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Gehl 383Z Operator's Manual

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®
Form No.
383Z
918196
Revision D
Sept. 2013
Compact Excavator
Beginning Serial Number: AE00465
© 2013 All Rights Reserved. • Printed in USA

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Summary of Contents for Gehl 383Z

  • Page 1 ® Form No. 383Z 918196 Revision D Sept. 2013 Compact Excavator Beginning Serial Number: AE00465 © 2013 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: Table Of Contents

    TABLE OF CONTENTS Chapter 1 - General Information ........... . 1-1 Introduction .
  • Page 4 Transporting ..............2-10 Safety Decals .
  • Page 5 Maintenance Safety............4-2 Maintenance Label Symbols.
  • Page 6 NOTES 918196/EP0913 Printed in U.S.A.

  • Page 7: Chapter 1 - General Information

    CHAPTER 1 – GENERAL INFORMATION INTRODUCTION The Gehl dealer network stands ready to provide any assistance you may require, including genuine Gehl This Operator’s Manual is intended to give the owner/ service parts. All service parts should be obtained from operator assistance in preparing, adjusting, maintaining your dealer.

  • Page 8: Ownership Change

    If this machine was purchased “used,” or if the owner’s der head cover. address has changed, please provide your dealer or the Gehl Company Service Department with the owner’s Engine serial number label name and current address, along with the machine Excavators serial numbers AG00573 and up model and serial numbers.

  • Page 9: Excavator Component Identification

    EXCAVATOR COMPONENT IDENTIFICATION Dipper Arm Cylinder Auxiliary Hydraulics Boom Connections Operator’s Seat Engine Cover Bucket Cylinder Boom Light Swing Frame / Super- Boom Cylinder structure Swing Cylinder Dipper Arm Travel Drive Motor Track Frame Dozer Blade Track Tension Lubrication Point Bucket Figure 1-3 Component Names Printed in U.S.A.

  • Page 10: Specifications

    SPECIFICATIONS Fluid Capacities/Lubricants Note: Capacities indicated are approximate. Component/Applica- Lubricant Specification Season/Temper- Capacity tion ature SAE 10W-40 (according to DIN 51502); API: CD, CF, -4°F (-20°C) Diesel Engine 7.5 qts. (7.1 L) Engine Oil CF-4, CI-4 +104°F (+40°C) SAE E3, E4, E5 Q8 T 55, SAE80W-90 Travelling Drive Gear- About 0.3 gal.

  • Page 11: Engine

    Engine Engine Model Yanmar 3TNV88-PNS Yanmar 3TNV88-BPNS EPA Tier 2 EPA Tier 3 Serial Numbers AE00465- Serial Numbers AG00573 AG00572 and up Type Water-cooled 3-cylinder Diesel Engine Displacement 100.2 cu. in. (1.6 L) Bore and Stroke 3.5 x 3.5 in. (88 x 90 mm) Horsepower (DIN) 28.8 hp (21.5 kW) @ 2400 rpm Max.

  • Page 12: Undercarriage And Swing System

    Undercarriage and Swing System Travel Speed Low Speed 1.7 mph (2.8 km/h) High Speed 2.9 mph (4.6 km/h) Ground Clearance 11” (280 mm) Swing Speed 8.8 rpm Gradability (58%) ° Rubber Track Width 12” (300 mm) Number of Track Rollers 4 per side Average Ground Pressure 4.8 psi (0.34 kg/cm...

  • Page 13: Fuse Box Under Seat

    Fuse Box Under Seat F3 F4 F5 F6 F7 F8 F9 F10 Fuse No. Rated Current Protected Circuit 10 Amp Indicators, Engine Relay, Cutoff Solenoid 10 Amp Boom Light 15 Amp Roof Lights 10 Amp s, Horn 15 Amp Heating, Air Conditioning 10 Amp Windshield Wiper, Interior Light 10 Amp...

  • Page 14: Relays

    Relays (located in the upper left inside the engine compartment) Relay No. Protected Circuit Preheating Timer Starting Relay Cutoff Solenoid Diode 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) % by volume...

