Page 2 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.
Page 3: Table Of Contents
503Z General Specifications........
Page 4 Battery Disconnection Precaution ..........2-9 Jump-starting or Charging the Battery .
Page 5 Auxiliary Hydraulic Hammer Operation ......... 3-43 Chapter 4 - Maintenance .
Page 6 NOTES Printed in U.S.A. 918070/FP0811...
Page 7: Chapter 1 - General Information
CHAPTER 1 – GENERAL INFORMATION The Gehl dealer network stands ready to provide any INTRODUCTION assistance you may require, including genuine Gehl The information in this Operator’s Manual was written service parts. All service parts should be obtained from to give the owner/operator assistance in preparing, your dealer.
Page 8: Ownership Change
The engine serial number label is located on the cylin- If this machine was purchased “used,” or if the owner’s der head cover address has changed, please provide your GEHL dealer or GEHL Company Service Department with the Engine serial number label owner’s name and current address, along with the...
Page 9: Excavator Component Indentification
Excavator Component Indentification Operation Controls Dipper Arm Cylinder Boom Dipper Arm Engine Cover Operator’s Seat Hydraulic/Fuel Tank Cover Counterweight Boom Cylinder Bucket Cylinder Swing Frame/ Superstructure Dozer Blade Bucket Travel Drive Motor Track Frame Swing Cylinder Figure 1-2 Component Names 918070/FP0811 Printed in U.S.A.
Page 10: Specifications
Note: Capacities indicated are approximate. Component/Applica- Lubricant Specification Season/Temper- Capacity tion ature SAE 10W-40 (according to Model 503Z: 8.2 DIN 51502); API: CD, CF, qts. (7.8 L) -4°F (-20°C) Diesel Engine Engine Oil CF-4, CI-4 +104°F (+40°C) Model 603: 10.8 SAE E3, E4, E5 qts.
Page 11: Engine
Engine Engine 503Z Engine Model Serial Numbers AH00579 and up: Serial Numbers AH00645 and up: Yanmar 4TNV88-BPNS Yanmar 4TNV98-ZVNS EPA Tier III EPA Tier III S/N AC02471-AH00578: S/N AC02513-AH00644: Yanmar 4TNV88-PNS Yanmar 4TNV98-VNS EPA Tier II EPA Tier II Type...
Page 12: Undercarriage And Swing System
Undercarriage and Swing System Undercarriage and Swing System 503Z Travel Speed Low Speed 1.7 mph (2.74 km/h) 1.7 mph (2.76 km/h) High Speed 2.8 mph (4.56 km/h) 3.0 mph (4.76 km/h) Ground Clearance 11.8” (300 mm) 13.2” (335 mm) Swing Speed 8.7 rpm...
Page 13: Main Fuse Box And Relays
Main Fuse Box and Relays Fuse No. Rated Current Protected Circuit 40 Amp Start, preheat, cut-off solenoid 50 Amp Main fuse, ignition lock Relay No. Protected Circuit Cut-off solenoid Preheating Relays Relay No. Protected Circuit Preheating timer Starting relay Cut-off solenoid Diode 918070/FP0811 Printed in U.S.A.
Page 14: Sound Levels
Sound Levels 503Z Sound Power 96 dB(A) 98 dB(A) Sound Pressure 76 dB(A) 74 dB(A) Coolant Compound Table Coolant: Halvoline XLC (based on ethylene glycol) Outside temperature Water Anticorrosion agent Antifreeze agent % by vol- Up to °F (°C) in³/gal (cm³/L)
Page 15: 503Z General Specifications
503Z General Specifications 11’9” (3583 mm) 3’3” (995 mm) 1’3” (380 mm) 3’10” 1’3” 12’ 2” (3097 mm) 8’2” (2500 mm) 1’3” (1190 mm) (400 mm) (400 mm) 18’4” (5600 mm) 6’6” (1990 mm) 2’11” 3’1” General Specifications 503Z (893 mm)
Page 16: General Specifications
603 General Specifications 13’0” (3967 mm) 4’9” (1465 mm) 1’5” (425 mm) 3’10” 1’3” 10’9” (3280 mm) 8’2” (2500 mm) (1190 mm) (400 mm) 19’2” (5800 mm) 6’6” (1990 mm) General Specifications 1’9” 2’5” (535 mm) (745 mm) Weight 12,566 lbs. (5700 kg) Height 8’5”...
Page 17: Fields Of Applications
36 in. (900 mm) 9.8 ft (0.278 M Ditching Bucket 48 in. (1000 mm) 5.9 ft (0.167 M Ditch Bucket (503Z only) 48 in. (1000 mm) 7.0 ft (0.196 M 55 in. (1400 mm) 8.4 ft (0.238 M Swivel Bucket 48 in.
