Gehl Z27 Operator's Manual
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Gehl Z27 Operator's Manual

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Z27
®
Form No.
Z35
50940101
Revision A
Jun. 2012
Compact Excavator
© 2012 Manitou America • All Rights Reserved. • Printed in USA

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Summary of Contents for Gehl Z27

  • Page 1 ® Form No. 50940101 Revision A Jun. 2012 Compact Excavator © 2012 Manitou America • All Rights Reserved. • Printed in USA...
  • 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 1. Introduction This Operation and Maintenance Manual for the model Z27/Z35 Excavators is designed to provide you with important information and suggestions necessary for using the machine with safety and efficiency. Please be sure to read through the manual before using the machine, to make yourself familiar with the procedures and instructions for operating, inspecting and servicing.

  • Page 4: Safety Information

    2. Safety Information • The following Signal Words have been used in this Manual and on the Safety Signs to indicate the seriousness of the hazards that could be encountered by failing to comply with the applicable Product Warnings, as follows: Could result in death or catastrophic bodily injury.

  • Page 5: Product Overview

    3. Product Overview 3-1. Intended uses Model Z27/Z35 Excavators are intended to perform the following tasks: • Digging • Leveling of ground The machine should not be used for unintended tasks • Shoveling • Ditching and Guttering • Loading For the details of how to work with the machine, refer to OPERATION Section "13-13. Operations using the bucket".

  • Page 6: Conditions To Insure Compliance With Epa Emission Standards

    3. Product Overview 3-3. Conditions to insure compliance with EPA emission standards Conditions de conformité avec les standards d’émission EPA An EPA approved engine has been mounted on this machine. The following are the conditions that must be met in order to insure that the emission during operation meets the EPA standards. Be sure to follow these. •...

  • Page 7: Operation License

    4. Operation License Before you operate this machine, confirm the licensing requirements that are applicable to the operation of this machine. Comply with all applicable laws. Ask your dealer about licensing requirements.

  • Page 8: Ordering Replacement Parts And Service Call

    5. Ordering Replacement Parts and Service Call 5-1. Location of machine serial number plate The machine serial number plate is located on the turning frame as illustrated at right. Never remove the plate for any reason. 015396-00X 5-2. Location of engine serial number plate The engine serial number plate is located on the top of the Viewed from top cylinder head cover.

  • Page 9: Ordering Replacement Parts And Service Calls

    5. Ordering Replacement Parts and Service Call 5-4. Ordering replacement parts and service calls When ordering replacement parts or calling for service, let your dealer know the model designation, the machine se- rial number, and the engine serial number on the machine serial number plate as well as the reading of the hour me- ter.

  • Page 10: Table Of Contents

    6. Contents 1. Introduction ............................0-1 2. Safety Information ..........................0-2 3. Product Overview ..........................0-3 3-1. Intended uses ..........................0-3 3-2. Break in period.........................0-3 3-3. Conditions to insure compliance with EPA emission standards ..........0-4 4. Operation License ..........................0-5 5. Ordering Replacement Parts and Service Call.................0-6 5-1.
  • Page 11 6. Contents 12-8. Operator’s seat ........................2-18 12-9. Ash tray (for cabin).......................2-19 12-10. Headlight..........................2-19 12-11. Air outlet (for cabin)......................2-20 12-12. Right window glass (for cabin) ...................2-20 12-13. Cabin side door........................2-21 12-14. Replenishment of windshield washer fluid .................2-21 12-15. Fuse ...........................2-22 12-16. Power outlet ........................2-23 13.
  • Page 12 6. Contents 16-1. Before storing........................2-89 16-2. Storing..........................2-90 16-3. Using the machine again .....................2-90 17. Troubleshooting ...........................2-91 17-1. Phenomena that are not breakdowns ..................2-91 17-2. Towing ..........................2-92 17-3. If the battery is overdischarged....................2-93 17-4. Troubleshooting ........................2-98 MAINTENANCE 18. Precautions for Servicing .......................3-2 19.
  • Page 13 6. Contents 27. General Precautions ........................5-2 27-1. Safety precautions .........................5-2 27-2. Precautions for mounting an attachment (implement) ............5-3 2 ..............................5-4 28. Optional Parts and Attachments ....................5-5 28-1. Optional parts and attachments .....................5-5 29. Handling Air Conditioner (for Z35-5B Cabin)..................5-6 29-1. Description of lever and switches for air conditioner..............5-6 29-2.
  • Page 14 MEMO 0-12...

  • Page 15: Safety

    SAFETY Never attempt to operate or service this Excavator until you have first read and understood all of the applicable Safety Instructions that are set forth in this Manual. The failure to comply with all relevant Safety Instructions could result in bodi- ly injury.

  • Page 16: Basic Precautions

    7. Basic Precautions These instructions should be strictly followed WARNING for the safety of you, others and your machine. Follow safety rules at your workplace • The operation and servicing of this machine is restricted to qualified persons. • When operating or servicing the machine, follow all the safety rules, precautions and procedures. •...
  • Page 17 7. Basic Precautions WARNING Neglecting these instructions may cause extreme hazards. Avoid unauthorized modifications • Unauthorized modifications may cause safety hazards. • When you wish to modify your machine, contact your dealer. The implementation of unauthorized modifications or the use of unauthorized attachments could result in bodily injury, since those ac- tions would also violate, the terms of the Warranty, it would be voided Always lock up your machine when leaving the operator's seat •...
  • Page 18 7. Basic Precautions WARNING These instructions should be strictly followed for the safety of you, others and your machine. Keep fuel and oil away from sources of ignition • Open flames can ignite fuel, oil, hydraulic oil or antifreeze solutions, which are flammable and dangerous. Special attention must be paid to the following matters.
  • Page 19 7. Basic Precautions WARNING Neglecting these instructions may cause extreme hazards. Prevent crush injuries by the implements • Keep hands, arms and all other parts of your body away from all the moving parts, particularly between the implements and the machine and between the hydraulic cylinder and the implements, as pinch points are created in those areas.

  • Page 20: Operating Precautions

    8. Operating Precautions These instructions should be strictly followed WARNING for the safety of you, others and your machine. 8-1. Precautions before starting the engine Ensure the safety of your workplace • Before starting the machine, check to see if there are any hazards in your working area.
  • Page 21 8. Operating Precautions WARNING Neglecting these instructions may cause extreme hazards. Provide adequate ventilation when working in an enclosed area Engine exhaust fumes are harmful to the human body and their in- halation is extremely hazardous. When starting the engine in an en- closed area, open the windows and doors for ventilation.

  • Page 22: Precautions For Starting The Engine, Working And Parking

    8. Operating Precautions WARNING These instructions should be strictly followed for the safety of you, others and your machine. 8-2. Precautions for starting the engine, working and parking Signal before starting the engine • Check the machine carefully before initial start up for the day. •...
  • Page 23 8. Operating Precautions WARNING Neglecting these instructions may cause extreme hazards. Precautions for traveling • When traveling with the machine, keep the bucket 16 to 20 in. (40 to 50 cm) above the ground with boom and arm folded as illustrated below. •...
  • Page 24 8. Operating Precautions WARNING These instructions should be strictly followed for the safety of you, others and your machine. Avoid hazardous work • Undermining a cliff is dangerous as it may cause a rockslide or landslide. • Undercutting the machine is dangerous as it may cause a cave-in, resulting in the machine over- turning and falling into the excavation..
  • Page 25 8. Operating Precautions WARNING Neglecting these instructions may cause extreme hazards. Prevent bumping the implements • When traveling through tunnels or under bridges, or working at a site near other overhead obsta- cles, operate the machine carefully so as not to bump the boom, arm, or the implement against those overhead obstacles.
  • Page 26 8. Operating Precautions WARNING These instructions should be strictly followed for the safety of you, others and your machine. Working on a slope • Be aware that the machine may tip over when swinging the upperstructure or swinging the implement on a slope. •...

  • Page 27: Precautions For Transportation

    8. Operating Precautions WARNING Neglecting these instructions may cause extreme hazards. 8-3. Precautions for transportation Precautions for loading and unloading the machine • Be careful in loading and unloading the machine, because it is a job of high hazard potential. •...

