This is the factory service manual for the Gehl 680 wheel loader, Form No. 918123, for the 2005 build beginning at serial number 343010001. Across 212 pages it documents the Deutz BF4M 2011 diesel, rated at 75 hp (56 kW), and covers the machine from operation through the electrical system.The content is organized into operation, specifications, maintenance, engine, power train, axles, brakes, steering, hydraulic system, electrical system, and torque specifications. It carries fluid capacities, pressure settings, wiring detail, and tightening torques for real repairs.Owners and independent mechanics use it to service the engine and cooling system, test the hydrostatic power train, work the axles and brakes, adjust the steering circuit, trace wiring faults, and set fasteners to spec. The PDF has a text layer and bookmarks, downloads instantly after purchase, and prints on standard paper.
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
Engine overheating under load
Overheating after short runs usually means low coolant, a blocked radiator or restricted airflow, a faulty thermostat, or a cooling fan issue. The Engine section covers the BF4M 2011 and its oil cooling circuit.
Manual Section: Engine p. 67Slow or weak hydraulic functions
Loss of lifting power or slow response often traces to low or contaminated fluid, a leak, or a worn pump. The Hydraulic system section covers the control valve, pilot control, and test report procedures.
Manual Section: Hydraulic system p. 145Loss of drive or uneven travel
Poor travel performance or delayed engagement points to the hydrostatic power train. This section covers the variable displacement pump, hydraulic motor, and power train diagrams.
Manual Section: Power train p. 85No-start or intermittent electrical faults
A weak battery, corroded terminals, loose wiring, or a charging fault can cause hard starting and intermittent operation. The Electrical system section covers terminal descriptions, relays, fuses, and cable color coding.
Manual Section: Electrical system p. 167Loose wheel or axle hardware
Wheel and axle fasteners that back off cause vibration and uneven handling. The Axles section covers front and rear axle screw connections and their tightening torques.
Manual Section: Axles p. 113Soft or dragging brakes
A spongy pedal or dragging brakes usually needs bleeding or an inching valve and parking brake adjustment. The Brakes section covers the brake circuit and service brake bleeding procedure.
Manual Section: Brakes p. 135Frequently Asked Questions
Which machine and year does this manual cover?
It covers the 2005 Gehl 680 wheel loader, Form No. 918123, beginning at serial number 343010001, built with the Deutz BF4M 2011 diesel engine.
What engine and power does it document?
The Engine section covers the Deutz BF4M 2011, rated at 75 hp (56 kW) at 2300 rpm, including oil cooling, the fuel system, and valve clearance procedures. p. 67
Does it list torque specifications?
Yes. A dedicated Torque Specifications section covers hydraulic fittings and coarse and fine pitch thread values, and the specs list the 295 lb-ft wheel nut torque. p. 210
Does it cover wiring and electrical faults?
Yes. The Electrical system section starts on page 167 with terminal descriptions, cable color coding, relays, and fuse box layouts for tracing faults. p. 167
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 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.
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