Page 18: Load Diagrams
Load Diagrams 503Z Load Diagram - Standard Dipper Arm Maximum Permissible Loads 16'3" 13'0" 9'9" 6'6" 3'3" 0'0" 13’0” 9’9” 6’6” (5.0 m) (4.0 m) (3.0 m) (1.0 m) (0.0 m) (2.0 m) 16'3" (4.0 m) (3.0 m) (2.0 m) (5.0 m)
Page 19 503Z Load Diagram - Extended Dipper Arm (Option) Maximum permissible loads 13’0” 9’9” 6’6” 16'3" 13'0" 9'9" 6'6" 3'3" 0'0" (5.0 m) (4.0 m) (3.0 m) (2.0 m) (1.0 m) (0.0 m) 16'3" (4.0 m) (3.0 m) (2.0 m) (5.0 m) 13'0"...
Page 20 503Z Load Diagram - Standard Dipper Arm with Counterweight Maximum permissible loads 16'3" 13'0" 9'9" 6'6" 3'3" 0'0" (5.0 m) (4.0 m) (3.0 m) (2.0 m) (1.0 m) (0.0 m) 13’0” 9’9” 6’6” 16'3" (5.0 m) (4.0 m) (3.0 m) (2.0 m)
Page 21 503Z Load Diagram - Extended Dipper Arm with Counterweight Maximum permissible loads 16'3" 13'0" 9'9" 3'3" 0'0" 6'6" (5.0 m) (4.0 m) (3.0 m) (2.0 m) (1.0 m) (0.0 m) 13’0” 9’9” 6’6” 16'3" (5.0 m) (4.0 m) (3.0 m) (2.0 m)
Page 22 603 Load Diagram - Standard Dipper Arm Maximum permissible loads (standard arm) 16'3" 13'0" 9'9" 3'3" 0'0" 6'6" 16’0” 13’0” 9’9” 6’6” (5.0 m) (4.0 m) (3.0 m) (2.0 m) (1.0 m) (0.0 m) 16'3" (5.0 m) (5.0 m) (4.0 m) (3.0 m) (2.0 m) 13'0"...
Page 23 603 Load Diagram - Extended Dipper Arm (Option) Maximum permissible loads (extended arm) 16'3" 13'0" 9'9" 6'6" 3'3" 0'0" 16’0” 13’0” 9’9” 6’6” (5.0 m) (4.0 m) (3.0 m) (2.0 m) (1.0 m) (0.0 m) 16'3" (5.0 m) (5.0 m) (4.0 m) (3.0 m) (2.0 m)
Page 24 603 Load Diagram - Standard Dipper Arm with Counterweight Maximum permissible loads (standard dipper w/counterweight) 16'3" 13'0" 9'9" 6'6" 3'3" 0'0" 13’ 0" 6’ 6" 16’ 3" 9’ 9" (5.0 m) (4.0 m) (3.0 m) (2.0 m) (1.0 m) (0.0 m) 16'3"...
Page 25 603 Load Diagram - Extended Dipper Arm with Counterweight Maximum permissible loads (extended dipper w/counterweight) 16'3" 13'0" 9'9" 6'6" 3'3" 0'0" 13’ 0" 6’ 6" 16’ 3" 9’ 9" (5.0 m) (4.0 m) (3.0 m) (2.0 m) (1.0 m) (0.0 m) 16'3"...
Page 26: Checklists
Start the engine and test run the unit while  Completely fill out the Owner’s Registration, including checking that all controls operate properly. customer’s signature and return it to the Gehl Company.  Explain that a copy of the product warranty is included ...
Page 27 Start the engine and test run the unit while  Completely fill out the Owner’s Registration, including checking that all controls operate properly. customer’s signature and return it to the Gehl Company.  Explain that a copy of the product warranty is included ...
Page 28 INTENTIONALLY BLANK (To be removed as dealer’s file copy) 918070/FP0811 Printed in U.S.A. 1-22...
Page 29: Chapter 2 - Safety
CHAPTER 2 – SAFETY SAFETY ALERTS IMPORTANT Manitou Americas, Inc., in cooperation with the Soci- ety of Automotive Engineers (SAE), has adopted this “IMPORTANT” is used to draw attention to safety alert symbol: This warning symbol, used a procedure that must to be followed to pre- with a “signal word,”...
Page 30: Unauthorized Modifications
Different applications may require optional safety For safety reasons, use only genuine replacement ser- equipment. Users must evaluate the worksite hazards vice parts. For example, using incorrect fasteners could and equip the machine and the operator as necessary. lead to a condition in which the safety of critical The information in this manual does not replace any assemblies is dangerously compromised.
Page 31: During Operation
Remove all trash and debris from the machine every Work crew members should observe and monitor all day, especially in the engine compartment, to minimize terrain and soil conditions at the work site, along with the risk of fire. traffic, weather-related hazards and any above- or below-ground obstacles and hazards.
Page 32 Use care on loose ground. Working heavy loads over On sloping surfaces, use caution when positioning the loose, soft ground or uneven, broken terrain can cause excavator prior to starting a work cycle. Stay alert for dangerous side-load conditions and possible tip over instability situations.
Page 33: Exposure To Crystalline Silica
Before coupling or uncoupling the hydraulic lines for Parking the Machine the attachment, stop the engine and release the pressure When shutting down the machine for the day, plan in the hydraulic system by moving the joysticks in all ahead so that the excavator will be on a firm, level sur- directions a couple of times.
