Gehl GE 802 Operator's Manual
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Gehl GE 802 Operator's Manual

Gehl GE 802 Operator's Manual

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Form No.
908147
English
GE 802
Crawler
Excavator
OPERATOR’S MANUAL

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Summary of Contents for Gehl GE 802

  • Page 1 Form No. 908147 English GE 802 Crawler Excavator OPERATOR’S MANUAL...
  • Page 2 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...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Chapter Description Page INTERNATIONAL SYMBOLS .......Inside Front Cover GENERAL INFORMATION Introduction .
  • Page 4 TABLE OF CONTENTS (continued) Chapter Description Page MAINTENANCE General Information ..........4-1 Care and Servicing .

  • Page 5: General Information Introduction

    GEHL service maintaining and servicing the Crawler Excavator. More parts. All service parts should be obtained from your GEHL importantly, this manual provides an operating plan for safe Dealer. Give complete information about the part and and proper use of the machine.

  • Page 6: Machine Identification

    MACHINE IDENTIFICATION Arm Cylinder Boom Left-hand & Right-hand Travel Levers Bucket Cylinder Operator’s Seat Bucket Engine Hood Boom Cylinder Control Lever Console Dozer Superstructure Blade Track Frame PRINTED IN U.S.A. 908147/0999...

  • Page 7: Specifications

    SPECIFICATIONS GE 802 ENGINE Make Yanmar Model 4TNE98-NSR-Diesel Type 4-Cyl. Water-Cooled Displacement 202 cu. in. (3318 cc) Rated Power Output 62 hp (45.6 kW) @ 2300 rpm Battery 12V (88 Ah) Fuel Tank 23.75 gal. (90 L) HYDRAULIC SYSTEM Pumps Double Axial Piston Pump &...

  • Page 8: General Specifications

    SPECIFICATIONS (continued) GE 802 GENERAL SPECIFICATIONS Operating Weight w/Cab (SAE) 17,416 lbs. (7900 kg) Height 101 in. (2570 mm) Width 84.6 in. (2150 mm) Length 12.5 ft. (3800 mm) Max. Digging Depth 173.2 in. (4400 mm) Max. Digging Height 284.25 in. (7220 mm) Max.
  • Page 9 Model GE802 15" (3800 mm) 284" (7220 mm) 59" 214" 204" (1500 mm) (5440 mm) (5180 mm) 101" 72.8" (2570 mm) (2150 mm) 21.3" 17.7" (540 mm) (450 mm) 17.7" 173" (450 mm) (4400 mm) 109" (2780 mm) 72.8" (2150 mm) 285"...

  • Page 10: Checklists

    (no pilot control pressure). Completely fill out the Owner’s Registration, including customer’s signature and return it to the Gehl Company. All hydraulic functions are NOT operational with the left-hand control console in the pivoted rearward position.
  • Page 11 (no pilot control pressure). Completely fill out the Owner’s Registration, including All hydraulic functions are NOT operational with the customer’s signature and return it to the Gehl Company. left-hand control console in the pivoted rearward position. Customer’s Signature Date Delivered Retain for Dealer’s Records...
  • Page 12 This Page Intentionally Blank PRINTED IN U.S.A. 908147/0999...

  • Page 13: Safety Information General Safety Information

    Gehl service parts. throughout this Operator’s Manual and on the machine. • Gehl units are designed and intended to be used ONLY Before you operate this equipment, read and study the with Gehl Company attachments or approved referral following safety information.

  • Page 14: Fire Prevention

    • Never drive across the incline on sloping ground. Safety Reminders (continued) Extreme caution is required when working across an incline or changing direction. • When driving on or across roads, the machine must be equipped according to the road/traffic laws, and these •...

  • Page 15: Safety Decal And Sticker Locations

    • Check all electrical wiring and connections for damage. Mandatory Safety Shutdown Procedure Keep the battery terminals clean and tight. Repair or replace any damaged parts. Before leaving the machine: • Check fuel and hydraulic tubes, hoses and fittings for Lower the working equipment to the ground and support damage and leakage.

  • Page 16: Safety Decals And Stickers

    SAFETY DECAL & STICKER LOCATIONS WARNING: TO AVOID INJURY: Load and transport unit properly. Inspect job-site for hazards. Operate only from operator’s seat. Fasten seat- 25, 26 belt. Keep people out of DANGER ZONE. Operate within stability limit of machine. DO NOT 20, 21 OVERLOAD.
  • Page 17 SAFETY DECALS WARNING DANGER ZONE Keep away! HYDRAULIC OIL WARNING WARNING HYDRAULIC RESERVOIR DO NOT OPEN WHILE DIESEL UNDER PRESSURE ENGINE IS RUNNING TRAVEL RIGHT TRAVEL LEFT BOOM DOWN FORWARD FORWARD DOZER BLADE DOWN BUCKET BUCKET OPEN CLOSED REVERSE REVERSE DOZER BLADE UP BOOM UP WARNING...
  • Page 18 SAFETY DECALS (continued) WARNING TO AVOID INJURY: Load and transport unit properly. Inspect job-site for hazards. Operate only from operator's seat. Fasten seatbelt. Keep people out of DANGER ZONE. Operate within stability limit of machine. DO NOT OVERLOAD. Use only approved attachments. WARNING STOP WARNING...

