle is in a condition perfectly
compatible with these regulations!
• In conditions of poor visibility and after dark always switch on the lights!
• Persons accompanying the driver must be seated on the passenger seats provided for
this purpose.
• No lifting, lowering or carrying of persons in the work equipment/implements!
• No mounting of a man basket or working platform!
• When crossing underpasses, bridges and tunnels, or when passing under overhead
lines always make sure there is sufficient clearance!
• Always keep at a safe distance from the edges of building pits and slopes!
• When working in buildings or in enclosed areas, look out for the
• Height of the ceiling/clearances
• Width of the entrances and
• Maximum bearing load of ceilings and floors
Provide for sufficient room ventilation – danger of poisoning!

Safety instructions
• Avoid any operation that might be a risk to vehicle stability!

• During operation on slopes, drive or work uphill or downhill. If driving across a slope
cannot be avoided, bear in mind the tilting limit of the vehicle!
Always keep the implements/work equipment close to the ground. This also applies to
driving downhill!
When driving or working across a slope, the load must be on the uphill side of the
vehicle.
• On sloping terrain always adapt your driving speed to the prevailing ground conditions.
Never change to a lower gear on a slope but always before reaching it!
• Before leaving the vehicle
• Lower the work equipment/implements to the ground
• Before leaving the operator seat always secure the vehicle against accidental
movement and unauthorised use!
• Before starting work check whether
• All safety devices are properly installed and functional
• Warning triangle
• Approved warning light and
• First-aid kit
are on hand
• Before moving the vehicle or before taking up work:
• Make sure visibility is sufficient (do not forget rearview mirrors!)
• Adjust correct seat position (brake pedal must be depressed to the limit).
Never adjust the operator seat when driving or working!
• Fasten your seat belt
• Inspect the immediate area (children!). In the work area the operator is responsible
for third parties!
• Caution when handling fuel – increased danger of fire!
Make sure fuel does not come into contact with hot parts!
Do not smoke during refuelling, and avoid fire and sparks! Stop the engine during refu-
elling and do not smoke!
• Never get on or off a moving vehicle! Never jump off the vehicle!
• Should the lights of the vehicle not be sufficient for the safe execution of certain work
processes, provide additional lighting of the work area.
• Installed work lights must not be switched on for travel on public roads. They can be
switched on in work operation if users of public roads are not dazzled.
• Hydrostatic four wheel steering takes time getting used to it. Therefore, adjust the
driving speed to your abilities and the circumstances. Selection and change of steering
mode at vehicle standstill only!

Safety instructions
Applications with lifting accessories Definition:

Applications with lifting accessories are understood as procedures involving the lifting,
transporting and lowering of loads with help of slings and load-securing devices (e.g.
ropes, chains). In doing so, the help of persons is necessary for securing and detaching
the load. This applies for example to lifting and lowering of pipes, shaft rings or containers.
• The vehicle may be used for applications with lifting accessories only if the prescribed
safety devices are in place and functional.
These are e.g.:
• Safe possibilities of slinging and securing a lifting attachment (load hook)
• Load diagram
Also, get informed on the legal regulations of your country which deal with maximum
loads and overturning moments. These legal regulations may require you to provide
your vehicle with the following equipment:
• Safe load indicator
• Hose burst valves
• Loads must be secured so as to prevent them from falling or slipping.
• Persons guiding the load or securing it must stay in visual contact with the vehicle
operator.
• The vehicle operator must guide the load the nearest possible to the ground and avoid
any oscillating or swinging movements.
• The vehicle may be moved with raised load only if the path of the vehicle is as level as
possible.
• The persons attaching or securing loads may approach the boom from the side only,
and only after the vehicle operator has given his permission. The vehicle operator may
give his permission only after the vehicle is at a standstill and the work implement no
longer moves.
• Do not use any damaged lifting attachments or such lifting attachments (ropes, chains)
which are not sufficiently dimensioned. Always wear protective gloves when working
with lifting attachments.

Safety instructions
Trailers and implements • Prior to driving on public roads remove all implements which cannot be secured in
compliance with the legal regulations of your country!
• Get informed on the legal regulations of your country which deal with the use and appli-
cations of trailers towed by the vehicle!
• Trailer operation in connection with the towing device of the vehicle is not allowed!
• Implements and counterweights affect handling, as well as the steering and brake
capability of the vehicle!
• Fit the implements with the specially required devices only!
• Before uncoupling or coupling hydraulic lines (hydraulic quick couplers)
• Switch off the engine
• Reduce the hydraulic oil pressure in the hydraulic system. To do so, move the control
levers of the hydraulic control units back and forth several times
• Coupling of implements requires special care!
• Secure the implements against accidental movement!
• Operate the vehicle only if all protective facilities have been installed and are functional,
and if all brake, light and hydraulic connections have been connected!
• If optional equipment is installed, all additionally required light installations, telltales
etc., must be provided for and functional.
• Mount the implements only if the engine has been stopped and the drive switched off.
• Depressurise the hydraulic system before connecting or disconnecting hydraulic lines.
• Especially when driving or working with vehicles provided with a quickhitch facility for
the implements, make sure that the implement is securely locked in the quickhitch
facility. The lock pin must be visible on both sides of the bores on the implement. Check
before starting work.
• Prior to attaching implements to the loader unit, secure the control lever of the hydraulic
control unit against accidental movement.
• Be careful when coupling implements to the loader unit: danger of personal injury due
to crushing and shearing. Make sure nobody is between the vehicle and the equipment
without securing the vehicle and the implement against movement.
Transport • The vehicle must be towed, loaded and transported only in accordance with the
operation manual!
• For towing the vehicle observe the prescribed transport position, admissible speed and
itinerary.
• Use only appropriate means of transport and lifting gear of adequate capacity/payload!
• Safely secure the vehicle on means of transport! Use suitable mounting points and
load-securing devices.
• The recommissioning procedure must be strictly in accordance with the operation
manual!

Safety instructions
2.5 Safety instructions for maintenance

• Avoid any operational mode that might be prejudicial to safety!
• Observe the adjusting, maintenance and inspection activities and intervals set out in
the operation manual, including information on the replacement of parts/partial
equipment.
These activities may be carried out by skilled personnel only.
• The vehicle may not be serviced, repaired or test-driven by unauthorised personnel.
• Brief operating personnel before beginning special operations and maintenance work!
Appoint a person to supervise the activities!
• In any work concerning the operation, conversion or adjustment of the vehicle and its
safety-oriented devices, or any work related to maintenance, inspection and repair,
observe the start-up and shut-down procedures set out in the operation manual, and
the information on maintenance work.
• If required, secure the maintenance area appropriately!
• Prior to carrying out service, maintenance and repair work, attach a warning label, such
as “Repair work – do not start vehicle!”, to the ignition lock/steering wheel or to the
control elements.
Remove the ignition key!
• Carry out service, maintenance and repair work only if
• Vehicle is positioned on firm and level ground
• Lever for selecting the driving direction is in neutral position
• Parking brake has been applied
• All hydraulically movable implements and working equipment have been lowered to
the ground
• Engine is at a standstill
• Ignition key is removed and
• Vehicle has been secured against accidental movement
• Should maintenance or repair be inevitable with the engine running:
• Only work in groups of two
• Both persons must be authorised for the operation of the vehicle
• One person must be seated on the operator seat and maintain visual contact with the
other person
• Observe the specific safety instructions in the respective work manual
• Keep a safe distance to all rotating and moving parts, e.g. fan blades, V-belt drives,
PTO shaft drives, fans etc.
• Prior to carrying out assembly work on the vehicle, make sure no movable parts will roll
away or start moving.
• To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes must be carefully attached and secured to lifting tackle.
Use only suitable lifting gear and suspension systems in a technically perfect state with
adequate lifting capacity!
Never work or stand under suspended loads!

Safety instructions
• Fastening of loads and instruction of crane operators must be entrusted to experienced

persons only!
The person giving the instructions to the operator must be within sight or sound of him.
• For carrying out overhead assembly work always use specially designed or otherwise
safety-oriented ladders and working platforms.
Never use vehicle parts or implements/superstructures as a climbing aid!
Wear a safety harness when carrying out maintenance work at greater heights!
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow
and ice!
• Clean the vehicle, especially connections and threaded unions, of any traces of oil, fuel
or preservatives before carrying out maintenance/repair work!
Do not use aggressive detergents!
Use lint-free cleaning rags!
• Before cleaning the vehicle with water, steam jet (high-pressure cleaning) or deter-
gents, cover or tape up all openings which – for safety and functional reasons – must
be protected against water, steam or detergent penetration. Special care must be taken
with the electrical system.
• After cleaning, remove all covers and tapes applied for that purpose!
• After cleaning, examine all fuel, lubricant and hydraulic oil lines for leaks, chafe marks
and damage!
Rectify all defects without delay!
• Tighten all screw connections that have been loosened during maintenance and repair!
• All safety devices removed for set-up, maintenance or repair purposes must be refitted
and checked immediately upon completion of the maintenance and repair work.
• Ensure that all consumables and replaced parts are disposed of safely and with
minimum environmental impact!
• Do not use the work equipment as lifting platforms for persons!
• Before taking up work on vehicle parts/implements dangerous for life and limb
(bruising, cutting), always ensure safe blocking/support of these areas.
• Carry out maintenance and repair work beneath a raised vehicle, work equipment/
implements or additional equipment only if a safe and secure support has been
provided for (the sole use of hydraulic rams, jacks etc. does not sufficiently secure
raised vehicles or equipment/implements).
• Avoid contact with hot parts, such as the engine block or the exhaust system during the
operation of the vehicle and for some time afterwards – danger of burns!
• Retainer pins can fly out or splinter when struck with force – danger of personal injury!
• Do not use starting fuel! This especially applies to those cases in which a heater plug
(intake-air preheating) is used at the same time – danger of explosions!
• Apply special care when working on the fuel system – increased danger of fire!

Safety instructions
2.6 Warning of special hazards

Electric energy • Use only original fuses with the specified current rating!
Switch off the vehicle immediately and rectify malfunction if trouble occurs in the
electrical system!
• When working with the vehicle, maintain a safe distance from overhead electric lines! If
work is to be carried out close to overhead lines, the equipment/implements must be
kept well away from them. Caution, danger! Get informed on the prescribed safety
distances!
• If your vehicle comes into contact with a live wire
• Do not leave the vehicle
• Drive the vehicle out of the area of danger
• Warn others against approaching and touching the vehicle
• Have the live wire de-energised
• Do not leave the vehicle until the damaged line has been safely de-energised!
• Work on the electrical system may only be carried out by a skilled technician, in
accordance with the applicable electrical engineering rules.
• Inspect and check the electrical equipment of the vehicle at regular intervals. Defects
such as loose connections or scorched cables must be rectified immediately.
• Observe the operating voltage of the vehicle/implements!
• Always remove the earthing strap from the battery when working on the electrical
system or when carrying out welding work!
• Starting with a battery jump cable can be dangerous if carried out improperly. Observe
the safety instructions regarding the battery!
Gas, dust, steam, smoke • Operate the vehicle only on adequately ventilated premises! Before starting internal
combustion engines or operating fuel-operated heating systems on enclosed premises,
make sure that there is sufficient ventilation!
Observe the regulations in force at the respective site!
• Carry out welding, flame-cutting and grinding work on the vehicle only if this has been
expressly authorised. There may be a risk of explosion and fire, for example!
• Before carrying out welding, flame-cutting and grinding work, clean the vehicle and its
surroundings from dust and other inflammable substances, and make sure that the
premises are adequately ventilated – danger of explosions!

Safety instructions
Hydraulic equipment • Work on the hydraulic equipment of the vehicle may be carried out only by persons
having special knowledge and experience in hydraulic systems!
• Check all lines, hoses and screwed connections regularly for leaks and obvious
damage! Repair any damage and leaks immediately! Splashed oil may cause injury
and fire.
• In accordance with the operation manual/instructions for the respective assembly,
depressurise all system sections and pressure pipes (hydraulic system, compressed-
air system) to be opened before carrying out any implementing/repair work!
• Hydraulic and compressed-air lines must be laid and fitted properly. Ensure that no
connections are interchanged. The fittings, lengths and quality of the hoses must
comply with the technical requirements.
Noise • During operation all sound baffles must be closed

• Wear ear protectors if necessary!
Oil, grease and other chemical sub- • When handling oil, grease and other chemical substances (e.g. battery electrolyte —
stances sulphuric acid), observe the product-related safety regulations (safety data sheet)!
• Be careful when handling hot consumables – risk of burning or scalding!
Battery • When handling the battery observe the specific safety instructions and regulations
relevant to accident prevention. Batteries contain sulfuric acid – caustic!
• Especially when charging batteries, as well as during normal operation of batteries, a
hydrogen-air mixture is formed in the cells – danger of explosion!
• Do not attempt to jump-start the vehicle if the battery is frozen or if the acid level is low.
The battery may rupture or explode!
Tyres • Repair work on tyres and rims may be carried out by skilled personal or by an
authorised workshop only!
• Damaged tyres and/or wrong tyre pressure reduce the operational safety of the vehicle.
Therefore carry out regular checks of the tyres for
• Prescribed tyre pressure and
• Damage
• Do not inflate tyres with inflammable gas – danger of explosion!
• Carry out regular checks of the wheel nuts for tightness, however after 600 service
hours at the latest. Subsequent to changing tyres check the wheel nuts after 10 service
hours – tighten if necessary!

Safety instructions

Section 3
Operation
3
3
Operation
This chapter describes the controls, and contains information on the function and handling of the telltales and controls in the operator cab.
The pages stated in the table refer to the description of the corresponding controls.
The identification of controls with a combination of digits or a combination of digits and letters, such as 39/25 or 39/A, stands for:
Figure no. 39 control element no. 25 or position A in Figure no. 39.
A figure carries no number when it is placed to the left of the text.
Unfold the double pages for a better overview.
The symbols used in the description have the following meanings:
• This symbol stands for an enumeration
• Subdivision within lists or an activity. If possible, follow the order recommended
☞ This symbol requires you to carry out the activity described
➥ This symbol marks the passages in the text describing the effects or results of an activity
n. s. = not shown
SO = option
Overview: see overleaf
Stated whenever controls or other components of the vehicle are installed as an option.
This symbol shows the direction of travel –for better orientation in figures and graphics.
BA 302 01 US-Gehl –Edition 1.0 * 30101b0310.fm 3-1

Operation
3.1 Overview of cab

1 2
Ref. no. Description for more information see page
1 Sun visor
2 Interior light..............................................................................................................................................................................................3-35
3 Hydrostatic steering.................................................................................................................................................................................3-32
4 Instrument panel........................................................................................................................................................................................3-4
5 Access handle
6 Air vents – front window
7 Door lock..................................................................................................................................................................................................3-46
8 Washer fluid tank.....................................................................................................................................................................................3-41
9 Air vents – leg room
10 Control lever console.................................................................................................................................................................................3-5
11 Control lever console lock........................................................................................................................................................................3-18
3
Fig. 19: Overview of cab 12 Side console ..............................................................................................................................................................................................3-5
4 13 Drink holder
14 Rotary switch – auxiliary heating (option) ................................................................................................................................................3-40
5 15 Door arrester – left and right....................................................................................................................................................................3-46
30 16 Rear wiper ...............................................................................................................................................................................................3-41
6 17 Armrest ....................................................................................................................................................................................................3-43
5 18 Operator's seat ........................................................................................................................................................................................3-42
19 Seat belt...................................................................................................................................................................................................3-44
7
105
40
60
˚F
175
80
˚C 100
120
250
20 30
10
12 14
16
7 20 Storage compartment – operation manual
Volt
10 20
10 40
P
120
165
˚F
270
100
500 MPH 30 0
1/2
1/1
21 Air vents – cab/operator's seat

6
75
50 ˚C 125
150
Km/h 50
0236
8 22 Tool kit
29 23 Emergeny seat (option)/storage area
24 Parking brake...........................................................................................................................................................................................3-12
28 9 25 Accelerator pedal.....................................................................................................................................................................................3-10
26 Multifunctional lever.................................................................................................................................................................................3-13
10 27 Brake/inching pedal .................................................................................................................................................................................3-11
27
28 Fuse box....................................................................................................................................................................................................7-6
11
26 29 Steering column lock ...............................................................................................................................................................................3-18
30 Front wiper...............................................................................................................................................................................................3-41
25
12
9
13
24
14
15 15
30300b03023.eps
23 22 21 20 19 18 17 16

Overview: see overleaf

Operation
3.2 Overview: switches, levers and consoles

26 31 32 33 34 Ref. no. Description for more information see page
Multifunctional lever
31 Lever – turn indicators, high beam, headlight flasher ........................................................................................................... 3-14, 3-35, 3-37
32 Rotary switch – front wiper .............................................................................................................................................................3-14, 3-41
33 Tip switch – washer pump ..............................................................................................................................................................3-14, 3-41
34 Tip switch – horn.....................................................................................................................................................................................3-14,
Instrument panel
35 Rocker switch – front window heater (option)..........................................................................................................................................3-39
Fig. 20: Multifunctional lever or
36 Rocker switch – 3rd electrically operated control circuit ON/OFF (option) ..............................................................................................3-56
37 Rocker switch – front working light (option) .............................................................................................................................................3-36
38 Rocker switch – electrically operated implements (option)......................................................................................................................3-64
36 39 Rocker switch – rear wiper with tip switch for wiper water.......................................................................................................................3-41
4 40 Rocker switch – load stabiliser ................................................................................................................................................................3-30
41 Rocker switch – lights..............................................................................................................................................................................3-35
42 Tip switch (red)– steering synchronisation ..............................................................................................................................................3-32
43 Telltales (green) – four-wheel/front axle steering ....................................................................................................................................3-32
35 48 59 60 54 42
44 Rocker switch – steering/high speed (option).................................................................................................................................3-28, 3-32
˚F
175
37 49 105
60
80
100
250
12 14 55 43 45 Rocker switch – rotating beacon (option) ................................................................................................................................................3-37
40 ˚C 120 10 16
46 Rocker switch – rear working light...........................................................................................................................................................3-36

50 20 30 Volt
56
38 10 20 44 47 Rocker switch – hazard warning light ......................................................................................................................................................3-37
10 40
51 P
120
165
˚F
270
500 0
1/2
1/1
57 48 Telltale (red) – alternator charge function................................................................................................................................................3-15
75 100 30
39 52
50 ˚C 125
150 MPH
45 49 Telltale (red) – engine oil pressure ..........................................................................................................................................................3-15
Km/h
0002836h
50
58
50 Not assigned
40 53 46 51 Telltale (red) – parking brake...................................................................................................................................................................3-15
61 62 63
52 Telltale (red) – service brake pressure ...................................................................................................................................................3-15
41 47 53 Telltale (red) – hydraulic oil reflux filter ...................................................................................................................................................3-16
30100b0080.eps HAZARD
54 Telltale (yellow) – air filter ........................................................................................................................................................................3-16

55 Telltale (blue) – high beam ......................................................................................................................................................................3-16
Fig. 21: Instrument panel
56 Telltale (green) – turn indicator right/left..................................................................................................................................................3-16
57 Telltale (yellow) – cold starter ..................................................................................................................................................................3-16
58 Telltale (green) – differential lock.............................................................................................................................................................3-16
10 12 76
75 59 Temperature gauge – hydraulic oil ..........................................................................................................................................................3-17
70 60 Voltmeter – battery ..................................................................................................................................................................................3-17
74
61 Temperature gauge – engine and cooling oil ..........................................................................................................................................3-17
69
73 82 62 Hour meter with speedometer (speedometer only with high speed option).............................................................................................3-17
68 81 63 Fuel level indicator...................................................................................................................................................................................3-17
72
77
84
64 78
65 79
83
66 80
67
71
11
Fig. 22: Control lever console Fig. 23: Side console

Operation
Operation
Ref. no. Description for more information see page

Control lever console
64 Control lever – loader unit........................................................................................................................................................................3-53
65 Control lever – 3rd control circuit/implements..........................................................................................................................................3-54
66 Lock/transport lock for 3rd control circuit/implements..............................................................................................................................3-54
67 Lock for loader unit and implements........................................................................................................................................................3-55
68 Tip switch – lock with 3rd electrically operated control circuit (option)....................................................................................................3-56
69 Tip switch – differential lock.....................................................................................................................................................................3-31
70 Tip switch – front electric socket (option)........................................................................................................................................3-53, 3-64
and/or
tip switch – unlock with 3rd electrically operated control circuit (option) ................................................................................................3-56
71 Lever – manual throttle (option)...............................................................................................................................................................3-11
72 Tip switch – reverse driving direction ................................................................................................................................... 3-10, 3-29, 3-53
73 Telltale – reverse driving direction ....................................................................................................................................... 3-10, 3-29, 3-53
74 Telltale – forward driving direction ....................................................................................................................................... 3-10, 3-29, 3-53
75 Tip switch – forward driving direction ................................................................................................................................... 3-10, 3-29, 3-53
Side console
76 Preheating start switch ..............................................................................................................................................................................3-9
77 Rocker switch – drive range selection ..............................................................................................................................................3-9, 3-27
78 Rocker switch – air conditioning (option) .................................................................................................................................................3-39
79 Rotary switch – 3 level heater fan............................................................................................................................................................3-38
80 Rotary switch – heater fan temperature regulation..................................................................................................................................3-38
81 Rotary switch – fresh air/recirculated air..................................................................................................................................................3-38
82 Radio (option)
83 Socket/cigarette lighter ..............................................................................................................................................................................7-6
84 Control lever – low-speed control (option) ...............................................................................................................................................3-12

Operation
3.3 Taking into service

3.3.1 Safety instructions
•
3 Only use the steps and handles provided when entering and leaving the cab
• Never use the controls or movable lines and cables as handles
• Never board or jump off a moving vehicle
• Refer to the corresponding load diagrammes for the loader unit pallet forks
3.3.2 Taking the vehicle into service for the first time
Important information • The vehicle may be taken into service by authorised personnel only – see
also section 1 "Regulations" on page 1-6 of this operation manual
• The operating personnel must have read and understood this operation manual before
taking the vehicle into service
• The vehicle may only be used in technically perfect condition in accordance with its
designated use and the instructions set out in the operation manual, and only by
persons who are fully aware of the risks involved in operating the vehicle
• Go through the “Start-up” checklist in the following section
Running-in period Handle the vehicle carefully during its first 100 operating hours.
The future performance and service life of the vehicle are heavily dependent on the
observance of the following recommendations during the running-in period.
• Do not overload the vehicle, but at the same time do not drive too cautiously either, as
the vehicle will never reach the proper operating temperature
• Do not run the engine at high revs for extended periods
• Increase the load gradually whilst varying the engine revs
• Strictly observe maintenance schedules and carry out (or have carried out) the
specified maintenance work – see Maintenance plan (overview) on page 5-48

Operation
3.3.3 Checklists
The checklists below are intended to assist you in checking and monitoring the vehicle
before, during and after operation.
The check lists cannot claim to be exhaustive; they are merely intended as an aid for you
in fulfilling your duties as a conscientious operator.
The checking and monitoring jobs listed below are described in greater detail in subse-
quent sections.
If the answer to one of the following questions is NO, first rectify the cause of the fault
before starting or continuing work.
Start-up checklist Check the following points before taking the vehicle into service or starting the engine:
No. Question ✔
1 Sufficient fuel in the tank? (➠ 5-1)
2 Engine oil level OK? (➠ 5-7)
3 Oil level in hydraulic tank OK? (➠ 5-18)
4 Water level in washer tank OK? (➠ 3-41)
5 Loader unit lubricated? (➠ 5-32)
6 Tyre condition OK? (➠ 5-33)
7 Lights, signals, indicators, warning lights and telltales OK?
(➠ 3-35, 3-37, 3-15)
8 Windows, mirrors, lights and steps clean?
9 Is the implement on the loader unit correctly locked? (➠ 3-60)
10 Is the engine cover firmly locked?
11 Especially after cleaning, maintenance or repair work:
Rags, tools and other loose objects removed?
12 Approved warning triangle, hazard light and first aid kit in the vehicle? (➠ 1-6)
13 Seat position and rearview mirror correctly adjusted? (➠ 3-18)
14 Seat belt fastened? (➠ 3-44)

Operation
Operation checklist After starting the engine and during operation, check and observe the following points:
No. Question ✔
1 Telltales for engine oil pressure and alternator gone out? (➠ 3-15)
2 Braking effect sufficient? (➠ 3-24)
3 Temperature indicator for engine coolant in normal range? (➠ 3-15)
4 Steering working properly? (➠ 3-24)
5 Is anyone dangerously close to the vehicle? (➠ 2-5)
When travelling on public roads, particular attention must be paid to the following
points:
6 Bucket and implements in transport position? (➠ 3-22)
7 Transport locks installed? (➠ 3-22)
8 Control lever for lift and tilt hydraulics of the loader unit locked? (➠ 3-22)
9 Tooth guard fitted to bucket? (➠ 3-22)
Parking checklist Check and observe the following points when parking the vehicle:
No. Question ✔
1 Implements on the loader unit lowered to the ground? (➠ 3-34, 3-53)
2 Parking brake applied? (➠ 3-12)
3 Cab locked, especially if the vehicle cannot be supervised?
When parking on public roads:
4 Vehicle adequately secured? (➠ 3-34)
When parking on uphill and downhill gradients:
5 Vehicle additionally secured with chocks under the wheels to prevent it from
rolling away? (➠ 3-34)