Page 34: Snow, Ice And Cold Temperature Operation Precautions
Snow, Ice and Cold Temperature Fire Extinguisher Recommendation Operation Precautions It is recommended that a 5 lb. (2.27 kg) or larger, multi-purpose “A/B/C” fire extinguisher be mounted in In cold weather, avoid sudden travel movements and the cab. Check the fire extinguisher periodically and be stay away from even very slight slopes.
Page 35: Maintenance Safety
Never use hands to search for hydraulic fluid leaks. Eye Protection and Safety Clothing Instead, use a piece of paper or cardboard. Escaping Wear full eye protection, ear and head protection, fluid under pressure can be invisible and can penetrate safety shoes, gloves and any other protective clothing the skin and cause serious injury.
Page 36 Use warning tag/control lockout procedures during Cool-down is required prior to radiator or hydrau- service. lic reservoir checks. Alert others that service or maintenance is being per- Stop the engine and allow it to cool before performing formed and tag operator’s cab controls — and other service on the engine radiator or hydraulic reservoir.
Page 37: Safety Decals
Battery Electrolyte and Explosive Gas Dispose of all petroleum-based oils and fluids prop- erly. Hazard Dispose of all petroleum-based oils and fluids properly. Flush eyes with water for 10-15 minutes if battery acid Used motor oil may pose a health risk. Wipe oil from is splashed in the face.
Page 38: Transporting
• Secure the machine against unintentional SAFETY DECALS movement. Use taglines as needed. The machine has decals shown on the following pages • Do not lift the machine with persons on or in that provide safety information and precautions. These the machine.
Page 39: Iso-Style Safety Decal Locations (Serial Numbers Aj02993 And Up)
ISO-Style Safety Decal Locations (Serial Numbers AJ02993 and Up) WARNING! Stay Clear Decal WARNING! Danger Zone Decal AVOID INJURY OR DEATH! AVOID INJURY OR DEATH! Located next to the track tension grease fitting on Located on both sides of the boom. both sides of the machine.
Page 40 WARNING! Read Operator’s Manual AVOID INJURY OR DEATH! WARNING! Rotating and Hot Components Decal Located on the door pillar inside the cab. AVOID SERIOUS INJURY! Read the operator’s manual Located on the fan shroud inside the before operating or performing engine compartment.
Page 41 WARNING! Mandatory Safety Shutdown Decal AVOID INJURY OR DEATH! Before leaving the machine, or performing any service on the WARNING! Danger Zone Decal machine, perform the “Mandatory Safety Shutdown Procedure” on AVOID INJURY OR DEATH! page 2-2.. Located on the back of the swing frame. 1.
Page 42: Iso-Style Information Decal Locations (Serial Numbers Aj02993 And Up)
ISO-Style Information Decal Locations (Serial Numbers AJ02993 and Up) Track Front Decal Tie-Down Point Decal Located near the front of the Located on both ends of the track frame on both sides of the dozer blade and near the rear machine end of the track frame on both sides of the machine.
Page 43 KF K - KF K - KF K - KF K - KF K - KF K - Maintenance Decal Located on the back window of the cab. Provides maintenance intervals quick-reference. Read the operator’s manual before maintenance on the machine. Refer to “Maintenance Schedule” on page 4-5..
Page 44: Ansi-Style Safety Decal Locations (Serial Numbers Ah02282 And Before)
ANSI-Style Safety Decal Locations (Serial Numbers AH02282 and Before) Danger Zone Warning Decal To Avoid Injury Warning Decal PN 161985 Hydraulic Oil Warning Decal PN 161986 PN 161966 Printed in U.S.A. 2-16 918070/FP0811...
Page 45 Cab Ceiling Decals To Avoid Injury Warning Decal (Cab Only) PN 163976 PN 163973 PN 164854 PN 177443 PN 177444 Warning Avoid Injury or Death Decal PN 163975 BOTH SIDES 918070/FP0811 2-17 Printed in U.S.A.
Page 46 Entanglement Hazard, Rotating Fan, and Hot To Avoid Injury or Death Decal Surface Decals PN 177441 Diesel Warning Decal PN 161987 PN 163977 PN 163978 PN 161965 Printed in U.S.A. 2-18 918070/FP0811...
Page 47: Chapter 3 - Operation
• Know how to stop the machine before starting. • Use only with GEHL Company approved accessories or referral attachments. GEHL Company cannot be responsible for safety if the unit is used with non- approved attachments. •...
Page 48 Figure 3-2 Equipment and Controls Model 503Z/603 -- Serial Numbers AJ02993 and Up Printed in U.S.A. 918070/FP0811...
Page 49 Pos. Description For more information see page Auxiliary Hydraulics Pedal Cover ................................3-18 Auxiliary Hydraulics Pedal..................................3-18 Joystick (left) ......................................3-17 Joystick (right) - optional proportional auxiliary hydraulic joystick shown....................3-17 Control Lever Base (left) Control Lever Base (right) Armrest (left) Armrest (right) Seat Horizontal Adjustment Lever................................