  • Page 15: General Specifications

    General Specifications 10’4” (3158 mm) 2’10” (870 mm) 1’2” (345 mm) 1’0” 1’0” 3’9” (1140 mm) 9’0” (2725 mm) 6’10” (2075 mm) (300 mm) (300 mm) 15’9” (4800 mm) 5’9” (1740 mm) Weight (with cab) 8003 lbs. (3630 kg) Weight (with canopy) 7826 lbs.

  • Page 16: Load Diagrams

    Load Diagrams Figure 1-4 Standard Long Dipper Arm Load Diagram Maximum permissible loads (standard long dipper arm) 16'3" 13'0" 9'9" 6'6" 3'3" 0'0" 13'0" (5.0 m) (4.0 m) (3.0 m) (2.0 m) (1.0 m) (0 m) 14’9” 11’6” 8’2” (4.0 m) (4.5 m) (3.5 m) (2.5 m)
  • Page 17 Figure 1-5 Standard Long Dipper Arm with Counterweight Load Diagram Max. permissible loads (long dipper arm / counterweight) 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 m) 13'0" 14’9” 11’6” 8’2” (4.0 m) (4.5 m) (3.5 m)
  • Page 18 Figure 1-6 Optional Short Dipper Arm Load Diagram Maximum permissible loads (short dipper arm) 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 m) 13'0" 14’9” 11’6” 8’2” (4.0 m) (4.5 m) (3.5 m) (2.5 m) 9'9"...
  • Page 19 Figure 1-7 Optional Short Dipper Arm with Counterweight Load Diagram Max. permissible loads (short dipper arm / counterweight) 16'3" 13'0" 9'9" 6'6" 3'3" 0'0" 13'0" (5.0 m) (4.0 m) (3.0 m) (2.0 m) (1.0 m) (0 m) 14’9” 11’6” 8’2” (4.0 m) (4.5 m) (3.5 m)

  • Page 20: Checklists

    CHECKLISTS I acknowledge the pre-delivery procedures were performed Pre-Delivery Checklist on this unit as outlined on this page. The following checklist is an important reminder of valuable information and inspections that MUST be ________________________________________________ made before delivering the machine to the customer. Dealership’s Name Check off each item after the prescribed action is taken.
  • Page 21 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 CHECK THAT: on the inside front cover of this Operator’s Manual.
  • Page 22 INTENTIONALLY BLANK (To be removed as dealer’s file copy) 918196/EP0913 1-16 Printed in U.S.A.

  • Page 23: Chapter 2 - Safety

    CHAPTER 2 – SAFETY GENERAL SAFETY INFORMATION IMPORTANT Manitou Americas, Inc, in cooperation with the Society of Automotive Engineers (SAE), has adopted this “IMPORTANT” is used to draw attention to a procedure that must to be followed to pre- safety alert symbol: This warning symbol, used vent machine damage.

  • Page 24: 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 25 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 26 Stay away from ditches and other weak support sur- If the machine becomes unstable and starts to tip, keep faces. Be sure the surrounding ground has adequate the seat belt fastened, hold on firmly and brace your- strength to support the weight of the machine and the self.

  • Page 27: Exposure To Crystalline Silica

    Do not use the machine to lift or transport people. After the machine has been parked properly, shut down Never carry riders. Do not allow others to ride on the the machine according to the “Mandatory Safety Shut- machine or attachments, because they could fall or down Procedure”...

  • Page 28: Fire Hazards

    FIRE HAZARDS ADDITIONAL SAFETY EQUIPMENT The machine has several components that operate at high temperature under normal operation conditions, Severe operation may require use of additional primarily the engine and exhaust systems. Also, the safety equipment electrical system, if not properly maintained or if dam- Work in mines, tunnels, deep pits or on loose or wet aged, can arc or produce sparks.

  • Page 29: Maintenance Safety

    Safety-critical parts must be periodically replaced. Use care when seating retainer pins — retainer pins can Replace the following potentially fire-sensitive compo- fly out or splinter when struck and could cause injury. nents as soon as they begin to show signs of deteriora- Do not smoke or have any spark- or flame-producing tion: equipment or materials in the area while filling the fuel...