Operation
3.4 Driving the vehicle

3.4.1 Overview of control elements
Preheating start switch [76]
1
0 2 Important!
P 3 The engine will not start unless the parking brake is applied and telltale 21/51
lights!
☞ Pull lever 19/24 up
76
Fig. 24: Preheating start switch Position Function Power consumer
P No function None
0 Inserting or removing the None
ignition key
1 ON/drive position ➥ All functions are operational
➥ Telltale 21/51 comes on if parking brake
19/24 is applied
2 Preheting engine (with cold start at < 0 C: 10-15 seconds)
3 Start the engine ➥ Starter is actuated
➥ Telltales must go out
Drive range selector [77] Function

Drive range selection
A
Rocker switch 77 Drive range
Position Change-over switch 77 Standard High speed option
77
A ☞ Push downward 1st = 0 – 5 kph 1st = 0 – 10 kph
B ☞ Push symbol 2nd = 0 – 20 kph 2nd = 0 – 40 kph
B
Fig. 25: Selection of drive range with rocker switch

Operation
Driving direction tip switch [72/75] Function

Selection of driving direction
75 Driving direction Effect
74 • Forward ☞ Press the green tip switch ➥ Green telltale 74 in joystick comes
75 on
73 64 • Reverse ☞ Press yellow tip switch 72 ➥ Red telltale 73 in joystick comes
on
72
• Neutral ☞ Press both tip switches at ➥ Telltale 73 or 74 in joystick goes
the same time out
Fig. 26: Tip switch for driving direction on joystick
Important!
The driving direction can be selected only after releasing the parking brake!
Applying the parking brake automatically switches to neutral position!
Accelerator pedal [25]
50
75
˚C
100
125
150
Km/h 50
Function
0236
Accelerator pedal 25 controls the drive speed as follows:
Position Drive speed

25 • Press pedal ➥ Drive speed is increased
• Release pedal slowly ➥ Drive speed is reduced
• Release pedal fully ➥ Hydrostatic braking
Fig. 27: Accelerator pedal

Operation
Manual throttle lever [71] (option)
B A Danger!
Do not operate the manual throttle lever when driving on public roads –
Accident hazard!
71 ☞ Use manual throttle only for work operations!
☞ Before driving on public roads:
Fig. 28: Lever – manual throttle • Set manual throttle lever 71 to idling speed position
• Regulate engine revs only with the accelerator pedal/drive pedal 27/25
Function
Sets the engine revs for work operations
Important!
This function is especially useful for the operation of hydraulically operated imple-
ments to ensure constant hydraulic oil supply. The driving speed must be control-
led with the brake/inching pedal or the low-speed control (option).
Position Engine revs

A Idling speed = minimum revolutions
B Full speed = maximum revolutions
Brake/inching pedal [27]
P ˚F
Function
270 1/2
165
120 500 MPH 30 0 1/1
75 100
50 ˚C 125
150
Km/h 50
0236
1 To brake the vehicle irrespective of the driving direction and the position of accel-
erator pedal 19/25
2 In the inching range of the brake pedal (pedal pressed in lightly), the pedal can be
used like a car’s clutch. The drive system is supplied with less hydraulic oil which
means the entire engine output is available to the work hydraulics. This allows
especially to raise the loader unit more rapidly
27 Braking
Fig. 29: Brake/inching pedal
☞ Press brake inching pedal 27 down with force
Inching
☞ Press brake inching pedal 27 down lightly

Operation
Control lever [84] – low-speed control

(option)
Function
Regulation of maximum vehicle speed irrespective of the engine revs
Important!
A B This function is identical to inching with the brake/inching pedal, whereby the max-
imum speed can be set with more precision.
84 The maximum possible speed depends on the drive range selected.
Fig. 30: Control lever – low-speed control
Position Drive speed

A Maximum speed
B Vehicle at a standstill
Parking brake [24] Function

1 Prevents the vehicle from rolling away
2 Emergency brake in case of a breakdown of the service brake
Danger!
Use parking brake 19/24 instead of the service brake in an emergency only,
i.e. in case of a breakdown of the service brake. The brake lights do not light
up, and the vehicle brakes abruptly –
Accident hazard!
☞ In normal operation, only use brake/inching pedal 19/27 as a service brake
Important!
The engine will not start unless the parking brake is applied and telltale 21/51
lights!
☞ Pull lever 19/24 up

Operation
To prevent the vehicle from rolling away

a ☞ Pull up lever 24 to the last notch
➥ Telltale 51 comes on
24
P 51 To release the parking brake:
☞ Pull up lever 24 slightly
312b0090.eps ☞ Depress button a
☞ Move lever 24 all the way down
Fig. 31: Parking brake
Using the parking brake as emergency brake when driving the vehicle
Danger!
Operating the parking brake when driving causes the vehicle drive to
disengage. This causes sudden deceleration at full speed –
Accident hazard!
☞ Use the parking brake as service brake only in case of emergency
☞ Before using the parking brake reduce driving speed if possible
☞ Pull lever 24
Multifunctional lever [26]

Function
26 33 34 1 Switches on the turn indicators with lever 31
32 2 Switches high beam on and off with lever 31
3 Flashes headlight flasher with lever 31
31
4 Turns front wiper on and off with rotary switch 32
5 Switches on front window washer pump with tip switch 33
6 Sounds horn with tip switch 34
30300b0312.eps
Fig. 32: Multifunctional lever

Operation
High beam, low beam and headlight flasher

Lever 31 Effect
III
☞ Lower pos. I ➥ High beam ON, telltale 21/55 comes on if
II low beam is switched on with rocker
switch 21/41
I ☞ Centre pos. II ➥ Low beam ON if low beam is switched on
31 with rocker switch 21/41
30300b0312.eps ☞ Raise further to pos. III and ➥ Headlight flasher ON, telltale 21/55 comes
Fig. 33: Actuating high beam, low beam and headlight keep in this position on
Turn indicators
Lever 31 Effect
31
L ☞ Push forward ➥ Left turn indicators actuated, telltale 21/56
flashes
☞ In centre position ➥ None
30300b0313.eps
R ☞ Pull back ➥ Right turn indicators actuated,
telltale 21/56 flashes
Fig. 34: Actuating the turn indicators
Important!
Lever 31 has an automatic reset; this means the lever is automatically set to centre
position after turning the steering lock after a large steering angle.
Horn
Tip switch 34 Effect
☞ Press ➥ Horn ON
☞ Release ➥ Horn OFF
30300b0313.eps
34
Fig. 35: Actuating the horn
Front wiper
32 Rotary switch 32 Effect
J ☞ Turn to the right to pos. J ➥ Intermittent wipe ON
0 ☞ Turn back to pos. 0 ➥ OFF
I ☞ Turn to the left to pos. I ➥ Slow wipe ON
II ☞ Turn to the left to pos. II ➥ Fast wipe ON
30300b0313.eps
Fig. 36: Actuating the wiper
Washer pump ON
33 Tip switch 33 Effect
☞ Slide to the left and hold ➥ Washer pump ON
☞ Release ➥ Washer pump OFF
30300b0313.eps
Fig. 37: Actuating the washer pump

Operation
3.4.2 Overview Telltales and warning lights

48 Telltale (red) – alternator charge function
Caution!
The engine cooling fan no longer runs if the V-belt is faulty.

Danger of engine overheating or breakdown!
If telltale 48 comes on with the engine running:
☞ Switch off the engine immediately and repair or have the cause repaired
The telltale comes on when the ignition is turned on and goes out as soon as the engine
runs.
The V-belt for the alternator, or the charging circuit of the alternator is faulty if the telltale
comes on with the engine running. The battery is not charged any more (➠ page 5-16).
49 Telltale (red) – engine oil pressure

Comes on if the engine oil pressure is too low. In this case:
☞ Stop the vehicle
☞ Switch off the engine immediately and check the oil level (➠ page 5-7)
The telltale comes on when the ignition is turned on and goes out as soon as the engine
runs.
50 Not assigned
51 Telltale (red) – parking brake

Comes on when parking brake lever 19/24 is applied.
The electric drive interlock prevents driving the vehicle with the parking brake applied.
P
52 Telltale (red) – service brake pressure
Indicates inadmissibly low pressure of the service brake.
Danger!
If telltale 52 comes on with the engine running, the accumulator of the bake
system has only a small pressure reserve.
Accident hazard!
☞ Stop the vehicle immediately
☞ Have pressure loss repaired by an authorised workshop

Operation
53 Telltale (red) – hydraulic oil reflux filter

Indicates an inadmissibly high pressure in the hydraulic reflux line to the tank. In this case:
☞ Replace the hydraulic oil reflux filter (➠ page 5-22)
In cold weather telltale 53 may come on immediately when the engine is started. This is
caused by increased oil viscosity. In this case:
Let the engine run at idling speed for about 2 minutes
54 Telltale (yellow) – air filter

Indicates air filter contamination. In this case:
☞ Clean or replace the air filter (➠ page 5-13)
55 Telltale (blue) – high beam
Comes on if high beam is switched on, or during headlight flashing.
56 Telltale (green) – turn indicator right/left

Flashes intermittently when the turn indicators are used (lever 19/31)
57 Telltale (yellow) – cold starter

Indicates that the heater plug filament is switched on.
The telltale only lights when the preheating start switch 23/76 is in pos. 2 or in pos. 3
(= preheat intake air and start).
58 Telltale (green) – differential lock

Indicates engagement of the differential lock on the front and rear axle. The telltale does
not come on if the rear axle differential lock is engaged by pressing the service brake.
Caution!
The differential lock may be damaged if it is switched on at the wrong moment,

e.g. when turning corners or if the wheels are already spinning.
☞ Actuate the differential lock only if you expect a wheel to spin, e.g. when
working on slopes or on slippery ground!

Operation
59 Temperature gauge – hydraulic oil

Indicates the temperature detected by a sensor on the oil tank.
Caution!
Danger of hydraulic damage when oil temperature exceeds admissible limit

value (max. 90 °C, briefly) –
☞ Relieve work and driving hydraulics. To do this:
• Move driving direction control lever to neutral position
• Move control lever of the loader unit and implements to neutral position
• Run the engine at increased revs
• Clean radiator if necessary – see page 5-12
Important!
The hydraulic temperature must be between 60 and 85 °C. Max. authorised tem-
perature is 90 °C for brief periods.
60 Voltmeter – battery
Indicates battery charging state with engine off or charging voltage with engine running.
61 Temperature gauge – engine and cooling oil

Indicates the engine oil temperature detected by a sensor behind the engine oil cooler.
Important!
The engine oil temperature must be between 80 and 120 °C, max. authorised tem-
perature is 130 °C (red section).
62 Hour meter with speedometer (speedometer only in high speed option)

Counts the engine service hours with the engine running.
63 Fuel level indicator

Indicates fuel tank level
Important!
Never drive until the fuel tank is completely empty otherwise dirt particles can be
drawn into the fuel system.

Operation
Operation
3.4.3 Before starting the engine3

☞ Run through the “Start-up” checklist on page 3-7
☞ Switch on the battery master switch – see Battery master switch (option) on page 3-47
☞ Adjust steering wheel position. To do this:
• Release lock 19/29
• Adjust the height and longitudinal direction of the steering wheel
• Tighten the lock again
☞ Adjust seat position and rearview mirror
☞ Adjust joystick position. To do this:
• Adjust control lever console 19/10 in longitudinal direction, if necessary. To do this:
Release lock 22/11 and firmly retighten it
• Or adjust the height of the armrest – see Armrest setting on page 3-43
Important!
All controls must be within easy reach. You must be able to move the brake and
accelerator pedals to their limit positions!
☞ To fasten seat belt

☞ Make sure that:
• Parking brake 19/24 is applied and
• Control levers 22/64 and 22/65 for the loader unit are in neutral position
• Manual throttle lever (option) 22/71 is set to idling speed
3.4.4 Start the engine

General • The engine will only start if parking brake 19/24 is applied
• The starter cannot be operated if the engine is already running (start repeat interlock)
• Do not run the starter for more than 10 seconds
• Wait for about 1 minute to let the battery recover before trying again
• The engine cannot be started by tow starting the vehicle, as there is no driving
connection between the engine and gearbox when the engine is switched off
• When the vehicle is used for extended periods at outside temperatures of less
than –10 °C, we recommend retrofitting the vehicle with an engine preheater (“oil
preheater” option)

Operation
Procedure After you have completed the starting preparations in accordance with 3.4.3 Before start-
ing the engine:
1 ☞ Turn ignition key in the preheating start switch 76 to pos. “1”
0 2 ☞ Check whether the following telltales come on:
3 • Telltale 48 for alternator charge function
• Telltale 49 for engine oil pressure
• Telltale 51 if the parking brake is applied
76 • During the telltale check, telltales 51, 52, 53 and 54 must come on for
Fig. 38: Preheating start switch
about 5 seconds
☞ Replace defective telltales immediately
48 54
☞ Press accelerator pedal 19/25 through about a quarter of its travel
49 ☞ Turn the ignition key to pos. “3” and hold in this position until the engine starts
˚F
175
105 250
80 12 14
60 100
40 ˚C 120 10 16
☞ Release the ignition key

20 30 Volt
51 P ˚F
10
10 20
40
1/2
165 270
120 500 0 1/1

75 100 30
50 ˚C 125
150
MPH
Km/h 50
52 0002836h
312b0050.eps
53
Fig. 39: Telltales
Starting at temperatures below 0 °C ☞ Turn the ignition key to pos. 2 and hold it in this position for about 15 seconds
☞ Press accelerator pedal 19/25 all the way through
☞ Turn the ignition key to pos. “3” and hold in this position until the engine starts
☞ Release the ignition key
When the engine runs smoothly (increasing engine speed):
☞ Release accelerator pedal 19/25
Important!
In general, a battery delivers less energy in cold conditions. As a result, you must
make sure the battery is always well charged.

Operation
When the engine has started ... ☞ Check that the following telltales have gone out:
• Telltale 21/48
• Telltale 21/49
• Telltales 21/51, 52, 53 and 54
☞ Let the engine warm up
... for a cold start at outside temperatures below 0 °C:

☞ Let the engine run at increased idling speed for about 1 minute
☞ Do not exceed the mean engine speed for 10 minutes, however you may start using
drive and work hydraulics gently. Do not extend or retract the hydraulic rams to the lim-
its if possible
☞ Increase the diesel engine speed and hydraulic forces gradually
... for a cold start at outside temperatures below +10 °C:

☞ Increase the engine revs slowly
☞ Do not run the engine at full load for the first 10 minutes
Connecting the oil preheater (option)

This equipment is for cold-starting at temperatures below -5 °C. The engine and hydraulic
B oil is heated by means of heating elements in the engine oil pan and in the hydraulic oil
tank according to the gravity principle (warm oil rises and is replaced by cold oil). The oil
can only be thoroughly warmed up to service temperature if the oil preheater is connected
over a longer period of time – preferably over night.
A ☞ Connect the oil preheater as follows:
• Park the vehicle near a 220 V socket
• First connect special cable A to vehicle socket B on the service panel on the left side
of the vehicle, then
• Insert the plug into the 220 V socket
☞ Before starting the engine:
• Pull out the plug from the 220 V socket
• Unplug special cable A from vehicle socket B
Fig. 40: Oil preheater (option) Important!
The oil preheater (option) reduces pollutant emissions during the warm-up phase
by up to 50%, saving fuel at the same time.
Fuel preheater (option) The fuel preheater (option) prevents paraffin crystals forming, which otherwise clog the
fuel filter at low temperatures.
A temperature switch automatically switches on a heating element in the fuel line between
the tank and fuel prefilter when ignition is switched on at temperatures below + 10 °C.

Operation
3.4.5 Jump-starting the vehicle

Starting the engine with starting aid Safety instructions
(supply battery) • Never jump-start the engine if the battery of the vehicle is frozen – danger of explosion!
• The vehicle must not touch the jump-starting vehicle when connected with jump leads –
danger of sparking!
• The external power source must deliver a rated voltage of 12 V; higher supply voltages
will damage the electrical system of the vehicle!
• Use only authorised jump leads which conform to the safety requirements and which
are in perfect condition!
• The jump lead connected to the positive (+) terminal of the starting battery must never
be brought into connection with electrically conductive vehicle parts – danger of short
circuit!
• Route the jump leads so they cannot catch on rotating components in the engine
compartment!
Procedure
☞ Drive the jump-starting vehicle close enough to the vehicle so that the jump leads can
reach to connect the two batteries
☞ Start the engine of the jump-starting vehicle
☞ First connect one end of the red jump lead (+) to the (+) terminal of the flat battery, then
Flat battery clip the other end to the (+) terminal of the starting battery
☞ Connect one end of the black jump lead (–) to the (–) terminal of the starting battery
12 V ☞ Clip the other end of the black jump lead (–) onto a solid metal component attached
firmly to the engine block or onto the engine block itself. Do not connect it to the nega-
tive terminal of the flat battery, as otherwise explosive gas emerging from the battery
may ignite if sparks are formed!
☞ Start the engine of the vehicle with the flat battery
Once the engine has started:
12 V ☞ With the engine running, disconnect the jump leads in exactly the reverse sequence
(first remove (–) terminal, then (+) terminal) – this prevents sparking in the vicinity of
Starting the battery!
Batterie
501tdi_3800.eps
Fig. 41: Starting aid with jump leads

Operation
3.4.6 Before moving off

Special instructions for driving on The vehicle is subject to the
public roads • Applicable regulations of your country
• Regulations specified in the operation license or in the vehicle papers
• Only the equipment items (implements) listed in the operation licence or in the vehicle
papers are admissible for driving on public roads!
• Also bear in mind the footnotes/instructions in Section 1.4 “Fields of application” on
page 1-4
In addition, bear in mind the mandatory regulations relevant to accident prevention.
Preparing the vehicle for driving on ☞ Remove any protective mesh (optional) fitted over the front window
public roads ☞ Dump out the bucket
A
Danger!
Make sure the front-edge protection for the front blade or teeth is installed,
B otherwise –
Accident hazard!
c ☞ Cover the blade or teeth of the bucket across their entire width with the
tooth guard A provided
Fig. 42: Driving on public roads ☞ Buckets/implements which have not been authorized or released for travel
on public roads must be transported with an appropriate means of transport
– see section 1.4 Fields of application on page 1-4!
☞ Adjust the bucket to transport position. To do this:

D • Lower loader unit completely
• Tilt the bucket to the rear B and
• Raise the loader unit until the centre of rotation of the bucket is at a minimum 150 mm
above the ground C
Important!
Fig. 43: Marks for transport position In transport position (with standard tyres), the two red marks D on the lift frame
and on the bulkhead are aligned. These marks are visible from the operator's com-
partment.

Operation
Before moving off: ☞ Carry out a functional check of the:

• Brakes
• Steering and
• Lights
☞ Dump out the bucket
☞ Adjust the bucket to transport position. To do this:
• When driving on public roads: – see section Preparing the vehicle for driving on
public roads on page 3-22
• When not driving on public roads (construction site, company premises):
– see section Checking the transport position of the bucket on page 3-69
☞ Secure control lever 19/10 for the loader unit and the implements against accidental
operation. To do this:
• Turn lever 67 counterclockwise, across the driving direction
67
30300b03015.eps
Fig. 44: Lock for control levers
A Danger!
Do not operate the manual throttle lever (option) when driving on public roads –
Accident hazard!
71 ☞ Use manual throttle (option) only for work operations!
☞ Before driving on public roads:
Fig. 45: Lever – manual throttle • Move manual throttle lever (option) 71 to idling speed pos. A
• Regulate engine revs only with the accelerator pedal/drive pedal 19/25

Operation
Inspection of important functional Steering

units
Important!
The steering system is only operational when the engine is running!

In the event of a failure of the diesel engine or of the hydraulic steering aid (e.g.
failure of the pump drive), the vehicle can still be steered (emergency steering fea-
ture).
After switching high speed on or off, and after synchronizing the wheels, always
carry out a functional check of the steering system!
Danger!
Failure of steering assistance:

Turning the steering wheel requires great effort! Take this into account
especially when towing the vehicle!
☞ Adapt towing speed to the altered steering behaviour!
☞ Use a towing bar!
☞ Functional check: Move the steering wheel to the left and right
Synchronous wheel position
Important!
Tyre wear increases and straight-ahead driving becomes more difficult if the vehi-
cle is not driving in exactly the correct track.
If you notice from the way the vehicle handles that the wheels of both axles are not driving
in exactly the correct track:
☞ Synchronise the steering – see Synchronising the steering on page 3-32

Operation
Service brake
Danger!
The brake lights at the rear of the vehicle do not light up when the parking
brake is applied or the vehicle is braked by means of the drive with its hydro-
static braking effect
Accident hazard!
☞ When driving on public roads and during work operation, especially for
abrupt brake manoeuvres, use the brake/inching pedal 19/27 to brake the
vehicle. Only this causes the brake lights to light up
Dirt accumulation in the area of the brake pedal can result in brake malfunc-
tions
Accident hazard!
☞ Keep the brake/inching pedal 19/27 clean!
If telltale 21/52 comes on with the engine running, the accumulator of the bake
system has only a small pressure reserve –
Accident hazard!
☞ Have pressure loss repaired by an authorised workshop
☞ Before moving off, press down the brake/inching pedal 19/27 to check whether
• After a maximum of half the pedal travel there is a firm resistance to be felt
• Brake lights come on if the brake pedal is pressed down
☞ After moving off, check in the rearview mirror that no-one will be hindered by a brake
manoeuvre
☞ Check the brake action at low speed
Danger!
Especially when stopping on slopes:

Pressing brake/inching pedal 19/27 (inching valve responds!) down slightly
has hardly any braking effect –
Accident hazard!
☞ Depress brake/inching pedal 19/27 until the braking effect is felt

Operation
3.4.7 Moving off
Important!
The vehicle can be moved only after releasing parking brake 19/24.
After starting the engine:

☞ Release parking brake 19/24
➥ Telltale 21/51 goes out
75
☞ Select driving direction with the tip switches on joystick 64
74
Driving direction Effect
73 64 • Forward ☞ Press the green tip ➥ Green telltale 74 in joystick comes on
switch 75
72
• Reverse ☞ Press the yellow tip ➥ Red telltale 73 in joystick comes on
switch 72
Fig. 46: Tip switch for driving direction on joystick • Neutral ☞ Press both tip ➥ Telltale 73 or 74 in joystick goes out
switches at the same
time
Important!
Applying the parking brake switches to neutral position!
☞ Adjust the desired maximum speed on the low-speed control (option) 23/84
☞ Gradually depress accelerator pedal 19/25
➥ Vehicle moves off
☞ Test the brakes at low speed

Operation
3.4.8 Gear shift

The vehicle has 2 drive ranges. The high speed version (option) has an additional 2 drive
ranges.
Selecting the drive range ☞ Stop the vehicle with the brake/inching pedal 19/27
Select the desired drive range with rocker switch 77. To do this:
☞ Press rocker switch 77B
A
➥ 2nddrive range selected
☞ Press rocker switch 77A
77 ➥ 1st drive range selected
Drive speed without high speed (option)

B
Symbol Meaning Recommended
Fig. 47: Selection of drive range with rocker switch
1st drive range = 0 – 5 kph Specially used for work involving short load-
ing cycles, i.e. a rapid succession of loading
and unloading operations, e.g. onto a lorry,
and for work requiring precise speed adjust-
ment, e.g. rotary broom applications.
2nd drive range = 0 – 20 kph For long-haul travel
Drive speed with high speed (option)

1st drive range = 0 – 10 kph Specially used for work involving short load-
ment, e.g. rotary broom applications, how-
ever allowing for speeds above 5 kph
Drive speed with restricted high speed (option)

1st drive range = 0 – 7,5 kph Specially used for work involving short load-
ment, e.g. rotary broom applications, how-
ever allowing for speeds above 5 kph

Operation
High speed (option) Engaging high speed (option)
Caution!
Shifting to or from high speed during full operation may cause serious damage
to the gearbox!
☞ Switch high speed on and off at vehicle standstill only
Important!
Front axle steering is automatically selected when shifting to high speed.
☞ Stop the vehicle with the brake/inching pedal 19/27

44 ☞ Press lock A of rocker switch 44 in the direction of the arrow and at the same time,
ON press down the right-hand side of rocker switch 44
➥ The integral red telltale comes on
OFF ☞ Select the required drive range with rocker switch 23/77
A
☞ Select the required driving direction with tip switch 22/72 or 22/74 in joystick 22/64
Fig. 48: Rocker switch for high speed ☞ Start the vehicle slowly
☞ Carry out a functional check of the steering system
Shifting from high speed (option)
Important!
Shifting from high speed automatically selects 4 wheel steering.
☞ Stop the vehicle with brake/inching pedal 19/27

☞ Press down the left side of rocker switch 44
➥ The integral red telltale goes out
☞ Select the required drive with rocker switch 23/77
☞ Select the required driving direction with tip switch 22/72 or 22/75 in joystick 22/64
☞ Start the vehicle slowly
☞ Carry out a functional check of the steering system

Operation
3.4.9 Changing direction
Danger!
When changing the driving direction with the vehicle –

Accident hazard!
☞ Make sure that nobody is within the area of danger of the vehicle when
changing the driving direction!
Changing direction at high speed and full throttle causes the vehicle to brake
abruptly.
☞ Switch over driving direction at vehicle standstill only. Depending on the
legal regulations of your country, this may be necessary when driving on
public roads
☞ Stop the vehicle: release accelerator pedal 19/25

☞ Select the new driving direction with tip switch 72 or 75 in joystick 64:
75 Driving direction Effect

• Forward ☞ Press green tip ➥ Green telltale 74 in joystick comes on
74 switch 75
73 • Reverse ☞ Press yellow tip ➥ Red telltale 73 in joystick comes on
64
switch 72
72 • Neutral ☞ Press both tip ➥ Telltale 73 or 74 in joystick goes out
switches at the same
time
Fig. 49: Tip switch for driving direction on joystick
Backup warning system (option)

Danger!
When backing up with the vehicle –

Accident hazard!
☞ Make sure that nobody is within the area of danger of the vehicle when
changing the driving direction!
☞ Do not rely exclusively on the backup warning system (option)!
A Important!
In certain countries, a backup warning system is mandatory.