Page 50 Figure 3-3 Equipment and Controls Model 603 -- Serial Numbers AH00579 to AH02282 Printed in U.S.A. 918070/FP0811...
Page 51 Figure 3-4 Equipment and Controls Model 503Z -- Serial Numbers up to AH02282; Model 603 -- Serial Numbers AH00578 and Before 918070/FP0811 Printed in U.S.A.
Page 52 Pos. Description For more information see page Auxiliary Hydraulics Pedal Cover................................3-18 Auxiliary Hydraulics Pedal ..................................3-18 Joystick (left) ......................................3-17 Joystick (right) - optional proportional auxiliary hydraulic joystick shown ....................3-17 Control Lever Base (left) Control Lever Base (right) Armrest (left) Armrest (right) Seat Horizontal Adjustment Lever ................................3-19 Air Vent (cab only, rear window, on the left) Air Vent (cab only, rear window, on the right)
Page 53 Figure 3-5 Instrument Panel, Switches and Indicators Model 503Z/603 -- Serial Numbers AJ02993 and Up DP24 918070/FP0811 Printed in U.S.A.
Page 54 Pos. Description Hydraulic oil filter indicator (red) – Hydraulic oil filter indicator light comes on when hydraulic oil filter is too restricted. Air filter indicator (red) – Air filter indicator light comes on when air filter is too dirty. Battery charge fault indicator (red) – Battery charge indicator light comes on when the ignition is turned on and goes off when the engine starts.
Page 55 Figure 3-6 Instrument Panel, Switches and Indicators Model 603 -- Serial Numbers AH00579 to AH02282 DP24 918070/FP0811 Printed in U.S.A.
Page 56 Figure 3-7 Instrument Panel, Switches and Indicators Model 503Z -- Serial Numbers up to AH02282; Model 603 -- Serial Numbers AH00578 and Before Printed in U.S.A. 3-10 918070/FP0811...
Page 57 Pos. Description Hydraulic oil filter indicator (red) – Hydraulic oil filter indicator light comes on when hydraulic oil filter is too restricted. Air filter indicator (red) – Air filter indicator light comes on when air filter is too dirty. Battery charge fault indicator (red) – Battery charge indicator light comes on when the ignition is turned on and goes off when the engine starts.
Page 58 15. Windshield washer reservoir (cab only) 16. Hydraulic oil cooler 17. Air conditioning condenser (option, cab only) 18. Battery (503Z up to serial numbers AH02282 shown; Model 603 and 503Z machines with serial numbers AJ02993 and up battery is located under...
Page 59: Ignition Key Switch
Model 603 -- Serial Numbers AH00579 and up released after starting the engine). Model 503Z -- Serial Numbers AJ02993 and up Note: The key must always be returned to the “I” posi- tion between attempts to start the engine in order to activate the glow plug system.
Page 60: Travel Controls
Travel Controls WARNING • Levers and controls should return to neutral position when released. • Be sure the levers and controls are in the neutral (middle) position before starting the engine. • Operate controls gradually smoothly. Excessive speed and quick control movements without regard for conditions and circumstances are haz- ardous and could cause an accident.
Page 61: Tilting The Cab Or Canopy
5. Reinstall the cab lock-down nuts (2) and (3). Tilting the Cab or Canopy 6. Place the jack handle tubes (4) back in the tool kit. WARNING • Always tighten cab lock-down nuts before driving or using the machine. • Always close the cab door before tilting the cab.
Page 62 CAUTION Check tilt rod (9), the retention pin and safety cable (8) at regular intervals for cracks and cuts. Replace defective parts immediately. SAE/ISO Operating Controls Selector Valve Located on the lower left side of the chassis, under the cab, is the SAE/ISO Selector Valve. See (1), Figure 3- 13.
Page 63: Sae Operating Controls
SAE Operating Controls ISO Operating Controls SAE boom and bucket functions are controlled by the ISO boom and bucket functions are controlled by the right and left joystick control levers located on the seat right and left joystick control levers located on the seat consoles.
Page 64: Boom Swivel/Auxiliary Hydraulics Pedal
Boom Swivel/Auxiliary Hydraulics Dozer Blade Pedal The dozer blade is controlled by the dozer control pedal/lever (1) located next to the travel controls. See The boom can be swiveled without moving the swing Figure 3-19. frame by pressing and holding the auxiliary hydraulic/ changeover valve button (1) on top of the left joystick, •...
Page 65: Throttle Lever
• Pull throttle lever (1) rearward to increase engine speed. Model 503Z/603 -- Serial Numbers AJ02993 and Up Models 503Z/603 -- Serial Numbers AJ02993 and Up Model 503Z/603 -- Serial Numbers AH00611 to AH02282 Model 603 -- Serial Numbers AH00579 to AH02282...
Page 66: Operator's Seat Adjustments
To raise the seat height, grasp the seat and lift up until you hear an Model 503Z/603 -- Serial Numbers AJ02993 and up audible click. To lower the seat, raise the seat to the...
Page 67: Seat Belt
Seat Belt Ventilation WARNING WARNING ALWAYS fasten the seat belt securely and Never use ether starting aids. Glow plugs properly. Never operate the machine with- are used for cold weather starting. The glow out the seat belt fastened around the opera- plug can cause ether or other starting fluid tor.