  • Page 30: Safety Decals

    Always use adequate equipment supports and Pressurized hydraulic oil leaks can be hazardous. blocking. Fluid leaks from hydraulic hoses and pressurized com- Lower bucket to the ground before leaving the opera- ponents can be difficult to see, but pressurized oil can tor’s seat.

  • Page 31: Hydraulic Cylinder Seal Periodic Replacement

    Hydraulic Cylinder Seal Periodic Batteries contain acid and produce explosive gases. Keep sparks, flames and lit cigarettes away from bat- Replacement teries at all times. Check cylinder drift rate at regular intervals. Maximum Connect positive cable first when installing jumper allowable rates are included at the end of the Hydraulic cables.

  • Page 32: Transporting

    TRANSPORTING Obey state and local over-the-road regulations. Check state and local restrictions regarding weight, width and length of a load. The hauling vehicle, trailer and load must all be in compliance with local regulations. Refer to the Transporting section of this manual. SAFETY DECALS The machine has decals shown on the following pages that provide safety information and precautions.

  • Page 33: Iso-Style Safety Decal Locations (Serial Numbers Ag04058 And Up)

    ISO-Style Safety Decal Locations (Serial Numbers AG04058 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 34 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 35 WARNING! Danger Zone Decal WARNING! Danger Zone Decal AVOID INJURY OR DEATH! AVOID INJURY OR DEATH! Located next to the boom swivel bracket. Located on the back of the swing frame. Keep bystanders away from the machine when it Keep bystanders away from the machine when it is in use.

  • Page 36: Iso-Style Information Decal Locations (Serial Numbers Ag04058 And Up)

    ISO-Style Information Decal Locations (Serial Numbers AG04058 and Up) KF K - KF K - KF K - KF K - KF K - KF K - 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...
  • Page 37 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 38: Ansi-Style Safety Decal Locations (Serial Numbers Ag04057 And Before)

    ANSI-Style Safety Decal Locations (Serial Numbers AG04057 and Before) Swing Radius Warning Decal (both sides of Hydraulic Pressure Warning Decal (top of tank boom) cover) WARNING Hydraulic Reservoir Under Pressure WARNING DANGER ZONE Keep away! Operation/Warning Decal (cab/canopy ceiling) Read Operator’s Manual Decal inside right of cab/canopy wall) WARNING TO AVOID INJURY:...
  • Page 39 Shutdown/Warning Decal (cab/canopy ceiling) Track Tensioner Warning Decal (track frame — both sides) WARNING TO AVOID INJURY: 1. Lower all equipment to ground. WARNING 2. Reduce throttle; shut off engine. AVOID INJURY: 3. Lock-out controls before exiting. Do not loosen lubricator more than 2-3 turns. Do not loosen parts other than adjustment fitting.
  • Page 40 Cab Tilt Warning Decal (under cab/canopy) Diesel Fuel Decal (inside engine compartment by fuel fill) WARNING TO AVOID INJURY OR DEATH: Read the Operator’s Manual before reaching or leaning under tilted cab. SAE/ISO Control Decal (front of unit next to swing cylinder) Pinch Point Decal (above inside windshield [cab unit only])
  • Page 41 Lubrication Chart Decal (cab back window/ right inside canopy wall) Printed in U.S.A. 2-19 918196/EP0913...
  • Page 42 NOTES 918196/EP0913 2-20 Printed in U.S.A.