The backup warning system consists of a signal transmitter A, fitted to the rear top
left of the cab. The signal transmitter generates an acoustic signal when shifting
into reverse. The acoustic level is 103 dB (A) at a distance of 1 m, and at a fre-
quency of 2800 Hz.
Fig. 50: Backup warning system (option)

Operation
3.4.10 Load stabiliser
Danger!
Driving on public roads:

Beware of vehicle instability when the load stabiliser is not switched on –
Accident hazard!
☞ Always switch on the load stabiliser when driving on public roads.This
increases drive safety and comfort
☞ Observe the procedure described in Section 3.4.6 “Before moving off” when
setting the transport position!
Caution!
The load stabiliser may be damaged when it is switched on during heavy-duty

work.
☞ Switch off load stabiliser during heavy-duty work!
It depends on the individual situation whether the load stabiliser must be switched on or
off. We recommend:
Load stabiliser
Switched off Switched on May be switched on
• In general for heavy-duty • For driving on public • For lighter work with the
work, e.g. picking up roads loader unit
excavated material • For light off-road
transport
Switched on
40
☞ Press rocker switch on the left 40A
➥ Telltale in rocker switch comes ON
B Switched off
A
☞ Press rocker switch on the right 40B
Fig. 51: Rocker switch for load stabiliser
➥ Telltale in rocker switch goes OUT

Operation
3.4.11 Differential lock
58 Important!
The differential lock neutralises the compensating effect of the differential, i.e. trac-
69
tion is distributed evenly to the front and rear wheels.
64
Caution!
Fig. 52: Tip switch for differential lock The differential lock may be damaged if it is switched on at the wrong moment,
e.g. when turning corners or if the wheels are already spinning.
☞ Actuate the differential lock only if you expect a wheel to spin, e.g. when
working on slopes or on slippery ground!
Engaging differential lock ☞ Proceed as follows:

• Press and hold tip switch 69
➥Telltale 21/58 comes on
Switching off the differential lock ☞ Proceed as follows:

• Reduce engine revs
• Release tip switch 69
➥Telltale 21/58 goes out

Operation
3.4.12 Steering
Synchronising the steering
Definition
42 Steering synchronisation or wheel synchronisation designates the line-up of the wheels so
that the wheels of both axles run in the same track.
a A
The steering must be synchronised at the latest if the wheels of the vehicle no longer fol-
low the same track when driving straight-ahead on level ground. Synchronisation is only
possible in the slow drive range.
Fig. 53: Tip switch for steering synchronisation
☞ Proceed as follows:
• For vehicles with high speed option:
Check that high speed is disengaged (with the vehicle at standstill!)
• Select low drive range
• Drive at walking pace on level ground and press switch 42A
• Move on while steering to the left and right until telltale 42a goes out
• Carry out a functional check of the steering system
Important!
Although the steering electronics automatically synchronises the front and rear
axles, the synchronisation process is not complete until the steering rams have
passed through the straight-ahead position from both directions. Telltale 42a in the
synchronrisation switch 42 goes out.
The following applies to all vehicle models with automatic steering synchronisation:
Only the first drive range is active during synchronisation – telltale 42a flashes. You can
use rocker switch 23/77 to select the second range, but the shift into the second range is
delayed until the synchronisation process has been completed.

Operation
Changing steering mode in vehicles

without high speed option
☞ Switch on front axle steering as follows:
42 • Stop the vehicle
a • Push lock 44c to the right and depress right-hand side d of rocker switch 44
(telltale 43b for front axle steering)
43 • However, front-axle steering is not switched until the rear axle has been set to
straight-ahead. Telltale 43a flashes until the shift is completed
a b ☞ Switch on 4 wheel steering as follows:
44
• Stop the vehicle
e d • Push lock c to the right and depress left-hand side e of rocker switch 44 (telltale 43a
for 4 wheel steering)
c • However, 4 wheel steering is not switched until the front axle has been set to straight-
ahead. Telltale 43b flashes until the shift is completed
Fig. 54: Controls for steering mode selection
Changing steering mode in vehicles Front wheel steering

with high speed option ... is automatically selected when shifting to high speed. Change-over is carried out only
after the rear axle has been set to straight-ahead. Telltale 43b flashes until the shift is
completed.
Four wheel steering

... is automatically selected when shifting from high speed. In this case the shift is not car-
ried out until the front axle has been set to straight ahead. Telltale 43a flashes until the
shift is completed.

Operation
3.4.13 Stop the vehicle

• Reduce engine revs: Take your foot off the accelerator pedal 19/25
• Stop the vehicle with service brake 19/27
• Set driving direction to neutral position
• Apply the parking brake to ensure permanent braking action. To do this:
Pull up lever 19/24 to the last notch
➥Telltale 22/51 comes on
3.4.14 Parking the vehicle
Danger!
Vehicles parked on slopes may roll away

Accident hazard!
☞ Use the parking brake to park the vehicle safely and to prevent it rolling
away! See Section 3.4.13 “Stop the vehicle”
☞ Additionally secure the vehicle by placing chocks under the downhill sides
of the wheels!
☞ Stop the vehicle

☞ Apply the parking brake permanently – see Section 3.4.13 “Stop the vehicle”
➥ Telltale 22/51 comes on
☞ Lower the loader unit. To do this:
Push control lever 22/64 forward, out of neutral
☞ Align the bucket with the ground so that the blade rests on the ground. To do this: Move
control lever 22/64 to the left or right
After operation at full power:
☞ Allow the engine to run idle and without load for a while so that the temperature can sta-
bilise
☞ Switch off the engine by turning the ignition key to pos. “0”
☞ Remove the ignition key!
☞ Lock the doors of the operator’s compartment after leaving the cab
On uphill and downhill gradients:
☞ Additionally secure the vehicle by placing chocks under the downhill sides of the
wheels!

Operation
3.4.15 Light system
Parking lights
41
ON ☞ Press rocker switch 41A down ➥ Telltale in rocker switch 41 comes on
1 step
OFF ☞ Press rocker switch 41B down ➥ Telltale in rocker switch 41 goes out
A B Low beam
ON ☞ Press rocker switch 41A down ➥ Telltale in rocker switch 41 comes on
2 steps ➥ Telltale 21/55 comes on with high beam
switched on
Fig. 55: Light switches OFF ☞ Press rocker switch 41B down ➥ Telltale in rocker switch 41 goes out
Important!
Only the parking light stays lit if the ignition is switched off (with low beam switched
on) – key in preheating start switch 23/76 in pos. 0!
High beam
III
ON ☞ With low beam switched on, ➥ Telltale 21/55 comes on
II move lever 31 downward until
it locks in pos. I
I OFF ☞ Move lever 31 upward until it ➥ Telltale 21/55 goes out
31 locks in pos. II
30300b0312.eps
Fig. 56: Actuating high beam, low beam and headlight
flasher Headlight flasher
ON ☞ Pull lever 31 upward to pos. III ➥ Telltale 21/55 comes on
and hold in this position
OFF ☞ Release lever 31 ➥ Telltale 21/55 goes out

Operation
Danger!
The working light may dazzle motorists on public roads –

Accident hazard!
☞ Do not switch on the working light when driving on public roads. When
operating the vehicle, only switch the working light on when no-one can be
dazzled by it!
37 Front working light (option)

ON ☞ Press rocker switch 37B ➥ Telltale in rocker switch 37 comes on
OFF ☞ Press rocker switch 37A ➥ Telltale in rocker switch 37 goes out
B A
Fig. 57: Switch for front working light
46 Rear working light (option)

A B
Fig. 58: Switch for rear working light
2 Interior light
A B
ON ☞ Press switch 2A at front
OFF ☞ Press switch 2B at rear
Fig. 59: Interior light

Operation
3.4.16 Signalling system
Hazard warning system

47 ☞ Press rocker switch 47B ➥ Telltale in rocker switch flashes
ON
OFF ☞ Press rocker switch 47A ➥ Telltale in rocker switch goes out
A B
HAZARD
Fig. 60: Signalling system switch
31 Turn indicators
L LEFT ☞ Push lever 31 forward ➥ Telltale 20/56 flashes
RIGHT ☞ Pull lever 31 to the rear ➥ Telltale 20/56 flashes
R OFF ☞ Lever 31 in centre position ➥ Telltale 20/56 goes out
30300b0313.eps
Fig. 61: Turn indicators
Caution!
The turn indicator system is not in order if telltale 22/56 flashes about twice as
fast as normally!
☞ Check the front and rear indicators immediately
Important!
Lever 31 has an automatic reset; this means the lever is automatically set to centre
position after turning the steering lock after a large steering angle.
Rotating beacon (option)

45
ON ☞ Rocker switch 45B ➥ Telltale in rocker switch flashes
OFF ☞ Rocker switch 45A ➥ Telltale in rocker switch goes out
A B
Important!
Fig. 62: Switch for rotating beacon
Legal regulations of your country may require you not to switch on the rotating
beacon on public roads unless the road is within the vehicle’s working range and
the vehicle is an obstruction to the normal flow of traffic when the vehicle is in
working operation. Get informed on and follow the legal regulations of
your country.

Operation
3.4.17 Cabheating and ventilation
Important!
The heater of the vehicle can be set to 4 operating modes:

• Ventilation, fresh air
• Heating, fresh air
• Heating, mixed mode
• Heating, recirculated air.
The flow of air is directed to the windscreen via a defroster nozzle and to the oper-
ator compartment via a footwell nozzle.
The footwell nozzles can be closed and directed separately.
Fresh air is directed into the cabin via a fine dust filter (option).
Ventilation, fresh air

79 0 ☞ Rotary switch 79 in pos. 1 (ventilation)
1
2 ☞ Lever 81 in pos. B (fresh air)
3
Fig. 63: Fan switch
Heating, fresh air

80 ☞ Rotary switch 79 in pos. 2 or 3 (fan level 1 or 2)
☞ Set the required temperature with rotary switch 80
☞ Lever 81 in pos. B (fresh air)
cold warm
Fig. 64: Heating adjustment
Heating, mixed mode

B
☞ Rotary switch 79 in pos. 2 or 3 (fan level 1 or 2)
81 ☞ Set the required temperature with rotary switch 80
☞ Lever 81 between pos. A and B (mixed mode)
A Heating, recirculated air
Fig. 65: Change-over lever recirculated air – fresh air ☞ Rotary switch 79 in pos. 2 or 3 (fan level 1 or 2)
☞ Set the required temperature with rotary switch 80
☞ Lever 81 in pos. A (recirculated air)

Operation
Front window heater (option) To avoid misting on the front window in winter service, the window can be heated by an
optional electric front window heater.
The switch for the optional front window heater is located on the left side of the instrument
panel
35 Front window heater (option)

B A
Fig. 66: Switch for front window heater (option)
Air conditioning (option)
78 B Air conditioning (option)

A
Fig. 67: Fan switch
Important!
See the separate operator manual on using the air conditioning.

Operation
3.4.18 Auxiliary heating (Not available)

Operation
3.4.19 Washer system
32 Front wiper
Position Function
I Intermittent wipe
30300b0313.eps 0 OFF
Fig. 69: Front wiper rotary switch 1 Slow wipe
2 Fast wipe
33 Front window washer pump

ON ☞ Press tip switch 33
OFF ☞ Release tip switch 33
30300b0313.eps
Fig. 70: Washer pump tip switch
39 Rear wiper
ON ☞ Press rocker switch 39A
OFF ☞ Press rocker switch 39B
A B Rear window wash pump
ON ☞ Press actuated rocker switch 39A further down (touch function)
Fig. 71: Rear wiper rocker switch
Tank
Important!
8
Fill with clean tap water only! Add a suitable cleaning agent if required. In winter:
Add antifreeze for washer systems to the water. Refer to the instructions for using
the antifreeze, which give information on concentrations.
312b0220.eps
Fig. 72: Tank for washer system

Operation
3.4.20 Seat adjustment
Danger!
Never change the seat position when driving or working –

d
Accident hazard!
☞ Adjust the seat before moving the vehicle
The seat can be set to the following positions:

• Weight setting a with weight indicator b
c
• Height setting c
• Armrest inclination d
e • Backrest setting (depending on version) e
• Longitudinal setting f
f a b
Fig. 73: Seat adjustment
Weight setting
Important!
Adjust the seat suspension correctly to ensure a high level of driving comfort. Use
lever a to set the seat suspension to the operator's weight. The weight indicator b
shows the set operator weight [kg].
a ☞ Sit down on the operator’s seat

b To set to a higher operator weight:
☞ Turn lever a clockwise
Fig. 74: Weight setting
To set to a lower operator weight:
☞ Turn lever a counterclockwise
Height setting
Upwards:
☞ Raise seat as required until it engages with an audible click
c Downwards:
☞ Raise seat as far as possible and
☞ Lower seat to bottom position
Fig. 75: Height setting

Operation
Armrest setting
The armrest can be folded back as required. Set the armrest as follows:
Upwards:
d ☞ Turn handwheel d clockwise as required
Downwards:
☞ Turn handwheel d counterclockwise as required
Fig. 76: Armrest setting
Backrest setting
☞ Sit down on the operator’s seat
☞ Pull lever e upwards and at the same time
☞ Lean back to push the backrest into the required position
☞ Let lever e lock into place
Fig. 77: Backrest setting
Longitudinal setting
☞ Sit down on the operator’s seat
☞ Pull lever f upwards and at the same time
☞ Move the operator’s seat forward or backward
Fig. 78: Longitudinal setting

Operation
3.4.21 Seat belt
Danger!
Do not drive or work with the seat belt unbuckled –

Danger of personal injury!
☞ Buckle up before moving or working with the vehicle!
• Seat belt must not be twisted!
• Seat belt must run over the hips – not over stomach – and must always
be applied tightly!
• Do not place seat belt over hard, edged or fragile items (tools, meter-
rule, glasses, pen) carried inside your clothes!
• Never buckle up 2 persons (children!) with a single seat belt!
• Check seat belts regularly. Have damaged parts immediately replaced
in an authorised workshop!
• Always keep seat belt clean, as coarse dirt may impair proper function-
ing!
• Seat belt buckle must not be obstructed by foreign bodies (paper or sim-
ilar); otherwise the buckle latch cannot lock into place!
After an accident the belt strap is stretched, and no longer serviceable. In an
accident, the seat belt
Will not provide adequate protection!
☞ Replace the seat belt after an accident
☞ Have fastening points and seat fixture checked for loading capacity!
The seat belt 19 is designed for the driver's safety during work on construction sites and
during road travel.
A To fasten seat belt 19:

19 ☞ Before starting, fasten seat belt 19 as follows:
• Hold belt on buckle latch A and run it slowly and steadily over the hips to buckle B
• Insert buckle latch A into buckle B until it engages audibly (pull test)
B
• Tighten seat belt by pulling at its end
➥The seat belt must always be tightly in place over the hips!
30763b0007.eps
Fig. 79: To fasten seat belt

Operation
To unfasten seat belt 19:

☞ Unfasten seat belt 19 as follows:
• Hold the seat belt
19 • Press red button C on buckle B
A ➥Latch A is released from buckle B by spring pressure
• Slowly return the belt to the seat belt retractor (option)
C
B
30763b0006.eps
Fig. 80: Unfastening the seat belt
To extend/shorten the seat belt 19 (lap belt only):

A ☞ Lengthen the lap belt as follows:
• Hold the buckle latch at a right angle to the seat belt and pull the seat belt to the
required length – see Fig. 81
☞ To shorten the lap belt, just pull on the free end D of the belt – see Fig. 81.
Important!
When pulled slowly, the automatic seat belt (option) offers full freedom of move-
ment. It locks however during abrupt braking.
The automatic seat belt (option) may also lock when passing through potholes or
D uneven terrain.
30763b0005.eps
Fig. 81: Longer/shorter seat belt setting

Operation
3.4.22 Vehicle doors

Opening from outside:
☞ Press door button a
a
Lock door:
☞ Turn ignition key in door lock to the right
Unlock door:
☞ Turn ignition key in door lock to the left
Fig. 82: Outside door lock
Opening from inside:

☞ Pull lever 7 up
7
Fig. 83: Inside door lock
Securing open driver's door

15 ☞ Press the operator's door against the door arrester 15 until it engages
Important!
Lubricate the door arrester at regular intervals, at least every 600 service hours.
Fig. 84: Securing open doors
Unlocking the door arrester

15
☞ In the cab, pull lever a forward or
a ☞ From the outside, pull lever b downward
Fig. 85: Unlocking the door arrester

Operation
3.4.23 Other controls

Tank lock
Unlocking:
a ☞ Turn the filler cap key in lock a to the left
☞ Turn filler cap counterclockwise
Closing:
☞ Turn the filler cap key in lock a to the right
☞ Turn filler cap clockwise
Fig. 86: Filler cap
Engine cover
Unlocking:
b
☞ Pull handle c to the front
☞ Pull the engine cover upwards
Closing:
c
☞ Press the engine cover firmly down
Locking:
☞ Turn key in lock b to the left
Fig. 87: Engine cover lock Unlocking:
☞ Turn key in lock b to the right
Battery master switch (option)
Important!
D
The vehicle can be equipped with a battery master switch (option, Fig. 88). This
allows interruption of the electrical supply
0
• Before working on the electrical system and
1 • As an antitheft precaution
Key D can be removed in OFF position (crosswise direction)!
38b03600.ai
Fig. 88: Battery master switch (option)

Operation
3.4.24 Towing the vehicle

Safety instructions • The vehicle may only be towed using suitable towing equipment (towing bar or cable) in
connection with suitable towing facilities, such as a towing coupling, hooks and eyes!
• Move off slowly! Make sure no-one is dangerously close to the towing bar
• The vehicle may only be towed with a cable if the service brakes and steering are fully
operational!
Towing
Danger!
Turning the steering wheel requires greater effort if the diesel engine breaks
down. Take this into account, especially when towing the vehicle!
☞ Use a towing bar!
Caution!
The hydrostatic drive can be damaged when towing the vehicle!

☞ Set driving direction to neutral position
☞ Short-circuit the hydraulic circuit before towing (see below)
☞ Do not tow the vehicle for more than 100 metres and do not tow it faster
than 3 – 4 kph!
☞ Tow away the vehicle as follows:

• Switch driving direction to neutral position (➠ page 3-10)
• Apply the parking brake (➠ page 3-12)
• Fit an adequately sized towing bar to the towing facilities
• Switch over the HP pressure relief valves A on the hydraulic pump. To do this:
C B
• Release hexagon lock nuts B on both HP valves A
A • Screw in hexagon socket head screws C on both HP valves A until they are flush
with lock nuts B
• Secure hexagon socket head screws C on both HP valves A with lock nuts B
• If possible, run the engine at idling speed when towing the vehicle
• The HP valves must be changed over before the vehicle is taken back into service!
A Do this by unscrewing hexagon socket head screws C up to the stop and secure
B
them with lock nuts B
Fig. 89: Hydraulic pump when towing the vehicle

Operation
3.4.25 Handling the vehicle with a crane

Safety instructions • The crane and the lifting gear must be sufficiently dimensioned – see section Specifica-
tions for the vehicle's dimensions and weights!
• Crane handling requires lifting gear with 4 cables or chains of equal length
• Secure the vehicle against accidental movement!
Crane handling
Danger!
Handle the vehicle with a crane with due care –

Accident hazard!
☞ Make sure no-one is in the vehicle!
☞ Loads must be fastened, and crane operators instructed by experienced
persons only! The person giving the instructions to the crane operator must
be within sight or sound of him.
☞ Make sure the crane and the lifting gear (cables, chains) have sufficient lift-
ing capacity!
☞ Vehicle must be fitted with an empty standard bucket in transport position
during crane handling. (See Fields of application on page 1-4)!
☞ Stay clear of the suspended load!
☞ Under all circumstances, read the safety instructions at the beginning of
this chapter and follow any other safety instructions relevant in
your country!
☞ Handle the vehicle with a crane as follows:

• Fit the standard bucket and lock it safely –
See Re-equipping the loader unit on page 3-60
• Empty the standard bucket
• Set the drive to neutral position – see Driving direction tip switch [72/75] on page 3-10
• Tilt in the standard bucket and lower it to transport position – see section 3.5.7 Re-
equipping the loader unit on page 3-60
• Apply the parking brake – See Parking the vehicle on page 3-34
30101b3002.iso
• Remove the ignition key!
• Get out of the cab, close the vehicle doors and the engine cover
• Fasten the loader to the 4 lashing points – see section 1.2 Vehicle overview on
page 1-2 – with sufficiently dimensioned lifting gear
Danger!
Stay clear of suspended loads!
• Carefully raise the vehicle

30101b3001.iso
Fig. 90: Crane handling

Operation
3.4.26 Loading and transporting the vehicle

Safety instructions • The transport vehicle must be of adequate size – refer to section Specifications for the
vehicle's dimensions and weights!
• Remove any mud, snow or ice from the tyres so that the vehicle can be safely driven
onto the ramps
• Secure the vehicle against accidental movement!
Loading the vehicle
Danger!
Load and transport the vehicle properly, otherwise

Accident hazard!
this chapter and follow all other safety instructions relevant in your country!
☞ Load as follows:
• Secure the transport vehicle with chocks to prevent it rolling
• Position the ramps so that the angle is as small as possible. Do not exceed an angle
of 30 °. Only use ramps with an anti-skid surface.
• Make sure the loading area is clear and access to it is not obstructed – e.g. by super-
structures
30864brampe.eps • Make sure the ramps and the wheels of the vehicle are free of oil, grease and ice
Fig. 91: Ramps • Start the engine of the vehicle
• Raise the bucket sufficiently so that it will not touch the ramps
• Carefully drive the wheel loader onto the middle of the transport vehicle
• Set the drive to neutral position – see Driving direction tip switch [72/75] on page 3-10
• Lower the bucket to the loading area
• Apply the parking brake – See Parking the vehicle on page 3-34
• Remove the ignition key!
• Get out of the cab, close the vehicle doors and the engine cover

Operation
Lashing down the vehicle
Danger!
Load and transport the vehicle properly, otherwise

Accident hazard!
30101b3003.iso this chapter and follow all other safety instructions relevant in your country!
• Make sure the authorised maximum height is not exceeded

• Secure all tyres of the wheel loader with chocks in front of, behind and at the sides of
each wheel
• Securely lash the wheel loader onto the loading area using straps and chains of
adequate size at the lashing points provided – see section 1.2 Vehicle overview on
page 1-2
30101b3004.iso
Fig. 92: Lashing down the vehicle
• Before transporting the vehicle for a longer period through heavy rain: Close the
outlet of the exhaust silencer with a simple cap or suitable adhesive tape
• Make sure the driver of the transport vehicle knows the overall height, width and
weight of his vehicle (incl. loader) before departure, as well as the legal transport
regulations of the country or countries where transport is to take place!

Operation
Operation
3.5 Working with the vehicle

3.5.1 General safety instructions
•
3 Increased caution when working off-road:
Work only on firm ground, as far as possible!
• Never drive up to the edge of a pit from outside – danger of cave-in!
• Never undermine the foundations of walls – danger of collapse!
• Operation of the vehicle by unauthorised personnel is prohibited!
• When excavating, look out for high-voltage cables, underground cables, gas and water
pipes!
• When using lifting accessories such as pallet forks, comply with the load diagrams valid
for this vehicle
• The hydraulic system of the vehicle is still pressurised even when the engine is not
running! Depressurise the sections of the system and hydraulic lines which are to be
opened before starting setup or repair work, e.g. fitting/removing an implement with
hydraulic functions – see Section 3.5.5 “Depressurising the quick couplers on the
loader unit”
• Also pay attention to the operation manuals of the implements used!
3.5.2 Load diagram

Compliance with the load diagram is mandatory when using pallet forks with fork arms on
the loader unit. This diagram specifies maximum load on the fork arms for industry and off-
road applications – see section 1.9 Other Signs and symbols on page 1-10. The maximum
load varies according to the distance from the load centre.
Important!
The load diagrams shown on the front window are valid only for applications with
pallet forks. Observe the specific load diagrams of other implements used,
e.g. rotary crane jib!