Page 68 Before closing the windshield, first re-install (if removed) and lower the bottom windshield (See “Mov- able Bottom Window – Optional Cab” on page 3-22). Close the windshield by squeezing/turning the latches, and then lower the windshield and lock the latches in the closed position.
Page 69 To release the latch, use the black knob (1) located on the inside of the door. See Figure 3-28. IMPORTANT Model 503Z/603 -- Serial Numbers AH02282 and earlier shown -- later serial numbers similar Re-install the lower window before lowering the windshield.
Page 70 Cab Heat Control – Optional Cab Recirculated Air Mode During the colder months, the operator’s cab heater can When heating or cooling the cab, the recirculated air be turned on by rotating the dial near the vent (Figure mode can be utilized to heat or cool only the air in the 3-30).
Page 71: Mounting/Removing Buckets
Preheated Fresh Air Mounting/Removing Buckets Selection of “cold” or “preheated” fresh air in winter. ALWAYS wear protective goggles, helmets, gloves, steel-toed shoes, etc. DO NOT service the bucket while the engine is running. DO NOT stand behind the bucket when removing the pins.
Page 72 Attaching A Bucket 1. Grease the dipper arm and bucket holes. 2. Since the bucket is on the ground and stationary, maneuver the machine until the dipper arm holes align flush with the bucket holes. WARNING DO NOT use your hands or fingers to align the bucket and dipper arm holes.
Page 73: Auxiliary Hydraulics Connections
7. To connect each coupling: Auxiliary Hydraulics Connections a. If necessary, rotate lock sleeve (2, Figure 3-37) so notch (3) aligns with lock ball (4). IMPORTANT b. Pull lock sleeve (2) down in the direction of arrow (5). Follow the instructions in the operator’s c.
Page 74: Machine Operation
• Clean engine area of any flammable materials. MACHINE OPERATION • Engine oil level (fill as required) (page 4-9) • Hydraulic system for leaks WARNING • Hydraulic oil level (fill as required) (page 4-9) • Read and understand this entire man- •...
Page 75 Engine Start Procedure IMPORTANT DANGER Indicator lamps should go out when the engine starts. If they do not, turn the engine DO NOT run the engine in an enclosed area off IMMEDIATELY. Do not use machine until without proper ventilation. Be sure there is the problem has been identified and adequate fresh air if running the machine in repaired.
Page 76: Engine Shut Down
Engine Shut Down Travel Mandatory Safety Shutdown Procedure WARNING Before leaving the machine: 1. Bring the machine to a complete stop on a level • Before operating the travel levers, be surface. Avoid parking on an incline or a hillside, sure that you know in which direction but if this is not possible, park across the slope.
Page 77 Travel Speed Switch (1) located on the control console. mm) off the ground. If the machine starts to slide See Figure 3-38. The 503Z and 603 units use an Auto- or becomes unstable, lower the bucket to regain 2-Speed transmission on the drive motors. This feature control.
Page 78: Machine Operation
Machine Operation Operating Precautions Joystick Controls DANGER Extending and retracting the cylinders (boom, arm and bucket) are controlled by the joysticks located on the consoles attached to the operator’s seat. See page 3-17 • DO NOT elevate the front end of the for control configurations.
Page 79: Operating On Slopes
DO NOT jam bucket into the ground and use machine weight to provide additional breakout force. When working on soft or muddy ground, be sure that the machine is not sinking. DO NOT use the bucket as a hammer or ramming device.
Page 80: Cold Weather Operation
The excavator boom can be swiveled from the front position 61º to the right and 65º to the left on the 503Z, and 51º to the right and 75º to the left on the 603. This allows excavation of trenches along walls, fences, etc.
Page 81: Grading
Grading Model 503Z/603 -- Serial Numbers AJ02993 and Up Bulldozing WARNING • Be sure there is proper clearance for the front end attachments when bulldozing. • Be sure that the front end attachments do not contact any overhead power lines or obstructions during bulldozing.
Page 82: Excavation
• When excavating, lower the dozer blade to the Excavation ground to aid machine stability. Whenever possi- The following section applies to an excavator with a ble, it is best to position the dozer blade on the standard bucket, which is used mainly for digging into same side as the excavation.
Page 83: Excavating
4. After the bucket is sufficiently filled: Excavating a. Continue moving the dipper arm toward the Proper Bucket Position excavator. Move the flat side of the bucket so it is parallel to the b. Extend the dipper arm cylinder so the bucket is ground (Figure 3-47).
Page 84: Loading Vehicles
When excavating in confined areas, excavate by rotating the upper carriage and swiveling the boom (Figure 3-50). WARNING Placing the dozer blade on the opposite side of the excavation decreases machine stability. Always consider operator safety when operating the machine, especially under less-than-ideal working conditions.
Page 85: Transporting
The towing bracket has a maximum admissible load of 6992 • Model 503Z: length L1 on the lifting sling for the lbf (3110 daN). boom must be 5’, 7” (1.70 m) long; length L2 on the lifting sling must be 12’, 11” (3.93 m) long. See Fig- •...