  • Page 43: Chapter 3 - Operation

    CHAPTER 3 – OPERATION OPERATING CONTROLS Machine Orientation All references to “right” and “left” are determined from the operator's position facing forward. WARNING Guards and Shields • Read and understand this entire man- Whenever possible, guards and shields are used to pro- ual.
  • Page 44 Figure 3-2 Equipment and Controls 918196/EP0913 Printed in U.S.A.
  • Page 45 Pos. Description For more information see page Boom Swivel Pedal ....................................3-12 Joystick (left) ......................................3-9 Joystick (right) ......................................3-9 Control Lever Base (left) Control Lever Base (right) Armrest (left) Armrest (right) Seat Horizontal Adjustment Lever................................3-13 Air Vent (cab only) Radio (option) Seat Backrest Adjustment ..................................
  • Page 46 Figure 3-3 Instrument Panel, Switches and Indicators 918196/EP0913 Printed in U.S.A.
  • Page 47 Pos. Description Hydraulic oil filter indicator (red) – Hydraulic oil filter indicator light comes on when hydraulic oil filter requires servicingor while the hydraulic oil is cold. Engine air filter indicator (red) – Air filter indicator light comes on when air filter requires servicing. Battery charge fault indicator (red) –...
  • Page 48 Excavator Components 1. Fuel/water separator 2. Battery disconnect switch 3. Air cleaner 4. Fuel filter 5. Engine oil filter 6. Engine oil dipstick 7. Engine oil fill (2 places) 8. Fuel filler cap 9. Hydraulic fluid filler cap 10. Hydraulic fluid level sight gauge 11.

  • Page 49: Ignition Key Switch

    Ignition Key Switch Battery Disconnect Switch A battery disconnect switch is located in the engine Note: The engine can only be started if the left control compartment under the hood. The switch allows elec- lever console is pivoted down into the operation posi- trical lockout of all functions of the excavator.

  • Page 50: 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 51: Sae/Iso Selector

    SAE/ISO Selector ISO Operating Controls See page 3-11. ISO boom and bucket functions are controlled by the right and left joystick control levers located on the seat SAE Operating Controls consoles. ISO Left Joystick – See Figure 3-11. SAE boom and bucket functions are controlled by the right and left joystick control levers located on the seat 1 –...

  • Page 52: Tilting The Cab Or Canopy

    Tilting the Cab or Canopy onto the release pin (6). Slowly twist the release pin counter-clockwise until the cab is lowered. 4. Turn the release pin (6) clockwise. WARNING 5. Reinstall the cab lock-down nuts (2) and (3). • Always tighten cab lock-down nuts 6.

  • Page 53: Throttle Lever

    Throttle Lever SAE/ISO Operating Controls Selector Note: See page 3-9 for SAE/ISO joystick operation. The engine speed is controlled by the throttle lever (1) located behind the left joystick. See Figure 3-15. The SAE/ISO selector is located inside the front of the chassis at the top of the swing cylinder opening.

  • Page 54: Boom Swivel Pedal

    Boom Swivel Pedal Dozer Blade The boom can be swiveled without moving the swing The dozer blade is controlled by the dozer control lever frame by pressing and holding the auxiliary hydraulic/ (1) located next to the right joystick. See Figure 3-18. changeover button (1, Figure 3-17) on top of the left •...

  • Page 55: Operator's Seat Adjustments

    Operator’s Seat Adjustments 3. Armrest Adjustments Angle Adjustment Note: The operator’s seat left console must be raised in order to exit the cab. In the lowered or work posi- Use the armrest angle adjustment spindle (1, Fig- tion, all operational functions are activated, and oper- ure 3-20) to change the angle of the armrest.

  • Page 56: Seat Belt

    Seat Belt Ventilation – Cab Only Windshield WARNING WARNING ALWAYS fasten the seat belt securely and properly. Never operate the machine with- When opening the windshield, be sure to out the seat belt fastened around the opera- lock both latches. When closing the wind- tor.
  • Page 57 CAUTION Support the windshield when releasing it from the ceiling catches to avoid possible head injury. To close the windshield, re-install the lower windshield Figure 3-24 Interior Light (if removed), and squeeze/turn the latches, and then lower the windshield and lock the latches in the closed Cab Heat Control (cab only) position.

  • Page 58: Machine Operation

    MACHINE OPERATION • Engine oil level (Fill if required) • Water drained from fuel pre-filter • Hydraulic system for leaks • Hydraulic fluid level (Fill if required) WARNING • Pivot points lubricated and operating properly • Track tension • Read and understand this entire man- •...