  • Page 28: Precautions For The Battery

    8. Operating Precautions WARNING These instructions should be strictly followed for the safety of you, others and your machine. 8-4. Precautions for the battery Be careful in handling the battery • The battery electrolyte contains dilute sulfuric acid, which can severely burn the eyes or skin. Al- ways wear safety goggles and protective clothing when servicing the battery.

  • Page 29: Precautions For Towing

    8. Operating Precautions WARNING Neglecting these instructions may cause extreme hazards. 8-5. Precautions for towing Hook the wire rope on the frame when towing • Improper towing procedures can cause death or serious injury. • When towing a machine with another machine, use a wire rope strong enough to sustain the ma- chine weight.
  • Page 30 8. Operating Precautions WARNING These instructions should be strictly followed for the safety of you, others and your machine. 1-16...

  • Page 31: Precautions For Servicing

    9. Precautions for Servicing Neglecting these instructions WARNING may cause extreme hazards. 9-1. Precautions before servicing Attach the "SERVICING IN PROGRESS" tag to an implement control lever • If another person should start the engine or operate the control levers while service is in progress, the service personnel can sustain serious bodily injury.
  • Page 32 9. Precautions for Servicing WARNING Neglecting these instructions may cause extreme hazards. Periodically replace the parts essential to safety • Aging or damage to the parts listed below can cause a fire. Make sure that they are replaced periodically. • Fuel system : Fuel hose and fuel tube cap •...

  • Page 33: Precautions During Servicing

    9. Precautions for Servicing WARNING These instructions should be strictly followed for the safety of you, others and your machine. 9-2. Precautions during servicing Keep unauthorized persons away • Never admit any persons into the work area who are not taking part in the work. Be conscious of the safety of other persons.
  • Page 34 9. Precautions for Servicing WARNING Neglecting these instructions may cause extreme hazards. Precautions for fueling and oiling • Spilled fuel and oil could cause a fire and they are dangerously slippery. Wipe up spills immediately. • Close the fuel cap and oil cap securely. •...
  • Page 35 9. Precautions for Servicing WARNING These instructions should be strictly followed for the safety of you, others and your machine. Handling high-pressure hoses • Leaks of fuel and oil could cause a fire. • Do not bend a high-pressure hose forcibly, or strike it with a hard object. Because abnormally bent or damaged piping, tubes, and hoses easily burst under high pressure, never use them.
  • Page 36 9. Precautions for Servicing WARNING Neglecting these instructions may cause extreme hazards. Hazards from the high-pressure grease when adjusting the track tension High-pressure grease is enclosed in the track adjuster. Failure to use the specified procedures for adjusting the track tension, could cause grease plugs or nipples to eject, which could result in bodily injury.

  • Page 37: Safety Messages (Warning Labels)

    10. Safety Messages (Warning Labels) There are a number of Warning Labels on the machine. Full descriptions of all Warning Labels and their locations are reviewed in this section. Periodically confirm whether all Warning Labels are still mounted in their correct locations and can be easily read. If a warning label is missing, damaged or cannot be read, it must be promptly replaced.
  • Page 38 10. Safety Messages (Warning Labels) WARNING Neglecting these instructions may cause extreme hazards. For canopy For cabin (18) (21) (18) (22) (17) (21) (26) (15) (14) (16) (15) (14) (12) (11) (10) (12) (19) 015662-00E 1-24...
  • Page 39 10. Safety Messages (Warning Labels) WARNING These instructions should be strictly followed for the safety of you, others and your machine. WARNING WARNING ROLLOVER HAZARD! OPERATION HAZARD! NEVER drive on slopes greater than 20 degrees. Read and understand NEVER turn on or drive across slopes. Operation Manual before ALWAYS drive with bucket 8 to 12 inches operating, maintaining or...
  • Page 40 10. Safety Messages (Warning Labels) WARNING Neglecting these instructions may cause extreme hazards. DANGER WARNING EXPLOSION HAZARD! Improper connection or disconnection can cause an PROPER OPERATING PROCEDURE: explosion. ALWAYS follow Operation & Maintenance Manual when ALWAYS wear seat belt. using booster cables. NEVER start excavator unless all safety Battery generates hydrogen gas which can explode if ignited.
  • Page 41 10. Safety Messages (Warning Labels) WARNING These instructions should be strictly followed for the safety of you, others and your machine. (11) (12) WARNING WARNING SERVER HAZARD! BURN HAZARD! MOVING FAN BLADE AND BELTS! ALWAYS allow exhaust pipe and muffler to cool NEVER open engine access panel before servicing.
  • Page 42 10. Safety Messages (Warning Labels) WARNING Neglecting these instructions may cause extreme hazards. (18) (17) WARNING WARNING Lock LOCK LEVERS BEFORE OPERATING PATTERN LEAVING SEAT! Never leave operator's seat unless all lock levers are in locked position, and starter switch key Unlock has been removed.
  • Page 43 10. Safety Messages (Warning Labels) WARNING These instructions should be strictly followed for the safety of you, others and your machine. (21) Z27 Excavator Z35 Excavator (22) (23) WARNING CAUTION Pull out SEVER HAZARD! DO NOT DAMAGE NEVER insert fingers into pin hole.
  • Page 44 10. Safety Messages (Warning Labels) WARNING Neglecting these instructions may cause extreme hazards. (24) CAUTION Be sure to remove earth and sand piled in quick coupler. This may damage hydraulic hoses. 172472-03271 (25) (26) WARNING WARNING WINDOW CAN FALL! CRUSH HAZARD! Always lock window securely.

  • Page 45: Operation

    OPERATION...

  • Page 46: Identification Of Important Parts

    11. Identification of Important Parts 11-1. Overview of the machine Arm cylinder Bucket cylinder Boom Headlight Bucket link Bucket pin Lock lever Accelerator lever Bucket Boom cylinder Blade cylinder Right Rear Left Front Blade Headlight FOPS guard Canopy Cabin type Boom light (Work lamp) Boom swing cylinder Boom bracket...

  • Page 47: Controls And Switches

    11. Identification of Important Parts 11-2. Controls and switches Foot rest Travel lever Boom swing pedal Control lever (R) Horn switch Lock lever Control lever (L) (For canopy type only) Blade lever Lock lever High-speed pedal Travel pedal Monitor Starter switch Accelerator lever For cabin type Room lamp switch...

  • Page 48: Description Of Control Devices

    12. Description of Control Devices This section describes several of the control devices necessary to operate the machine. In order to en- sure safety and comfort in working with the machine, it is imperative for you to fully understand how to operate and interact with these devices.
  • Page 49 12. Description of Control Devices (1) Fuel gauge The fuel gauge works while the starter switch key is in the “ON” position and indicates the fuel amount in the fuel tank. When the gauge pointer indicates close to E (empty), refill fuel oil soon.
  • Page 50 12. Description of Control Devices (6) Preheat pilot lamp When the starter switch is turned to the "HEAT" position, the preheat pilot lamp goes on and then goes off in 15 sec- onds, which indicate it is okay to finish the preheat opera- tion.

  • Page 51: Switch

    12. Description of Control Devices 12-2. Switch For cabin type 015402-00E (1) Starter switch Use this switch to start and stop the engine. • OFF position START Turn the key to "OFF" to stop the engine and disconnect electrical circuit or remove the key. HEAT •...
  • Page 52 12. Description of Control Devices (2) Light switch The boom light and the headlight go on when the switch is turned on with the starter switch set to the “ON” position. • ON : The lamps go on. • OFF : The lamps go off. IMPORTANT 000328-00X Do not keep on the lamps on for a long time while the...
  • Page 53 12. Description of Control Devices (5) Heater switch (for cabin) Use this switch to warm up the air in cabin. Move the switch to select fan speed. The heater switch allows you to select a high or low draft volume by setting it as follows: •...

  • Page 54: Control Levers And Pedals

    12. Description of Control Devices 12-3. Control levers and pedals (11) (8)-1) (8)-2) : Conpy type only (12) (12) (10) 015404-00E (1) Lock levers (for implement control levers on both sides, boom swing pedal, blade lever and travel lever) The lock levers lock the implement control levers, boom swing pedal, blade lever and travel levers. When pulling the left lock lever back, the control lever stand (L) comes up.
  • Page 55 12. Description of Control Devices When pushing the lock levers down forward, be careful not to touch the implement control lever. Unlock Lock lever (Left side) The relationship between the control lever shift 009003-00E configuration and the implement movement is de- tailed in this manual.
  • Page 56 12. Description of Control Devices (5) Travel levers and pedals The travel levers and pedals control the traveling of the machine. • If the blade is in the reverse direction, the travel Blade levers and pedals should also be operated in re- 000340-00E verse for forward and backward travel.
  • Page 57 12. Description of Control Devices (8) P.T.O. switches Single acting attachment 1) Foot switch Foot switch Unfold the foot rest and press the foot switch to operate a single acting attachment. Foot rest 2) Lever switch Use this switch to control the attachment. Lever switch 009006-00E •...