Page 86 10. Place chocks under the machine tracks and secure cient capacity for the size and weight of the machine to prevent slipping, overturning and the machine. See “503Z General Specifi- moving on the transport machine. cations” on page 1-9 and “603 General Specifications”...
Page 87: Optional Controls
Secure the machine properly so it cannot slip, slide, OPTIONAL CONTROLS roll, tip over or fall, or cause the transport vehicle to tip over under transport conditions. Use anti-slip bases and Proportional Auxiliary Hydraulic linings, load-securing straps and chains, clamping Joystick Control (Option) beams, protective paddings, nets, edge protectors, etc.
Page 88: Two-Speed Variable Auxiliary Hydraulic Mode Selection
Select the appropriate mode depending upon the Model 503Z/603 -- Serial Numbers AJ02993 and Up job requirements. 1. Shut down the excavator. 2. To set the auxiliary hydraulics to power mode,...
Page 89: Auxiliary Hydraulic Hammer Operation
Auxiliary Hydraulics Proportional Auxiliary Hydraulic Hammer Operation Joystick Control Note: Use the power mode (refer to “Two-Speed Vari- When the excavator is running, use the thumb switch able Auxiliary Hydraulic Mode Selection”) when oper- (C, Figure 3-59) on the right joystick to control the ating a hydraulic hammer attachment.
Page 90 NOTES Printed in U.S.A. 3-44 918070/FP0811...
Page 91: Chapter 4 - Maintenance
CHAPTER 4 – MAINTENANCE GENERAL INFORMATION Care and Servicing Care and servicing have a significant influence on the readiness for operation and service life of the machine. WARNING For additional service information about the engine, see the service manual provided with the machine. Instructions are necessary before operating Use of lubricants that do not correspond to the manu- or servicing the machine.
Page 92: Maintenance Safety
Maintenance Safety • Never service the machine without reading the • Avoid contact with leaking hydraulic fluid and applicable instructions. diesel fuel under pressure, which can penetrate the skin and eyes. NEVER use your hands to • Always lower bucket and dozer blade to the search for hydraulic fluid leaks;...
Page 93: Maintenance Label Symbols
Maintenance Label Symbols Symbol Assembly Explanation General Visual check General Lubrication instructions Fuel system Drain condensation water Fuel system Replace the fuel filter; clean the fuel pre-filter Radiator Check the coolant level Radiator Change coolant Engine Check valve clearance; adjust if necessary Engine Check engine oil level Engine...
Page 94: Maintenance Label
Maintenance Label Printed in U.S.A. 918070/FP0811...
Page 95: Maintenance Schedule
MAINTENANCE SCHEDULE The following service schedule is a recommended. Maintenance work must be done at regular intervals. Failure to perform scheduled maintenance work will result in excessive wear and early machine failures. The following ser- vice schedule is a recommended. Check, Clean and Inspect Service Activity Daily...
Page 96: Fluid And Filter Changes
Check, Clean & Inspect (Cont.) Service Activity Daily Every 50 Every 250 Every 500 Every Customer Dealer Hours Hours Hours 1000 Hours Check tracks for cracks or cuts Check track tension; adjust if necessary Inspect cylinder piston rods for damage Ensure bucket and attachment pins are secure and locked Inspect hydraulic line clamps for tight-...
Page 97: Cab Air Conditioning
Cab Air Conditioning Service Activity Daily Every 50 Every 250 Every 500 Every Customer Dealer Hours Hours Hours 1000 Hours Test air conditioning function Check dehumidifier for corrosion Replace cab air filter Check refrigerant Replace dehumidifier Replace compressor oil a. Replace every 1000 hrs or once every 2 years, whichever comes first. Cab Functional Checks Service Activity Daily...
Page 98: Lubrication
Lubrication (See Figure 4-1). Service Activity Daily Every 50 Every 250 Every 500 Every Customer Dealer Hours Hours Hours 1000 Hours Dozer blade Swivel console Boom Dipper arm Attachments Chassis (front of undercarriage) D = Daily W = Weekly Figure 4-1 Lubrication Points Printed in U.S.A.
Page 99: Recommended Lubricants
Recommended Lubricants Engine Engine Oil IMPORTANT IMPORTANT Be sure to read the service manual supplied Be sure to read the engine manual supplied Checking Engine Oil Level with this machine for detailed engine speci- fications. IMPORTANT See “Fluid Capacities/Lubricants” on page 1-4 for engine oil specifications.
Page 100: Changing Engine Oil And Filter
Changing Engine Oil and Filter Air Cleaner Service 1. Perform the “Mandatory Safety Shutdown Proce- 1. Perform the “Mandatory Safety Shutdown Proce- dure” on page 2-2, but do not allow the engine to dure” on page 2-2, fully cool; warm oil will drain more completely.. 2.
Page 101: Fuel System
See Figure 4-4. Fill using clean diesel fuel with a cetane rating over 45. Re-install fuel cap. DP24 Model 503Z — S/N AJ02993 Model 503Z — S/N AH02282 and up and before Model 603 — S/N AH00579 Model 603 —...