  • Page 59: Engine Shut-Down

    Engine Start Procedure 7. Allow engine to warm up at idle speed for approxi- mately 10 - 15 minutes to fully warm up all sys- tems. DANGER 8. Test the controls. DO NOT run the engine in an enclosed area Cold-weather Engine Starting Procedure without proper ventilation.

  • Page 60: Travel

    Travel Speed Selection 5. Move the joysticks in all directions to verify the hydraulic system is de-pressurized. Two travel speed ranges can be selected by using the travel speed switch (1) located on the control console. 6. Lock out controls by raising left control console. See Figure 3-26.
  • Page 61 General Travel Instructions Traveling on Slopes 1. Avoid sudden movements and sharp turns. 2. Travel slowly on rough, frozen, or uneven terrain. WARNING 3. Travel straight up and down slopes — never across. See Figure 3-27. Extend arm and lower •...
  • Page 62 8”–12” (20 cm–30 cm) 8”–12” (20 cm–30 cm) Figure 3-28 Traveling Up or Down Slopes 918196/EP0913 3-20 Printed in U.S.A.

  • Page 63: Operating Instructions

    Operating Instructions Operating Precautions Joystick Controls DANGER Extending and retracting the cylinders (boom, arm and bucket) are controlled by the joysticks located on the • DO NOT push down with the dozer blade consoles attached to the operator’s seat. See “Equip- to elevate the front end of the tracks.

  • Page 64: Operating On Slopes

    Operating on Slopes 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 WARNING device. • Do not travel up or across a slope IMPORTANT steeper than 15°.

  • Page 65: Operating In Cold Weather

    Operating in Water Do not operate or immerse the machine in water higher than the top of the upper track rollers. Thoroughly grease the machine if it has been operated in deep water. Operating Auxiliary Hydraulics Use the auxiliary hydraulics pedal (1, Figure 3-32) to regulate oil flow through auxiliary attachments.

  • Page 66: Swiveling The Boom

    Swiveling the Boom Press and hold the auxiliary control button (1, Figure 3- 34), located on top of the left joystick. Then press the auxiliary hydraulics pedal (2) with your toe or heel. Pressing and holding the auxiliary hydraulic/change- WARNING over button (1) and pressing the front of the auxiliary hydraulics pedal (2) swiveled the boom to the left.

  • Page 67: Excavating

    Excavating • When excavating, lower the dozer blade to the ground to aid machine stability. It is best to posi- The following section applies to an excavator with a tion the dozer blade on the same side as the excava- standard bucket, which is used mainly for digging into tion, but position the blade on the opposite side of the ground to loosen, excavate and load loose or solid...

  • Page 68: Digging

    Digging 4. After the bucket is sufficiently filled: 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 3-37).

  • Page 69: Loading Vehicles

    Loading Vehicles When trench excavating is needed in confined areas, the excavating can be done by rotating the upper When loading vehicles, consider the following: carriage and swiveling the boom (Figure 3-40). • Whenever loading in a confined area with a limited range of motion, position the truck so maximum visibility is ensured for the excavator operator.

  • Page 70: Grading

    Grading Mounting/Removing Buckets ALWAYS wear protective goggles, helmets, gloves, Bulldozing steel-toed shoes, etc. DO NOT service the bucket while the engine is running. WARNING DO NOT stand behind the bucket when removing the • Be sure there is proper clearance for the pins.
  • Page 71 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 72: Auxiliary Hydraulics Connections

    Auxiliary Hydraulics Connections 7. To connect each coupling: a. If necessary, rotate lock sleeve (2, Figure 3-46) 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 manual from the attachment manufacturer c.

  • Page 73: Transporting

    Transporting Lifting the Machine Towing WARNING WARNING • Use a lifting device and rigging with suf- ficient capacity for the weight of the • When towing the machine, make sure machine plus any attachments. no one is close to the towing apparatus, •...

