PDF Service Manual Gehl SL7600 & SL7800 Skid Steer Loader - 2 MB
This comprehensive service manual covers both the Gehl SL7600 and SL7800 skid steer loaders.
It is the go-to resource for technicians, providing detailed instructions for maintenance, troubleshooting, and complete machine overhaul.
The manual includes information on the engine, hydrostatic system, hydraulics, and electrical components.
Ensure all repairs are done to factory specifications with this essential guide.
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--- Page 1 ---
SL7600
Form No.
908275
SL7800
Skid Steer
Loader
Service Manual
--- Page 3 ---
SAFETY SL7600/7800
Loader Stability - A skid loader’s stability is DO NOT drive too close to an excavation or ditch. BE
determined by its wheel base. The following elements SURE that the surrounding ground has adequate
can affect stability: terrain, engine speed, load being strength to support the weight of the loader and the load.
carried or dumped, and sudden control movements.
DO NOT smoke or have any spark
DISREGARDING ANY OF THESE FACTORS CAN producing equipment in the area while
CAUSE THE LOADER TO TIP, POSSIBLY filling the fuel tank or while working on the
RESULTING IN DEATH OR SERIOUS INJURY. fuel or hydraulic systems.
Therefore, ALWAYS have the operator restraint bar Exhaust Gases - Exhaust fumes can kill. DO NOT
lowered and wear the seat belt. Operate the controls only operate this machine in an enclosed area unless there is
from the operator’s seat. Operate the controls smoothly adequate ventilation.
and gradually at an appropriate engine speed that
matches the operating conditions. Engine - NEVER use ether or starting fluid.
DO NOT exceed the rated operating load of the People - NEVER carry riders. DO NOT allow others to
machine. For additional stability when operating on ride on the machine or attachment, because they could
inclines or ramps, ALWAYS travel with the heavier end fall or cause an accident.
of the loader toward the top of the incline. BE SURE all persons are away from the machine and
ALWAYS look to the rear before backing up. give a warning before starting the engine.
When parking machine, before leaving seat, check ALWAYS face machine and use hand holds and steps
restraint bar for proper operation. The restraint bar, when getting on or off. DO NOT jump off machine.
when raised, applies parking brake and deactivates Wear appropriate ear protection for
lift/tilt controls and auxiliary hydraulics. prolonged exposure to excessive noise.
Keyswitch - NEVER attempt to bypass the keyswitch to ALWAYS perform a daily inspection of the
start the engine. Use the jump-starting procedure machine BEFORE using it. Look for
detailed in the Service chapter of your Operator’s damage, loose or missing parts, leaks, etc.
Manual.
Remove trash and debris from the machine and engine
Hydraulic Fluid Leaks - NEVER use hands to search compartment each day to minimize risk of fire.
for hydraulic fluid leaks. Instead, use paper
New operators MUST operate loader in an open area
or cardboard. Fluid under pressure can be
away from bystanders. Practice with controls until
invisible, penetrate the skin and cause a
loader can be operated safely and efficiently.
serious injury. If any fluid is injected into
skin, see a doctor at once. Injected fluid MUST be
surgically removed by a doctor or gangrene may result. Mandatory Safety Shutdown Procedure
Wear Safety Glasses - ALWAYS wear safety glasses BE FORE clean ing, ad just ing, lu bri cat ing, servicing
with side shields when striking metal the unit or leaving it unattended:
against metal. In addition, it is
recommended that a softer (chip-resistant) 1. Move the drive control handle(s) to the
material be used to cushion the blow. NEUTRAL po si tion.
Failure to heed could lead to serious injury to eye(s) or 2. Lower the liftarm and attachment completely.
other parts of the body. Also, see Step 4 be low.
ALWAYS wear safety glasses when searching for 3. Move the throttle to the low idle po si tion, shut off
hydraulic leaks or when working near batteries. the engine and re move the key.
Loaded Bucket/Fork - DO NOT raise or drop a loaded 4. If the liftarm MUST be left in the “raised”
bucket or fork suddenly. Abrupt movements under load position, BE SURE to prop erly en gage the liftarm
can cause serious loader instability. support device in stead of per form ing Step 2.