Page 102 Fuel Filter IMPORTANT WARNING Unless draining fuel tank for servicing, never operate the machine until the fuel Use care to catch any spilled fuel when ser- tank is completely empty. The fuel system vicing the fuel filter. Spilled fuel can cause a has to be bled of air whenever the fuel tank fire.
Page 103 Purging Air from the Fuel System WARNING DO NOT air bleed a hot engine. Spilled fuel can cause a fire. Starting from the fuel tank, the fuel system runs through the water separator, fuel filter, fuel injection pump and high pressure piping to the fuel injection nozzles.
Page 104: Cooling System
Work on the machine’s electrical system 603. must be done only by a trained technician. 4. If low, (2), Figure 4-8 for the 503Z, or Figure 4-9 for the 603, remove cap and overflow tube. Fuses The fuse panel is located on the right consoles. See (1) 5.
Page 105: Battery
In case of acid contact, wash immediately with water for several minutes. In case of eye contact, get medical attention immediately. Model 503Z – serial numbers AH02282 and before: the battery (1, Figure 4-11) is located under the engine cover in front of the oil cooler.
Page 106 Model 503Z -- Serial Numbers up to AH02282 IMPORTANT Damage to the electrical system can occur • the engine is operated with the battery cables disconnected, • the battery cables are connected when using a fast charger or when welding on...
Page 107: Hydraulic System
5. Connect one end of the cable to the positive (+) ter- minal on the booster battery. Connect the other end WARNING of the same cable to terminal (3) on the battery dis- connect switch. Stay away from moving components when the engine is running.
Page 108 5. Open the engine cover. Check the hydraulic oil level indicator tube (1, Figure 4-16) in the back corner of the engine compartment. Oil level should be visible in the sight gauge (2). Figure 4-13 Excavator Position for Checking FULL and Changing Hydraulic Oil Figure 4-14 Hydraulic Oil Level Indicator Tube 6.
Page 109 c. Using the assembled tools, slowly open the Re-install hydraulic oil filter insert and filler hydraulic oil filler cap (4, Figure 4-16) to allow cap and tighten securely. pressure to escape from the hydraulic system. g. Replace the fuel tank/hydraulic reservoir cover and secure it with the three screws with lock- washers removed earlier.
Page 110 8. Disconnect the pilot control filter/restrictor fitting Hydraulic Cooling System (B) from the valve. The hydraulic system uses a hydraulic cooler to keep the hydraulic fluid at the proper temperature. The cooler is located inside the engine compartment near the engine radiator. Inspect the cooler for leaks or damage.
Page 111 Hydraulic Hose Maintenance 1 Q/10 WARNING • Hydraulic hoses and connections must be inspected by a trained technician before the first use of the machine, and at least annually thereafter, for leaks and/or damage. • Leakages and damaged pressure lines must immediately repaired...
Page 112: Checking And Adjusting V-Belt Tension
Checking and Adjusting V-Belt Tension approx. 5/16” (8 mm) 1. Position the machine on a level surface. 2. Lower the bucket and dozer blade to the ground. Move the joysticks in all directions to verify the hydraulic system is de-pressurized. 3.
Page 113: Track System
a. Loosen jam nut (2) and rotate the adjustment nut (3) until reaching the correct V-belt ten- sion. b. Tighten jam nut (2) and re-check V-belt ten- sion. Close the engine cover when finished. approx. 11/32” (9mm) Figure 4-21 Track Cleaning Note: When using the boom and dipper arm to lift any portion of the machine, roll the bucket until the round base is against the ground.
Page 114 Checking and Adjusting Track Tension 1. Position the machine on a level surface. On machines equipped with rubber tracks, position the excavator so the tracks are positioned with mark (1, Figure 4-23) on the top span of the track in between drive pinion (2) and track tension roller (3).
Page 115 Note: A grease gun is supplied with machine tool kit. Figure 4-24 Track Adjustment IMPORTANT Do not over-tension the track. If track is too tight, loosen the grease fitting to relieve pressure. WARNING Do not loosen grease fitting more than two turns, or grease fitting could be ejected under pressure and cause injury.
Page 116: Windshield Washer Fluid
Windshield Washer Fluid LONG-TERM STORAGE 1. Shut off the engine. Remove the ignition key and If storing the machine for a long period (longer than take it with you. Lock-out the controls by raising two months), perform the procedures in this section. left control console.
Page 117: After Storage
During Storage About once each month, connect the battery and check all fluid levels to make sure they are at the proper level before starting the engine. Start the engine and allow it to run until it warms up and then move the machine a short distance to help relubricate the internal parts.
Page 118 NOTES Printed in U.S.A. 4-28 918070/FP0811...
Page 119: Chapter 5 - Troubleshooting
CHAPTER 5 – TROUBLESHOOTING ENGINE Problem Possible Cause Corrective Action Engine will not start No fuel Add fuel to tank; bleed air from fuel system Incorrect engine oil SAE grade Replace engine oil with proper grade; see “Fluid Capacities/Lubricants” on page 1-4 Incorrect fuel grade Replace fuel with proper grade;...