  • Page 58: Engine Hood B

    12. Description of Control Devices 12-4. Engine hood B (1) Opening the engine hood B Lever 1) Insert the starter switch key and turn counterclockwise Unlock Open to unlock. Lock 2) Pull the engine hood B lever to release the lock, and Engine hood B then the engine hood B opens.

  • Page 59: Engine Hood Rear Cover

    12. Description of Control Devices 12-5. Engine hood rear cover Do not open the engine hood while the engine is running. Rotating fan and fan belt and high tem- perature components can cause personal injury. Check and service the inside of the engine hood after the engine stops.

  • Page 60: Windshield (For Cabin)

    12. Description of Control Devices 12-7. Windshield (for cabin) • To avoid bodily injury while operating the ma- chine, make sure the door and windshield are locked in either the open or shut position. • When the side door or the windshield is opened and it is not securely locked, it may be closed suddenly on impact during operation.
  • Page 61 12. Description of Control Devices • To avoid bodily injury, securely grasp the han- dles with both hands when opening and closing Unlock the windshield. • Securely lock the windshield using the lock le- Lock lever (Left side) vers and the window locks when storing or clos- 009003-00E ing the upper and lower front windshields.

  • Page 62: Operator's Seat

    12. Description of Control Devices  Opening and closing the lower windshield Lower windshield Open and close the lower windshield after housing the upper windshield. 1) Hold the lower windshield with both hands to lift it up. 009017-00E 2) Put the lower windshield in the storage area on the rear left of the cabin.

  • Page 63: Ash Tray (For Cabin)

    12. Description of Control Devices  Weight adjustment (Except air conditioner spec. type) 1) The seat can be adjusted for the operator’s weight by turning the weight adjuster lever (B) with the seat emp- The setting weight can be read at the indicator (C). 2) Turn the weight adjuster lever (B) clockwise the setting weight is increased.

  • Page 64: Air Outlet (For Cabin)

    12. Description of Control Devices 12-11. Air outlet (for cabin) The wind direction is adjusted by changing the grille direc- tion. Move the grille to the desired position with a knob in the center of the grille. Air outlet 009019-00E Wind direction Knob Close...

  • Page 65: Cabin Side Door

    12. Description of Control Devices 12-13. Cabin side door 12-13-1. Opening and closing the cabin side door (1) From outside. Outer handle 1) Turn the starter switch key counterclockwise to unlock Pull the side door. 2) Pull the outer handle to this side to open the side door. Unlock Inner handle Lock...

  • Page 66: Fuse

    12. Description of Control Devices 12-15. Fuse Open • When replacing the fuse, be sure to turn off the pow- er by setting the starter switch at the OFF position. • Using a wire, aluminum foil or the like instead of the fuse could cause burnouts of the gauges, the elec- trical equipment and the wiring due to overheating.

  • Page 67: Power Outlet

    12. Description of Control Devices 12-16. Power outlet The socket type outlet for appliances is available when the Cover key switch is in "ON" position. Open The appliances for DC12V-120W (10A) or less are avail- able. Close IMPORTANT Outlet • Always close the cover when the outlet is not used 015410-00E for dust-proof.

  • Page 68: Operating Instructions

    13. Operating Instructions 13-1. Checking before starting the engine 13-1-1. Walking check (visual inspection) around the machine • If there are any combustibles in any heat build- up areas, or if there are any fuel and/or oil leaks, a fire can result. •...
  • Page 69 13. Operating Instructions (2) Removing dust deposits from around the engine, battery, and radiator Check that there are no dust deposits around the engine or on the radiator, and that there are no com- bustibles (dead leaves, twigs, etc.) in the heat build-up areas, such as the engine muffler, or around the battery.
  • Page 70 13. Operating Instructions 13-1-2. Checking before start-up Check the following points before initial start-up for the day.  Checking and replenishing the cooling water • Do not remove the fill cap from the radiator un- less refilling the coolant. • Check the coolant water level in the sub-tank when the engine is cool.
  • Page 71 13. Operating Instructions  Checking and replenishing the engine oil • At operating temperature, oil and dipstick areas are hot. Do not allow hot oil or components to contact skin to prevent bodily injury. 015413-00X • Check oil level and refill oil after engine has cooled down.
  • Page 72 13. Operating Instructions  Checking the fuel level in the fuel tank and refueling Be careful not to overfill the fuel tank because it could cause a fire. If the tank is overfilled, com- pletely wipe off the spilled fuel. 000319-00X •...
  • Page 73 13. Operating Instructions  Checking and replenishing the hydraulic oil tank When removing the plug of the oil supply port, slowly loosen it to release the pressure in the tank to prevent a dangerous high-pressure leak. 1) Park the machine as illustrated in the right figure. When the machine is not in the posture in the right fig- ure, start the engine, retract the bucket and arm cylin- ders to their stroke ends at low speed, lower the boom...
  • Page 74 13. Operating Instructions  Checking the fan belt tension 1) Open the engine hood rear cover. 2) Press down the fan belt between the crankshaft pulley (1) and the fan pulley (2) with a finger to check the fan belt tension. Pressing load : Approximately 22.1 lbs.
  • Page 75 13. Operating Instructions  Greasing  Implement IMPORTANT Grease the fittings thoroughly after washing the ma- chine or after operation in rain, on soft ground, or in muddy water. 1) Put the bucket and the blade on the ground and stop the 015556-00X engine.
  • Page 76 13. Operating Instructions  Checking the electrical equipment If a fuse blows out frequently, contact your dealer for assistance. Check fuses for damage, wiring for poor connections or short circuits, and battery terminals for corrosion or loose fits. Take corrective action. Check the following items after the starter switch is turned to the "ON"...
  • Page 77 13. Operating Instructions 13-1-3. Operating and checking instructions before starting up the engine • Accidentally operating a control lever can cause the machine to move suddenly, possibly causing a serious accident. 015561-00X • When leaving the operator's seat, be sure to place the lock levers securely in the lock posi- Lock tion.

  • Page 78: Starting Up The Engine

    13. Operating Instructions 13-2. Starting up the engine 13-2-1. Normal start-up • First check that there are no people or obstacles around the machine. Then sound the horn and start the engine. • Be sure that you are seated in the operator's seat 015562-00X when starting the engine.
  • Page 79 13. Operating Instructions 13-2-2. Starting the engine in cold weather • First check to see that there are no people or ob- stacles around the machine. Then sound the horn and start the engine. • Be sure that you are seated in the operator's seat when starting the engine.
  • Page 80 13. Operating Instructions 5) When the engine speed has increased, push the accel- erator (1) forward to the "IDLING" position immediately. Idling 009045-00E IMPORTANT To protect the starter motor and the battery: 15 seconds 10 seconds 30 seconds 15 seconds •...