NEVER push the lift control into the “float” position Only after these pre cau tions can you be sure it is
with the bucket or attachment loaded or raised, because safe to proceed. Failure to follow the above
this will cause the liftarm to lower rapidly. pro ce dure could lead to death or se ri ous in jury.
908275/AP0402 2 -2 PRINTED IN USA
--- Page 4 ---
LUBRICATION SL7600/7800
Cooling System Drain Procedures
Gehl SL76/7800 skid loaders use a split radiator design
to help keep the engine (with anti-freeze coolant) and
hydraulic oil from overheating. Many procedures in this
Service Manual require you to partially or fully drain
one or both to perform those procedures.
WARNING
BEFORE be ginning this service pro cedure,
per form the fol low ing SAFETY pro ce dure:
q Shut off the engine and allow to cool.
Fig. 3-11 Coolant recovery tank location.
(For detailed instructions, refer to the Safety
chapter of this manual).
Anti-freeze Cool ant Drain Pro ce dure
1. Open engine access cover, lower tailgate and
remove left engine side cover. Fig. 3-11
2. Remove the radiator cap.
3. A drain cock is located on back left side of radiator
with a drain hose attached. Open drain cock and
drain coolant into a suitable container. Fig. 3-12
4. Below engine oil filter, find another coolant drain
cockand drain coolant into a suitable container. Fig.
3-13
5. Close both drain cocks.
Fig. 3-12 Location of the radiator coolant drain cock.
Hy drau lic Oil Drain Pro ce dure (Fig. 3-2)
1. Remove small rear access panel underneath loader
near the left rear tire.
Oil Filter
2. Place a 15 gallon (56,8 L) catch pan under the
hydraulic oil drain plug.
3. Remove the drain plug and drain oil.
4. Replace the drain plug.
Fig. 3-13 Location of the engine coolant drain cock
underneath the oil filter on the engine.
908275/AP0402 3 -4 PRINTED IN USA
--- Page 5 ---
MAINFRAME SL7600/7800
All-Tach™ Hitch Components
1 - Hex Nut
2, 3, 4 - Washer
5, 6 - Pivot Pin
7, 8 - Shim
9 - Handle
10 - Spring Stop Link
11 - Spring Slide Link
12 - Adjustable Link
13 - Pin Link
14 - Latch Link
15 - Latch Pin
16 - Grease Cap
17 - Pin Plate
18, 19, 20 - Spring Pin
21 - Handle Pivot
22 - Stop Pin
23 - All-Tach™
24 - Grease Fitting
25 - Capscrew
26 - Capscrew
27 - Capscrew
28 - Capscrew
29 - Stalk Guide Spring
Fig. 4 -26 As sem bly view of the All- Tach™ h itch.
Liftarm Components
1 - Hex Nut
2 - Hex Nut
3 - Locknut
4 - Washer
5 - Timing Link
6 - Thrust Washer
7 - Timing Link Pin
8 - Pivot Pin
9 - Liftarm
10 - Timing Link Pin
11 - Rear Arm Pivot Pin
12 - Rear Link
13 - Liftarm Support
14 - Grease Fitting
15 - Capscrew
16 - Capscrew
17 - Capscrew
18 - Capscrew
19 - Capscrew
20 - Spring Bushing
21 - Spring Bushing
22 - Spring Bushing
Fig. 4 -27 As sem bly view of the liftarm.
908275/AP0402 4-10 PRINTED IN USA
--- Page 6 ---
MAINFRAME SL7600/7800
Control Console Removal and Installation
The lower control consoles may be removed for access
to handle assemblies and connections to control take-up
rods.
WARNING
BEFORE be gin ning this Service pro cedure,
per form the fol low ing SAFETY pro ce dures:
q Raise liftarm, engage liftarm support
device.
q Shut off the engine. Fig. 4-64 Remove the set screw securing the flow control
knob to the flow rod.
q Roll ROPS back until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual).
Re moval Pro ce dure
1. Unscrew and remove the following on right lower
console: set screw on the flow control knob, throttle
handle and high flow auxiliary hand lever (High
Flow Models only). Figs. 4-63, 4-64
2. Remove four screws securing right lower console.
Remove console up and over right control handle.
Figs. 4-65, 4-66
3. Remove four screws securing left lower console.
Crossmember
Remove console up and over left control handle.