Page 120 Problem Possible Cause Corrective Action Engine overheats Oil level too low Add engine oil; see “Checking Engine Oil Level” on page 4-9 Fouled oil cooler fins Clean oil cooler; contact authorized service center Damaged fan. Damaged or loose V-belt Replace the fan / service V-belt; see “Checking and Adjusting V-Belt Tension”...
Page 121: Indicator Lamps
INDICATOR LAMPS Problem Possible Cause Corrective Action Engine oil pressure indicator Engine oil pressure too low Stop engine immediately. Check oil level and light comes on during opera- add oil if necessary. If oil level is correct, oil tion pump may have failed Engine oil level too low Add engine oil;...
Page 122: Traveling Gear
TRAVELING GEAR Problem Possible Cause Corrective Action Machine will not travel in any Foreign object jammed in track Remove object direction Gears not operative Repair gears. Contact authorized service cen- Machine will not travel straight Foreign object jammed in track Remove object forward or backward Track tension unequal...
Page 123: Engine Error Codes
The specific engine error can be determined based on Model 603 Serial Numbers AH00579 and Up upon the number and duration of flashes displayed by Model 503Z Serial Numbers AJ02993 and Up the engine error indicator. Figure 5-2 shows three possible engine error code examples.
Page 124: Engine Diagnostic Codes Table
Engine Diagnostic Codes Table Flashing Error Sender Associated Component Troubleshooting Code Fuel injection pump regula- Loose connector Tighten connector tor sensor Wiring error Check/replace defective component(s) Defective sensor Contact dealer Throttle Wiring error Check/replace defective component(s) Defective throttle lever sensor Replace throttle lever sensor ECU temperature sensor Internal ECU error...
Page 125 Flashing Error Sender Associated Component Troubleshooting Code Fuel injection pump regula- Loose connector Tighten the connector tor relay Defective fuel injection pump Contact dealer Internal ECU error Contact dealer Wiring harness error Check/replace defective component(s) Start relay Loose connector Tighten connector Wiring harness error Check/replace defective component(s)
Page 126 Flashing Error Sender Associated Component Troubleshooting Code Main relay Loose connector Tighten connector Wiring harness error Check/replace defective component(s) Defective main relay Replace main relay Internal ECU error Contact dealer CAN connection Battery voltage too low Charge battery Loose connector Tighten connector Wiring harness error Check/replace defective...
Page 127: Chapter 6 - Index
INDEX Air Cleaner Service .........4-10 Electrical System ......1-6, 4-14 Air Conditioning ........4-7 Engine ..........1-5, 4-9 Arm rests ..........3-20 Checking Engine Oil Level ....4-9 Cold Weather Starting Procedure ..3-29 Mandatory Safety Shutdown Procedure ........3-30 Battery .............4-15 Shut Down ........3-30 Disconnect Switch ......3-13 Start ...........3-28 Boom Slew/Auxiliary Hydraulics...
Page 128 Relays ............1-7 Joystick Controls ........3-32 SAE/ISO Operating Controls ISO Operating Controls ....3-17 Load Diagram SAE Operating Controls ....3-17 503Z ......1-12, 1-13, 1-14, 1-15 Selector Valve ........3-16 603 ......1-16, 1-17, 1-18, 1-19 Safety ............2-1 Load Diagrams ........1-12 Decals ..........2-10 Loading ...........3-38 Serial Number Location ......1-1...
Page 129 Index Spin Turn ..........3-14 Turning During Travel ......3-14 Trench Excavating ........3-37 Troubleshooting ........5-1 Bucket, Boom and Dozer Blade ..5-4 Engine ..........5-1 Indicator Lamps ........5-3 Seals and Hoses ........5-3 Traveling Gear ........5-4 Undercarriage ..........1-6 V-belt Tension Adjusting ...........4-22 Checking ...........4-22 V-belt Tension (Air Conditioning) Adjusting ...........4-22 Checking ...........4-22 Water Separator ........4-13...
Page 130 TORQUE SPECIFICATIONS Note: Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread forming and sheet metal screws) unless specified otherwise. Hydraulic fittings with various seals (light application). All torque values are in lb.-ft. (Nm) unless marked otherwise. Straight pipe fitting with thread and screwed plug (GE) Non-return valve Identification aid...
Page 131 Bolts and capscrews with coarse-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise. Threads according to DIN 912, DIN 931, DIN 933, etc. Threads according to DIN 7984 Thread 10.9 12.9 10.9 4.1 (5.5) 6 (8) 7 (10) 4 (5) 5 (7) 7 (10)
Page 132 If you have any questions on proper operation, adjustment or mainte- nance of this machine, contact your dealer or the GEHL Company service department before starting or continuing operation. California Proposition 65 Warnings: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer and birth defects and other reproductive harm.

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Gehl 503Z Operator's Manual

Chapter 1 - General Information

Chapter 2 - Safety

Chapter 3 - Operation

Chapter 4 - Maintenance

Chapter 5 - Troubleshooting

Chapter 6 - Index

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