Operation
3.5.3 Control valve of the loader unit: overview

Control lever for hydraulics of lift and
tilt ram of loader unit
Danger!
Accidental operation of control lever 64 when driving on public roads –

Accident hazard!
☞ Lock the control lever – see Before moving off on page 3-22
D
Position Symbol Lever 64 Function
64 C A ☞ To the left ➥ Tilts in implement
B ☞ To the right ➥ Dumps out implement

A B
C ☞ Forward ➥ Lowers lift frame
E D ☞ Fully forward ➥ Lift frame remains lowered in float

position (option)
E ☞ Backward ➥ Raises the lift frame
Fig. 93: Loader unit: control lever
Tip switch on control lever
70 58 Tip switch no. Function with tip switch pressed

75
68 ➥ Electric front socket (option) ON
69 69 ➥ Differential lock ON
70 ➥ Tip switch not assigned
72 ➥ Forward driving direction
72 75 ➥ Reverse driving direction
68
64 Selection of driving direction – see Driving direction tip switch [72/75] on page 3-10
Fig. 94: Tip switch on joystick

Operation
Control lever for implements and 3rd

control circuit
Important!
Control lever 65 can be locked separately in neutral position by pressing lock

lever 66C down. This is a safeguard against accidental unlocking of the quickhitch
facility.
64 65 Position Lever 65 Function

A ☞ Forward ➥ Unlocks the quickhitch facility
A
Implement with hydraulic function:
C ➥ E.g. opens the multipurpose bucket
B ☞ Backward ➥ Locks the quickhitch facility
Implement with hydraulic function:
B ➥ E.g. closes multipurpose bucket
Lock control lever 65 in neutral position (centre position)
66 ☞ Lock in neutral position as follows:
Fig. 95: Control lever for implements • Press lock lever 66 down (C)
➥Control lever remains in neutral position
☞ To unlock
• Pull lock lever 66 up
➥Control lever can be moved forward and backward
Locking control lever 65 for continuous operation in final position
Important!
The control lever can be locked in final pos. B. This enables the following func-
tions:
• Hydraulic movements/procedures over a longer period of time or operation of
hydraulic motors
• Operation of hydraulic equipment with a control valve adjusted to maximum oil
flow, with a bypass
☞ For continuous operation, proceed as follows:

• Pull control lever 65 fully back to final position B until it locks
➥Control lever stays in rear pos. B
☞ To stop continuous operation
• Push control lever 65 forward and release it
➥Control lever returns automatically to neutral

Operation
Securing control levers for driving on

public roads
Danger!
When driving on public roads, accidental operation of the control lever of the
loader unit may result in
Accident hazard!
☞ Before moving off, engage transport locks 67 and 22/66!
☞ If the 3rd control circuit is electrically operated (option) also switch off
rocker switch 36 !
To lock the control lever:

☞ Follow the instructions given in Section 3.4.6 “Before moving off”
☞ Turn lever 67 counterclockwise, across the driving direction
To unlock the control lever:
67
☞ Turn lever 67 upward
30300b03015.eps
☞ If the 3rd control circuit is electrically operated (option) also switch off rocker switch 36 !
36
OFF
Fig. 97: Rocker switch – 3rd electrically operated control

circuit ON/OFF (option)

Operation
3rd electrically operated control

circuit (option)
Danger!
When working with implements without hydraulic function:

Operating control lever 65 or tip switch 70 unlocks the quickhitch facility
☞ Lock control lever 65 with transport lock 67 and switch off rocker switch 36 !
Important!
The vehicle can be equipped with an extra electrically operated 3rd control circuit
(option).
The electrically operated 3rd control circuit (option) is beneficial for working with
implements with extra hydraulic functions used for short intervals only (e.g. multi-
purpose bucket, heavy duty bucket etc.). Continuous operation of the 3rd control
circuit is carried out with control lever 65.
36 3rd electrically operated control circuit (option)

ON ON ☞ Slide lock A to the left and press ➥ Telltale in rocker switch 36 comes on
rocker switch 36 on the symbol ➥ Tip switches 68 and 70 are functional
OFF (left)
A OFF ☞ Press rocker switch 36 in position ➥ Telltale in rocker switch 36 goes out
B (top)
Important!
The vehicle is equipped with a safety circuit.

The rocker switch has no function if the vehicle is started even though rocker
switch 36 was switched on. To switch on the function of the 3rd control circuit, first
switch off rocker switch 36 and then switch it on again.
With rocker switch 36 switched on, the 3rd control circuit can be operated as follows:
70 Press tip switch ... Function

☞ Press tip switch 70 With the quickhitch facility fitted:
➥ Unlocks the quickhitch facility
With an implement fitted:
➥ Pressurises the right-hand blue hydraulic line (e.g. close
multipurpose bucket)
68
64
☞ Press tip switch 68 With the quickhitch facility fitted:
➥ Locks the quickhitch facility
With an implement fitted:
Fig. 99: Tip switch for 3rd electrically operated control cir-
cuit (option) ➥ Pressurises the left-hand red hydraulic line (e.g. open
multipurpose bucket)

Operation
3.5.4 Lowering the loader unit with the engine switched off
Important!
A pressure accumulator in the pressure line of the hydraulic pilot control system
maintains the control pressure so the loader unit can be lowered when the engine
is switched off!
64 C • Make sure no-one is dangerously close to the vehicle
• Push and hold control lever 64C to the front until the loader unit is fully lowered
• Return control lever 64 to neutral
Fig. 100: Lowering the loader unit with the engine switched
off
3.5.5 Depressurising the quick couplers on the loader unit
Important!
The hydraulic system of the 3rd control circuit/implement is still pressurised even
when the ingine is not running! The hydraulic quick couplers can be released, how-
ever they cannot be fitted back on since the pressure in the hydraulic lines is too
high. Therefore:
☞ Depressurise sections of the system and hydraulic lines which are to be
opened before starting setup or repair work, e.g. fitting/removing an imple-
ment!
Depressurise as follows:
☞ Apply parking brake 19/24 – see Parking brake [24] on page 3-12
65 ☞ Switch off the engine
A ☞ Push lever 65 forward A and backward B once
➥ Hydraulic pressure is released
Fig. 101: Depressurising hydraulic lines

Operation
3.5.6 Connecting pressurised quick couplers
Danger!
Careful when connecting pressurised quick couplers –

Accident hazard!
☞ Depressurise sections of the system and hydraulic lines which are to be
opened before starting setup or repair work, e.g. fitting/removing an imple-
ment!
See Depressurising the quick couplers on the loader unit on page 3-57
☞ Never connect pressurised quick couplers by force
Important!
Oil temperature, and hence the pressure in the ram can rise if an implement (e.g.
side swing bucket or multipurpose bucket) or the quickhitch facility (lock ram) is
exposed to the sun for a longer period of time, without being connected to the vehi-
cle via the flexible lines. This pressure cannot be lowered by means of depressuri-
sation as described in section 3 "Depressurising the quick couplers on the loader
unit" on page 3-57 .
Connection of pressurised quick couplers of the lock ram of the quickhitch facility to the
65 hydraulic system of the vehicle is described below. Proceed accordingly when fitting imple-
ments with pressurised quick couplers.
Connect pressurised quick couplers as follows:
☞ Apply parking brake 19/24 – see Parking brake [24] on page 3-12
☞ Start the engine and run it at idling speed for about 30 seconds
➥ The pressure accumulator of the pilot control is filled!
☞ Lower the loader unit to the ground
☞ Switch off the engine
66 ☞ Depressurise – see section 3.5.5 Depressurising the quick couplers on the loader unit
Fig. 102: Locking the lever on page 3-57
☞ Pull lever 65 fully backward until it locks into place

Operation
☞ Disconnect flexible line A from the implement

☞ Connect flexible line A (in driving direction on the right) on the vehicle, to blue plug C of
A the quickhitch facility (in driving direction on the left, crosswise!)
☞ Disconnect flexible line A again
Fig. 103: Depressurisation
☞ Connect flexible line A to blue plug D of the quickhitch facility (in driving direction on
A
the right)
☞ Connect flexible line B to red plug C of the quickhitch facility (in driving direction on the
left)
D
B
Fig. 104: Connecting hydraulic lines
☞ Return lever 65 back to neutral position

65 ☞ Unlock/lock the implement – see section 3.5.7 Re-equipping the loader unit on page 3-60
66
Fig. 105: Releasing the lock

Operation
3.5.7 Re-equipping the loader unit

Re-equipping the loader unit is described below for the standard bucket! If you are fitting or
removing implements with their own hydraulic functions – e.g. multipurpose or side swing
bucket – you must follow the special information given in the operation manual of the
implement.
Fitting implements onto the quick-

hitch facility Danger!
The implement must always be safely locked onto the quickhitch facility;
otherwise –
Accident hazard!
☞ Before starting work, make sure the implement is securely locked onto the
quickhitch facility by means of the lock ram. You must be able to see the
lock pins on both sides of the mounting holes on the implement
☞ When working with implements without additional hydraulic function:
Switch off lock control lever 65 and rocker switch 36 for 3rd electrically
operated control circuit (option)!
• Release the transport lock. To do this:
☞ Turn lever 67 upward in driving direction
67
30300b03015.eps
• Approach the vehicle to the implement

64 • Tilt the quickhitch facility all the way forward. To do this:
C
B ☞ Move lever 64B to the right
D • Adjust the height of the pin shanks L of the quickhitch facility so that they are under
the catch hooks of implement K. To do this:
30300b03060.eps
Loader unit Lever 64

K • Lower ☞ Push forward C
L or
Fig. 107: Driving up to the implement
• Raise ☞ Pull backward D
• Drive forward until the pin shanks L of the quickhitch facility are directly beneath the
catch hooks of implement K
Fig. 108: Picking up the implement

Operation
• Raise the loader unit. To do this:

☞ Pull lever 64D ( ) backward and
• Tilt in the quickhitch facility. To do this:
☞ Push lever 64A ( ) to the left
64
A
D
30300b03060.eps
Fig. 109: Raising the implement
• Secure the implement with the lock pins of the quickhitch facility. To do this:
65
☞ Pull lever 65F backward
F
➥ Lock pin G engages in the mounting bores of the implement
30300b03060.eps
G
Fig. 110: Locking the implement
• Make sure the implement is securely locked onto the quickhitch facility by means of
G the lock ram.
☞ Carry out a visual check!
Important!
Lock pin G must be visible on both sides of the mounting bores on the implement,
Fig. 111: Checking the lock pins as in Fig. 111.

Operation
Vehicle with implements without extra hydraulic functions:

• Lock control lever 65 in neutral position with lock lever 66
66
Fig. 112: Locking the control lever
Additionally on vehicles with a 3rd electrically operated control circuit (option):

36
• Switch off rocker switch 36!
OFF

Implements with hydraulic function:

• Apply the parking brake
• Depressurise the quick couplers
– see section 3.5.5 Depressurising the quick couplers on the loader unit on page 3-57
• Fit the hydraulic and, if used, electrical connections for the implement in accordance
with its operation manual
• Follow the instructions given in
Section 3.5.6 “Connecting pressurised quick couplers” on page 3-58
• Section 3.5.8 “Connection of electrically operated implements (option)” on page 3-64

Operation
Taking an implement off the quick-

hitch facility
Danger!
The implement must be placed on the ground so that it will not fall over;
otherwise
☞ Position the implement so that after unlocking it will stand safely and not tip
over
☞ Take the implement off the quickhitch facility as follows:

C 64
A • Drive the vehicle with the empty implement up to the drop-off position
• Tilt in the quickhitch facility. To do this:
30300b03060.eps
• Lower the loader unit until the implement is about 5 – 10 cm above the ground. To do
this
☞ Push lever 64C ( ) forward
Fig. 114: Lowering and tilting in the implement
• In addition, in the case of implements with hydraulic and/or electrical connec-

tions:
A • Switch off the engine
D • Depressurise the quick couplers
C – see section 3.5.5 Depressurising the quick couplers on the loader unit on page 3-57
B
• Connect flexible line A to blue plug D of the quickhitch facility (in driving direction on
the right)
Fig. 115: Changing round the hydraulic connections
• Connect flexible line B to red plug C of the quickhitch facility (in driving direction on
the left)
• Remove the electric connections
• Start the engine again
• Retract the catch bolt of the quickhitch facility. To do this:
Push lever 65E forward
• Tilt the quickhitch facility slightly forward. To do this:
☞ Push lever 64B ( ) to the right
• Lower the loader unit. To do this:
C
B ☞ Push lever 64C ( ) forward
E
64 65
Fig. 116: Setting down the implement 30300b03060.eps

Operation
As soon as the pin shanks of quickhitch facility L are below catch hooks K of the imple-
ment:
• Reverse away from the implement
K
Fig. 117: Reversing from the implement
3.5.8 Connection of electrically operated implements (option)

Operation with rocker switch on instrument panel
As an option, a 4 pole socket can be fitted at the front of the vehicle. Rocker switch 38 is
used to permanently switch the power supply for electrically operated implements ON and
OFF, e.g. a spray water pump for the rotary broom. Tip switch 70 in joystick 64 is used to
switch the power supply ON for a short time for electrically operated implements.
Electrical connection of an implement

☞ Connect the electric consumers of the implement as follows:
• Open the protective cap on the socket
• Fully insert the 4 pole plug (cable connection to implement) into the socket
Fig. 118: 4 pole socket on front side of vehicle
Permanently switching on and off the electric function of the implement

☞ Permanently switch on or off the electric function of the implement
(e.g. water pump ON or OFF) as follows:
A B To permanently switch the power supply for implements (option)
ON ☞ Press rocker switch 38A ➥ Power supply at front socket is switched
38 on
➥ Telltale in switch comes on
OFF ☞ Press rocker switch 38B ➥ Power supply is interrupted
➥ Telltale goes out
Fig. 119: Switch for electrically operated implements (option)
Briefly switching on the electric function of the implement on joystick 64

☞ Briefly switch on the electric function of the implement
70 (e.g. water pump briefly ON) as follows:
Briefly switching the power supply for implements (option)
ON ☞ Push tip switch 70 and ➥ Power supply at front socket is switched
hold down on
OFF ☞ Release tip switch 70 ➥ Power supply is interrupted
64
Fig. 120: Tip switch on joystick

Operation
Briefly switching on the electric function of the implement with the tip
switch (option) on control lever 65 of the 3rd control circuit
65
E ☞ Briefly switch the electric function of the implement on and off
(e.g. solenoid valve for verge grading bucket) as follows:
Briefly switching the power supply for implements (option)
ON ☞ Press tip switch S on ➥ Power supply at front socket is switched
lever 65 on
S OFF ☞ Release tip switch S on ➥ Power supply is interrupted
lever 65 ➥ Telltale goes out
Fig. 121: Tip switch for electrically operated implements

(option)
To switch the lights on the implement on and off

☞ Switch the additional lights on the implement on and off as follows:
Lights for implements (option)
ON ☞ Press rocker switch 41A ➥ Lights are switched on
41 ➥ Telltale in switch comes on
OFF ☞ Press rocker switch 41B ➥ Lights are switched off
A B ➥ Telltale goes out
Fig. 122: Light switch of vehicle

Operation
3.5.9 Operation of the restrictor unit on the tilt ram (option)
Important!
Fit the tilt ram of the loader unit with a restrictor unit for operation of heavy imple-
ments – see table “Fields of application” on page 1-4 marked with footnote 3. The
restrictor unit avoids damage to the tilt ram and other vehicle parts by reducing
dump-in and dump-out speed.
A
Stop cock A is .... Description of implement
Closed (Fig. 123, across driving Heavy implements are marked in table
direction) “Fields of application” on page 1-4 with
footnote 3
Fig. 123: Stop cock closed
A
Stop cock A is .... Description of implement
Open (Fig. 124, in driving direction) For use of all other implements released for
vehicles model 521
Fig. 124: Stop cock open

Operation
3.5.10 Safety equipment "Hose burst valve" (option)
Important!
When working with lifting gear and specific implements, the hydraulic rams of the
loader unit must be equipped with “hose burst valves” – see Applications with lift-
ing accessories on page 2-8.
Hose burst valves avoid the loader unit from being lowered or dumped without
being braked, in the event of a bursting hose or pipe.
Danger!
Damage to the hydraulic system leads to activation of the “hose burst valve” –
Accident hazard!
☞ Unlock the emergency lowering of the hose burst valve in an emergency
only
☞ Have damage to the hydraulic system and to the hose burst valve immedi-
ately repaired and checked by trained and skilled personnel
In case of damage to the hydraulic system:

☞ Apply the parking brake
☞ Switch off the engine
☞ Remove the ignition key!
☞ Secure the vehicle
Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container. Dispose of
drained hydraulic oil by an ecologically safe method!
Always contact the relevant authorities or commercial establishments in charge of oil dis-
posal before disposing of biodegradable oil.
☞ Collect the drained oil and dispose of it by an ecologically safe method!

Operation
☞ Actuate emergency lowering as follows:
Danger!
Emergency lowering of loader unit –

Accident hazard!
☞ Keep clear of area of danger under loader unit, always approach from the
sides!
☞ Always actuate emergency lowering with extreme care
• Unscrew locknut B
B A • Carefully turn in screw A by 1 to 2 turns until the loader unit starts lowering
Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container. Dispose of
Fig. 125: Hose burst valve (option)
• Collect the drained oil and dispose of it by an ecologically safe method!

• Carefully lower the loader unit to transport position
• Turn out screw A again by the equal number of turns and secure it with locknut B
• Drive the vehicle out of the area of danger with the loader unit lowered
☞ If necessary, have the setting of the hose burst valve and damage to the hydraulic sys-
tem immediately checked and replaced by a specialist workshop

Operation
3.5.11 Working with standard bucket and pallet forks

Implements Read and follow the operation manuals of the implements before and when using them
(special buckets, pallet forks, rotary broom etc.)!
Standard bucket The following section describes work operations with the vehicle equipped with the stand-
ard bucket (called bucket in the following).
The standard bucket is mainly used for digging earth, and for loosening, lifting, transport-
ing and loading loose or solid materials.
Checking the tilt position of the bucket
Important!
A
Angle of red mark A = angle of cutting blade B
B
Checking the transport position of the bucket
Fig. 126: Tilt position of the bucket
Important!
C The bucket is in transport position if

• Bucket C is fully tilted in and
• Target marks E on the loader unit and the vehicle frame are lined up
307b0460.eps D Distance D of the centre of rotation of the bucket to the ground is about 150 mm.
Fig. 127: Transport position of the bucket
Fig. 128: Marks for transport position

Operation
Transporting with a full bucket
Danger!
Never transport full buckets in raised position, even over a short distance –
Accident hazard!
Pay particular attention to this when cornering or driving on slopes. The lower
the bucket and the centre of gravity, the less danger there is of tipping over.
☞ To avoid accidents:
• Tilt the bucket all the way in
• Lower or raise the bucket to transport position
Important!
Tax and safety regulations in your country may prohibit the transport of material
when driving on public roads!
• Lower or raise the loader unit to transport position
• When transporting over longer distances: select 2nd drive mode (transport mode)
Picking up/ loading loose material

C • Select the1st drive mode
• Align blade A of the bucket parallel with the ground – see also “Checking the tilt
64 position of the bucket” on page 3-69“
• Lower the loader unit to the ground. To do this:
30300b03060.eps
☞ Push lever 64C ( ) forward
• Drive into the material
A When the engine revs decrease:
• Raise the loader unit slightly. To do this:
Fig. 129: Horizontal lowering of the loader unit
☞ Pull lever 64D ( ) backward
64 D
30300b03060.eps
Fig. 130: Driving into the material

Operation
If the material is hard to penetrate:

A B ☞ Proceed as for loading loose material, but in addition:
64 • Tilt the bucket in and out slightly to release the material. To do this:
☞ Move lever 64 to the left A and right B
30300b03060.eps
Fig. 131: Loading, if the material is hard to penetrate
Ending loading:
A ☞ Proceed as follows:
64 • Tilt the bucket in. To do this:
30300b03060.eps
• Reduce engine revs
• Reverse out of the material
• Raise the bucket to transport position. To do this:
☞ Pull lever 64D ( ) backward
Fig. 132: Tilting in the bucket
64
D
30300b03060.eps
Fig. 133: Reversing out of the material

Operation
Removing material/digging in soft soil
Danger!
If foundations or walls are undermined – danger of collapse!

Accident hazard!
☞ Never undermine foundations or walls!
C • Select the 1st drive range
• Lower the loader unit horizontally to the ground. To do this:
64 ☞ Push lever 64C ( ) forward
• Set digging angle. To do this:
30300b03060.eps
☞ Move lever 64B to the right
• Drive forward
Once the bucket has penetrated the soil:
Fig. 134: Lowering the loader unit horizontal to the ground
• Set digging angle slightly flatter (see Fig. 136). To do this:
☞ Push lever 64A to the left, so that:
➥ Layer being removed is as even as possible
B
➥ Wheel spin is reduced
64
• Proceed as for loading loose material
30300b03060.eps
α
Fig. 135: Setting the digging angle
64
30300b03060.eps
a
Fig. 136: Removing an even layer

Operation
Removing material/digging in hard soil

Proceed as follows:
• Select the 1st drive range
C • Lower the bucket horizontal to the ground. To do this:
A ☞ Push lever 64C ( ) forward
• Set digging angle flatter than for digging in soft soil. To do this:
64
1. ☞ Push lever 64A to the left
30300b03060.eps
• Drive forward (1.) and in doing so
2.
• Press the bucket downward slightly (2.). To do this:
a ☞ Push lever 64C slightly forward
Fig. 137: Removing hard soill
Once the bucket has penetrated the soil:
A B
• Set digging angle slightly flatter. To do this:
☞ Push lever 64A to the left, so that:
64 ➥ Layer being removed is as even as possible
30300b03060.eps
➥ Wheel spin is reduced
• Push lever 64A to the left, or
• Move it alternately to the left A and right B , to loosen the material
α
• Proceed as for loading material hard to penetrate
Fig. 138: Setting the digging angle flatter

Operation
Loading heaped material (non-compacted material)
Danger!
Digging under heaped material can cause it to collapse

Accident hazard!
☞ Never undermine heaped material!
C
• Select the1st drive range
A B
• Set the cutting blade of the bucket parallel to the ground. To do this:
64 ☞ Push lever 64 to the left A or right B
30300b03060.eps
• Lower the loader unit horizontal to the ground. To do this:
☞ Push lever 64C forward
• Drive forward
After penetrating the heaped material:
Fig. 139: Penetrating heaped materiall • Smoothly raise the loader unit
• Keep the bucket level
When the loader unit cannot be raised further:
C • Tilt in the bucket (1.)
A B
• Raise the loader unit (2.)
1. 64 • Reverse out of the material (3.)
3.
30300b03060.eps • Lower the loader unit to transport position
2.
Fig. 140: Reversing away from heaped materiall
Loading heaped material (compacted material)

A B
Proceed as follows:
64 • Select the 1st drive range
30300b03060.eps
• Proceed as for non-compacted material, however when raising the loader unit
through the heaped material:
• Tilt the bucket in and out slightly. To do this:
☞ Push lever 64 alternately to the left A and right B
Fig. 141: Heaped compacted materiall ➥ Material is loosened
Grading
After having finished removing/loading the material:
☞ Select the 1st drive range
☞ Lower the loader unit parallel to the ground (1.)
2. ☞ Reverse across the surface to be graded (2.)
1.
Fig. 142: Grading

Operation
Further practical hints for digging

When planning and carrying out digging work, we recommend that you observe the follow-
ing points:
• Exits from pits must be outside the digging line and as level as possible
• Dig by removing adjacent strips if possible
• Make sure you can drive forward when driving out of the digging area with a fully
loaded bucket
• Whenever possible, drive in reverse when transporting a full bucket down a steep slope
Loading vehicles
When loading vehicles, we recommend to take into account the following:
• Select the 1st drive range
• If possible, the lorry and the working direction of the loader should form an angle of 45°
(Fig. 143)
• Only raise the full bucket to the dumping height when you are driving in a straight line
toward the lorry
• If possible dump with the wind behind you to keep the dust away from your eyes, air
filters and fans!
Fig. 143: Loading vehicles Freeing the vehicle

☞ If your vehicle gets stuck in the ground:
• Dump out the bucket until the blade is vertical above the ground
• Lower the loader unit all the way down
• Reverse slowly and at the same time
• Gradually tilt in the bucket
➥The vehicle is pushed backward
• Repeat this procedure until the wheels reach firm ground
• Reverse the vehicle away
Working with pallet forks Safety instructions

• Always follow the “Load diagram (Fig. 18)” on page 1-12. Never exceed maximum load!
• Follow the special instructions in the operation manual of the implement!
• Approach the material as closely as possible!
• Always approach the material with the vehicle wheels in straight-ahead position!
• Always load on firm and level ground with sufficient load-bearing capacity (for a fully
loaded vehicle)!
• Never raise a load with only one fork arm!
• Maintain a distance of at least 6 m between boom/load and overhead lines!
• Before starting work, make sure the fork arms on the fork frame are securely locked –
visual check!
• Never operate boom and implements at higher vehicle speed!
• Never leave the vehicle with the load raised!
• Always transport the load close to the ground!

Operation

Section 4
Troubleshooting
Troubleshooting
Troubleshooting
4 Troubleshooting 4
The information given in this section is intended for operating personnel when carrying out
repair work. It allows for fast and reliable detection of errors and malfunctions so that
appropriate measures can be taken for troubleshooting.
The detailed description of repair work is limited to the work which can be carried out by
persons without special training.

Troubleshooting
4.1 Engine trouble

Problem Possible causes See
Parking brake not applied 3-18
Engine starting temperature too low
Wrong SAE grade of engine lubrication oil 5-42
Fuel quality does not comply with operation manual 5-42
Engine does not start or is not easy to start Battery defective or flat 5-38
Loose or oxidised cable connections in starter circuit
Starter defective, or pinion does not engage
Wrong valve tip clearance 7-1
Fuel injector defective
Engine starts, but does not run smoothly or faultless
Injection line leaks
Oil level too low 5-7
Oil level too high 5-7
Air filter fouled/exhaust turbocharger defective
Air filter maintenance switch or gauge defective
Engine overheats. Temperature warning system
Radiator fins soiled 5-11
responds
Fan defective/V-belt torn or loose
Cooling air heats up/overheating interruption
Resistance in cooling system too high/flow capacity too low
Insufficient engine output
Charge-air line leaks
Engine does not run on all cylinders
Oil level too low 5-7
Insufficient or no engine oil pressure Engine inclination too high 7-1
Wrong SAE grade of engine lubrication oil 5-42
Engine oil consumption too high
Engine inclination too high 7-1
4-2 BA 302 01 US-Gehl –Edition 1.0 * 30101b0410.fm

Troubleshooting
Problem Possible causes See

Blue
Engine inclination too high 7-1
Engine starting temperature too low
Fuel quality does not comply with operation manual
White
Engine smokes
Full-load stop (dependent on charge-air pressure) defective
Black
Charge-air line leaks

Troubleshooting
4-4 BA 302 01 US-Gehl –Edition 1.0 * 30101b0410.fm

Section 5
Maintenance
5
Maintenance
Maintenance
5 Maintenance 5
5.1 Introduction
Before carrying out service and maintenance work, always read, understand and follow
the instructions given in
• Section 2 “SAFETY INSTRUCTIONS” of this operation manual
• The operation manual for the engine
Daily service and maintenance work, and maintenance work according to maintenance
plan A, can be carried out by specially trained operators. All other maintenance work must
be carried out by qualified mechanics only.
The intervals for the maintenance work described below are listed in the maintenance
plans in the annex.
5.2 Fuel system

5.2.1 Specific safety instructions
• Extreme caution is essential when handling fuel – high risk of fire!
• Never work on the fuel system if the engine is hot – e.g. for changing filters!
• Never carry out work on the fuel system in the vicinity of naked flames or sparks!
• Do not smoke when working on the fuel system or when refuelling!
• Before refuelling, switch off the engine and remove the ignition key!
• Do not refuel in closed rooms!
• Wipe away fuel spills immediately!
• Keep the vehicle clean to reduce the risk of fire!