Installation Procedure - Follow all WARNINGS Fig. 4-65 Remove four screws securing both consoles to
the crossmember.
first, then re verse the re moval steps
Fig. 4 -63 Parts to unscrew on the right control console to Fig. 4-66 Remove the console over the control handle.
facilitate the removal of that console. (High
Flow Model shown).
908275/AP0402 4-20 PRINTED IN USA
--- Page 7 ---
WHEEL DRIVES SL7600/7800
Drive Chain Removal and Installation
Re moval Pro ce dure
WARNING
BEFORE be ginning this service pro cedure,
per form the fol low ing SAFETY pro ce dures:
q Shut off the engine.
q Raise and securely block the loader so
all four tires are off the ground.
(For detailed instructions, refer to the Safety
chapter of this manual). Fig. 5-7 After loosening the axle housing locknuts and
sliding the axle inward, slack appears in the
chain, resting on the floor of the chaincase.
1. Remove wheels and tires on side of loader being
serviced. Wheel nut torque is 180 ft-lbs (244 N•m).
2. Remove 18 machine screws on chaincase access Drive Motor
cover to gain access to drive chain. Sprocket
3. For each drive chain: Loosen eight locknuts on axle
assembly attached to chain. Slide axle assembly in
its slots to loosen chain tension. Fig. 5-7
4. Supporting the axle with a suitable hoist, pull axle
housing out of chaincase to allow axle housing
sprocket to drop inside chaincase. Fig. 5-8
5. Slip drive chain off axle housing sprocket. Then,
slip drive chain off drive motor sprocket. Fig. 5-9
6. Remove drive chain from chaincase.
Fig. 5-8 Reach in to slip off the drive chain over the
axle housing sprocket.
In stal la tion Pro ce dure - Fol low Re moval Procedure
WARN INGS first
NOTE: When installing left and right side drive chains Axle Housing
Sprocket
of loader, install inside chain first.
Axle Sprocket
1. Wrap chain around sprocket of axle. Stop
2. Wrap chain around drive motor sprocket.
3. Adjust drive chain to proper tension per the
procedure in this chapter.
4. Refill chaincase oil level until oil is up to oil level
check plug. Then install chaincase access covers
using oil-resistant RTV sealant (or equivalent)
between covers and chaincase.
Fig. 5-9 Remove the chain on the drive motor
sprockets.
908275/AP0402 5 -4 PRINTED IN USA
--- Page 8 ---
CONTROLS SL7600/7800
Control Handle Removal and Installation
WARNING Elastomeric Elastomeric
Rod End
BEFORE be ginning this service pro cedure, Rod End
per form the fol low ing SAFETY pro ce dures: Capscrew
q Raise liftarm, engage liftarm support Capscrew
device.
Rod End Rod End
q Shut off the engine.
q Roll ROPS back until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual). Fig. 6-7 Left T-Bar control handle.
Re moval Pro ce dure
1. Remove control consoles per the procedure in the
Mainframe chapter.
2. Disconnect electrical connector in control handle
from wiring harness. Locknut
IMPORTANT Elastomeric
Rod End
Note the wire terminal connections in the
electrical connector for assembling the
control handle if replacing the handle’s Rod End
electrical cable.
3. Remove locknuts to disconnect studded rod end(s)
on control rod(s) from control handle assemblies on Fig. 6-8 Right T-Bar control handle.
handle(s) being removed. Figs. 6-7, 6-8, 6-9
4. Remove two capscrews, washers and locknuts on
elastomeric rod ends attaching control handle
assembly to chassis crossmember. Remove
assembly. Figs. 6-7, 6-8, 6-9
Elastomeric
Installation Procedure - Follow all WARNINGS Elastomeric Rod End
first, then re verse re moval steps (see NOTE be low) Rod End
NOTE: When the control handle is installed, and if the
control rod(s) are adjusted correctly, the control handle
shafts are vertically straight, up and down. If changes are Electrical
needed, refer to the “Control Handle Position Connector
Adjustment” procedure in this chapter. Locknut
Rod End
Fig. 6-9 Left Dual Hand control handle (other side
similar).