  • Page 81: Operating And Checking Instructions After Starting The Engine

    13. Operating Instructions 13-3. Operating and checking instructions after starting the engine • Emergency stop. If abnormal operation occurs, turn the starter switch key to the "OFF" position, to stop the electrical system and the engine. Then ask your dealer to check the machine. •...
  • Page 82 13. Operating Instructions 3) Unlock the lock levers, and lift the bucket from the ground. 4) Operate the bucket and arm control levers slowly to Unlock move the bucket and arm cylinders to their stroke ends. Operate the bucket for thirty seconds and the arm for Lock lever thirty seconds alternately for approximately five minutes (Left side)

  • Page 83: Traveling

    13. Operating Instructions 13-4. Traveling 13-4-1. Traveling forward • Always check the position of the blade before operating the travel levers and pedals. When the blade is in the rear, the travel levers and pedals operate in the reverse of the normal operation.
  • Page 84 13. Operating Instructions 3) Pull back the blade lever (3) to lift the blade. 015565-00X 4) Operate the left and right travel levers (4) or pedals (5) as follows: • When the blade is in the front of the machine; (Right) Slowly push the travel levers (4) forward or step on the (Left)
  • Page 85 13. Operating Instructions 13-4-2. Traveling in reverse • Always check the position of the blade before operating the travel levers and pedals. When the blade is in the rear, the travel levers and pedals operate in the reverse of the normal operation.
  • Page 86 13. Operating Instructions 3) Pull back the blade lever (3) to lift the blade. 015565-00X 4) Operate the left and right travel levers (4) or pedals (5) as follows: • When the blade is in the front of the machine; (Right) Slowly pull the travel levers (4) back or step on the rear (Left)

  • Page 87: Steering

    13. Operating Instructions 13-5. Steering 13-5-1. Steering (Turning the machine) Always check the position of the blade before op- erating the travel levers. When the blade is in the rear, the travel levers op- erate in the reverse of the normal operation. Do not use the travel pedals to steer the machine, or the machine may not be controlled expectedly, causing a serious accident.
  • Page 88 13. Operating Instructions  Steering the machine while traveling (the left and right travel levers are both tilted in the same direc- tion) To turn left, return the left travel lever to the neutral posi- tion. Note : To turn right, operate the right travel lever in the same manner as above.

  • Page 89: Stopping The Machine

    13. Operating Instructions 13-6. Stopping the machine Do not stop the machine suddenly but provide a safety margin. • Park on solid, level ground. • Do not park on a slope. If it is unavoidable to park on a slope, put solid pieces of wood under the track as blocks, place the blade on the ground, and dig the Put the bucket into the ground.

  • Page 90: Swinging The Upperstructure

    13. Operating Instructions Front Rear 009218-00E 13-7. Swinging the upperstructure Before swinging, make sure that there are no peo- ple or obstacles within the swing range of the im- plement or the machine tail. 1) To swing the upperstructure, operate the left control le- ver as illustrated in the right figure.

  • Page 91: Operating The Implements

    13. Operating Instructions 13-8. Operating the implements Operating the arm <STD Pattern> • Check the area around the machine for safety and sound the horn before beginning to operate the machine. Control lever (L) • According to the switching of pattern change le- Operating the arm <OPT Pattern>...

  • Page 92: Precautions For Operating The Implement

    13. Operating Instructions 13-9. Precautions for operating the implement • Do not operate the implement control levers while traveling. Stop traveling first and then op- erate the implement. • Do not operate the implement on a rocky surface (on hard and soft rocks). ...
  • Page 93 13. Operating Instructions  Do not operate the implement by using the drop- ping force of the machine Do not excavate the ground by using the dropping force of the machine. 000424-00X  Excavating a hard rock It is recommended that a hard rock first be broken into small pieces by other means.
  • Page 94 13. Operating Instructions Do not bump the blade against a large rock or boulder Do not bump the blade against a large rock or boulder. Do- ing so may cause the blade or the hydraulic cylinder to be damaged. 000426-00X ...

  • Page 95: Precautions For Working

    13. Operating Instructions 13-10. Precautions for working  Precautions for traveling Driving over a stone or a stump subjects the machine (es- pecially undercarriage) to a shock, which may cause dam- age to the machine. Avoid such obstacles by driving around them, or removing More than them.

  • Page 96: Precautions For Going Up And Down A Slope

    13. Operating Instructions 13-11. Precautions for going up and down a slope • When traveling on a slope, place the implement in the direction of travel and raise the bucket 8 to 12 in. (20 to 30 cm) above the ground. •...
  • Page 97 13. Operating Instructions  Braking when going down a slope When going down a slope, you can automatically brake the machine by setting the travel levers to the neutral position.  When the tracks are slipping If you cannot climb a slope by operating the travel levers because the tracks are slipping, retract the arm and make use of the pull-back power of the implement to climb the slope.

  • Page 98: Escaping From The Mud

    13. Operating Instructions 13-12. Escaping from the mud Carefully operate the machine not to allow it to get mired in mud. If the machine is mired in mud, the machine can escape as follows: 13-12-1. If only one track is mired in the mud If only one track is mired in the mud, place the bucket on the muddy side, lift the track above the ground, lay a log or a wood block under the track shoe, and raise the bucket to...

  • Page 99: Operations Using The Bucket

    13. Operating Instructions 13-13. Operations using the bucket You can greatly widen the range of work described here by using optional attachments. 13-13-1. Backhoe operation Backhoe operation is suitable for digging the ground below the machine. Suppose that the machine is operating as illustrated in the 90 degrees right figure : a maximum digging force of each cylinder can be obtained when the angle between the bucket cylinder...

  • Page 100: Handling Quick Coupler

    13. Operating Instructions 13-14. Handling quick coupler 13-14-1. Features of quick coupler The quick coupler is the device to simplify the replacement of a variety of attachments for hydraulic im- plement. The distance between pins is adjustable so that the attachments with different distances be- tween pins are available.
  • Page 101 13. Operating Instructions 13-14-3. Structure of quick coupler Bucket link Lock pin Hose Bucket link pin Lock plate Cylinder pin Arm link pin Movable hook Cylinder pin Fixed hook Cylinder 015569-00E Hose Pilot check valve 015570-00E 2-57...
  • Page 102 13. Operating Instructions 13-14-4. Attachment types 1) The attachments, which can be mounted on the machine with quick coupler, are only the same 2-pin type as the bucket. The 1-pin type such as clamshell cannot be mounted in the quick coupler. 2) The following 2-pin type of attachments exceptionally cannot be mounted in the quick coupler.
  • Page 103 13. Operating Instructions 13-14-6. Phenomena that are not breakdowns While setting the control switch of the quick coupler in the dismounting mode, stop the engine and then restart it to open the hook of the quick coupler. 13-14-7. Posture for storing the machine without attachment Place the quick coupler on the ground as illustrated in the right figure for a long-term storage.
  • Page 104 13. Operating Instructions 13-14-8. Dismounting attachment • Never dismount the Attachment while it is still el- evated, as it will drop to the ground and could cause bodily injury. • Never dismount the Attachment unless it is rest- ing on stable level ground, as it could otherwise fall over.
  • Page 105 13. Operating Instructions 5) Open the switch box cover. Cover Switch box 000491-00E 6) Press the power supply switch. Then, beeps sound and the power supply switch blinks. Press Power supply switch 000492-00E 7) Turn the control switch to the dismounting position on Turn to the left the left side, and the attachment is dismounted.
  • Page 106 13. Operating Instructions 13-14-9. Mounting attachment • Never place your hands or any other part of your body between the Quick Coupler and the Attach- ment to prevent bodily injury. • Never stand near the Attachment unless it is resting on stable level ground to avoid bodily in- jury.
  • Page 107 13. Operating Instructions 5) Curl the attachment so that it is level. Level 000498-00E 6) Turn the control switch to the mounting position on the Turn to the right right side, and the attachment is mounted. Control switch Quick coupler 000499-00E 7) Only one of the bores allows the whole lock pin.
  • Page 108 13. Operating Instructions 13-14-10. Maintenance 1) Checking specifications • Check there are no cracks and plays. • Check the bolts and nuts for looseness. • Check the hydraulic piping for oil leak. 2) Installation instruction of the Lock Pin (1) Remove the damaged lock pin if any, and clean the bore of the lock plate.

  • Page 109: Parking The Machine

    13. Operating Instructions 13-15. Parking the machine Do not stop the machine suddenly, but try to stop with a safety margin. • Park on solid, level ground. Place the blade on • Do not park on a slope. If parking on a slope is unavoidable, the ground block the tracks with solid pieces of wood, place the blade on the ground, and dig the bucket into the ground.

  • Page 110: Inspection Requirements After Completing Operation

    13. Operating Instructions 3) Place the bucket on the ground with its bottom surface in contact with the ground. 4) Place the blade on the ground. 000451-00X 5) Set the lock levers to the "LOCK" position. Lock (Left side) 009042-00E 13-16.

  • Page 111: Stopping The Engine

    13. Operating Instructions 13-17. Stopping the engine IMPORTANT • Stopping the engine after rotation at high speed may shorten the engine life. Do not stop the engine sud- denly except in case of emergency. • If the engine is overheated, do not stop the engine immediately.