Maintenance
5.2.2 Refuelling
Danger!
All work involving fuel carries an increased

Danger of fire and poisoning!
☞ Do not refuel in closed rooms
☞ Never carry out work on the fuel system in the vicinity of naked flames or
sparks!
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an environmen-
tally friendly manner!
Stationary fuel pumps General

If possible, only refuel from stationary fuel pumps. Fuel from barrels or canisters is usually
contaminated.
Even the smallest particles of dirt can cause
• Increased engine wear
• Malfunctions in the fuel system and
• Reduced effectiveness of the fuel filters
Refuelling from barrels
If refuelling from barrels cannot be avoided, note the following points (see Fig. 144):
• Barrels must neither be rolled nor tilted before refuelling
wrong ✗ • Protect the suction pipe opening of the barrel pump with a fine-mesh strainer
• Immerse it down to max. 15 cm above the floor of the barrel
• Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter
• Keep all refuelling containers clean at all times
right ✓
Fig. 144: Refuelling from a barrel

Maintenance
Specification for diesel fuel Only use high-grade fuels according to DIN 51601 :
Cetane
Grade Use
number
• No. 2-D as per DIN 51601 For normal temperatures
• No. 1-D as per DIN 51601 Min. 45 For temperatures below 4°C or for opera-
tion above 1500 m altitude
Caution!
Do not add petrol (regular and premium-grade petrol) to diesel fuel!

☞ Refuel winter-grade diesel fuel to avoid the formation of paraffin at low tem-
peratures!
PME fuel
The vehicle cannot be operated with PME fuels (Plant Methyl Ester).
PME fuels have not been tested and approved by producer. They may have a negative
effect on the safety of the vehicle. Producer assumes no liability for resulting damage.
5.2.3 Cleaning the fuel tank
Environment!
Deposits of dirt particles and water in the tank cannot be entirely avoided. The fuel tank
should therefore be cleaned occasionally, particularly before winter operation.
Clean the fuel tank when the fuel level in the tank is as low as possible!
☞ Clean the fuel tank as follows:
• Place a drip tray under the fuel tank
• Remove drain plug A
• Flush out the fuel tank with fuel, several times if necessary
• Screw in drain plug A with a new gasket B
B • Fill the tank
• Check for tightness after a test run
A
Fig. 145: Drain plug on fuel tank

Maintenance
5.2.4 Changing the fuel filter
Danger!
If the fuel, as it drains, comes into contact with hot engine parts or the exhaust
system, there is an increased
Danger of burns!
B
A ☞ Never change the fuel filter if the engine is hot!
Fig. 146: Fuel filter position
Environment!
☞ Change the fuel filter 146/A as follows:

• Pinch off fuel feed line 146/B with a suitable tool
• Thoroughly clean the outside surfaces of fuel filter 146/A
• Release and unscrew fuel filter cartridge using a commercially available tool
• Collect the drained fuel!
Fig. 147: Unscrewing the fuel filter
• Clean the sealing surface of the filter carrier if it is fouled

• Lightly oil the rubber gasket of the new filter cartridge or apply a thin coat of clean
diesel fuel to it
• Screw on the cartridge by hand until the gasket makes contact
Fig. 148: Cleaning the sealing surface and oiling the gasket
• Tighten the fuel filter cartridge by turning it a further half revolution

• Remove the tool which has been used to pinch off fuel feed line 146/B
• Make a test run – and check for tightness!
• Dispose of the old fuel filter cartridge by an ecologically safe method
Important!
The fuel system bleeds itself automatically!

Fig. 149: Screwing down the fuel filter

Maintenance
5.2.5 Cleaning the screen filter of the fuel pump
Danger!
Danger of burns!
☞ Never clean the screen filter when the engine is hot!
Environment!
• Pinch off fuel feed line 146/B with a suitable tool
• Release and unscrew hexagon head screw A
• Remove fuel screen B (cover and screen come out together)
B C
• Clean fuel screen B with fuel, replace if necessary
• Position sealing rings C
• Fit fuel screen B (cover with screen) back on
A • Tighten hexagon head screw A
• Remove the tool which has been used to pinch off the fuel feed line 146/B
• Make a test run – and check for tightness!
Fig. 150: Removing the screen filter
Important!

Maintenance
5.2.6 Changing the leak oil line
Danger!
Danger of burns!
☞ Never change the fuel leak oil line when the engine is hot!
Caution!
Always replace the complete fuel leak oil line when the hose is pulled off from
the hose stem (fuel injector/hose connecting pieces)
☞ On pulling off the hose, the inner area of the hose and the textile coating
can be damaged. Slide the hose onto the hose stem as far as possible
Environment!
1 2 4 3 • Pinch off fuel feed line 146/B with a suitable tool
• Remove rubber hoses 3 from the fuel injector valves
• Remove rubber hose 1 from the fuel tank
• Remove rubber hoses 4, 3 and 1 from connecting pieces 2 and dispose of them in an
environmentally friendly manner
• Install the new fuel leak oil line. To do this:
• Connect the rubber hoses 3 to the fuel injector valves
• Connect rubber hose 1 to the fuel tank
leckoel.eps
• Open the fuel stop cock
Fig. 151: Changing the leak oil line
• Check for leakage after start-up
Important!

Maintenance
5.3 Engine lubrication system

5.3.1 Checking the oil level
38b07601.eps
Important!
Check the oil level every 10 service hours or every day.

We recommend checking the oil level before starting the engine. After switching off
a warm engine, wait at least 5 minutes before checking.
A
Fig. 152: Oil dipstick
☞ Check the oil level as follows:

• Park the vehicle on level ground
A • Lower the loader unit
• Lower the bucket blade to the ground
max • Apply the parking brake
min • Switch off the engine
• Open the engine cover
In addition, if the engine has been started:
• Wait about 5 minutes for the oil to return to the sump
Fig. 153: Checking the oil level
• Oil dipstick A
• Pull it out and wipe it with a lint-free cloth
• Push back in as far as possible
• Withdraw and
• Read off the oil level
• Top up the oil level if necessary, at the latest when the oil reaches the MIN mark on
the dipstick

Maintenance
5.3.2 Filling in engine oil
Caution!
Excessive or incorrect engine oil may result in engine damage! For this
reason:
☞ Do not add engine oil above the MAX mark of the oil dipstick 153/A
☞ Use only the specified engine oil – see section 5.14 Engine fluids and lubri-
cants on page 5-42
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in an environ-
mentally friendly manner!
☞ Top up the oil level as follows:

OIL • Park the vehicle on level ground
• Lower the loader unit
38b07601.eps • Apply the parking brake
B • Open the engine cover
A
• Clean the area around oil filler cap B with a lint-free cloth
• Open filler cap B
• Raise oil dipstick A slightly to allow any trapped air to escape
• Filling in engine oil
• Wait a moment until all the oil has run into the oil sump
• Check the oil level – see section 5.3.1 Checking the oil level on page 5-7
Fig. 154: Topping up engine oil • Top up if necessary and check the oil level again
• Shut the filler cap B
• Push in oil dipstick A into the filler inlet as far as it will go
• Completely remove all oil spills from the engine

Maintenance
5.3.3 Changing the engine oil
Danger!
Caution when draining hot engine oil –

Danger of burns!
+ 80°C ☞ Wear protective gloves
☞ Use suitable tools
OIL Environment!
Fig. 155: Optimum engine oil temperature
Use a suitable container to collect the engine oil as it drains and dispose of it in an environ-
mentally friendly manner!
☞ Change the engine oil as follows:

D E
C
• Let the engine run until reaching service temperature (oil temperature about 80 °C)
38b02700.eps • Remove cover plate
• Place an oil drip tray (with a capacity of about 12 litres) under the opening
• Unscrew filler cap C of oil drain valve D
Fig. 156: Drain plug on vehicle rear end
• Screw on drain coupling with a hose F of adequate length. The hose end must be well
D in oil collector G
➥Oil drain valve D opens and the engine oil drains
E • Completely drain the oil
• Unscrew drain coupling E
F
G • Screw on filler cap C of the oil drain valve
• Fill with engine oil – see section 5.3.2 Filling in engine oil on page 5-8
• Check the oil level – see section 5.3.1 Checking the oil level on page 5-7
Fig. 157: Drain coupling with hose • Start the engine and run it at low speed for a short time
• Wait a moment until all the oil has run into the oil sump
• Check the oil level again
• Top up if necessary and check again

Maintenance
5.3.4 Changing the engine oil filter cartridge
Danger!
Caution when draining hot engine oil –

H Danger of burns!
☞ Wear protective gloves
Fig. 158: Engine oil filter position

Environment!
Use a suitable container to collect the engine oil as it drains.
Dispose of used oil and filters in an environmentally friendly manner!
☞ Change the filter as follows:

H • Apply the parking brake
• Place a suitable container under the oil filter to collect the oil
• Unscrew oil filter cartridge H using a commercially available tool
Fig. 159: Unscrewing the engine oil filter
• Make sure the thread adapter is correctly placed in the filter head
• Clean the inside of the filter head
• Apply a thin coat of fresh engine oil to rubber seal I of the new oil filter cartridge
• Tighten the new filter cartridge by hand until the gasket makes contact
I • Tighten oil filter cartridge H by hand with about a further half revolution
• Check the oil level and top up if necessary – see section 5.3.1 Checking the oil level
on page 5-7
• Run the engine for a short time
Fig. 160: Cleaning the filter head and oiling the gasket
• Check the seal of oil filter cartridge H and retighten by hand

• Check the oil level again and top up if necessary
H
• Dispose of the used oil filter in an environmentally friendly manner
Fig. 161: Tightening the filter cartridge

Maintenance
5.4 Engine and hydraulics cooling system

Engine oil and hydraulic oil are cooled via separate radiators.
The oil cooler is located in the engine compartment, on the right side behind the engine. It
cools the hydraulic oil of the drive and work hydraulics. The engine oil is cooled via the oil
cooler fitted to the diesel engine.

• Dirt on the cooling ribs reduces the cooler’s heat dissipation capacity! To avoid this:
• Clean the outside of the cooler at regular intervals. Refer to the maintenance plans in
the Annex for the cleaning intervals
• In dusty or dirty work conditions, clean more frequently than indicated in the mainte-
nance plans
5.4.2 Engine oil cooler

Cleaning
Danger!
Never remove cooling air cover A if the engine is warm.
Danger of burns!
☞ Wait at least 10 minutes after switching off the engine!
☞ Wear protective goggles, gloves and clothing!
A • Park the vehicle on level ground
B
• Switch off the engine and let it cool down
Fig. 162: Removing the engine cooling air cover
1. • Remove cooling air hood A. To do this:

• Release screws B
• Blow compressed air, starting from the exhaust end 1, to clean the engine
• Remove dirt which has been blown into area 2
• Clean cooling fan 3
• Fit cooling air hood A
2. 3.
Fig. 163: Direction of blown air when cleaning the oil cooler

Maintenance
5.4.3 Hydraulic oil cooler

Cleaning
Danger!
Warm engine –
Danger of burns!
☞ Wait at least 10 minutes after switching off the engine!
☞ Wear protective goggles, gloves and clothing!
A
• Switch off the engine and let it cool down
• Clean radiator fins 164/A by blowing compressed air from fan end 164/B
B
Fig. 164: Cleaning the oil cooler

Maintenance
Maintenance
5
5.5 Air filter
Caution!
The filter cartridge will be damaged if it is washed, blown or brushed out!

☞ Do not clean the filter cartridge!
☞ Replace the filter cartridge when the telltale comes on!
☞ Never reuse damaged filter cartridges. Replace them if you are unsure!
☞ Ensure cleanliness when replacing the filter cartridge!
Telltale 54 in the instrument panel monitors the filter cartridge. The filter cartridge must be
˚F
175
replaced:
105 250
• If telltale 54 comes on
80 12 14
60 100
54
40 ˚C 120 10 16
20 30 Volt
• At the latest after 1200 service hours (once every year)

10 20
10 40
P ˚F
270 1/2
165
120 500 0 1/1

75 100 30
50 ˚C 125
150
MPH
Km/h 50
0 002836h
312b0050.eps
Important!
Fig. 165: Telltale in the instrument panel The air filter is fitted with a safety cartridge which cannot be cleaned. Replace the
safety cartridge every third time maintenance is carried out!
Caution!
The filter cartridge may degrade prematurely when in service in acidic air for
longer periods of time. This risk is present for example in acid production facil-
ities, steel and aluminium mills, chemical plants and other nonferrous-metal
plants.
☞ Replace the filter cartridge and safety cartridge as per telltale 54, after 300
service hours at the latest!
☞ Clean dust valve regularly according to the maintenance plan!
A
Important!
The air filter is located behind the maintenance flap in the engine compartment on
the right side of the vehicle.
☞ Open maintenance flap A as follows:

Fig. 166: Dust valve position
• Open the maintenance flap on the right. To do this
• Press button A on the inside

Maintenance
Functional check of the dust valve
• Compress the discharge slot of dust valve B
• Remove hardened dust by compressing the upper area of the valve
☞ Clean the discharge slot if necessary
➥ The discharge slot must close again upon releasing it
B
Fig. 167: Dust valve position

Maintenance
Replacing the filter cartridge

Caution!
The filter cartridge will be damaged if it is washed, blown or brushed out!

Dust on the clean side of the filter causes accelerated engine wear!
Danger of engine damage!
☞ Do not clean the filter cartridge!
☞ Replace the filter cartridge when the telltale comes on!
☞ Never reuse damaged filter cartridges. Replace them if you are unsure!
C
• Pull bow clip C on lower housing section D to the outside
• Remove lower housing section D
Fig. 168: Opening the air filter housing
• Remove filter cartridge E with a slightly turning movement

E
308b1040.eps
Fig. 169: Removing the main filter element
• In addition after every 3rd replacement of the filter cartridge E:

E • Remove safety cartridge F with slightly turning movements
• Carefully insert new safety cartridge F into the upper housing section
• Carefully insert new filter cartridge E into the upper housing section
F
Fig. 170: Air filter with safety cartridge (option)
• Position lower housing section D so that dust valve B shows downward

C
• Close bow clip C
➥The filter cartridge is automatically pressed into the correct position
D
Fig. 171: Closing the air filter housing

B

Maintenance
5.6 V-belt
Danger!
Only check or retighten/replace the V-belt when the engine is switched off –

☞ Switch off the engine before carrying out maintenance work in the engine
compartment!
Check the V-belt every day or every 10 hours of operation and retighten it if necessary.
New V-belts:
☞ Retighten after about 15 minutes of running time
☞ Check V-belt tension again after the first 25 service hours, retighten if necessary
Checking the V-belt tension ☞ Check as follows:

about 10 mm
• Prevent the vehicle from rolling away and remove the ignition key
• Carefully inspect the V-belt for damage
If the V-belt is damaged:
• Replace the V-belt (or have it replaced)
Fig. 172: Checking V-belt tension
• Press with your thumb in the middle of the longest section between two pulleys (figure
172) to check whether the V-belt can be deflected, by no more than about 10 mm
• Retighten the V-belt if necessary
Retightening the V-belt ☞ Proceed as follows:

A • Switch off the engine
B
C • Prevent the vehicle from rolling away and remove the ignition key
• Loosen screws B and C
D • Use a suitable tool to move tensioning pulley D until the correct V-belt tension is
obtained
• Maintain tensioning pulley D in this position
• Retighten screws B and C
• Check V-belt tension once again
Fig. 173: Retightening the V-belt
38B03300.eps
Important!
Check V-belt tension again after the first 25 service hours if a new V-belt is
mounted!

Maintenance
5.7 Hydraulic system

• All lines carrying hydraulic oil must be depressurised prior to all maintenance and repair
work. To do this:
• Lower all hydraulically controlled implements to the ground
• Move all control levers of the hydraulic control valves several times
• Apply the parking brake to prevent the vehicle from rolling away before you carry out
service and maintenance work
• Hydraulic oil escaping under high pressure can penetrate the skin and cause serious
injuries. Always consult a doctor immediately even if the wound seems insignificant –
otherwise serious infections could set in!
• If the hydraulic oil in the level glass is cloudy, this indicates that water or air has
penetrated the hydraulic system. This may cause damage to the hydraulic pump!
☞ Contact your dealer immediately
Caution!
Contaminated hydraulic oil, lack of oil or wrong hydraulic oil –

Danger of severe damage to the hydraulic system!
☞ Take care to avoid contamination when working!
☞ Always use the filling screen when filling in hydraulic oil!
☞ Only use authorised oils of the same type – see Engine fluids and lubri-
cants on page 5-42
☞ Always top up the hydraulic oil before the level gets too low
☞ If the hydraulic system is filled with biodegradable oil, then only use biode-
gradable oil of the same type for topping up – observe the sticker on the
hydraulic oil tank!
☞ Always contact customer service if the hydraulic system filter is contami-
nated with metal chippings. Otherwise, follow-on damage may result!
Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container! Dispose of
drained oil and used filters by an ecologically safe method.

Maintenance
5.7.2 Hydraulic oil level

Checking the oil level
✓
• Retract all hydraulic rams. To do this:
A • Fully lower the loader unit
• Check hydraulic oil level A in the sight glass:
If the oil level is:
Fig. 174: Oil level glass on the hydraulic oil tank • Visible in the sight glass In working order
• Below the sight glass ☞ Top up the hydraulic oil
• Above the sight glass ☞ Drain the hydraulic oil
Topping up hydraulic oil

Important!
Do not top up the hydraulic oil unless the engine is switched off, otherwise hydrau-
lic oil will flow out of the hydraulic oil tank filler inlet.
The hydraulic oil tank is located on the left in the engine compartment.
☞ Top up as follows:
B • Fully lower the loader unit
C
A • Open the engine cover
• Clean the area around the filler inlet of the hydraulic oil tank with a cloth
• Open filler cap B
With filter screen C installed:
38b03400.eps
• Top up the hydraulic oil
Fig. 175: Hydraulic oil tank • Check the hydraulic oil level on oil level sight glass A
• Top up the hydraulic oil if necessary and check again

Maintenance
Changing the hydraulic oil

Danger!
Draining hot hydraulic oil and removing the filter element is hazardous:
Danger of burns!
☞ Fit a sufficiently long hose to the oil drain coupling
Environment!
E
F • Fully lower the loader unit
B
H G • Switch off the engine and prevent the vehicle from rolling away
D
C
• Unscrew breather filter D to depressurise the hydraulic oil tank
– the hydraulic system must be depressurised!
• Place a suitable container J underneath the vehicle rear end
38b04900.eps (minimum capacity: 90 litres)
• Unscrew filler cap F of oil drain valve E
Fig. 176: Overview of the hydraulic oil tank • Hold the end of the hose of oil drain coupling G into container J
• Screw oil drain coupling G onto oil drain valve E
➥Oil drain valve G opens and the oil drains into the container
• Open cover B
• Remove filter insert C and clean with diesel
I • Re-insert cleaned filter insert C
J • Flush out the hydraulic oil tank with a little hydraulic oil
38b05700.eps
about
ca.
• Remove oil drain coupling G on oil drain valve E
6060litres
Liter
• Screw filler cap F of oil drain valve E
Fig. 177: Hose routing for draining hydraulic oil
• Screw breather filter D onto the hydraulic tank. If necessary, use a new breather filter
as per the maintenance intervals – see section 5.7.4 Changing the breather filter on
page 5-23
• Follow the maintenance intervals for hydraulic oil filter insert H, if necessary replace
the filter insert – see section Changing the filter insert on page 5-22

Maintenance
Caution!
Contaminated hydraulic oil can cause serious damage to the hydraulic system!
☞ Always fill in hydraulic oil through the screen filter insert C!
• Fill the system with fresh hydraulic oil up to the middle of oil level sight glass A
• Screw on cover B of the hydraulic oil tank
• Start the engine
With the engine running at low speed:
• Raise the loader unit as far as it will go
• Fully dump out the bucket
• Turn the steering wheel to the left and right several times, from lock to lock
• Retract all hydraulic rams again. To do this:
• Fully lower the loader unit
• Check the hydraulic oil level again and top up again if necessary

Maintenance
Important information for the use of • Use only the biodegradable hydraulic fluids which have been approved by producer
biodegradable oil – see Engine fluids and lubricants on page 5-42. Always contact producer for the use of
other, not recommended products. In addition, ask the oil supplier for a written decla-
ration of guarantee. This guarantee is applicable to damage occurring on the hydraulic
components, which can be proved to be due to the hydraulic fluid
• The remaining amount of initial hydraulic fluid in the hydraulic system must not exceed
8 % when using another type of biodegradable oil (manufacturer indications)
• Do not top up with mineral oil – the content of mineral oil must not exceed 2 % in order
to avoid foaming problems and to ensure biological degradability (hazardous waste!)
• When running the vehicle with biodegradable oil, the same oil and filter replacement
intervals are valid as for mineral oil – see maintenance plans in the Annex
• Drain the condensation water in the hydraulic oil tank every 600 service hours, in any
case before the cold season. The water content must not exceed 0.1 % by weight
• The instructions in this operation manual concerning environmental protection are also
valid for the use of biodegradable oil
• If additional hydraulic implements are mounted or operated, use the same type of
biodegradable oil for these implements to avoid mixtures in the hydraulic system
Subsequent change from mineral oil to biodegradable oil

☞ Completely flush the hydraulic components. To do this:
• Park the vehicle on level ground when it is at operating temperature
• Fully lower the loader unit
• Switch off the engine and prevent the vehicle from rolling away
• Completely drain the hydraulic oil
• Fill up the hydraulic system with the new oil type
• Start the engine
• Operate all components of the hydraulic system, such as rams, to “flush” the lines,
H
rams and pumps
• Retract all hydraulic rams
• Completely drain the hydraulic oil again
• Replace hydraulic oil filter insert H
38b04900.eps
• Fill up the hydraulic system with fresh oil up to the required level
• Check the oil level and top up if necessary
Fig. 178: Hydraulic oil filter insert

Maintenance
5.7.3 Hydraulic oil reflux filter

The red telltale 53 on the instrument panel monitors the reflux filter. The filter insert must
˚F
175
be replaced:
105 250
• If telltale 53 comes on when the hydraulic oil is at operating temperature

80 12 14
60 100
40 ˚C 120 10 16
20 30 Volt
P
165
˚F
270
10
10 20
40
1/2
• At the latest after 1200 service hours (once every year)
120 500 0 1/1
30
In cold weather telltale 53 may come on immediately when the engine is started. This is
75 100
50 ˚C 125
150
MPH
Km/h 50
0002836h
caused by increased oil viscosity. In this case:

53 312b0050.eps
☞ Set engine speed so that telltale 53 goes out
Fig. 179: Telltale for reflux filter ☞ Bear in mind the instructions concerning warmup
– see Starting at temperatures below 0 °C on page 3-19
Changing the filter insert

Danger!
Be careful when removing the filter element –

Danger of burns!
Caution!
Insufficiently filtered hydraulic oil can cause serious damage to the hydraulic
system!
☞ Take care to avoid contamination when working!
☞ The filter insert H must not be cleaned!
Environment!

Maintenance
O
N • Apply the parking brake
M • Switch off the engine
L • Open the engine cover
H
D • Unscrew breather filter D to depressurise the hydraulic oil tank – the hydraulic system
must be depressurised!
• Loosen and remove cover D
• Pull out filler pipe M with filter insert H upward, turning them slightly
• Pull filter insert H off filler pipe M and dispose of the filter element in an environmen-
38b04900.eps
tally friendly way
• Check sealing rings N and L for proper condition
Fig. 180: Filter insert and sealing rings • Replace damaged sealing rings
• Slide filler pipe M on new filter insert H and insert
• Tighten cap D by hand (tightening torque 20 Nm)
• Carry out a test run
• Check the filter for leakage
• Check the hydraulic oil level, top up oil if necessary
5.7.4 Changing the breather filter

Replace breather filter D for the hydraulic oil tank every 1200 service hours or at least
once a year.
D
• Unscrew breather filter D
38b04900.eps • Screw in new breather filter D
Fig. 181: Breather filter on hydraulic oil tank

Maintenance
5.7.5 Hydraulic pressure lines

Specific safety instructions
Danger!
Caution when checking hydraulic lines, especially when searching for leaks.
Hydraulic oil escaping under high pressure can penetrate the skin and cause
serious injuries –
☞ Always consult a doctor immediately, even if the wound seems insignificant
– otherwise serious infections could set in!
☞ Always observe the following instructions:
• Retighten leaking screwed fittings and hose connections only when the
system is not under pressure; i.e. release the pressure before working
on pressurised lines!
• Never weld or solder faulty or leaking pressure lines and connections.
Replace damaged parts with new ones!
• Never search for leakages with your bare hands, but wear protective
gloves!
• Use paper or wood to check for minor leaks. Never use an unprotected
light or naked flame!
• When replacing hose lines, ensure that they are not twisted!
• Leakages and damaged lines must be repaired or replaced as quickly as possible. This
not only increases the operating safety of the vehicle, but also helps to protect the
environment
• Replace hydraulic hoses every 6 years from the date of manufacture, even if they do
not seem to be damaged
In this respect, we recommend that you observe all relevant safety regulations for hydrau-
lic lines, as well as the safety regulations regarding accident prevention and occupational
health and safety in your country. Also observe DIN 20066, Part 5.
The date of manufacture (month or quarter and year) is indicated on the flexible line.
1 Q/00
Example:
The indication “1 Q/00” means manufactured in the 1st quarter of 2000.
Fig. 182: Date of manufacture of hydraulic lines

Maintenance
Maintenance
5
5.8 Gearboxes and axles
Maintenance of these components is limited to checking the oil levels and to changing the
oil at prescribed intervals – see Maintenance plan (overview) on page 5-48.
Danger!
Handling hot gear oil causes

Danger of burns!
☞ Use suitable tools, e.g. for unscrewing the drain plug
Important!
Only use new sealing rings for oil filler and drain plugs. Drain oil only after running
the vehicle for a longer period of time!
Environment!
Use a suitable container to collect the gearbox oil as it drains and dispose of it in an envi-
ronmentally friendly manner!