908275/AP0402 6 -6 PRINTED IN USA
--- Page 9 ---
CONTROLS SL7600/7800
Pivot Tube Removal and Installation -
T-Bar, Hand/Foot and Dual Hand
Pivot tube assembly views are a good reference for pivot
tube’s removal/installation procedures. Refer to views
for names of components and locations in assemblies. Arm Assembly
Re moval Pro ce dure
WARNING
BEFORE be ginning this service pro cedure,
per form the fol low ing SAFETY pro ce dures:
q Raise liftarm, engage liftarm support Fig. 6-38 Disconnect control rod at the arm assembly.
device.
q Shut off the engine.
q Roll ROPS back until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual).
1. Remove the control consoles per the procedure in Centering
the Mainframe chapter. Devices
2. Remove the crossmember per the procedure in the
Mainframe chapter.
NOTE: If loader is equipped with a backup alarm,
remove two capscrews and locknuts securing alarm
switch bracket to crossmember. Set them aside.
NOTE: It’s recommended that good notes be taken to
Fig. 6-39 Location of two adjustment capscrews between
aid in reassembly. If necessary, mark holes on levers. the centering devices.
3. Remove one control rod from pivot tube, and one
from arm assembly. Fig. 6-38
4. Remove two front hex nuts on two centering
devices. Allow centering devices to hang from their
brackets.
5. Remove hex head machine screws: Fig. 6-42
a. Hand/Foot and Dual Hand: Six screws on two
right control brackets. Slide control brackets, Control Rods
two washers and arm assembly off pivot shaft.
Bronze bearings are pressed into control
brackets, if not, remove from pivot shaft.
Pivot Tube Shaft
b. T-Bar : Three screws on one right control
bracket. Slide control bracket, two washers and
arm assembly off pivot shaft. Bronze bearing is
pressed into control bracket, if not, remove from Fig. 6-40 Location of the left control bracket.
pivot shaft.
908275/AP0402 6-16 PRINTED IN USA
--- Page 10 ---
CONTROLS SL7600/7800
Auxiliary Hydraulics Cable Removal and
Installation - T-Bar and Dual Hand
Refer to the exploded view as a reference in identifying
parts and components. Cable Bracket U-Bolt
Re moval Pro ce dure
WARNING
BEFORE be ginning this service pro cedure,
per form the fol low ing SAFETY pro ce dures:
q Raise liftarm, engage liftarm support
device. Fig. 6-65 The auxiliary hydraulics cable is located
farthest out on the control cable bracket.
q Shut off the engine.
q Roll ROPS back until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual).
1. Disconnect auxiliary yoke end on control valve.
Fig. 6-65
2. Remove u-bolt securing cable to cable bracket. Fig.
6-65
3. Remove toe plate at front of chassis. Fig. 6-66
4. Disconnect rod end on cable from auxiliary pedal
assembly. Fig. 6-67
Toeplate Access
5. Loosen control cable jam nut securing the cable to
the welded bracket. Fig. 6-67 Fig. 6-66 The auxiliary cable routing underneath the
6. Remove cable. If replacing cable, remove yoke end, floor plate.
rod end and jam nuts from old cable.
In stal la tion Pro ce dure - T-Bar and Dual Hand Con-
trols - Fol low all WARN INGS first, then re verse the
re moval steps*
* For cable adjustment, refer to “Auxiliary Hydraulics
Cable Adjustment” procedure in this chapter.
Rod End
Fig. 6-67 Location of the control cable jam nut securing
cable to welded bracket.
908275/AP0402 6-26 PRINTED IN USA
--- Page 11 ---
CONTROLS SL7600/7800
NOTES
908275/AP0402 6-36 PRINTED IN USA
--- Page 13 ---
HYDROSTATIC SYSTEM SL7600/7800
Hydrostatic Pump Drive Coupling
Removal and Installation
Re moval Pro ce dure
WARNING
BEFORE be ginning this service pro cedure,
per form the fol low ing SAFETY pro ce dures:
q Raise liftarm, engage liftarm support
device.
q Shut off the engine.
q Roll ROPS back until lock engages. Fig. 7-14 There are two hoses that route out of the
bottom of the hydrostatic pump to disconnect.
(For detailed instructions, refer to the Safety
chapter in this manual).
1. Remove hydrostatic pump per the procedure in this
chapter.