  • Page 112: Inspection Requirements After Stopping The Engine

    13. Operating Instructions 13-18. Inspection requirements after stopping the engine 1) Check oil and water for leaks, and visually inspect the implement, the machine, and the undercarriage by walking around them. If there are any leaks of oil or water, or any observed ab- normality, take corrective action.

  • Page 113: Handling The Rubber Track (For Rubber Track Type)

    13. Operating Instructions 13-20. Handling the rubber track (for rubber track type) 13-20-1. Using the rubber track properly The rubber track has some advantages over the steel track. However, you cannot take full advantage of it if you use it in the same manner as for the steel one.
  • Page 114 13. Operating Instructions 13-20-3. Precautions for using the rubber track  Prohibitions Observe the following prohibitions: • Do not operate or swing on sharp stones, a hard, uneven rock base, or around steel rods, scrap iron, or edges of iron plates. Failure to observe these prohibitions may damage the rubber track.
  • Page 115 13. Operating Instructions 13-20-4. Other precautions for using the rubber track Observe the following precautions when operating the machine: • Never spin-turn on concrete or asphalt roads. • Do not change course suddenly. Doing this will cause the rubber track to wear early or be damaged. •...
  • Page 116 13. Operating Instructions • Keep the track in appropriate tension to prevent it from coming off. If the tension is too low, the rubber track may come off under the following conditions. Even if the tension is adequate, take care when operating the track. •...
  • Page 117 13. Operating Instructions 2) If the machine further travels in reverse, clearance may also be created between the track rollers and the idler Idler and, the rubber track, causing the rubber track to easily come off. 000463-00E • When the machine is steered while the rubber track is blocked in the transverse direction by an obstacle or the Rubber track side Frame side...

  • Page 118: Handling Hydraulic P.t.o

    13. Operating Instructions 13-21. Handling hydraulic P.T.O. 13-21-1. Description of stop valve, P.T.O. selector valve, P.T.O. pedal and pedal lock 015574-00X (1) Stop valve This valve can stop the flow of the hydraulic oil. (A) Open : The hydraulic oil flows (B) Close: The hydraulic oil stops.
  • Page 119 13. Operating Instructions 13-21-2. Hydraulic circuit 1) When mounting any attachment, follow the procedure below to connect the circuit. (1) Make sure the stop valves are in the closed position and remove the screw plugs. Take care not to loose or damage the removed parts.
  • Page 120 13. Operating Instructions 13-21-3. Operating attachment Open When changing the hydraulic piping connection, stop the engine and slowly loosen the connection to release the inner pressure. Cover 009147-00E If you use the oil pressure for other hydraulic devices as the power source, connect the piping by using the follow- Selector valve Double acting Double...
  • Page 121 Screw plug R (PT) 3/4 015580-00E overheating. 13-21-5. Specification Approximate hydraulic oil flow at the rated engine speed. Model Z27 : 14.0 GPM (53 L / m) Model Z35 : 17.4 GPM (66 L / m) 2-77...

  • Page 122: Replacing The Bucket Without The Quick Coupler

    13. Operating Instructions 13-22. Replacing the bucket without the quick coupler • When driving pins into the bucket with a ham- mer, metal chips may fly. If metal chips should get into your eyes, they can cause serious injury. Use goggles, a hard hat, and gloves for safety when replacing the bucket.
  • Page 123 13. Operating Instructions 5) Clean the bucket boss section and install the O-ring. IMPORTANT O-ring • Check that the O-ring is not damaged. If it is dam- Bucket aged, replace it. • We recommend that you replace the O-ring when you replace the bucket.

  • Page 124: Transportation

    14. Transportation 14-1. Loading and unloading the machine For safety in transporting the machine, comply with all ap- plicable regulations and laws. • Be careful when loading and unloading the ma- chine, because it is a job of high hazard poten- tial.
  • Page 125 14. Transportation 1) Firmly brake the truck and apply wheel stoppers to the tires. Securely install the ramp plates on the bed of the Hook truck in a position where the center of the truck aligns Ramp plate with the center of the machine. Make sure that the left and right ramp plates are at the same level.

  • Page 126: Precautions For Loading The Machine

    14. Transportation 14-2. Precautions for loading the machine Load or unload the machine on level, solid ground far away from the shoulder of the road. After loading the machine in a safe position on the truck, secure the machine as follows: 1) Place the blade down on the ground.

  • Page 127: Precautions For Transporting The Machine

    14. Transportation 14-3. Precautions for transporting the machine • Select a route for transporting the machine based on the road width and clearance, and the height and weight of the machine. • Make sure that the side door of the cabin is closed and locked before shipping.

  • Page 128: Suspending The Machine

    14. Transportation 14-4. Suspending the machine • Never suspend the machine if any person is on the machine or the implement. • Use wire ropes strong enough for the weight of the machine. • Do not suspend the machine in any way other than that explained on the following page.
  • Page 129 (or a wire rope) to the shackles. 1° 6) Suspend the machine above the ground, wait until the 015660-00E machine is stable and then suspend it slowly. Approximate shipping weight: lbs. (kg) Items Model Z27 Model Z35 Quick Canopy Rubber 6945 8157 coupler...

  • Page 130: Care And Service In Cold Weather

    15. Care and Service in Cold Weather 15-1. Preparing for cold weather In cold weather, you may have difficulty in starting the en- gine or the cooling water may freeze. So take measures as follows: 15-1-1. Fuel and lube oil Use low viscosity fuel and lube oil.
  • Page 131 15. Care and Service in Cold Weather 15-1-3. Battery • The battery generates flammable gas and it can cause a fire and an explosion. Keep sparks or flames away from the battery. • Battery electrolyte contains dilute sulfuric acid which is a strong acid.

  • Page 132: Precautions After A Day's Work

    15. Care and Service in Cold Weather 15-2. Precautions after a day's work To prevent the machine from getting stuck in the morning due to the mud or water and frozen deposits on the under- carriage, be sure to observe the following precautions. •...

  • Page 133: Long-Term Storage

    16. Long-term Storage 16-1. Before storing IMPORTANT Retract the bucket and arm cylinders to place When storing the machine, set up the machine as illus- the bucket on the ground. trated in the right figure to protect the hydraulic cylin- der rods from being corroded.

  • Page 134: Storing

    16. Long-term Storage 16-2. Storing When you have to operate the machine indoors for the antirust procedure, be sure to ventilate the area well by opening windows and doors to pre- vent asphyxiation. Move the machine at least once a month to form new oil films on all the moving parts during long-term storage, and recharge the battery at the same time.

  • Page 135: Troubleshooting

    17. Troubleshooting 17-1. Phenomena that are not breakdowns The following phenomena are not breakdowns: • Shaking of the bucket When the boom is raised immediately after extending the arm while curling the bucket, the bucket may shake. This phenomenon is not a breakdown. 000513-00X •...

  • Page 136: Towing

    17. Troubleshooting 17-2. Towing Always safely tow a disabled machine by using the proper equipment and procedures. The use of incorrect methods or improper proce- dures could result in bodily injury. Follow the recommendations below to properly perform the towing procedure. If the machine becomes mired in the muddy ground and cannot come out by itself, or when it is necessary to tow a heavy object with the machine tractive force, tie the sling...

  • Page 137: If The Battery Is Overdischarged

    17. Troubleshooting 17-3. If the battery is overdischarged • Stop the engine and turn the starter switch key to the "OFF" position before checking or servicing the battery. • Flammable hydrogen gas is produced by the bat- To disconnect, begin with the negative terminal tery, which may cause ignition.

  • Page 138: Troubleshooting

    17. Troubleshooting 17-3-1. Starting the engine using booster cables To start the engine using booster battery cables, do the fol- lowing.  Precautions for connecting and disconnecting the booster cables • When you start the engine using booster cables, wear safety goggles. •...
  • Page 139 17. Troubleshooting  Charging with the battery mounted on the machine • Remove the battery cables from the positive and nega- tive terminals of the battery before charging it. If this is not done, abnormal voltage may be applied to the gen- erator which could damage it.
  • Page 140 17. Troubleshooting  Connecting the booster battery cables Battery on Turn the starter switch to the "OFF" position, and connect normal machine the booster battery cables as follows: 1) Turn the starter switches on the normal machine and Battery on the machine in trouble to the "OFF"...
  • Page 141 17. Troubleshooting  Disconnecting the booster battery cables Battery on After the engine on the machine in trouble has started, dis- normal machine connect the booster battery cables in the reverse order of the connecting procedure. Battery on 1) Remove the clip of the booster battery cables (B) from machine in trouble the engine block on the machine in trouble.
  • Page 142 17. Troubleshooting 17-4. Troubleshooting 17-4-1. Engine and electrical equipment • Contact your dealer about the measures shown in pa- rentheses in the list below. • If there is any abnormality or trouble whose cause is un- known other than those shown below, ask your dealer for repair.
  • Page 143 17. Troubleshooting 17-4-2. Machine performance • Contact your dealer about the measures shown in pa- rentheses in the list below. • If there is any abnormality or trouble whose cause is un- known other than those shown below, ask your dealer for repair.
  • Page 144 MEMO 2-100...
  • Page 145 MAINTENANCE...