Maintenance
5.8.1 Rear axle gearbox

Checking/topping up the oil level in
the rear axle gearbox
Important!
The rear axle differential and the gearbox have separate oil circuits.
Standard gearbox ☞ Proceed as follows:

• Park the vehicle on level ground when the gearbox is at operating temperature
• Clean and unscrew oil filler and inspection plug A on the gearbox. Hold a cloth under
the opening as you do so
If the oil level is below the opening or if the oil level cannot be seen at all:
A
• Fill in fresh oil through bore A up to the lower edge of the bore, oil grade – see Engine
B fluids and lubricants on page 5-42
If the oil level is correct:
ca142280_lubrif.eps
• Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal
High speed gearbox (option)
ca142281_lubrif.eps
B
Fig. 183: Checking the gearbox oil level

Maintenance
Changing the gearbox oil

Danger!
Handling hot gear oil causes

Danger of burns!
☞ Use suitable tools, e.g. for unscrewing the drain plug
Standard gearbox ☞ Proceed as follows:

• Park the vehicle on level ground when the gearbox is at operating temperature
• Place a suitable container under the rear axle gearbox to collect the oil
• Clean and unscrew oil filler and inspection plug A
A • Unscrew drain plug B
• Completely drain the old gearbox oil
B • Fit a new sealing ring to drain plug B and screw in to make an oil-tight seal
ca142280_lubrif.eps
• Fill in fresh oil through bore A up to the lower edge of the bore, oil grade
– see Engine fluids and lubricants on page 5-42
High speed gearbox (option)
• Tighten plug A with a new sealing ring to make an oil-tight seal
After carrying out a test run:
• Check the oil level again after about 5 minutes, and fill in oil if necessary
A
ca142281_lubrif.eps
B
Fig. 184: Changing the gearbox oil

Maintenance
5.8.2 Rear axle differential

Checking/topping up the oil level in
the rear axle gearbox
Important!
The rear axle differential and the gearbox have separate oil circuits.
A
• Park the vehicle on level ground when the differential is at operating temperature
• Clean and unscrew oil filler and inspection plug A on the differential. Hold a cloth
under the opening as you do so
Fig. 185: Oil filler and inspection plug on the differential • Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal
Changing the oil ☞ Proceed as follows:

• Park the vehicle on level ground when the differential is at operating temperature
• Place an adequately sized container under the differential housing of the rear axle to
collect the oil
• Clean and unscrew plug 185/A
• Unscrew drain plug B
• Completely drain the old gearbox oil
B
• Fit a new sealing ring to drain plug B and screw in to make an oil-tight seal
• Fill in fresh oil through bore 185/A up to the lower edge of the bore, oil grade –
see Engine fluids and lubricants on page 5-42
• Tighten plug 185/A with a new sealing ring to make an oil-tight seal
After carrying out a test run:
• Check the oil level again after about 5 minutes, and top up if necessary
Fig. 186: Drain plug on rear axle differential

Maintenance
5.8.3 Front axle differential
Important!
Only use new sealing rings for oil filler and drain plugs. Drain oil only after running
the vehicle for a longer period of time (operating temperature)!
Checking/topping up the oil level

• Clean and unscrew oil filler and inspection plug A on the differential. Hold a cloth
under the opening as you do so
A
Fig. 187: Oil filler and inspection plug on the differential If the oil level is correct:
Changing oil
• Park the vehicle on level ground when it is at operating temperature
• Place a drip tray under plug B to collect the oil
• Clean and unscrew oil filler and inspection plug A
B • Clean and unscrew drain plug B
A • Completely drain the old oil
• Fit a new sealing ring to drain plug B and screw in to make an oil-tight seal
Fig. 188: Oil filler and inspection plug on the differential • Fill in fresh oil through bore A up to the lower edge of the bore, oil grade

Maintenance
5.8.4 Front and rear axle planetary drives
Important!
Fit new sealing rings! Drain oil only after running the vehicle for a longer period of
time!
Checking/topping up the oil level ☞ Proceed as follows:

• Park the vehicle on level ground and secure it against rolling away
• Place plug C in the position shown in Fig. 189 (plug must be at the top)
• Clean and unscrew plug C (to relieve possible overpressure)
Fig. 189: Oil filler and inspection plug on planetary drive
• Place plug C in the position shown in Fig. 190 (plug must be horizontal)
• Unscrew plug C
• Fill in fresh oil through bore C up to the lower edge of the bore, oil grade
C – see Engine fluids and lubricants on page 5-42
• Screw in plug C with a new sealing ring to make an oil-tight seal
Changing the oil

• Park the vehicle at operating temperature on level ground and secure it against rolling
away
• Place a suitable container under drain plug C
C • Place plug C in the position shown in Fig. 191 (plug must be at the top)
• Clean and unscrew plug C (to relieve possible overpressure)
Never raise the vehicle on one side only for the following work!
Fig. 191: Drain plug on planetary drive • Turn planetary drive downward (plug must be at the bottom)
• Unscrew plug C
• Completely drain the old oil
• Place opening C in the position shown in Fig. 192 (plug must be in horizontal position)
• Fill in fresh oil through bore C up to the lower edge of the bore, oil grade
• Screw in plug C with a new sealing ring to make an oil-tight seal

Maintenance
5.8.5 Lubricating planetary drive bearings

• Apply lithium-saponified multipurpose grease to both grease nipples D on each
planetary drive bearing every 50 service hours or once a week – see section 5.14
Engine fluids and lubricants on page 5-42
Fig. 193: Grease nipples on planetary drive bearings
5.8.6 Lubricating the rear axle oscillation-type bearing
Important!
The vehicle has an oscillation-type rear axle. Lubricate the bearing every 50 serv-
ice hours or once a week, at the latest, through the 2 grease nipples E on the axle
bearing.
☞ Lubricate oscillation-type bearing through grease nipple E with lithium-saponified multi-

purpose grease – see section 5.14 Engine fluids and lubricants on page 5-42
E
Fig. 194: Grease nipples for oscillation-type bearing

Maintenance
5.9 Loader unit

5.9.1 Lubricating the pivots on the loader unit
Lubricate the following lubrication points on the loader unit of the vehicle:
☞ Lubricate grease nipple A of the tilt ram bearing every 50 service hours (or once a
week). Lubricate daily for heavy-duty operation
A
☞ Lubricate grease nipple B (2 x) of the loader unit bearing every 50 service hours (or
once a weak). Lubricate daily for heavy-duty operation
☞ Lubricate grease nipple C of the lift ram bearing every 50 service hours (or once a
B
Fig. 195: Upper lubrication points on loader unit
☞ Lubricate grease nipple D of the tilt ram bearing every 10 service hours (or daily), or
more often for heavy-duty operation
D ☞ Lubricate grease nipple E of the tilt ram bearing every 50 service hours (or once a
☞ Lubricate grease nipple F of lift ram and tilt lever bearing every 10 service hours (or
daily), or more often for heavy-duty operation
F
Fig. 196: Centre lubrication points on loader unit
☞ Lubricate grease nipple G of the tilt lever bearing every 10 service hours (or daily, or
more often for heavy-duty operation
☞ Lubricate grease nipple H of the tilt lever bearing every 10 operating hours (or daily),
or more often for heavy-duty operation
Fig. 197: Lower lubrication points on loader unit

Maintenance
5.10 Tyre care
Danger!
Improper tyre repairs constitute an

Accident hazard!
☞ All repair work on tyres and rims may only be carried out by authorised spe-
cialist workshops
Important!
Regular tyre inspection improves operating safety and the service life of the tyres,
and reduces vehicle downtimes.
Refer to the table in section “Specifications” on page 7-10 for the authorised tyre
types and the correct tyre pressures. This table is also on the label fixed to the
front window ex works.
5.10.1 Inspection work

Daily checks
☞ Carry out the following maintenance work daily:
• Visual check of the tyre condition, especially:
• Tyre pressure
• Outside and inside damage of tyres and rims
• Wear
• Remove foreign bodies from the tyre tread
• Remove traces of oil and grease from the tyres
Checks every week

☞ Carry out the following maintenance work every week:
• Check the tread depth of the tyres
• Check tyre pressure and correct as necessary

Maintenance
5.10.2 Wheel change
Caution!
The wheels are heavy and can damage the threads on the wheel studs if they
are handled incorrectly!
☞ Use suitable assembly tools, such as covering sleeves for the studs, a jack etc.
Removing the wheels ☞ Proceed as follows:

• Park the vehicle on level and firm ground and prevent it from rolling away
• Slightly loosen the wheel nuts of the tyre you want to remove
• Place a jack under the axle beam, making sure it is standing firmly
• Raise the side of the axle from which you want to remove the tyre
• Check the vehicle is standing firmly
• Completely remove the wheel nuts
• Remove the wheel
Fitting the wheels ☞ Proceed as follows:

• Place the wheel onto the wheel studs
• Tighten all wheel nuts part-way
• Lower the raised axle
• Tighten the wheel nuts to the prescribed tightening torque – see section 7.17.2 Spe-
cific tightening torques on page 7-12

Maintenance
5.11 Heating
The vehicle heater is equipped with a dust filter or a fine dust filter (EU4, option) which
must be cleaned at regular intervals or replaced once a year if necessary.
It is located under the access, on the left in driving direction.
5.11.1 Cleaning the dust filter of the heating system

A dust or fine dust filter (option) cleans the air taken in by the heater. The plastic filter cloth
A must be cleaned with water, adding a mild cleaning agent if necessary, or replaced. The
volume of warm air flowing out of the air vents decreases as filter cloth contamination
increases.
☞ Clean/replace the filter cloth as follows:
• Remove trim panel A on the right cab side. To do this:
B • Remove screws B
Fig. 198: Removing/installing the trim panel
• Remove dust filter C

C • Clean or replace dust filter C as required
• Insert cleaned dust filter and install trim panel A
Fig. 199: Replacing the dust filter of the heating system

Maintenance
5.12 Electrical system

• Battery A contains sulphuric acid! This acid must not come into contact with the skin,
the eyes, clothing or the vehicle.
Therefore when recharging or working near the battery:
☞ Always wear goggles and protective clothing with long sleeves
If acid is spilt:
☞ Thoroughly rinse all affected surfaces immediately with plenty of water
☞ Thoroughly wash any part of the body touched by the acid immediately with plenty of
water and seek medical attention at once!
• During charging in particular, but also during normal battery operation, an oxyhydrogen
mixture is formed in the battery cells – danger of explosion!
• Do not attempt to jump-start the vehicle if the battery is frozen or if the acid level is low.
A The battery may rupture or explode!
+ • Avoid sparks and unprotected light sources, and refrain from smoking in the vicinity of
opened battery cells – otherwise the gas produced during normal battery operation may
ignite!
– • Use only 12 V power sources. Higher voltages will damage the electrical components
• When connecting battery A ensure that the poles are not reversed, otherwise sensitive
electrical components will be damaged
38b03600.eps
• Do not interrupt voltage-carrying circuits at the battery terminals, because of the danger
Fig. 200: Battery of sparking!
• Never place tools or other conductive articles on the battery – danger of short circuit!
• Disconnect the negative battery terminal before starting repair work on the electrical
system
• Dispose of used batteries properly

Maintenance
5.12.2 Service and maintenance work at regular intervals

Before driving the vehicle
☞ Check every time before driving the vehicle:
• Is the light system OK?
Every week:
☞ Check every week:
• Cable and earth connections
• Chafing on wiring harnesses
• Condition of battery terminals
5.12.3 Instructions concerning specific components

Cables, bulbs and fuses Always observe the following instructions:
• Defective components of the electrical system must always be replaced by an expert.
Bulbs and fuses may be changed by unqualified persons
• When carrying out maintenance work on the electrical system, pay particular attention
to ensuring good contact in leads and fuses
• Blown fuses indicate overloading or short circuits. The electrical system must therefore
be checked before installing the new fuse
• Only use fuses with the specified load capacity (amperage) – see Electrical system on
page 7-6
Alternator Always observe the following instructions:

• Only test the engine with the battery connected
• When connecting the battery, ensure that the poles are not reversed
• Always disconnect the battery before carrying out welding work or connecting a quick
battery charger
• Replace a defective charge telltale as quickly as possible

Maintenance
Battery
Danger!
The battery electrolyte is highly caustic!

Danger of caustic injury!
Therefore when recharging and/or working near the battery:
☞ Always wear goggles and protective clothing with long sleeves
If acid is spilt:
☞ Thoroughly rinse all affected surfaces immediately with plenty of water
☞ Thoroughly wash any part of the body touched by the acid immediately with
plenty of water and seek medical attention at once!
In particular when charging, but also during normal battery operation, an
oxyhydrogen mixture is formed in the battery cells –
Risk of explosion!
☞ Avoid sparks and unprotected light sources, and refrain from smoking in the
vicinity of the battery!
☞ Do not attempt to jump-start the vehicle if the battery is frozen or if the acid
level is low. The battery may rupture or explode!
☞ Always disconnect the negative battery terminal first before starting repair
work on the electrical system!
Battery A is located in the engine compartment, on the right side. Battery A is mainte-
nance-free, and there is no need to top up the electrolyte level under normal operating
conditions. However, check battery A at regular intervals to make sure the electrolyte level
A is between the MIN and MAX marks.
+
Always observe the special safety instructions!
☞ Check the battery charge condition as follows:
– • Park the vehicle on level ground
38b03600.eps
Fig. 201: Battery When the battery caps are open:
• Measure the acid density with the acid meter
If the acid density is below 1.21 kg/l:
• Recharge disconnected battery

Maintenance
5.13 General maintenance work

5.13.1 Cleaning
Cleaning the vehicle is divided into 3 separate areas:
• Inside the operator compartment
• Exterior of the vehicle
• Engine compartment
The wrong choice of cleaning equipment and agents may impair the operating safety of
the vehicle on the one hand, and on the other undermine the health of the persons in
charge of cleaning the vehicle. It is therefore essential to observe the following instruc-
tions.
General instructions for all areas of Washing solvents

the vehicle
• Ensure adequate room ventilation
• Wear suitable protective clothing
• Do not use flammable liquids, such as petrol or diesel
Compressed air
• Work carefully
• Wear goggles and protective clothing
• Do not aim the compressed air at the skin or at other people
• Do not use compressed air for cleaning your clothing
When using a high-pressure cleaner or steam jet

• Electrical components and damping materials must be covered and not directly
exposed to the jet
• Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.
• Protect the following components from moisture:
• Engine
• Electrical components, e.g. alternator, plug and socket connections etc.
• Control devices and seals
• Air intake filters etc.
When using volatile and easily flammable anticorrosion agents and sprays:
• Ensure adequate room ventilation
• Do not use unprotected lights or naked flames
• Do not smoke!

Maintenance
Inside of operator compartment

Caution!
Never use high-pressure cleaners, steam jets or high-pressure water to clean

the inside of the operator compartment. Water under high-pressure may
• Penetrate into the electrical systems and cause short circuits
• Damage seals and disable the controls!
For cleaning the operator compartment, we recommend using the following aids:
• Broom
• Vacuum cleaner
• Damp cloth
• Bristle brush
• Bucket of water
Cleaning seat belt
• Clean the seat belt (which remains fitted in the vehicle) only with a mild soap solution;
do not use chemical agents as they may destroy the fabric!
Danger!
In the case of automatic seat belts (option) soiled belts may impair winding and
thereby affect safety
☞ Only wind seat belt when it is dry!
Exterior of the vehicle The following articles are generally suitable:

• High-pressure cleaner
• Steam jet
Engine compartment
Danger!
Clean the engine at engine standstill only –

☞ Switch off the engine before cleaning
Caution!
When cleaning the engine using a water jet or steam jet, do not point the jet
directly at electrical measurement sensors such as the oil pressure switch.
Otherwise, liquid penetrating such units can lead to corrosion and failure of the
measuring function!

Maintenance
5.13.2 Screw connections

All screw connections must be checked regularly, even if they are not listed in the mainte-
nance schedules.
Tighten loose connections immediately. Tightening torques can be found
in section 7 "Tightening torques" on page 7-12
5.13.3 Pivots and hinges

All mechanical pivot points on the vehicle (e.g. door hinges, joints) and fittings (e.g. door
arresters) must be lubricated regularly, even if they are not listed in the lubrication plan.

Maintenance
Maintenance
5
5.14 Engine fluids and lubricants
Component/ Engine/vehi- SAE grade Season/ 1Capacities

application cle fluid Specification temperature
Diesel engine SAE 10W; EO10 3 Below -5°C

SAE 20W/20; EO20 3 -10°C to +10°C
+5°C up to
Engine oil2 SAE 30; EO30 3 10.5 ltr.
+30°C
HD-C 10W-40; EO1040B 3
Year-round
HD-C 15W-40; EO1540B 3
20 kph gearbox (standard) 1.25 ltr.
40 kph high speed gearbox (option) 1.50 ltr.
SAE 80W -90EP;
Planetary drives – front/rear axle Gearbox oil4 Year-round 0.80 ltr. each
GO90 GL-4/GL-53
Differential – front axle 7.50 ltr.
Differential – rear axle 4.50 ltr.
Hydraulic oil tank SAE 5 W/30 Up to -25°C
3
SAE 5 W/40; EO 0540B Up to -25°C
Engine oil 2
SAE 10 W/40; EO 1040B 3 Up to -15°C
3
SAE 15 W/40; EO 1540B Up to -10°C
3 About 57 ltr.
ATF ATF 66 M/ATF 86 (ATF )
Hydraulic oil 5 HLVPD 46 6 (HYD0530 3)
Year-round
AVILUB Syntofluid 46
Biodegradable oil
PANOLIN HLP Synth 46
Grease nipples Multipurpose Lithium-saponified brand-name
Year-round As required
grease grease MPG-A3
Battery terminals Acid-proof grease SP-B 3 Year-round As required
Mounting of pins, shafts etc. Special grease Optimoly paste “TA”7 Year-round As required
Fuel tank Grade no. 2-D Over 4 °C
Diesel fuel 8 90 ltr.
Grade no. 1-D9 Below 4 °C
Washer system Cleaning agent Water + antifreeze Year-round10 About 1.2 ltr.
1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
2. MIL-L-2104C; API -CD/CE/CF4; CCMC-D4
3. Abbreviation for lubricants (Hauptverband der Deutschen Bauindustrie e. V. – German construction engineering association e.V.)
4. MIL-L-2105/MIL-L-2105D; API-GL4/API-GL 5 with EP additive (“Limited Slip”)
5. DIN 51 521 T3
6. Viscosity category as per ISO VG46
7. 250 gr tube: order no. 0 00 441 32 10
8. DIN 51 601, min 45 cetane
9. Applications above 1500 m
10. Observe the antifreeze compound table – see manufacturer's instructions on packaging

Maintenance
5.15 Service kits

Service kits
Part number Description Qty Remarks
Service kit f o r “ 1 st Inspection”

1380030530 Service kit 1
Parts for maintenance plan “ B ”

0009962406 O-ring (for planetary drives, front axle, 20 kph gearbox) 9 27 x 32 x 2.5
0000808520 Ring (40 kph gearbox, option) 2 31 x 38 x 2.5
Service kit for “ 2 nd Inspection” and Maintenance plan “ C ”

Service kit for Maintenance plan “ D ”

Additional parts for Maintenance plan “ D ”

0000805188 Safety cartridge 1 (not included in service kit))
Fine dust filter (EU4) for heating 1 (option, not included in service kit)

Maintenance
Maintenance
5
5.16 Proofs of maintenance
The following table provides clear information on the maintenance and service work to be
carried out after a certain amount of service hours.
The maintenance work to be carried out is shown in section “Maintenance plan (overview)”
on page 5-48.
Confirm the proper execution of the work in the respective box in the following table.
“1st and 2nd Inspections” must be carried out by an authorized workshop for warranty
claims to be acknowledged. Information on maintenance material and lubricants can be
found in section “Engine fluids and lubricants” on page 5-42 or in section “Service kits” on
page 5-43.
Proofs of maintenance Proofs of maintenance
Service hours
Service hours
After service
Maintenance
After service
Maintenance
Company/
signature
Company/
signature
hours
hours
Date
plan
Date
plan
Delivery 650 A
50 A 700 A
1st
100 Inspec- 750 A
tion
150 A 800 A
200 A 850 A
250 A 900 B
300 B 950 A
350 A 1000 A
400 A 1050 A
450 A 1100 A
500 A 1150 A
550 A 1200 D
2. Inspec- 1250 A
600
tion

Maintenance
Service hours
Service hours
After service
After service
Maintenance
Maintenance
Company/
Company/
signature
signature
hours
hours
Date
Date
plan
plan
1300 A 2150 A
1350 A 2200 A
1400 A 2250 A
1450 A 2300 A
1500 B 2350 A
1550 A 2400 D
1600 A 2450 A
1650 A 2500 A
1700 A 2550 A
1750 A 2600 A
1800 C 2650 A
1850 A 2700 B
1900 A 2750 A
1950 A 2800 A
2000 A 2850 A
2050 A 2900 A
2100 B 2950 A

Maintenance
Service hours
Service hours
After service
After service
Maintenance
Maintenance
Company/
Company/
signature
signature
hours
hours
Date
Date
plan
plan
3000 C 3850 A
3050 A 3900 B
3100 A 3950 A
3150 A 4000 A
3200 A 4050 A
3250 A 4100 A
3300 B 4150 A
3350 A 4200 C
3400 A 4250 A
3450 A 4300 A
3500 A 4350 A
3550 A 4400 A
3600 D 4450 A
3650 A 4500 B
3700 A 4550 A
3750 A 4600 A
3800 A 4650 A

Maintenance
Service hours
Service hours
After service
After service
Maintenance
Maintenance
Company/
Company/
signature
signature
hours
hours
Date
Date
plan
plan
4700 A 5550 A
4750 A 5600 A
4800 D 5650 A
4850 A 5700 B
4900 A 5750 A
4950 A 5800 A
5000 A 5850 A
5050 A 5900 A
5100 B 5950 A
5150 A 6000 D
5200 A 6050 A
5250 A 6100 A
5300 A 6150 A
5350 A 6200 A
5400 C 6250 A
5450 A 6300 B
5500 A 6350 A

5
Maintenance plan/service hour
5-48
5.17 Maintenance plan (overview)
Work description
Maintenance
„B“
“A”
“C”
“D”
yearly
(daily)
For service and maintenance work on the implement, please refer to the operation and maintenance manual of the
monthly
Delivery
10 hours
inspection
every week
at 100 hours
implement manufacturer as well.
every 50 hours
2nd Inspection
1st Inspection1
every 300 hours
Service work every

every 600 service hours2
every 1200 service hours
Oil change and filter replacement ( ):

Carry out the following oil and filter changes (check oil levels after test run):
• Engine oil ● ● ●
• Engine oil filter ● ● ●
• Fuel filter ● ● ●
• Clean screen filter of fuel feed pump. Replace if necessary ● ● ●
• Replace fuel leak oil line and connecting pieces3 ●
• Replace air filter insert 4, 5, safety cartridge after every 3rd replacement of the air filter insert ●
• Gearbox oil in front and rear axle differentials and in rear axle gearbox ● ●
• Gearbox oil in front and rear axle planetary drives, left and right side ● ●
• Hydraulic oil 6 ●
• Hydraulic oil filter insert 4 ● ●
• Breather – hydraulic oil tank ●
Inspection work ( ):
Check the following material. Refill if necessary:
• Engine oil ● ● ● ●
• Hydraulic oil ● ● ● ● ● ●
• Gearbox oil in front and rear axle differentials and in rear axle gearbox ● ● ●
• Gearbox oil in front and rear axle planetary drives, left and right side ● ● ●
Check engine oil cooler and hydraulic oil cooler for contamination. Clean if necessary7 ● ● ● ● ● ●
Clean dust valve on air filter housing 4 ● ● ● ● ● ● ●
V-belt: check condition and pre-tension. Retighten or replace if necessary ● ● ● ● ● ●
Check glow plugs. Replace if necessary ● ●
Check valve tip clearance (engine timing). Adjust if necessary ● ●
Battery: check electrolyte level and charge condition ● ●
Heating: clean dust filter and replace every 1200 service hours if necessary ● ●
Check and adjust brake linings of service and parking brake. Replace if necessary ● ●
Tyre check (damage, air pressure, tread depth) ● ● ● ● ● ●
BA 302 01 US-Gehl – Edition 1.0 * 30101b06w2.fm