  • Page 74: Loading And Transporting

    Loading and Transporting Note: Refer to Figure 3-49. Use only transporters that are in proper working order and are approved for use on public roads. When using ramps to load the transporter: • Do not exceed an incline of 17°. •...

  • Page 75: Chapter 4 - Maintenance

    CHAPTER 4 – MAINTENANCE GENERAL INFORMATION Care and Servicing CARE AND SERVICING The care and servicing of the machine has a significant influence on its operational readiness and service life. Use of lubricants not corresponding to the manufac- WARNING turer’s recommendations may invalidate warranty claims.

  • Page 76: Maintenance Safety

    Maintenance Safety • Never service the machine without reading the • Avoid contact with leaking hydraulic fluid and applicable instructions. diesel fuel under pressure. The pressurized flu- ids can penetrate the skin and eyes. NEVER • Always lower bucket and dozer blade to the use your hands to search for hydraulic fluid ground before performing any maintenance.

  • Page 77: Maintenance Label Symbols

    Maintenance Label Symbols Symbol Assembly Explanation General Visual check General Grease instructions Fuel system Drain condensation from fuel Fuel system Replace the fuel filter; clean the fuel pre-filter Radiator Check the coolant level Radiator Drain and fill with new coolant Engine Check valve clearance;...

  • Page 78: Maintenance Label

    Maintenance Label 918196/EP0913 Printed in U.S.A.

  • Page 79: 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 80: Fluid And Filter Changes

    Check, Clean & Inspect (continued) 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 Pin lock (dipper arm and attachment)

  • Page 81: Air Conditioning

    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. Functional Check Service Activity Daily...

  • Page 82: Daily Lubrication

    Daily Lubrication (See Figure 4-1 and Figure 4-2) 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) Lubricate daily at the points indicated Figure 4-1 Lubrication Points 918196/EP0913 Printed in U.S.A.
  • Page 83 Lubricate daily at the points indicated Figure 4-2 Lubrication Points (continued) Printed in U.S.A. 918196/EP0913...

  • Page 84: Recommended Lubricants

    Recommended Lubricants Engine Checking Engine Oil Level Engine Oil IMPORTANT IMPORTANT “Fluid Capacities/Lubricants” Be sure to read the engine manual supplied page 1-4 for engine oil grade. To prevent with this machine for detailed engine speci- damage to the engine, only use the engine fications.

  • Page 85: Changing Engine Oil And Filter

    Changing Engine Oil and Filter 6. Clean the filter housing surface. Put a film of clean oil on the filter gasket. Install the new filter and 1. Perform the “Mandatory Safety Shutdown Proce- tighten 1/2 rotation past where the filter contacts dure”...

  • Page 86: Air Cleaner

    Air Cleaner 1. Perform the “Mandatory Safety Shutdown Proce- dure” on page 2-2, but do not allow the engine to fully cool; warm oil will drain more completely. 2. The air cleaner is located under the engine cover. Press the engine cover release button and raise the engine cover.

  • Page 87: Fuel System

    Fuel System Filling the Fuel Tank IMPORTANT WARNING Unless draining fuel tank for servicing, never operate the machine until the fuel Stop the engine and allow it to cool before tank is completely empty. The fuel system filling the fuel tank. NO SMOKING! Failure has to be bled of air whenever the fuel tank to obey warnings can cause an explosion is run empty.
  • Page 88 Fuel Shut-off Valve and Water Separator Fuel Filter If water is seen in the water separator bowl or the indi- cator ring rises to position (4, Figure 4-8), the bowl will WARNING need to be drained. Note: The water separator is located on the engine Use care to catch any spilled fuel when ser- below the air cleaner.

  • Page 89: Cooling System

    Cooling System Bleed air from the fuel system according to the follow- ing steps: Checking Coolant Level 1. Fill the fuel tank. Note: The engine must be cold. 2. Make sure that the valve on the water separator 1. Press the engine cover release button and raise the valve (1, Figure 4-9) is in the “ON”...