  • Page 146: Precautions For Servicing

    18. Precautions for Servicing Do not use any inspection or servicing procedures that are not described and recommended in this manual. Park the machine on solid, level ground to inspect and service it. Check the hour meter Read the hour meter every day to check if any service item has reached the time prescribed for imple- mentation.
  • Page 147 18. Precautions for Servicing Attach the warning tag When the oil or the cooling water is drained, attach the "SERVICING IN PROGRESS" tag to the opera- tor's seat so that other persons will not start the engine. Observe the warning labels Observe the warning labels affixed to the machine.
  • Page 148 18. Precautions for Servicing Check before and after working If the machine is to be used in mud, rain, snow, or on a beach, check for loose plugs and cocks before working. After working, clean the machine and check each part for cracks and damage and check for loose or missing bolts and nuts.

  • Page 149: Basic Servicing Practices

    19. Basic Servicing Practices • Use genuine replacement parts. • Do not mix oils of different makes and types when replacing or replenishing oil. • The following types of oil and cooling water are used in the factory for shipping unless otherwise spec- ified: Item Type...
  • Page 150 19. Basic Servicing Practices Engine cooling water YANMAR genuine long-life coolant or equivalent (LLC) 51% added...

  • Page 151: Oils, Fuel, And Cooling Water

    19. Basic Servicing Practices 19-1. Oils, fuel, and cooling water 19-1-1. Oils • Because the oil is used in the engine and implement under extreme conditions (high temperature and pressure), it deteriorates as time elapses. Be sure to use oils of the grades which are specified in the Operation & Maintenance Manual and suit- able for the operating temperature range.
  • Page 152 19. Basic Servicing Practices 19-1-2. Fuel • Because the fuel injection pump is a precision device, using a fuel containing water or dust will cause problems. • Be careful that impurities will not be mixed into the fuel especially after storing the machine and refueling. •...
  • Page 153 19. Basic Servicing Practices 19-1-4. Grease • Grease ensures smooth operation of moving parts such as connectors and prevent operating noises. • The nipples not listed on the pages for periodic service are those for overhaul. Normally it is not nec- essary to refill them.

  • Page 154: Electrical Equipment

    19. Basic Servicing Practices 19-2. Electrical equipment • If electrical equipment gets wet or wiring insulation is broken, electric leaks may occur and the machine may malfunction which is very dangerous. • Check the fan belt for tension and damage, and also check the battery for electrolyte level. •...

  • Page 155: Hydraulic System

    19. Basic Servicing Practices 19-3. Hydraulic system • The hydraulic system is hot during and immediately after Retract the bucket and arm cylinders to place operation. It is also given high pressure during operation. the bucket on the ground. Therefore, check and service the hydraulic system care- Upper limit fully as follows: Lower limit...
  • Page 156 19. Basic Servicing Practices 3-12...

  • Page 157: Consumables

    20. Consumables Periodically replace consumable parts such as filter element and bucket teeth. Periodic replacement prevents malfunction of the machine. When you replace a part, be sure to use a genuine original equipment part. When ordering consumables, let us know the parts numbers given in the parts catalog. List of consumables The parts in ( ) represent those which must be replaced at the same time.

  • Page 158: Fueling, Oiling And Greasing Based On Temperature Range

    21. Fueling, Oiling and Greasing Based on Temperature Range 21-1. Fuel and oil Select fuel and oil based on to the air temperature range. The prescribed amount of oil means the total amount of oil included in the piping and equipment. The amount of oil to be changed means the amount of oil replaced in checking and servicing.

  • Page 159: Standard Tightening Torque For Bolts And Nuts

    22. Standard Tightening Torque for Bolts and Nuts 22-1. Required tools The following tools are required for servicing; refer to the parts manual for tools part numbers: Name Q'ty Screw driver (universal system) Filter wrench 68 Filter wrench 80 Filter wrench LO Pressuring nozzle Wrench 810 Wrench 1214...

  • Page 160: Torque Table

    22. Standard Tightening Torque for Bolts and Nuts 22-2. Torque table Bolts or nuts in the metric system should be tightened at the torque described below unless specified otherwise.  Item Thread size pitch Tightening torque ft•lbf (N•m) Remarks  Hexagon bolt (7T) Coarse 7.23 to 8.68 (9.8 to 11.8)

  • Page 161: Replacing Essential Parts Periodically

    23. Replacing Essential Parts Periodically For safe operation, the machine must be serviced periodically. To increase safety, be sure to periodically replace the parts listed in the table of safety parts on the next page. A fire could result if they deteriorate or are damaged.
  • Page 162 23. Replacing Essential Parts Periodically  List of safety parts Safety parts to be replaced periodically Q'ty Replacement time intervals Fuel hose (fuel tank to water separator) Fuel hose (water separator to feed pump) Fuel hose (feed pump to fuel filter) Fuel hose (fuel filter to fuel injection pump) Fuel hose (fuel filter to fuel tank) Earlier of either every 2 years or every 4000...

  • Page 163: Maintenance Table

    24. Maintenance Table Daily and periodic inspection are important to keep the machine in its best condition. The following is a summary of inspection and servicing items by inspection interval. Periodic inspection intervals vary de- pending on the use, loads, fuels and lube oils used and handling conditions, and are hard to establish definitively.
  • Page 164 24. Maintenance Table Check and service points Page  Every 50 hours Greasing the swing gear and the swing bearing 3-48 Draining the water and deposits in the fuel tank 3-48  Every 100 hours (Perform the same maintenance every 50 service hours) 3-49 Cleaning the water separator element 3-49...
  • Page 165 24. Maintenance Table  List of periodic inspection and servicing     : Check : Supply : Replace : Adjust (clean) : Oil & grease  Check & service items Daily Every Every Every Every Every 1000 hrs General Check falling off, breakage of parts ...
  • Page 166 24. Maintenance Table     : Check : Supply : Replace : Adjust (clean) : Oil & grease  Check & service items Daily Every Every Every Every Every Every 1000 2000 hrs Fuel oil Check & supply of oil to the tank ...

  • Page 167: Service Intervals When Using The Hydraulic Breaker

    24. Maintenance Table 24-2. Service intervals when using the hydraulic breaker When a hydraulic breaker is used, the hydraulic oil deteri- orates earlier than in usual bucket excavating work. Set up the service time intervals as follows: • Replacing the hydraulic oil return filter element 1000 Replace the hydraulic oil return filter element on the new machine once after the first 100 to 150 hours.

  • Page 168: Procedures For Maintenance

    25. Procedures for Maintenance 25-1. First services Service only once after the new machine has started to be used, as follows. 25-1-1. At first 50 hours • Replace the engine oil and the engine oil filter element. For these procedures, refer to Section "25-7. Mainte- nance every 500 service hours".