2. Remove 12 capscrews securing flywheel housing to
the engine. Fig. 7-17
3. Remove eight capscrews attaching coupling plate to
flywheel. Fig. 7-18
Installation Procedure - Follow all WARNINGS Pump Support Plate
first, then re verse the re moval steps
Fig. 7-15 Disconnect the pump support plate from the
hydrostatic pump.
Flywheel Housing
Pump Support
Fig. 7 -13 Hoses to remove off hydrostatic pump for Fig. 7-16 Disconnect two capscrews securing the
pump removal. There is a second set of these hydrostatic pump from the flywheel housing.
hoses on pump closer to engine.
908275/AP0402 7-10 PRINTED IN USA
--- Page 14 ---
HYDRAULIC SYSTEM SL7600/7800
Hydraulic System - High Flow Auxiliary
72 - Hose Pivot Linkage Bar 91 - Pressure Hose 110 - Threaded Stud 129 - Capscrew
73 - Hose Pivot 92 - Pressure Hose 111 - Threaded Stud 130 - Capscrew
74 - R. Crossmember Tube 93 - Pressure Hose 112 - Trim Stip 131 - Capscrew
75 - F. Crossmember Tube 94 - Pressure Hose 113 - L. Cylinder Base Tube 132 - Capscrew
76 - Safety Lock Valve 95 - Pressure Hose 114 - L. Cylinder Rod Tube 133 - Capscrew
77 - Special Flange Kit 96 - Pressure Hose 115 - Riser Tube 134 - Capscrew
78 - Special Flange Kit 97 - Pressure Hose 116 - Pressure Hose 135 - Carriage Bolt
79 - HF Coupler Bracket 98 - Pressure Hose 117 - 90° Fitting 136 - Machine Screw
80 - Case into Liftarm Tube 99 - Pressure Hose 118 - Breather 137 - Capscrew
81 - Front Auxiliary Tube 100 - Pressure Hose 119 - Hose Clamp 138 - Capscrew
82 - Rear Auxiliary Tube 101 - Pressure Hose 120 - Manifold 139 - Carriage Bolt
83 - Front Tilt Tube 102 - Pressure Hose 121 - Pressure Hose 140 - Hex Nut
84 - Rear Tilt Tube 103 - Pressure Hose 122 - Pressure Hose 141 - Hex Nut
85 - Tilt Tube 104 - Suction Hose 123 - Pressure Hose 142 - Jam Nut
86 - Tilt Tube 105 - Pressure Hose 124 - Dual Clamp Tie 143 - Flat Washer
87 - Tilt Tube 106 - Pressure Hose 125 - Rub Block 144 - Hex Nut
88 - 90° Fitting 107 - Pressure Hose 126 - Threaded Stud 145 - Filter Element
89 - Valve Mount Plate 108 - Pressure Hose 127 - Capscrew 146 - Service Indicator
90 - 90° Block Fitting 109 - 90° Elbow Fitting 128 - Capscrew 147 - Filter Element
Fig. 8-4 As sem bly view of the high flow hydraulic sys tem.
908275/AP0402 8 -8 PRINTED IN USA
--- Page 15 ---
HYDRAULIC SYSTEM SL7600/7800
coat of oil to new element gasket, then install it on
filter head. Fig. 8-29
7. Hand tighten element until gasket contacts filter
head. Turn element another 3/4 turn to seat gasket.
8. Refill hydraulic reservoir. Refer to the Lubrication
chapter in this manual for hydraulic fluid
requirements and specifications.
WARNING
NEVER use your hands to search for
hydraulic fluid leaks. Use a piece of
cardboard or paper. Escaping fluid Fig. 8-27 Location of the forward hydraulic filter.
under pressure can be invisible and Replace this filter when the restriction
penetrate the skin causing serious injury. If indicator light on the left instrument panel
any fluid is injected into your skin, see a lights.
doctor at once. Injected fluid MUST be
surgically removed by a doctor familiar with
this type of injury or gangrene may result. Service Indicator
ALWAYS wear safety glasses when
checking for hydraulic fluid leaks.
Escaping fluid under pressure can be
invisible and can cause permanent eyesight
damage if safety glasses are not worn.
9. ALWAYS check for hydraulic fluid leaks after
assembling components of the hydraulic system.