  • Page 19: Operation General Information

    In many places, and controls before operating the machine. decals are also provided to warn of potential hazards and/or Know how to stop before starting. This GEHL ® to display special operating procedures (see Safety Decals Company machine is designed for use only Locations in Section 2).

  • Page 20: Outer Cab Layout

    OPERATOR CONTROLS Outer Cab Layout Fuel Filler Hydraulic Reservoir Hydraulic Valves Diesel Pump (Option) Hydraulic Oil Filler Hydraulic Oil Filter Hydraulic Oil Sight Gauge Battery Hydraulic Reservoir Drain Fuel Tank Drain Fuel Tank Engine Hood Fire Extinguisher in Tool Box Inner Cab Layout Auxiliary Hydraulics Pedal Left-Hand Travel Lever w/Foot Pedal...

  • Page 21: Console Controls Layout

    Console Controls Layout Fuel Level Gauge Coolant Temperature Indicator Battery Voltage Indicator Engine Oil Pressure Indicator Glow Plug Indicator Engine Air Filter Indicator Hydraulic Oil Level Indicator Low Fuel Indicator Work Lights ON Indicator Hour Meter Heater Control 2-Speed Travel Switch Light Switch–Cab Front Work Light 00000000 HOURS...

  • Page 22: Travel Controls

    OPERATOR CONTROLS (continued) Left-Hand Lever w/Foot Pedal WARNING Right-Hand Lever w/Foot Pedal Levers and controls should return to neutral Dozer Lever position when released. Be sure the levers and w/Foot Pedal controls are in the neutral (middle) position before starting the engine. Operate lever con- trols gradually and smoothly.

  • Page 23: Console Controls

    LEFT-HAND CONTROL LEVER (FIGURE 3-3) 1. Move the left-hand lever forward to move bucket arm away from the machine. 2. Move the left-hand lever to the rear to move the arm towards the machine. 3. Move the left-hand lever to the left to slew superstruc- ture to the left.

  • Page 24: Operator's Seat Adjustment Controls

    OPERATOR CONTROLS (continued) Console Controls (continued) (Figure 3-6) Armrest Lever 10. HOUR METER Indicates total operating hours of the machine. Use the hour meter to log maintenance time in the log located in Left-Hand Console Section 4–Maintenance. In Raised Position 11.

  • Page 25: Ventilation

    Ventilation WINDSHIELD The windshield can be opened for ventilation. Turn the latch (Figure 3-9) located at the upper corners of the windshield. Grasp the handles and pull the windshield up until latches lock in position. Latch To close the windshield, turn the latches then lower the wind- shield until the latches lock in position.

  • Page 26: Machine Operation

    MACHINE OPERATION Starting/Stopping the Engine WARNING SAFETY DEVICES Instructions are necessary before operating or When the machine is stationary (no pilot control pressure), servicing the machine. Read this entire manu- the parking and travelling gear brake are automatically acti- al and all decals on the machine. Follow all vated.

  • Page 27: Moving The Excavator

    Throttle Lever Starting/Stopping the Engine (continued) IMPORTANT: Indicator lamps must go out when engine starts. If they do not, turn off the engine IMMEDIATELY until cause has been determined and fixed. COLD WEATHER STARTING PROCEDURE 1. Install an engine heater. 2.

  • Page 28: Earthmoving

    EARTHMOVING Operating on Slopes WARNING Do not travel up or across a slope steeper than 15°. Do not travel down a slope steeper than 25°. Keep boom centered while travelling. Keep attachments as low as possible when travelling on slopes or rough terrain. Operating on a slope is inherently dangerous.

  • Page 29: Excavator Boom Slewing

    Excavator Boom Slewing WARNING Always ensure adequate stability when work- ing with the machine. Particularly when work- ing with equipment slewed to the side. Changing the working equipment alters the stability (weight) of the machine. The excavator boom can be slewed 45° to the right and 80° to the left from the basic front position.

  • Page 30: Transporting

    TRANSPORTING Lifting Machine Loading Machine for Transport • Use only transport machines that are in proper working WARNING order and are approved for use on public roads. Use lifting device with sufficient capacity for • When using ramps to load machine onto the transport the weight of the machine plus any attach- machine: ments.

  • Page 31: Maintenance General Information

    DO NOT pour fluids use only with Gehl ® Company approved acces- onto the ground or down a drain. sories or referral attachments. The Gehl ® Company cannot be responsible for operator Maintenance Safety safety if the unit is used with non-approved •...
  • Page 32 GENERAL INFORMATION (continued) Maintenance Safety (continued) • Never fill fuel tank with engine running, while • Never service or adjust machine with the engine smoking or when near open flame. running unless service procedure calls for the engine to be running. •...