  • Page 169: Nonperiodic Services

    25. Procedures for Maintenance 25-2. Nonperiodic services 25-2-1. Checking the rubber track (for rubber track type) The rubber track in the following condition requires repair or replacement. Ask your dealer to repair or replace it.  Height of lugs • As the lug height "a" is reduced by wear, the tractive Track roller force decreases.
  • Page 170 25. Procedures for Maintenance  Crack in the rubber track If a crack occurs between any lugs of the rubber track, re- To be repaired if pair if the crack length reaches approximately 2.4 in. (60 2.4 in. (60 mm) long or more mm).
  • Page 171 25. Procedures for Maintenance 25-2-2. Checking and adjusting the rubber track tension (for rubber track type) • When adjusting the rubber track tension while raising the machine, do not support the machine with the implement only. The control levers could move or the hydraulic oil could flow out accidentally so that the ma- chine would fall.
  • Page 172 25. Procedures for Maintenance If the tension is improper, adjust it as follows:  Adjusting the rubber track tension • To increase the tension Prepare a grease gun. 1) Remove the cover. Cover 009156-00E 2) Raise the machine using the implement and inject grease through the greasing valve (1) using a grease gun until the rubber track tension is within the specified value of 0.3 to 0.5 in.
  • Page 173 25. Procedures for Maintenance • Loosening the tension • Grease is under high pressure. If the greasing valve (1) is opened suddenly, grease could be ejected or the valve could blow, which could cause bodily injury. • Do not rely on valve appearance alone to deter- mine whether or not grease has been dis- charged, but check that by measuring the tension of the rubber track.
  • Page 174 25. Procedures for Maintenance 25-2-3. Replacing the rubber track (for rubber track type) • To replace the rubber track with a new one, work Track roller with a partner. You must operate the machine in response to signs from your partner. •...
  • Page 175 25. Procedures for Maintenance  Removing the rubber track • It is very dangerous to discharge the grease by any procedure other than that described below. • If the tension of the rubber track cannot be prop- erly adjusted, ask your dealer to repair or replace the rubber track.
  • Page 176 25. Procedures for Maintenance  Installing the rubber track 1) Raise the machine with the implement. To do this, slowly operate the control lever. 2) Engage the rubber track with the sprocket, and put the rubber track on the idler. 000531-00X 3) Rotate the sprocket in the reverse direction to push the rubber track in and stop rotating it.
  • Page 177 25. Procedures for Maintenance 25-2-4. Replacing the bucket teeth When the bucket teeth are worn, replace them in accordance with the following procedure: • When replacing the bucket teeth, be careful not to Lock move the implement by mistake for safety. Place the implement in a stable position, stop the en- Lock lever gine, and securely lock the lock levers.
  • Page 178 25. Procedures for Maintenance 4) Clean the surface of adapter (4) with a putty knife to re- move the hard mud on it. 5) Press-fit the rubber pin lock (2) into the hole in adapter (4) by hand or by a hammer. IMPORTANT Do not let the rubber pin lock come out of the adapter surface.
  • Page 179 25. Procedures for Maintenance 25-2-5. Cleaning the inside of the cooling system • The cooling water is very hot immediately after the engine has stopped. Discharging the cooling water immediately after the engine has stopped may cause burns. Start cleaning the inside of the cooling system after the engine has cooled down sufficiently.
  • Page 180 25. Procedures for Maintenance Table of mixing ratio of anti-freeze to water °F Lowest temperature (°C) (-5) (-10) (-15) (-20) (-25) (-30) (-35) (-40) Qts. 0.53 0.85 1.06 1.16 1.37 1.59 1.70 1.90 Amount of anti-freeze (0.5) (0.8) (1.0) (1.1) (1.3) (1.5) (1.6)
  • Page 181 25. Procedures for Maintenance  How to clean the inside of the cooling water system • Container for cooling water Capacity : 8 Qts. (7 L) or more • Hose for supplying the water 1) Swing the upper structure so that the drain plug is posi- tioned in the middle of the right and left tracks.
  • Page 182 25. Procedures for Maintenance 8) After washing with running water, stop the engine, stop pouring water, drain water completely and then securely reinstall the drain plug and the bottom cover. 9) Pour water mixed with anti-freeze through the water supply port of the radiator to fill it up. 10) To release air, idle the engine for 5 to 6 minutes and then run the engine without load at high speed for 5 to 6 minutes.

  • Page 183: Checking Before Start-Up

    25. Procedures for Maintenance 25-3. Checking before start-up Check the items described here before starting the engine first in a day. 25-3-1. Checking and replenishing the cooling water Normally do not open the radiator cap. Check the cooling water in the sub-tank when the engine is cool.
  • Page 184 25. Procedures for Maintenance 25-3-2. Checking and replenishing the engine oil • At operating temperature, the oil and dipstick ar- eas are hot. • Do not allow hot oil or components to contact the skin to prevent bodily injury such as a burn. 015413-00X Check oil level and refill oil after engine has cooled down sufficiently.
  • Page 185 25. Procedures for Maintenance 25-3-3. Checking and replenishing the fuel in the fuel tank Be careful not to overfill the fuel tank because it could cause a fire. If the fuel tank is overfilled, completely wipe off the spilled fuel. •...
  • Page 186 25. Procedures for Maintenance 25-3-4. Checking and replenishing the hydraulic oil in the hydraulic oil tank When removing the plug of the oil supply port, slowly loosen it to release the internal pressure from the tank, or the oil will spout from the tank. 1) Park the machine as illustrated in the right figure.
  • Page 187 25. Procedures for Maintenance 25-3-5. Checking and adjusting the fan belt tension Generator Fan pulley • Stop the engine, take out the starter switch key, and attach the "SERVICING IN PROGRESS" tag to a control lever. Crankshaft pulley • The fan belt is hot immediately after the engine is 023224-00E stopped.
  • Page 188 25. Procedures for Maintenance 8) If the fan belt (6) cannot be adjusted since it has lost its elasticity or if it is damaged or cracked, replace the fan 0.4 to 0.6 in. (10 to 15 mm) Cooling water pump belt (6) with a new one.
  • Page 189 25. Procedures for Maintenance  Greasing  Implement IMPORTANT Grease the fittings thoroughly after washing the ma- chine or after operation in rain, on soft ground, or in muddy water. 1) Put the bucket and the blade on the ground and stop the 015556-00X engine.
  • Page 190 25. Procedures for Maintenance 25-3-7. Checking the electrical equipment If a fuse blows out frequently, contact your dealer for assistance. Check fuses for damage, wiring for poor connections or short circuits, and battery terminals for corrosion or loose fits. Take corrective action. Check the following items after the starter switch is turned to the "ON"...

  • Page 191: Maintenance Every 50 Service Hours

    25. Procedures for Maintenance 25-4. Maintenance every 50 service hours 25-4-1. Greasing the swing gear and the swing bearing Swing bearing Do not swing the upperstructure while greasing. Swing the upperstructure after each stage of greas- ing is completed to avoid serious bodily injury. Swing gear 015604-00E 1) Grease the swing gear and bearing through the grease...

  • Page 192: Maintenance Every 100 Service Hours

    25. Procedures for Maintenance 25-5. Maintenance every 100 service hours Perform the same maintenance every 50 service hours. 25-5-1. Cleaning the water separator element • Keep sparks, flames and lit cigarettes away. • At the operating temperature, the engine compo- nents are hot and can cause a burn.

  • Page 193: Maintenance Every 250 Service Hours

    25. Procedures for Maintenance 25-6. Maintenance every 250 service hours Also perform the maintenance every 50 and 100 service hours. 25-6-1. Checking and cleaning the air cleaner • Never attempt to clean and replace the air clean- er while the engine is running. Be sure to stop the engine when checking and cleaning it.
  • Page 194 25. Procedures for Maintenance 6) After cleaning, illuminate the element from inside with a light bulb to check it. If there are any small holes or thin- ner parts, replace the element with a new one. IMPORTANT • When cleaning the element, do not tap it or strike it against other objects.
  • Page 195 25. Procedures for Maintenance 25-6-2. Checking and cleaning the radiator and oil cooler fin • Never attempt to check and clean the radiator fin while the engine is running. Always stop the engine and allow it to cool first, before checking and cleaning it. •...
  • Page 196 25. Procedures for Maintenance 25-6-3. Adjusting the governor lever and accelerator device The governor lever and the accelerator devices (accelera- tor lever, petal, etc.) of the auxiliary machinery are con- nected by an accelerator wire. If the wire becomes stretched or the connections loose de- viation in the position may result and make operation un- safe.
  • Page 197 25. Procedures for Maintenance 25-6-4. Checking and replenishing the lube oil for the travel reduction gearbox • The gear oil and casing of the reduction gearbox are hot immediately after ceasing machine oper- ation and can cause bodily injury such as a burn. Do not allow hot oil or the gearbox to contact your skin.