Fig. 8-28 Location of the rear hydraulic filter. Replace
this filter when the service indicator above it
shows, or reads, red.
Fig. 8-29 Apply a light coat of new oil to the rubber seal
on the new filter element before installing in
the skid loader.
908275/AP0402 8-18 PRINTED IN USA
--- Page 16 ---
HYDRAULIC SYSTEM SL7600/7800
Self-Leveling Valve Removal and
Installation
Re moval Pro ce dure
WARNING
BEFORE be ginning this service pro cedure,
per form the fol low ing SAFETY pro ce dures:
q Raise liftarm, engage liftarm support Self-Level
device.
q Shut off the engine.
q Relieve hydraulic system pressure. Fig. 8-57 Location of two electrical connectors on the tilt
safety lock valve.
q Roll ROPS back until lock engages.
(For detailed instructions, refer to the Safety
chapter in this manual).
NOTE: Cap or plug hydraulic hoses and fittings after
disconnecting to prevent fluid loss and contamination of
the hydraulic system.
1. Disconnect two electrical connectors from safety
lock valve attached to the self-leveling valve.
Remove two hydraulic tubes from safety lock valve.
Figs. 8-57, 8-58, 8-59
2. Remove two locknuts securing safety lock valve to
valve mounting plate. Slide safety lock valve off
mounting plate. Fig. 8-60
3. Disconnect four total hydraulic tubes and hoses Fig. 8-58 Remove hydraulic tubes from safety lock
valve.
from hydraulic fittings on self-leveling valve. Fig.
8-61
4. Remove two capscrews securing self-leveling valve
and valve mounting plate to chassis. Fig. 8-62
5. Remove the self-leveling valve.
NOTE: After removing and/or replacing any
component in the hydraulic system, ALWAYS check Mounting
the level of hydraulic fluid in the reservoir. Add fluid if Plate
necessary. Refer to the Lubrication chapter for fluid
requirements and specifications.
Fig. 8-59 Location of hose and tube connections
underneath the safety lock and self-level
valves.
908275/AP0402 8-28 PRINTED IN USA
--- Page 17 ---
HYDRAULIC SYSTEM SL7600/7800
Control Valve Disassembly and Assembly
Valve Stack Bolt
The main control valve is made up of serviceable spool
sections. These sections may be removed for service.
The control valve also contains load-sense shuttles that Valve Stack Bolt
may be cleaned during this procedure, and that
procedure follows this procedure on the next page. Valve Stack Bolt
Dis as sem bly Pro ce dure
1. Remove main control valve per the procedure in this
chapter.
2. Remove three hex nuts on outside of end cover. Fig.
8-84
3. Pull end cover off three long valve stack bolts. Fig. Fig. 8-85 View of end cover removed from valve stack
8-85 bolts.
4. Lift each section off the valve stack bolts as needed,
being sure to account for all o-rings and three shims.
Figs. 8-86, 8-87
5. Check condition of o-rings on each section
removed.
As sem bly Pro ce dure - Re verse the dis as sem bly steps.
Fig. 8-86 One section of the control valve lifted off the
valve stack bolts.
Fig. 8 -84 Location of three hex nuts on end cover. Fig. 8-87 Keep track of these important shims on each
section of the control valve.
908275/AP0402 8-38 PRINTED IN USA
--- Page 18 ---
ELECTRICAL SYSTEM SL7600/7800
Left In stru ment Panel
The left instrument panel for Gehl SL76/7800 skid
loaders houses the manual parking brake switch and
light indicator. More standard or optional switches,
power ports and light indicators are also on this panel.
1. Two-Speed Indicator Lamp - it lights when skid
loader’s two-speed option is engaged.
2. Hydraglide™ Ride Control Indicator Lamp - it
lights when loader’s ride control option is engaged.
3. Fan Switch - controls the heater and/or air
conditioning package installed in select skid
loaders.
4. 12 VDC Power Outlet - a plug-in outlet with rubber
boot used for external electrical connections.
5. Power All-Tach™ Switch - controls the
electrically-driven attachment engagement system
option installed in select skid loaders.
Speed Control Ride Control
(Optional) (Optional)
Parking Brake
Power All-Tach™ Parking Brake
Switch (Optional) Switch
Fan Switch
(Optional)
12 VDC Power
Outlet