Working on a 2005 Gehl 680 Wheel Loader? This 212-page PDF (OEM #918123) collects the factory procedures for the BF4M 2011 engine, the variable displacement drivetrain, and the full electrical system. Hydraulic schematics trace the pilot control, load stabilizer, and hose burst valve circuits, while 43 pages of wiring diagrams map the cab harnesses, joystick, steering electronics, and every factory option. Exploded views, torque tables, a maintenance schedule sorted by service interval, and troubleshooting charts for engine and powertrain faults fill out the rest. Numbers come straight from the spec tables: torque the wheel nuts to 295 ±15 lb.-ft. (400 ±20 Nm), or swap the hydraulic return filter at 1,500 service hours. Bookmarked and keyword-searchable, it opens on any device, so the right figure sits with you at the machine, not back at the keyboard.
What's Inside This Gehl 680 Manual
| System | Pages | Key Topics |
|---|---|---|
| Operation | 5-14 | Important Information on This Service Manual, Serial Plates and Component Numbers, Machine Overview, Inside of Cab: Overview, Inside of Cab: Legend, Instrument Panel |
| Engine | 67-84 | Engine BF4M 2011: Overview, Engine Oil Cooling, Fuel System, Checking and Adjusting Valve Tip Clearance, Replacing the Fuel Injection Pump, Setting Charge Air Pressure |
| Power Train | 85-112 | Variable Displacement Pump 12 – 25 Mph, Hydraulic Motor – Control Element 12 Mph, Hydraulic Motor – Hydraulic Connections 12 Mph, Power Train Diagram 12 Mph |
| Axles | 113-134 | Serial Plate – Axle, Front Axle Screw Connections, Rear Axle Screw Connections, Drain, Fill and Check Plug – Front Axle, Fill and Check Plug – Rear Axle |
| Brakes | 135-138 | Brake Circuit, Brake Diagram, Service Brake (Bleeding: Brake System with Bleed Equipment, Inching Valve), Parking Brake Overview (Adjust Brake Lever a) |
| Steering | 139-144 | Steering Circuit, Hydraulic Ports on Servostat, Pressure Relief Valve – Servostat: Settings, Front/Rear Axle Steering Cylinder, Setting the Steering Sensors |
| Hydraulic System | 145-166 | Test Report, Control Valve Connections: Overview, Control Valve: Design, Pilot Control Unit: Design, Valve Block Connections: Overview, Pilot Control Circuit |
| Electrical System | 167-209 | Ohm's Law, Measuring Equipment and Methods, Terminal Description, Cable Color-Coding, Relays, Electrical Units, Fuse Box on Left and Right of Steering Column |
| Torque Specifications | 210-212 | Hydraulic Fittings with Various Seals, With Coarse-Pitch Thread, With Fine-Pitch Thread |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Wheel nut torque | 295 ±15 lb.-ft. (400 ±20 Nm) | p. 24 |
| Variable displacement pump displacement | 0 – 5 in.³/rev (0 – 74 cm³/rev) | p. 16 |
| Hydraulic hoses replacement interval | every six years from the date of manufacture | p. 53 |
| Hydraulic oil return filter replacement interval | 1500 service hours (or yearly if you use the machine less than 1500 service hours per year) | p. 51 |
| Battery voltage and capacity | 12-V, 72 Ah | p. 19 |
| Alternator voltage and current | 12-V, 95 A | p. 19 |
| Engine Output | 75 hp (56 kW) at 2300 rpm | p. 15 |
| Max. Engine Torque | 199 lb.-ft. (270 Nm) at 1600 rpm | p. 15 |
| Intake Valve Clearance (cold engine) | 0.01” (0.3 mm) | p. 15 |
| Variable Displacement Pump Max. Operating Pressure | 6527 psi (450 bar) | p. 16 |
| Diesel Engine Oil Capacity | 8.2 qt. (7.8 L) | p. 27 |
| Hydraulic Oil Tank Capacity | About 22 gal. (85 L) | p. 27 |
Gehl 680 Common Problems This Manual Covers
Gehl 680 engine overheating under load, temperature gauge climbing into red p. 82
Check coolant level and inspect the radiator for mud, chaff, or debris restricting airflow. The BF4M 2011 engine delivers 75 hp (56 kW) at 2300 rpm and overheats quickly with any airflow restriction. Verify the thermostat and cooling fan operation, then run the engine troubleshooting checklist on page 82 to pinpoint the root cause.