  • Page 33: Maintenance Schedule

    MAINTENANCE SCHEDULE IMPORTANT: 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 service schedule is a recommend- ed guide for servicing the machine. Engine Service Activity Daily Weekly...
  • Page 34 MAINTENANCE SCHEDULE (continued) Hydraulic System Service Activity Daily Weekly Every Every Every Every Annually 125-250 1000 Hours Hours Hours Hours Check hydraulic oil level Check system for leakage Check hydraulic pump bolts Clean cooler fins Change filter Change hydraulic oil Check filter Check hydraulic oil Check primary &...
  • Page 35 Travelling Gear Unit Service Activity Daily Weekly Every Every Every Every Annually 125-250 1000 Hours Hours Hours Hours Check for leakage Change final drive gear oil * First change only. Slewing Gear Ring Service Activity Daily Weekly Every Every Every Every Annually 125-250...

  • Page 36: Lubrication

    MAINTENANCE SCHEDULE (continued) General Service Activity Daily Weekly Every Every Every Every Annually 125-250 1000 Hours Hours Hours Hours Check hydraulic system Check bolts Check lights Check windshield wiper system Check for leaks LUBRICATION Lubrication Points Green Caps–lubricate weekly (points marked with a “W”) Blue Caps–lubricate daily Superstructure bearing system (W) Figure 4-1.

  • Page 37: Recommended Lubricants

    Recommended Lubricants SLEWING GEAR UNIT ENGINE OIL An EP grade gear oil that conforms to API GL 5, such as A diesel engine oil conforming to SAE grade 10W 30 or Chevron Delo Gear 80W 90 or BP Transgear 80W 90 15W 40, and API classification CD (or higher, e.g., CH-4), such as BP Vanellus MG 15W 40, BP Vanellus C-Extra EXCAVATOR ARM...

  • Page 38: Changing Engine Oil & Filter

    ENGINE (continued) Changing Engine Oil & Filter 1. Place the machine on a level surface. Run the engine until it is at operating temperature, then turn the engine off. 2. Pull the engine cover latch lever (located next the right Oil Fill side of the operator’s seat) and raise the engine cover.

  • Page 39: Fuel System

    FUEL SYSTEM Filling the Fuel Tank WARNING Stop and cool the engine before adding fuel. Low Fuel NO SMOKING! Failure to obey warnings can Indicator Light cause an explosion or fire. Fuel Gauge The fuel level in the tank is indicated by the fuel gauge on the console (Figure 4-6).

  • Page 40: Checking Coolant Level

    COOLANT SYSTEM Checking Coolant Level 1. Pull the engine cover latch lever (located next the right side of the operator’s seat) and raise the engine cover. 2. Check the coolant level in the expansion reservoir (Figure 4-9). Full 3. If low, slowly remove cap and fill reservoir to FULL line.

  • Page 41: Using A Booster Battery (Jump Starting)

    IMPORTANT: Damage to the alternator can Using a Booster Battery (Jump Starting) occur if: • Engine is operated with battery cables dis- WARNING connected. • Battery cables are connected when using a Keep arcs, sparks, flames and lighted tobacco fast charger or when welding on the away from batteries.

  • Page 42: Hydraulic System

    HYDRAULIC SYSTEM WARNING Hydraulic reservoir is under pressure. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes and cause severe injury. Sight Glass Checking Hydraulic Oil Level 1. Position the machine on a level surface. 2.

  • Page 43: Changing Hydraulic Oil

    Changing Hydraulic Oil 1. Position the machine on a level surface. Filter Filter Cover Gasket 2. Fully extend the bucket and boom. Lower bucket and dozer blade to the ground (Figure 4-12). Turn off the Cap w/Strainer machine. Slowly open the cap to relieve pressure (Figure 4-14). Filter Remove cap and clean strainer of any debris.

  • Page 44: Track System

    TRACK SYSTEM Changing Final Drive Oil 1. Position the machine on a level surface with final drive POSITION A plugs positioned as shown in POSITION A, Figure 4-14. Screw Plugs in position Turn off the engine. for draining oil 2. Open both plugs and drain oil into a suitable container. Re-install plugs.
  • Page 45 MAINTENANCE LOG DATE HOURS SERVICE PROCEDURE 4-15 PRINTED IN U.S.A. 908147/0999...
  • Page 46 MAINTENANCE LOG DATE HOURS SERVICE PROCEDURE 4-16 PRINTED IN U.S.A. 908147/0999...

  • Page 47: Troubleshooting General Information

    Know how to stop before starting. operate the machine unless all factory installed This GEHL ® Company machine is designed for guards and shields are in place. use only with GEHL ® Company approved accessories or referral attachments. The WARNING GEHL ®...

  • Page 48: Engine

    ENGINE PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Engine will not start. No fuel. Add fuel to tank; bleed fuel system. Battery power insufficient. Charge battery or replace if necessary. Fuel filter contaminated. Clean fuel filter. Pre-glow system not working. Replace pre-glow system (contact authorized repair center.).

  • Page 49: Travelling Gear

    TRAVELLING GEAR PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Machine will not travel in any Foreign body jammed in track. Remove foreign body. direction. Gears not operative. Repair gears (contact authorized repair center). Foreign body jammed in track. Remove foreign body. Machine will not travel straight ahead.
  • Page 50 NOTES PRINTED IN U.S.A. 908147/0999...
  • Page 52 ® Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 U.S.A. California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

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