Work description
„B“
“A”
“C”
“D”
yearly
(daily)
monthly
Delivery
10 hours
inspection
every week
at 100 hours
every 50 hours
2nd Inspection
1st Inspection1
every 300 hours
Service work every

Check screws and nuts or screw connections for tightness on the following assemblies/components. Retighten if necessary

• Engine and engine bearing ● ●
• Steering system ● ●
• Hydraulic system ● ●
• Loader unit (pin locking) ● ●
• Axle mounting, axle suspension ● ●
• Counterweight/additional counterweight (attachment) ● ●
• Fastening screws of propshafts ● ●
• Attachment screws of cab ● ●
• Wheel nuts ● ●
• Electrical system: wire and earthing lead connections, chafing on wiring harness, battery terminals ● ● ● ●
Lubrication service ( ):8
Lubricate the following assemblies/components:
• Rear axle oscillating bearing ● ● ● ● ● ●
• Front and rear axle planetary drive bearings, left and right ● ● ● ● ● ●
• Loader unit
• Lift frame bearing ● ● ● ● ● ●
• Tilt rod bearing ● ● ● ● ● ●
• Tilt lever bearing ● ● ● ● ● ●
• Lift ram bearing ● ● ● ● ● ●
• Tilt ram bearing ● ● ● ● ● ●
• Quickhitch facility: bearing on lift frame ● ● ● ● ● ● ●
• Hinges, joints and fittings (e.g. door arrester) ● ● ●
Functional check ( ? ):
Check the function of the following assemblies/components. Rectify if necessary:
• Service and parking brake ● ● ● ● ● ● ●
• Steering system ● ● ● ● ● ● ●
• Light system ● ● ● ● ● ● ●
5-49
Maintenance
5-50
Work description
Maintenance
„B“
“A”
“C”
“D”
yearly
(daily)
monthly
Delivery
10 hours
inspection
every week
at 100 hours
every 50 hours
2nd Inspection
1st Inspection1
every 300 hours
Service work every

Leakage check ( ):
Check for tightness, leakage and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary.
• Air intake line (air filter – engine) ● ● ● ● ● ●
• Engine lubrication (engine – filter) ● ● ● ● ● ●
• Fuel lines ● ● ● ● ● ●
• Cooling system (engine oil and hydraulic oil) ● ● ● ● ● ●
• Brake system ● ● ● ● ● ●
• Steering system (flexible lines and rams) ● ● ● ● ● ●
• Hydraulic system/loader unit (flexible lines and rams) 9 ● ● ● ● ● ●
1. Work to be carried out after the first 100 service hours only. This work must be carried out by an authorised workshop for warranty claims to be acknowledged
2. Work after the first 600 service hours (2nd Inspection) must be carried out by an authorized workshop for warranty claims to be acknowledged
3. Replace fuel leak oil line and the connecting pieces at least every 2 years
4. Replace filter insert as indicated by the telltale in the instrument panel, however at least every 12 months or 1200 service hours
5. When working in an acidic environment, replace the filter every 300 service hours!
6. When using biodegradable oil: Drain the condensation water in the hydraulic oil tank every 600 service hours, in any case before the cold season
7. It may be necessary to clean the cooler more frequently depending on operating and dust conditions
8. Lubricate implement as per manufacturer's instructions!
9. Replace flexible lines every 6 years or in accordance with the legal regulations of your country

Maintenance
BA 302 01 US-Gehl – Edition 1.0 * 30101b06w2.fm 5-51

Maintenance
5
5.18 Maintenance label
valid for model 521 Explanation of symbols on maintenance label
Symbol Description
Before starting maintenance work, take note of the safety instructions in the operation manual!
Before starting maintenance work, take note of the Section “Maintenance” in the operation manual!
Carry out a functional check of the light system!
Check tyres for damage, pressure and tread depth!
Carry out a functional check of the steering, synchronise the steering!
Carry out a functional check of the brake system!
Check hydraulic oil level. Top up if necessary!
Check engine oil level. Top up if necessary!
Clean dust valve on air filter housing!
Check cooler for engine coolant and hydraulic oil for contamination. Clean if necessary!
Check condition and initial tension of V-belt. Retighten or replace if necessary!
Leakage check:
Check for tightness, leakage and chafing: pipes, flexible lines and screw connections. Rectify if necessary!
Lubrication service:
Lubricate the assemblies concerned!
5-52 BA 302 01 US-Gehl – Edition 1.0 * 30101b06w3.fm

50 h
10 h
Daily
Täglich
521 0001

Tous les jours
˚F
175
105 250
80 12 14
60 100
40 ˚C 120 10 16
20 30
Volt
10 20
10 40
P ˚F
270 1/2
165
120 500 MPH 30 0 1/1
75 100
125 Km/h
50 ˚C 150 50
0236
HAZARD
0 00 435 28 89
30100w01a.eps
Maintenance
5-53
Maintenance
5-54 BA 302 01 US-Gehl – Edition 1.0 * 30101b06w3.fm

Section 6
Helpful information for using the spare parts list
Helpful information for using the spare
6 Helpful information6 for using the spare parts list

6.1 Introduction
This operation manual and a separate spare parts list have been handed over to you
together with your vehicle.
Please read this section carefully. It will make it easier for you to carry out your work and
find spare parts.
The illustrations in the spare parts list are not binding for design.
Subject to further development and technical modifications.
6.2 Composition of spare parts list

6.2.1 Groups
The spare parts list is divided in functional groups.
Groups are identified by numbers (e.g. 01 = engine)
01
Group
Fig. 202: Title page of a group

6.2.2 Group overview

The spare parts list contains the following groups:
Group Description
00 Service kits
00/1 Electrical components
01 Engine
08 Fuel system
10 Air filter
15 Cooling
17 Speed regulation
20 Vehicle frame
22 Hydrostatic drive
23 Front axle
24 Brakes
26 Rear axle
27 Steering
29 Operator's seat
30 Sheet-metal parts
31 Wheels and tyres
32 Exhaust system
33 Electrical system
34 Cab
36 Hydraulic system
41 Heating
41/3 Buckets
43 Tools, labels, vehicle documentation
A Number index

6.2.3 Figures
Groups consist of one or more figures. They are identified at the upper right by the figure
number.
The number before the hyphen identifies the group (e.g. 01).
The reference numbers in the figures identify the individual spare parts. The correspond-
ing part numbers are listed in the number index.
The figures are reduced representations of assemblies and component parts, and are not
binding for design.
Subject to further development and technical modifications.
Reference numbers 01-58
17 Figure number
20
21
22
21
18
19 19
Fig. 203: Example for figure
6.2.4 Number index

The number index is included at the end of the spare parts list and contains all part num-
bers corresponding to the reference numbers in the figures.
Part numbers are listed in the order of figures, and of reference number.
Part number
Reference number Validity
Figure Symbol
00-2 2
23
1234567890 l=> <=l
01-7. . . . . . . . 1 . . . . 7571646012 301 56 0128
01-7. . . . . . . . 2 . . . . 7578646001 301 56 0129 301 56 0150
01-7. . . . . . . . 3 . . . . 7578646002 301 56 0151
01-7. . . . . . . . 4 . . . . 0003330367
01-7. . . . . . . . 5 . . . . 7571646041
01-7. . . . . . . . 6 . . . . 7571646042 1410/04
01-7. . . . . . . . 7 . . . . 7571646043 C 39/3
01-7. . . . . . . . 8 . . . . 7578646011
01-7. . . . . . . . 9 . . . . 7578646012
01-7. . . . . . . . 10 . . . 7578646013

6.3 Symbols and abbreviations

Symbols and abbreviations are used in the figures for clear identification of parts.
Combinations of symbols and abbreviations are also used.
6.3.1 Description of symbols

Symbols may have the following meanings:
Symbol Description
Reference number
22 Identifies a component part.
The circled number identifies an assembly which may consist of several component
17 parts.
Assemblies are delivered as finished assemblies, or preassembled with all necessary
component parts.
17
20
21
22
21
18
19 19
Component parts can be grouped in brackets or in boxes, or appear below the reference
number of the assembly, e.g. reference numbers 18 and 19.
A component part can consist of several parts which may be deliverable as a whole only,
5
e.g. reference number 19.
4 3 6 2
10
12
11 Component parts grouped in a box, without reference number for the assembly, identify
8
details.

Symbol Description
Validity
➜❙ or <=l Components valid only up to including the number stated
❙➜ or l=> Components valid only starting including the number stated
Identification of serial number
Symbol for axle
Symbol for cab
Symbol for engine
Instructions for assembly
Do not disassemble parts. Components cannot be repaired.
Tighten parts with a torque spanner to the prescribed torque. Use the standard torques if
no specific torque is stated – see section 7 Tightening torques and "Specific torques"
Safety part! For reasons of safety, parts may be dismantled or repaired by qualified
mechanics only. Otherwise parts must be replaced as a whole!
Check parts for wear before reassembly, e.g. bearings, rotary shaft lip seals etc.
Parts are not reusable and must be replaced during repair work, e.g. sealing elements
Pay special attention to direction of installation when removing or fitting parts, e.g. rotary
shaft lip seals, bearings, bushings etc.
Use specified locking and sealing compounds, e.g. Loctite 242
Determine length/thickness of new component, e.g. shims, edge guard, sealing strip etc.
Round up to full metres when using material by the metre!
6 0.15
7 Measure thickness of new part, due to availability in various sizes.
0.2
8 0.5
State all dimensions in mm (millimetres).
Special symbols
Symbol for special version with float position
Symbol for hydraulic ram
Symbol for sealing kit
Identification of repair kit
Symbol for tool kit
Identification of machine documentation

6.3.2 Abbreviations
Indication of position Abbreviations specify position of spare part on/in vehicle in driving direction.
Combinations of abbreviations are also possible, e.g. HLO (upper rear left).
Abbreviation Description
V Front
H Rear
L Left
R Right
O Upper
U Lower
M Centre
A Outer
I Inner
Use Abbreviations specify use of spare part on/in vehicle.
BA Specifies operation manual
ET Specifies spare parts list
CD Identification for CD-ROM
MC Specifies microfiches
SO Specifies special equipment
n. B As required
n. l. Not available
Language codes Abbreviations specify language versions.
De German
En English
Fr French
Nl Dutch
Fi Finnish
It Italian
Es Spanish
Pl Polish

Colour codes Abbreviations specify colour of spare part on/in vehicle.
WH White
YE Yellow
GN Green
RD Red
VT Violet
BN Brown
BU Blue
BK Black
GN Grey
OG Orange
6.4 Vehicle data

Always include the exact vehicle data in your orders to ensure correct delivery of spare
parts required.
Refer to section 1 "Vehicle data" and “Type labels and implement numbers” for your rele-
vant vehicle data.
6.5 Helpful information for ordering spare parts

Delivery of spare parts cash on delivery.
Damaged samples will be scrapped if no request for return has been forwarded
within 4 weeks.
Spare parts can be returned only upon agreement with our Spare Parts Department.
Return excludes:
Seals, O-rings, sealing kits, electrical parts, special purchases and parts ordered without
exact vehicle data.

6.5.1 Order information

Always include the following information in your orders to ensure correct delivery of spare
parts:
• Customer and address
e.g. Jason Miller
High Street 7
Leighton Buzzard LU5 8RT
• Delivery address if not identical with customer's address
e.g. Construction site: Jeff Mason
Church Street 9
High Wycombe HP9 3ER
• Mode of shipment
e.g. United Parcel Service (UPS)
Shipment will be made at our own discretion if no indications are made
• Vehicle description
e.g.:
• Model and serial no. (see type label on vehicle)
e.g. 521, 521 0001
• Spare parts list and edition (see spare parts list cover)
e.g. edition 1.0
• Figure, reference (in spare parts list)
e.g. 01-8, reference 15
• Part number (in number index in spare parts list)
e.g.: 0000801987
• Quantity and unit
e.g. 1 off
• For component, identification number (see type label)
6.5.2 Address for your spare part order

Section 7
Specifications
Specifications
Specifications
7 Specifications 7
7.1 Frame
Sturdy U-section frame, rubber-mounted operator's cab and engine.
7.2 Engine
Engine
Product Deutz diesel engine
Model BF4L 1011
Design In line
No. of cylinders 4
Displacement 2732 cm³
Bore and stroke 91 x 105 mm
Compression ratio 17:1
Output (as per ISO 9249) 48.5 kW/66 DIN HP
at 2300 rpm
Max. torque 218 Nm, 1800 rpm
Specific minimum fuel consump-
215 g/kWh
tion
Fuel injection system Direct fuel injection
Firing order 1-3-4-2
Starting aid Glow plug
Max. inclined position (engine no Max. lateral inclination left/right:58/58
longer supplied with oil): Max. inclination upward/downward:47/84
Observe tilting limit of the vehicle!
Oil pressure Min. 2.3 bar at 2500 rpm
Valve tip clearance (engine at Intake valve 0.3 mm
cold temperature) Exhaust valve 0.5 mm
BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm 7–1

Specifications
7.3 Power train

Variable displacement pump model A4VG56DA1D4/32R – directly flanged on the
engine
Design Axial piston pump (swash plate design)
Displacement 0 – 56 cm³/rev
Max. operating pressure p 450 bar
Starting RPMs 1050 – 1150 rpm at 50 bar HP
Droop 1800 ±100 rpm, 400 bar high pressure
Boost pump:
Design Internal gear pump
Displacement 11.6 cm³/rev
Charging/boost pressure 25 bar, 1500 rpm
Control Speed-sensitive, hydraulic feed volume adjustment
with pressure cut-off
Driving direction Electrohydraulic control
Inching Hydraulic inching valve, controlled via the master
brake cylinder
Variable displacement motor model A6VM80DA5/63W – on rear axle intermediate
gearbox
Design Axial piston motor (swash plate design)
Capacity 27.1 to 80 cm³/rev
Standard 1st drive range: 0 – 5 kph, forward and reverse
2nd drive range: 0 – 20 kph, forward and reverse
High speed 1st drive range: 0 – 9,5 kph, forward and reverse
Drive speed option 2nd drive range: 0 – 40 kph, forward and reverse
Restricted high 1st drive range: 0 – 7,5 kph, forward and reverse
speed (option)1 2nd drive range: 0 – 30 kph, forward and reverse
Max. traction force 49.0 kN (521)
1. For countries (e.g. Switzerland) with specified maximum speeds!
7–2 BA 302 01 US-Gehl – Edition 1.0 * 30101b0710.fm

Specifications
7.4 Axles
Front axle (with 100% differential lock)
Design Planetary drive steering axle,
rigid screw connection with frame
King-pin inclination 0°
Camber 0°
Positive/negative wheel castor 0°
Steering angle 40°
Toe-in 0°
Track width 1460 mm
Rear axle (with 100 % differential lock)
Design Oscillating planetary drive steering axle
King-pin inclination 0°
Camber 0°
Total oscillation angle +/- 9 °
Positive/negative wheel castor 0°
Steering angle 40°
Toe-in 0°
Track width 1460 mm
7.5 Brakes
Service brake
Design Foot-operated, hydraulic power brake + hydrostat
Mounted in Front axle, drive (rear axle)
Effect On both axles via cardan shaft
Brake fluid Hydraulic oil from hydraulic oil circuit – see Engine
fluids and lubricants on page 5-42
Parking brake
Design Manual, mechanical disc brake
Mounted in Front axle input
Effect On both axles via cardan shaft

Specifications
7.6 Steering
Steering
Design Hydrostatic four-wheel steering with emergency
steering features (closed version)
Steering mode 1. 4 wheel steering
2. Front axle steering
On vehicles with high speed, only front axle steering
is possible in the 2nd drive mode!
Assemblies Manual pump, hydraulic pump, priority valve, safety
valves, 1 steering ram per axle, solenoid valve for
steering/wheel synchronisation.
Max. pressure of hydraulic lines 160 – 180 bar
Manual pump: Servostat
Displacement 120 cm³/rev
Hydraulic pump Gear pump (priority valve)
Maximum steering angle ±40°
7.7 Work hydraulics
Hydraulic pump Gear pump

70 litres minimum at 2300 rpm
Control valve 3-fold pilot control
Max. service pressure 235 bar
Secondary pressure limiting Tilt ram Rod side 280 bar
Bottom side 120 bar
Lift ram Bottom side 300 bar
Filter Reflux suction filter (0.5 bar initial stress)
7.8 Pilot control

Pilot control pump = boost pump of hydraulic pump
Displacement 11.6 cm³/rev
Charging/boost pressure 25 bar, 1500 rpm
Pilot control unit:
Joystick Four-way lever – control of lift and tilt rams
Pilot control unit (simple): Control of lock ram and implements
Ball-type stop cock: Lock against accidental actuation (for long-haul travel
and transport)

Specifications
7.9 Loader unit

Loader unit with bucket 1, 2
Bucket capacity heaped as per ISO 0.95 m³
Tipping load 3680 kg
Payload (tipping load x 0.5) 1840 kg
Lift load at max. height 3298 kg
Bucket width 1950 mm
Dumping height 2532 mm
Fulcrum height of quickhitch facility 3235 mm
Dumping reach 668 mm
Scraping depth 45 mm
Tilt-back angle 50°
Dump-out angle -45°
Breakout force (lift ram) 45.2 kN
Breakout force (tilt ram) 38.8 kN
Fork arms 3 (payloads stated for 500 mm load distance)
Tipping load (ISO 8313): 2750 kg
Payload (ISO 8313) at:
(S= 1,25)4 2200 kg
(S= 1,67)5 1650 kg
Pallet height mm
Movable payload in transport
2875 kg
position (S=1.25):4
1. With standard tyres 12.5-20

2. With standard bucket 10204-00
3. With pallet forks 01369-03
4. On firm and level ground
5. Off-road
7.10 Weights
Weights1
Kerb weight2 5050 kg
Gross weight rating 6000 kg
Front axle weight rating 4000 kg
Rear axle weight rating 4000 kg
Max. authorised load for towing 5500 kg
facility
1. With standard bucket 10204-00 and standard tyres 12.5-20

2. Without driver

Specifications
7.11 Electrical system

Alternator 14 V/80 A
Starter 12 V/2.2 kW
Battery 12 V/72 Ah1 278x175x190 mm)
Socket E.g. for cigarette lighter; max. 15 A
1. Low-temperature test current 570 A and vibration-proof according to EN 60095-1
Electrical fuses and relays – fuse box in cab
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14
F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28
K1 K2 K3 K4 K5
K6 K7 K8 K9 K10 K14
Fig. 205: Fuse box in cab 30100b1900.eps
Relay no. Protected circuit

K1 – Solenoid valve – forward driving
K2 – Solenoid valve – reverse driving
K3 – Not assigned
K4 – Solenoid valve differential lock
K5 – 4thcontrol circuit (option), implements
K6 – Front wiper motor, speed II
K7 – Front wiper motor, speed I
K8 – Not assigned
K9 – Hazard light unit
K10 – Solenoid valve load stabilizer
K14 – Not assigned

Specifications
Fuse no. Rated current (A) Protected circuit

F1 25 A – Heating
– Air conditioning (option)
F2 15 A – Rear wipe/wash system
– Front wipe system
F3 3A – Control lever, left half
F4 3A – Control lever, right half
F5 15 A – Solenoid valves:
telescopic loader unit (option, telescopic loader
unit only)
differential lock, high speed lock,
front attachment, quickhitch lock
F6 7.5 A – Start/drive solenoid valve
F7 7.5 A – High beam (right)
F8 7.5 A – High beam (left)
F9 7.5 A – Low beam (right)
F10 7.5 A – Low beam (left)
F11 5A – Parking light (right)
– Switch and numberplate lights
F12 5A – Parking light (left)
– Instrument lights
F13 7.5 A – Working light, interior light
F14 3A – Preheating/starting relay
F15 7.5 A – Hazard warning system, direction indicator
F16 7.5 A – Steering electronics
F17 7.5 A – Steering, high speed (option)
F18 3A – Steering sensor mechanism
F19 25 A – Condenser fan (option)
F20 3A – Instrument
F21 5A – Radio (option)
– Safe load indicator (option, telescopic loader unit only)
F22 7.5 A – Front wash system, horn, compressor (option)
F23 15 A – Seat motor (option)
– Load stabiliser
F24 10 A – Lights
F25 15 A – Auxiliary heating (option)
– Cigarette lighter/socket
F26 25 A – Main headlight
F27 15 A – Rotating beacon (option)
F28 5A – Brake lights
3A – Spare
5A – Spare
7.5 A – Spare
15 A – Spare
0390010191b – 11/01

Specifications
Electric relays – above the fuse box in the cab

K11 K12 K13 K14 K15 K11 – High current relay – terminal 15
K12 – High current relay terminal 15
K13 – Switching relay – high beam
K14 – Switching relay – low beam
K15 – Pulse generator – intermittent wiper
Fig. 206: Relay above fuse box
Electrical fuses – main fuse box in engine compartment
Fuse no. Rated current (A) Protected circuit

F29 F31
F29 50 A Power supply
F30 F32
F32 40 A Preheating system, starter
30101b720.eps
Fig. 207: Main fuse box in engine compartment
Electric relay – in the engine compartment
K16 – Preheating system
K17 – Starter
K16 K17
Fig. 208: Relay in the engine compartment
Electric relays – instrument panel/side console

K18 – Time lag relay for telltale check (in the instrument panel)
K19 – Switching relay – condenser grade 1/2 (option, in side console)
K20 – Switching relay – condenser (option, in side console)
K21 – Switching relay – condenser (option, in side console)

Specifications
7.12 Noise levels

Noise levels
Sound power level
Measured value 98 dB (A)
Guaranteed value 99 dB (A)
Noise level in the cab 76 dB (A)
Important!
Noise emission level measured according to EC Directive 2000/14 EC. Noise level
in the cab measured according to EC Directives 84/532/EEC, 89/514/EEC and
95/27/EEC. Measurements carried out on asphalted surface.
7.13 Vibration
Vibration
Effective acceleration value for the upper extremities of the
body < 2.5 m/s2
Effective acceleration value for the body < 0.5 m/s2

Specifications
7.14 Tyres
Caution!
Extreme steering angles cause some tyres (optional tyres!) to touch the
vehicle frame. This can damage the tyres!
☞ The steering angle must be limited by a specialist workshop according to
the assembly instructions when using these tyre models which are specially
marked in the following tyre table!
Bear in mind the label on the front window of the vehicle!
Tyre pressure1 Wheel rims

Tyre size (bar)
Front Rear Wheel rim Wheel offset
12.5-20 MPT 04 10PR
375/702 R20 MPT AC 70G 136G 2,50 2,00 11 x 20 20 mm
375/752 R20 XZSL 143B
405/702 R18 SPT 9 141B 3,00 2,50 13 x 18 10 mm
1. Increase front tyre pressure by 0.5 bar during pallet forks operation!
2. Steering angle must be limited to 35 ° !