Manual Section: Engine TroubleBucket lifts slowly or loses power mid-cycle, hydraulic functions feel weak and sluggish p. 145
Confirm hydraulic oil level; the tank holds about 22 gal. (85 L), and a low level is often the first thing behind sluggish lift. Inspect all hoses for leaks or collapse; standard replacement is every six years from manufacture date (page 53). Verify pump pressure hasn't dropped from the 6527 psi (450 bar) maximum shown on page 16.
Manual Section: Hydraulic System Test Report & Leakage CheckTransmission slips between speed ranges, shifts jerk hard, or engagement delays noticeably p. 103
Pull active error codes from the SUSMIC diagnostics on page 103 before any disassembly. Then trace hydraulic circuit pressures against the power train specs on page 85; the variable displacement pump should reach 6527 psi (450 bar) at maximum load. Contaminated fluid is the most common cause of delayed engagement, so drain and refill if in doubt.
Manual Section: SUSMIC System Error & Sensor DiagnosticsEngine won't crank or turns over slowly, dash instruments show no power p. 167
Test battery voltage against the 12-V, 72 Ah spec on page 19. Clean and tighten both terminal clamps, then check alternator charging output. If the machine still won't crank, trace fuse continuity in the electrical system section starting at page 167 and step through the engine troubleshooting flowchart on page 82.
Manual Section: Electrical systemUneven tire wear on one side or rapid pressure loss on rough terrain p. 113
Inspect all four tires for cuts, sidewall damage, and uneven tread wear. Retorque all wheel nuts to 295 +/-15 lb.-ft. (400 +/-20 Nm) per page 24 and check for loose or bent rim components. Review front and rear axle condition in the Axles section starting at page 113; worn bearings or bent knuckles accelerate tread wear on one side.
Manual Section: AxlesFrequently Asked Questions
What are the torque specs for Gehl 680 wheel loader wheel nuts / hub bolts?
Wheel nuts on the Gehl 680 torque to 295 ±15 lb.-ft. (400 ±20 Nm). You'll find it under the "Specific torques" subsection in the specifications.
What do the Gehl 680 error codes mean?
An "Error table" lists the system and sensor codes for the Gehl 680. For example, GPI error number 1, with LED code "- o o o" and DIA 1 error number 01, means "Sensor voltage not in valid range". Each listed error gets its own cause in that table.
How do I troubleshoot hydraulic problems on a Gehl 680?
Start with the "Hydraulic system" section, specifically the "Test report" on page 145. It lists rated values for hydraulic parameters, such as "Work hydraulics Max. engine speeds 2973 – 3191 psi (205 – 220 bar)" at a rated oil temperature of 122 – 140 °F (50 – 60 °C). Compare your actual readings against these specs, then review the detailed circuit diagrams to pin down the issue.
What are the replacement specifications for hydraulic pump?
Several hydraulic pumps run on the Gehl 680, each with its own specs. The variable displacement pump has a displacement of 0 – 5 in.³/rev (0 – 74 cm³/rev) and a maximum operating pressure of 6527 psi (450 bar). The charge/boost and pilot control pumps share a displacement of 0.8 in.³/rev (13 cm³/rev) and a charge/boost pressure of 435 psi (30 bar) at 1500 rpm. For loader hydraulics, the gear pump displaces 2 in.³/rev (38 cm³/rev), delivering 22 gpm (84 L/min) at 2300 rpm.
What do I get after purchasing this Gehl 680 manual?
Download starts instantly. The full 212-page searchable Service Manual is yours right after payment, ready to open on a laptop, tablet, or phone out in the shop.
Can I print this Gehl 680 manual?
Yes. There's no DRM or copy protection, so print the whole manual or just the pages you need on any home or office printer.
Does this Gehl 680 manual include wiring diagrams?
It does. Full electrical schematics are included, with wire routing diagrams, connector identification, and circuit descriptions.
Document Quality
This document is a scanned PDF with an OCR layer, allowing you to search and copy the full text content. The text throughout the manual is crisp and consistently easy to read, with no noticeable blurriness or fading. Diagrams and illustrations are a mix of clear raster images and vector-like drawings, and all labels are legible. Pages are clean, free of scan artifacts, stains, or skewed content, maintaining a professional appearance. There are a few "Notes:" pages that serve as filler.
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