  • Page 198: Maintenance Every 500 Service Hours

    25. Procedures for Maintenance 25-7. Maintenance every 500 service hours Also perform the maintenance every 50, 100, and 250 service hours. 25-7-1. Replacing the fuel filter • Keep sparks, flames and lit cigarettes away. • At the operating temperature, the engine compo- nents are hot and can cause a burn.
  • Page 199 25. Procedures for Maintenance How to release air: 1) Fill up the fuel tank. 2) Set the accelerator lever to the "RUN" position. 3) Turn the starter switch to the "START" position to crank the engine for approximately 10 seconds. Air is automatically released and the engine starts.
  • Page 200 25. Procedures for Maintenance 25-7-2. Replacing the engine oil and the engine oil filter element • Do not replace the oil immediately after the en- gine stops to prevent bodily injury, because all the components are hot. • Do not allow hot oil or components to contact skin. •...
  • Page 201 25. Procedures for Maintenance 8) When mounting the filter, turn it 2/3 of a turn after the seal surface has contacted with the filter mount. 9) After replacing the oil filter (cartridge), supply engine oil to the upper limit mark on the oil dipstick through the oil supply port (F).
  • Page 202 25. Procedures for Maintenance 25-7-3. Replacing the air cleaner element Never attempt to replace the air cleaner element while the engine is running. Replace the air cleaner element after the engine has been stopped and cooled sufficiently. 1) Open the engine hood rear cover. 2) Remove the clip (1) to remove the dust cup (2).
  • Page 203 25. Procedures for Maintenance 25-7-4. Replacing the hydraulic oil return filter element • The hydraulic oil and the tank are hot and under pressure at operating temperature. Never replace the oil immediately after operation is stopped. Wait until the tank has cooled enough to permit you to touch its surface with your bare hand.

  • Page 204: Maintenance Every 1000 Service Hours

    25. Procedures for Maintenance 25-8. Maintenance every 1000 service hours Also perform the maintenance every 50, 100, 250 and 500 service hours. 25-8-1. Replacing the lube oil for the travel reduction gearbox • The gear oil and casing of the reduction gearbox are hot immediately after ceasing machine oper- ation and can cause bodily injury such as a burn.
  • Page 205 25. Procedures for Maintenance 25-8-2. Replacing the hydraulic oil and cleaning the suction filter element • The hydraulic oil and the tank are hot and under pressure at operating temperature. Never replace the oil immediately after operation is stopped. Wait until the tank has cooled enough to permit you to touch its surface with your bare hand.
  • Page 206 25. Procedures for Maintenance 9) Degrease and wash the threads of the plug, and re- place the O-ring installed onto the plug with a new one. 10) After draining the waste oil, reinstall install and tighten Flange the drain plug. Tightening torque : 80 ft•lbf (108 N•m) 11) Take out the filter to remove the dirt from it and wash Filter...

  • Page 207: Maintenance Every 2000 Service Hours

    25. Procedures for Maintenance 25-8-3. Checking and adjusting the intake/exhaust valve clearances Ask your dealer for checking and adjusting. 25-8-4. Checking and adjusting the fuel injection valve Ask your dealer for checking and adjusting. 25-8-5. Retightening the cylinder head bolts Ask your dealer for retightening.
  • Page 208 25. Procedures for Maintenance 3-64...

  • Page 209: Specifications And Dimensional Diagrams

    SPECIFICATIONS AND DIMENSIONAL DIAGRAMS...
  • Page 210 26. Specifications and Dimensional Diagrams  Specifications Type Model Z27 Steel track Rubber track Items Canopy Cabin Canopy Cabin • Weight (in compliance with SAE standards) Operating mass lbs. (kg) 7165 (3250) 7452 (3380) 6945 (3150) 7231 (3280) • Working range and performance Bucket capacity, standard cu.ft (cu.m)
  • Page 211 26. Specifications and Dimensional Diagrams Type Model Z35 Steel track Rubber track Items Canopy Cabin Canopy Cabin • Weight (in compliance with SAE standards) Operating mass lbs. (kg) 8245 (3740) 8532 (3870) 8157 (3700) 8444 (3830) • Working range and performance Bucket capacity, standard cu.ft (cu.m) 3.88 (0.11)
  • Page 212 26. Specifications and Dimensional Diagrams  Model view and working range Unit : in. (mm) Outline drawing of excavator with canopy 51.57 (1310) 61.02 (1550) 015656-00E A <at boom swing> Model Z27 83.46 <74.80> 162.99 180.71 186.22 79.13 55.51 12.60 13.78...
  • Page 213 26. Specifications and Dimensional Diagrams  Model view and working range Unit : in. (mm) Outline drawing of excavator with cabin 51.57 (1310) 61.02 (1550) 015657-00E A <at boom swing> Model Z27 83.46 <74.80> 162.99 180.71 186.22 79.13 55.51 12.60 13.78...
  • Page 214 MEMO...

  • Page 215: Optional Parts And Attachments

    OPTIONAL PARTS AND ATTACHMENTS...

  • Page 216: General Precautions

    27. General Precautions 27-1. Safety precautions The mounting of unauthorized attachments and optional parts may cause accidents as well as shorten the machine life. If you need to mount any attachments other than those described in this manual, contact your dealer. If you fail to do so, the installation and use of unauthorized attachments and parts may void your Warranty.

  • Page 217: Precautions For Mounting An Attachment (Implement)

    27. General Precautions 27-2. Precautions for mounting an attachment (implement) A long implement may throw a machine off balance, and may cause the machine to roll over when the machine descends or swings on a slope. The following operations are especially dangerous, and must never be done. •...
  • Page 218 27. General Precautions...

  • Page 219: Optional Parts And Attachments

    The following options are available. Select options useful for your work. If you need an option, contact your dealer. • Bucket (Teeth...Point type) Width in. (mm) Capacity cu.ft (cu.m) Remarks 19.3 (490) 2.82 (0.08) Model Z27 Standard 23.2 (590) 3.88 (0.11) Model Z35 Standard 25.2 (640) 4.24 (0.12)

  • Page 220: Handling Air Conditioner (For Z35-5B Cabin)

    29. Handling Air Conditioner (for Model Z35 with Cabin) 29-1. Description of lever and switches for air conditioner Air outlet Fan switch Air conditioner switch Temperature control lever (The lamp goes on.) Air outlet 016146-00E Temperature control lever : It is used to control the temperature of the air blown by the air conditioner.

  • Page 221: How To Use Air Conditioner

    29. Handling Air Conditioner (for Model Z35 with Cabin) 29-2. How to use air conditioner • The eyes might get sore from smoking when the cabin is air conditioned. Ventilate the cabin by opening the window slightly when smoking. • Some mist might blow off with cooled air when the cabin is air conditioned.
  • Page 222 29. Handling Air Conditioner (for Model Z35 with Cabin) 5) Adjust the air direction with the air outlet grille. Air direction Knob • Set the fan switch for ventilation to apply preload to the inside of the cabin when the air conditioner is not used, Close Open so that no dust can come into the cabin easily during op-...

  • Page 223: Maintenance, Inspection And Servicing Of Air Conditioner

    29. Handling Air Conditioner (for Model Z35 with Cabin) 29-3. Maintenance, inspection and servicing of air conditioner Daily maintenance and periodic inspection and servicing are required for the air conditioner to use it comfortably in the best condition. Proper maintenance allows reduction in trouble and longer life of the air conditioner.
  • Page 224 29. Handling Air Conditioner (for Model Z35 with Cabin) 29-3-2. Checking and servicing compressor driving belt Stop the engine and remove the starter key before checking and adjusting the compressor driving belt. Press the middle of the condenser driving belt to check the slack of the condenser driving belt.
  • Page 225 29. Handling Air Conditioner (for Model Z35 with Cabin) 29-3-3. Checking refrigerant quantity Open the engine hood B to see the flow of the refrigerant Cover air foam from the sight glass (inspection window) of the liq- Sight glass Viewed from top Cover uid tank according to the following procedure to check the refrigerant quantity.
  • Page 226 MEMO 5-12...
  • Page 227 NOTES 6-13...

  • Page 228: Maintenance Log

    30. Maintenance Log Maintenance log Date Machine hours Service performed 6-14...
  • Page 229 30. Maintenance Log Date Machine hours Service performed 6-15...
  • Page 230 30. Maintenance Log Date Machine hours Service performed 6-16...
  • Page 231 30. Maintenance Log Date Machine hours Service performed 6-17...
  • Page 232 If you have any questions on proper operation, adjustment or main- tenance of the machine, contact your dealer or the Gehl 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.

This manual is also suitable for:

Z35

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