Specifications
7.15 Dimensions
e d 38b09200.ai 38b09300.ai
g f
A c
Fig. 209: Vehicle dimensions
Vehicle dimensions1
Overall length a 5090 mm
Overall height b2 2740 mm
Overall width c 1950 mm
Ground clearance d 315 mm
(gearbox on rear axle)
Ground clearance e in transport position of 150 mm
loader unit
Front/rear track width f 1460 mm
Wheelbase g 1910 mm
Turning radius
Between kerbs 2825 mm
Between walls 4050 mm
1. With standard bucket 10204-00 and standard tyres 12.5-20 MPT 04

2. With FOPS screen b = b + 125 mm
7.16 Coolant compound table

Outside tempera- Coolant
ture Water Anticorrosion agent Antifreeze agent
% by
Up to °C cm³/ltr. % by volume % by volume
volume
4 99 -
-10 79 20
-20 65 10 1 34
-25 59 40
-30 55 44

Specifications
7.17 Tightening torques

7.17.1 General tightening torques
Tightening torques in Nm1
Screw dimensions
8.8 10.9 12.9
M4 3 4 5
M5 5,5 8 10
M6 10 14 16
M8 23 34 40
M10 46 67 79
M12 79 115 135
M14 125 185 220
M16 195 290 340
M18 280 400 470
M20 395 560 660
M22 540 760 890
M24 680 970 1150
M27 1000 1450 1700
M30 1350 1950 2300
1. Values valid for screws with slightly oiled surfaces
7.17.2 Specific tightening torques

Description Tightening torque
Wheel nut 400±20 Nm
Track-rod end (steering ram) 200 Nm
Front axle mounting 250 Nm

Annex
Annex
Hydraulics diagram (options)

A
valid for model521

Ref. Description
Ref. Description 10 Option –high speed (40 kph –0382603101)
1 Float position option 11 Fast drive range valve block
2 Control valve float position 12 High speed control ram
521 = 235 bar 13 Option –hose burst valve for lift and tilt rams
3 Pilot valve float position (01376-02)
4 Option –depressurised reflux for implements 14 Lift ram
(0383604198) 15 Tilt ram
5 Standard control valve: 521 = 235 bar 16 Option –hose burst valve for lift and tilt rams
6 Connecting piece export version for France
7 Option –side swing bucket (01369-06) 17 Lift ram
8 Option –pallet forks with sliding fork arms 18 Tilt ram
9 Option –multipurpose bucket (01369-04/01369-05)
1 4
C1 A1 B1 C2 F A2 B2 C3 A3 B3
X2 X3
2 X1
3 C1 A1 B1
P 5
P
P
T
T 6
T
Y2 F Y1 Y3
D1 D2 D3
D1
0383604198
7 9 10
G T1 T3 T2
B
C
230 bar
11 D
E F
12
01369-06
8 10086-00
01369-04
01369-05
14 15 18
V1 C1 V1 C1
X 17 X
)
) )
C1 C2 M C1
1 C2 C2 M )1
X
C2
X
) V2 ) V2
) ) ) ) )
)
2 XM 2 XM
V1 V2 V1 V2
A2 A3 A2 A3
C1 A1 B1 C2 B2 C3 B3 C1 A1 B1 C2 B2 C3 B3
P P
T T
13 D1 D2 D3 01376-02 16 D1 D2 D3 a) ....................
b) 0383603898
0380011125a - 09/01
0380011225a - 09/01 0380011125a_SO.eps
BA 302 01 US-Gehl –Edition 1.0 * 30101b07hyd_so.fm A-1

A
A-2
Hydraulics diagram Annex
Ref. Description
Ref. Description 30 Pressure switch 80 bar
1 Hydrostatic steering 58.7 – 117.4 cm³ 31 Membrane accumulator for brake pressure
2 Priority valve (dynamic signal) 32 Brake pedal valve

69 bar with multi-disc brake in axle casing
3 Drive variable displacement pump 77 bar with multi-disc brake in planetary drive
4 Boost pressure pump V = 11.6 cm³/rev, Q = 25.6 l/min 33 Brake light switch 6 bar
5 Work hydraulics pump V = 32 cm³/rev, Q = 70 l/min 34 Inching valve 12 bar
6 Drive variable displacement motor 35 Multi-disc brake front axle left
7 Gear motor for fan drive V=8 cm³/rev, Pmax=230 bar 36 Multi-disc brake front axle right
8 Oil temperature controller 37 Rear axle steering ram ø 75/38, 171 mm stroke
9 Oil cooler 38 Front axle steering ram ø 75/38, 171 mm stroke
10 Pressure switch 39 Solenoid valve – steering mode
11 Temperature sensor 40 Check block
12 Reflux suction filter
13 Hydraulic oil tank V total = 77 l, V oil level = 62 l
14 Vent filter
15 Manifold block
16 Standard control valve 235 bar
17 Control ram for quickhitch facility
18 Lift ram
19 Tilt ram
20 Pressure accumulator PV = 20 bar
21 Solenoid valve – load stabiliser
22 Standard control valve
23 Stop cock for road travel
24 Valve block for differential lock
25 Pressure accumulator for pilot control
26 Rear axle differential lock
27 Front axle differential lock
28 Gear pump – brakes V = 13 cm³/U, Q = 28 l/min
29 Cut-off valve with integrated flow divider
(switch-on pressure 120 +10 bar, switch-off pressure 150 -10 bar)
BA 302 01 US-Gehl – Edition 1.0 * 30101b07hyd.fm

2
PA1 Pv=20 bar 20
EF P
CF 17 18 19
8 PA12
LS
P T
3 140 bar
T 185 bar
BA 302 01 US-Gehl – Edition 1.0 * 30101b07hyd.fm

T PB PA
Z 5-20 bar PA 5 T2 T G X1 X3 B U
P LS PA 6
1 B A 21
T PS x Fa x x
)) 7
T B B S
pmax =230 bar

x PA 8 P
25 bar
9
490
bar A
x x x M1 A 2,5 bar 10
X1 X2 G 460 bar S
PA-- 6 12
210 bar PA 7
A
T
P1
4 5 11 P2 14
L R
X
B2
A1 A2 ø4
0,5 bar
40
0,5 bar
13 ø3,5
10 bar 10 bar C1 A1 B1 C2 A2 B2 C3 A3 B3
B1 B2
16 X2 X3
X1
22
39 P
23
P T 36 5 +3 bar P
A B
28 T
T 220 bar (301-01)
26 235 bar (302-01)
Y2 Y1 Y3
15 300 bar 280 bar 120 bar
Pst
32 HA G T1 T3 T2 D1 D2 D3
69 bar 29 A B C
A T B A
A (21) (51) T 0,5 bar
(11) P PA 11
P PA 9 PA 10 VA
5 24 F E
12 bar
35 PA 2 PA--
34 2 1
33
38 37 27 25
31 (0380011125a/0380011225a)
0380011125a.eps
80 bar
30
A-3
Annex
Annex
Legend – wiring diagram

A
Ref. Description Section Pos. Ref. Description Section Pos.

A1 Radio (option) 4 S H12 Telltale – alternator charge function 4 MI
B1 Sensor – front axle centre position 2 - H13 Telltale – turn indicators 4 MI
B2 Sensor – rear axle centre position 2 - H14 Telltale – differential lock 4 MI
B3 Fuel level sensor 3 - H15 Telltale – high beam 4 MI
B4 Temperature sensor – engine oil 2 - H16 Turn indicator (front left) 4 +
B5 Temperature sensor – hydraulic oil 4 - H17 Turn indicator (front right) 4 +
B6 Horn 4 - H18 Turn indicator (rear left) 4 -
Load sensor (option only for telescopic H19 Turn indicator (rear right) 4 -
B7 3 -
loader unit) H20, H21 Brake lights (left, right) 4 -
B8 Speed sensor (option) 2 - H22/23 Rotating beacon (option) 4 D
B9 Backup warning system (option) 4 D H24/25 LED telltale – driving direction 2 -
B10/11 Loudspeakers (option) 4 - H27 Telltale – hydraulic 2nd gear 4 S
D1 Steering electronics 2 - K1 Switching relay driving direction forwards 2 Z
D2 Power electronics – control lever 2 - K2 Switching relay driving direction backwards 2 Z
E1...E4 Instrument panel lights P1...P6 3 MI Switching relay – telescopic extension
K3 2 Z
E5 Rear light (left) 4 - (option, only telescopic loader unit)
E6 Front parking light (left) 4 + K4 Switching relay – differential lock 2 Z
E7 Front parking light (right) 4 + K5 Switching relay front implement (option) 2 Z
E8 Rear light (right) 4 - K6 Switching relay – wiper, 2nd speed 4 Z
E9...E12 Switch light S10, S12, S15, S18 4 F K7 Switching relay – wiper, 1st speed 4 Z
E14 Switch light S17 4 F Switching relay – telescopic retraction
K8 2 Z
E15 High, low beam (left) 4 D (option, only telescopic loader unit)
E16 High, low beam (right) 4 D K9 Hazard light unit 4 Z
E17 Rear left working light 4 D K10 Switching relay – load stabiliser 2 Z
E18 Rear right working light (option) 4 D K11/12 High current relay (terminal 15) 1 +
E19/20 Front working light (option) 4 D K13 Switching relay – high beam 4 +
E21 Numberplate light (option) 4 D K14 Switching relay – low beam 4 +
E22 Interior light with switch 4 D K15 Pulse generator – intermittent wiper 4 +
E23 Cigarette lighter 6 S K16 High current relay – preheating 2 -
E25/26 Clearance lights 4 - K17 High current relay – starting 2 -
F1...F28 Fuses (central electrics) Z K18 Time lag relay – telltale check 3 +
F29...F32 Fuses (power supply) 1 - Switching relay – condenser stage 1/2
K19 5 S
(option)
G1 Alternator with current regulator 2 -
K20 Switching relay – condenser (option) 5 S
G2 Battery 1 -
K21 Switching relay – air conditioning (option) 5 S
H1 Telltale – synchronisation 2 F
M1 Starter 2 -
H2 Telltale – four wheel steering 2 F
M2 Front wiper motor 4 +
H3 Telltale – front wheel steering 2 F
M3 Front washer fluid pump 4 +
H4 Telltale – parking brake 4 MI
M4 Rear washer fluid pump 4 +
H5 Telltale – preheating 4 MI
M5 Rear wiper motor 4 +
H6 Telltale – hydraulic oil filter 4 MI
M6 Fan motor for heating (3 speeds) 5 +
H7 Telltale – engine oil pressure 4 MI
M7 Fan motor – condenser (option) 5 -
H8 Telltale – brake pressure 4 MI
P1 Fuel level indicator 3 MI
H9 Telltale – coolant level (no function) 4 MI
P2 Temperature gauge – engine oil 3 MI
H10 Telltale – air filter 4 MI
P3 Temperature gauge – hydraulic oil 3 MI
H11 Telltale – not assigned 4 MI
P4 Speedometer (option) 3 MI
A-4 BA 302 01 US-Gehl – Edition 1.0 * 30101b06e10.fm

Annex

P5 Hour meter 3 MI Blocking diode – telescopic loader unit/
V20 2 -
P6 Voltmeter 3 MI implement (option)
Safe load indicator V21 Blocking diode – high speed (option) 2 +
P7 3 -
(option, only telescopic loader unit) F22 Blocking diode – parking brake switch 3 +
R1 Heater-plug filament 2 - Blocking diode – bucket repositioning
V23 2 -
R2 Resistor 5 - (control lever)
S1 Preheating start switch 2 S V25...V32 Blocking diode – telltale check 2 +
S2 Drive switch forward (in control lever) 2 - W1 Rod aerial – radio (option) 4 -
S3 Drive switch reverse (in control lever) 2 - W2 Aerial cable (option) 4 +
Tip switch – telescopic extension (option, X1...X4 Plug and socket connections – cab/frame 2 +
S4 only telescopic loader unit) and front imple- 2 - X5 8-pole connection – shift lever 2 -
ment tip switch (option) X6 12-pole connection – shift lever 2 +
Tip switch – telescopic retraction (option, X7 2-pole plug bucket repositioning 2 -
S5 2 -
only telescopic loader unit)
X8/9 8-pole connection – steering electronics 2 +
Tip switch – differential lock (in control
S6 2 - X10 4-pole socket front implements (option) 2 -
lever)
X11 2-pole plug – front washer pump 4 +
S7 Parking brake switch 2 +
X12/13 12-pole plug – telltale check 3 +
S8 Tip switch – quickhitch lock (option) 2 F
X14 2-pole plug – rear wash water pump 4 +
S9 Switch – front implements (option) 2 F
X15 8-pole plug – radio connection 4 S
S10 Switch – load stabiliser 2 F
X16 8-pole plug – loudspeaker connection 4 S
S11 Switch – 1st./2nd gear 2 S
X17 Aerial connection 4 +
S12 Switch – steering/high speed 2 F
6 pole plug and socket connection safe load
S13 Tip switch – synchronisation 2 F X18 4 -
indicator (option, telescopic only)
S14 Switch – front working light (option) 4 F
X19 4-pole connection – rear window washer 4 +
S15 Switch – rear working light 4 F
X20 4-pole connection – front wiper motor 4 +
S16 Switch – rotating beacon (option) 4 F
X21.1 12-pole plug – steering-column control lever 4 +
S17 Switch – rear wiper/washer 4 F
X21.2 4-pole plug – steering-column control lever 4 +
S18 Switch – lights, parking light 4 F
X22 2-pole plug – seat motor connection 6 +
Multifunctional lever – steering column,
S19 4 + X23 2-pole plug – auxiliary heating connection 6 +
right
4-pole plug and socket connection – heat-
S20 Hazard warning light switch with telltale 4 F X24 5 +
ing
S21 Brake light switch – service brake 4 +
X25 8-pole plug and socket connection – cowl 4 -
S22 Switch – heater fan 5 S
3-pole plug and socket connection – safe
Pressure switch – load stabiliser (only tele- X26 3 -
S23 2 - load indicator sensor
scopic loader unit)
2-pole plug and socket connection – fuel
S24 Oil pressure switch – engine 2 - X27 3 -
level indicator
S25 Pressure switch – air filter 2 - 3-pole plug and socket connection – rear
X28 2 -
Pressure switch – brake pressure (normally axle steering sensor
S26 3 -
closed contact) 3-pole plug and socket connection – front
X29 2 -
S27 Pressure switch – oil reflux filter 4 - axle steering sensor
Tip switch – additional control circuit 2 pole plug – driving direction recognition –
S28 2 - X30 2 -
(option) black
S29 Battery master switch (option) 1 - 2-pole plug – driving direction indicator
X30.1 2 -
S30 Air conditioning switch (option) 5 S 40 kph – red
S31 Thermostat (option) 5 - 2-pole plug – driving direction indicator 20
X30.2 2 -
kph – black
S32 Pressure switch – air conditioning (option) 5 -
X31 3-pole plug – quitckhitch lock 2 -
U1 Amplifier – level switch 3 +
X32 2-pole plug – cutoff solenoid 2 -
V1...V14 Suppressor diode (in solenoid valve plug) 2 -
2-pole plug and socket connection – clear-
V16...V18 Blocking diode (in multi-instrument) 3 MI X33/34 4 -
ance lights
BA 302 01 US-Gehl – Edition 1.0 * 30101b06e10.fm A-5

Annex

X35 Starter earthing connection 2 - Explanation of symbols (location in vehicle)
X36 Fuse box earthing connection 2 + + Any location in/on the vehicle
X37 Cab/frame partition earthing connection 2 - D Roof
1-pole plug and socket connection – front F Front instrument panel
X38/39 2 F
implements MI Multi-instrument in instrument panel
X40...X43 2-pole plug – switch lights S8/S9/S14/S16 4 F S Side instruments
X44 2 pole plug switch lights S30 4 S Z Central electrics
2-pole plug and socket connection – con- - Not included in scope of delivery for cab
X45 2 -
nection S11
Fixed connections
2-pole plug and socket connection – con-
X46 2 - Current From – to
nection S28
path
Y1 Solenoid valve – driving direction indicator 2 -
15 F1 – F2, F3 – F4 – F5 – F6
Solenoid valve –
15 F15 – F16 – F17, F18 – F19 – F20, F21 – F22 – F23
Y2 reversing 20 kph (X30/30.2) 2 -
forward driving 40 kph (X30/30.1) 30 F7 – F8, F9 – F10, F11 – F12
Solenoid valve – 30 F24 – F25 – F26 – F27
Y3 forward driving 20 kph (X30/30.2) 2 - Fuses
reversing 40 kph (X30/30.1) 50 A F29, F30, F31
Y4 Solenoid valve – 1st gear / 2nd gear 2 - 40 A F32
Y5 Solenoid valve – 4 wheel steering 2 - 25 A F1, F19, F26
Y6 Solenoid valve – front axle steering 2 - 15 A F2, F5, F23, F25, F27
Y7, Y8 Solenoid valve – load stabiliser 2 - 10 A F24
Y9 Solenoid valve – high speed (option) 2 - 7.5 A F6, F7, F8, F9, F10, F13, F15, F16, F17, F22
Y10 Solenoid valve – high speed lock (option) 2 - 5A F11, F12, F21, F28
Y11 Solenoid valve – differential lock 2 - 3A F3, F4, F14, F18, F20
Solenoid valve – telescopic retraction Fuse assignment – see Electrical system on page 7-6
Y12 2 -
(option, only telescopic loader unit)
Solenoid valve – telescopic extension
Y13 2 -
Solenoid valve – quickhitch lock
Y14 2 -
Y16 Cutoff solenoid 2 -
Y17 Magnetic clutch /compressor (option) 5 -

A
Annex
1. Power 2 Starting and drive system 3 Controls and indicators (multi-instrument) 4 Lights/signal and wiper system/radio/roof electrics 5 Cooling 6 Other
supply Heating consumers
30 30 30 30 30
15 15 15 15 15
15 15 15 15 15
Control lever Steering-column control

F14 F4 F6 F3 F5 F16 F17 F18 F20 F21 F13 F27 F2 F24 F26 F22 F15 F28 F19 F1 F25 F23
3A 3A 7,5A 3A 15A 7,5A 7,5A 3A 3A 5A 7,5A 15A 15A 10A 25A 7,5A 7,5A 5A 25A 25A 15A 15A
56 30 S19 15 49 15
H24 S2 2 3
S4 S18 X23 1 X22
D2
6 1
56a 56b 53b 53 31bJ L R 53C H P S21 2
30 S1 S6 X21.1 12 4 3 5 1 2 6 (2) 9 11 7 (4) (1) 10 8 (X21.2)
15 50a S3 S5 Indicator instrument F12 F11
19 H25 5A 5A
V23
E23
5 7 6 1 XB S22 B
X7 XC
6
5 H7 H10 C L M H
P3 V17 E9 E14
S28 S11 1
H4 t˚ H15 1 2 8 7
X45 4
H8 E10 S20
X5
3 h P5
1 2 3 4 5 8 7 6 X46 7 5 H9 E1 S14 S15
6 3 5 10
7
V18 5 5 S16 5 2 S17 30 86
3 5 4 E11 X40 K7 K21 5
S12 P6 E2 W1 K13 K14 K6 (30) (87) 49a
S8 1 1
E22 1 5 7 30 86 30 86 86 30 3086 53M I 15 (87) 49 87 85 S10
V (85)
1 1 7
E3 E12 X41 G T
(85) K9 G 1
XD V16 H12 87 85 87 85 85 87 87 85 53S 31

(87a)K15(86)
C 31
(30) (86)
4 Kl. 15 E4 X14 H27 X42 5
X6 1 2 3 4 5 8 7 6 9 1 P2 M4 M
E6 S30
6 Kl. 31 H5 X43 E7 X11 1
P1 Q X17
2
S9 H6 P4 H13 W2 H16 H17
S13 3 5 H11 H14 X44 M3
5 1
V21
7 1
X39 X38 5 6 1 7 4 3 XA
X15
7 8
V20 X8 6 3 7 1 2 4 5 8
X12 A1
V32 X16
10
2 4 3 1
F7
1
6
6
2
5
4
7
3 4 5 6
12 F8 7,5A F9
V31 7,5A 7,5A 30 86 X24
K11 K12 D1
11 F10 K20
87 86 86 87 K2 K1 K8 K3 K4 V30 7,5A K10
30 86 30 86 86 30 86 30 86 30 86 30
10 X19 87 85
30 86
V29
14
11
13
12
15
16
9
8
30 85 85 30 K5 9 3 1 2 X20 4 3 2 1 6
87 85 87 85 85 87 85 87 85 87 85 87 X9 6 3 7 1 2 4 5 8 7
V28 87 85
8
6 M6
V22
V27 53 53a
7 4 6 1 2 X18 30 85
H2 H3 H1 1 K18 31
53b 53a 53 31b K19
2 1 58R 58L 9 M5 31
S7 54 31 87a 87 86
X10
t
3 4 6
V26 M2
31 2
V25 56a 56b 56a 56b
8
E21 E16
10 P7 B10 B11 E19 E20 E17 E18 H22 H23 T S33
X36 U1
11
12
Cab
X13 B9
X36
Engine compart-
ment fuse box Telltale check
X1 X2 X3 X4 X4
A B C 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 2 1 19 20 21
F29 F30 F31 31 31 31 31 31 31

50A 50A 50A
S24 S23 X37
Frame/engine/cowl/implements
F32 R2 2 1
40A B6 S34
4 3
K17
30 86 30 86 B4
K16 X25
87 85 87 85
3 4 8 1 2 5 6 7
X30.2-BK 2 1 5 4 3 8 7 6
D+
B+
50
S25
30
M1 G1 B- X30.1-RD A B C A B C A B 2 1 A B
G2 R1 31 X30-BK X31 X28 X29 X27 X26 M7
31
A B C A B C A B 2 1 A B X33 2 1
2 1
S31 B5 X34
t˚ P 2 1 E5 H18 H20 E8 2 1 H19
X32 V2 V3 V1 V12 V13 V11 V10 V14 V8 V7 V9 V4 V6 V5 S27
H21
E25 Y17
X35 P
Y16 Y2 Y3 Y1 Y12 Y13 Y11 Y10 Y14 Y8 Y7 Y9 Y4 Y6 Y5 B2 B1 B8 S26 B3 B7 E24 0380011390e.eps
Wiring diagram
valid for model 521
from serial no.: 521 0001
0 38 001 13 90e – (10/01)
BA 302 01 US-Gehl – Edition 1.0 * 30101b06e20.fm A-7

Annex
Wiring diagram legend – options
K8 (86) K3 (86)
Compo-
X40 F3 F5 Description Section Pos.
nent
3rd electrically operated control circuit
(option)
F3 Fuse 1 -
F5 Fuse 1 -
K3 Switching relay – unlocking 1 -
K8 Switching relay – locking 1 -
K102 Switching relay 1 -
K103 Switching relay – changing-over 1 -
K104 Switching relay – changing-over 1 -
S102 Switch with actuation interlock 1 -
V12 Suppressor diode 1 -
V13 Suppressor diode 1 -
V103 Blocking diode 1 -
X38 Diode connection front socket 1 -
X40 Connection switch lighting 1 -
Y102 Solenoid valve, unlock 1 -
0380011590.eps Y103 Solenoid valve, lock 1 -
Wiring diagram – option

valid for model 521
from serial no.: 521 0001
0380011590 – (12/01)

TORQUE SPECIFICATIONS
NOTE: Use these torque values when tightening GEHL hardware (excluding: Locknuts and Self-tap-
ping, Thread Forming and Sheet Metal Screws) unless specified otherwise.
All torque values are in Lb-Ft except those marked with an * which are Lb-In
(For metric torque value Nm, multiply Lb-Ft value by 1.355 or Lb-In value by 0.113)
Unified Grade 2 Grade 5 Grade 8

National Thread Dry Lubed Dry Lubed Dry Lubed
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 17 13 18
9 25
5/16-24 12 19 14 20
3/8-16 20 15 30 23 45
35
3/8-24 23 17 35 25 50
7/16-14 32 24 50 35 70 55
7/16-20 36 27 55 40 80 60
1/2-13 50 35 75 55 110 80
1/2-20 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
1-14 270 210 710 530 1000 740
Metric Grade 8.8 8.8 Grade 10.9 10.9 Grade 12.9 12.9
Course Thread Dry Lubed Dry Lubed Dry Lubed

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
WARNING
This Operator’s Manual is
provided for operator use.
DO NOT REMOVE
FROM THIS MACHINE.
DO NOT start, operate or work on this machine

until you have carefully read and thoroughly
understand the contents of this manual.
Failure to follow safety, operating and

maintenance instructions could result in
serious injury to the operator or bystanders,
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 Company
Service Department before starting or
continuing operation.
Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 U.S.A.
(www.gehl.com)
909881/AP0702 ©2002 GEHL Company, All rights reserved. Printed in U.S.A.

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Form No.

OPERATOR’S MANUAL PRELIMINARY

GEHL CONSTRUCTION DIVISION of the GEHL COMPANY, hereinafter referred to as Gehl,

GEHL CONSTRUCTION WARRANTY INCLUDES:

GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND,

GEHL WARRANTY SERVICE DOES NOT INCLUDE:

BA 302 01 US-Gehl - Edition 1.0 * 30201busg10IVZ.fm I-1

Battery .......................................................................................................... 2-13

I-2 BA 302 01 US-Gehl - Edition 1.0 * 30201busg10IVZ.fm

BA 302 01 US-Gehl - Edition 1.0 * 30201busg10IVZ.fm I-3

I-4 BA 302 01 US-Gehl - Edition 1.0 * 30201busg10IVZ.fm

Checking/topping up the oil level .................................................................. 5-30

Helpful information for using the spare parts list

BA 302 01 US-Gehl - Edition 1.0 * 30201busg10IVZ.fm I-5

I-6 BA 302 01 US-Gehl - Edition 1.0 * 30201busg10IVZ.fm

BA 302 01 US-Gehl - Edition 1.0 * 30201busg10SIX.fm I-7

N Specifications ........................................................................................ 7-1

I-8 BA 302 01 US-Gehl - Edition 1.0 * 30201busg10SIX.fm

BA 302 01 US-Gehl - Edition 1.0 * 30201busg10SIX.fm I-9

I-10 BA 302 01 US-Gehl - Edition 1.0 * 30201busg10SIX.fm

1.1 Notes on this operation manual

BA 302 01 US-Gehl – Edition 1.0 * 30101b0110.fm 1-1

1.2 Vehicle overview

1-2 BA 302 01 US-Gehl – Edition 1.0 * 30101b0110.fm

1.3 Brief description

BA 302 01 US-Gehl – Edition 1.0 * 30101b0110.fm 1-3

1.4 Fields of application

Description of implement Vehicle model Model Use

Loosening, picking up, transporting and loading loose or solid

Pallet forks 521 810138 Only with load diagram 0004353146

1-4 BA 302 01 US-Gehl – Edition 1.0 * 30101b0110.fm

BA 302 01 US-Gehl – Edition 1.0 * 30101b0110.fm 1-5

1-6 BA 302 01 US-Gehl – Edition 1.0 * 30101b0110.fm

Vehicle warning identification

1.6 Vehicle data

Vehicle model/version: ......................................................................................................................................

Serial number: ......................................................................................................................................

Commissioning/date of registration: ......................................................................................................................................

Service hours/kilometre reading: ......................................................................................................................................

Cab number: ......................................................................................................................................

Engine number: ......................................................................................................................................

Hydraulic pump ......................................................................................................................................

Hydraulic motor ......................................................................................................................................

Front axle number: ......................................................................................................................................

Rear axle number: ......................................................................................................................................

Gearbox number: ......................................................................................................................................

Optional implements: ......................................................................................................................................

Your local dealer • Address:

BA 302 01 US-Gehl – Edition 1.0 * 30101b0110.fm 1-7

1.7 Page left intentionally blank

1-8 BA 302 01 US-Gehl – Edition 1.0 * 30101b0110.fm

1.8 Type labels and component numbers

20 Type label information

Serial number: 521 0100

Fig. 3: Type label

Fig. 4: Cab type label

Fig. 5: Diesel engine number

Hydraulic pump number

Fig. 6: Hydraulic pump type label

BA 302 01 US-Gehl – Edition 1.0 * 30101b0110.fm 1-9

Hydraulic motor number

Fig. 7: Hydraulic motor: type label

Rear axle and gearbox number