  • Page 90: Electrical System

    Electrical System Battery WARNING WARNING Inspect and check the machine’s electrical Before servicing the battery or electrical sys- equipment at regular intervals. Defects, such tem, disconnect battery from the electrical as loose connections or scorched cables system by turning the battery disconnect much be repaired before using the machine.
  • Page 91 The battery is located under the cab near the rear of the undercarriage. See 1, Figure 4-12. Refer to “Tilting the cab or canopy” on page 3-10 for how to tilt and secure IMPORTANT the cab to gain access to the battery. Battery cables must be clean and tight.
  • Page 92 Start the engine of the machine with the discharged Jump-start Procedure: battery. Once the engine is running, remove the cable 1. Turn ignition key on the machine with the dis- connected to the frame first. Disconnect the other cable charged battery to the “P” position. from the positive (+) terminal on the battery disconnect 2.

  • Page 93: Hydraulic System

    Hydraulic System Note: A short hex shaft is included in the tool kit. This tool is designed to be used with a standard ratchet wrench to open the filler cap. WARNING c. With the filter insert (5) in place, add hydraulic oil until the oil level is between the marks on The hydraulic reservoir is under pressure.
  • Page 94 Changing Hydraulic Oil Hydraulic Cooling System 1. Position the machine on a level surface. The hydraulic system uses a hydraulic cooler to keep the hydraulic fluid at the proper temperature. The 2. Fully extend the bucket and boom, retract the arm cooler is located inside the engine compartment near and position as shown in Figure 4-14.
  • Page 95 8. Disconnect the pilot control filter/restrictor fitting 9. Check the filter/restrictor fitting filter screen (C) (B) from the valve. for contamination/dirt and clean if necessary. Replace the filter/restrictor if it is damaged. 10. Replace filter/restrictor fitting (B) back into the valve, and reconnect hose to the filter/restrictor (C).
  • Page 96 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 97: Checking And Adjusting V-Belt Tension

    Checking and Adjusting V-belt Tension 1. Position the machine on a level surface. approx. 5/16” (8 mm) 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 98: Checking And Adjusting Air Conditioning V-Belt Tension

    Checking and Adjusting Air b. Tighten bolt (2) and re-check V-belt tension. Conditioning V-belt Tension approx. 11/32” (9 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.

  • Page 99: Track System

    Track System 5. Shut off the engine. Remove the ignition key and take it with you. Lock out the controls by raising left control console. Track Cleaning If dirt or mud builds up in the track frame, raise the 6. Remove both screw plugs. Pour fresh oil (Chevron track frame using the boom and dipper arm and then Delo Gear 80-W90 or BP Transgear 80-W90) into rotate the elevated track to clean it.
  • Page 100 Checking and Adjusting Track Tension WARNING 1. Position the machine on a level surface. On machines equipped with rubber tracks, position the excavator so the tracks are positioned with mark Do not loosen the grease fitting more than (1, Figure 4-22) on the top span of the track in two turns, or the fitting could be ejected between drive pinion (2) and track tension roller under pressure and cause injury.

  • Page 101: Windshield Washer Fluid

    LONG-TERM STORAGE Windshield Washer Fluid 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 102: 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 103: Chapter 5 - Troubleshooting

    CHAPTER 5 – TROUBLESHOOTING ENGINE Problem Possible Cause Corrective Action Engine hard -starting or fails No fuel Add fuel to tank; bleed air from fuel system to start Incorrect engine oil SAE grade Replace engine oil with proper grade; see "Fluid Capacities/Lubricants”...
  • Page 104 Problem Possible Cause Corrective Action Engine overheats Oil level too low Add engine oil; see "Checking Engine Oil Level” on page 4-10 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 "Check- ing and Adjusting V-belt Tension”...

  • Page 105: 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; see "Checking Engine Oil tion Level” on page 4-10; if oil level is correct, oil pump may have failed Engine oil level too low Add oil;...

  • Page 106: Traveling Gear

    TRAVELING GEAR Problem Possible Cause Corrective Action Machine will not travel Obstruction jamming track mechanism Remove object Gears inoperative Repair gear; contact authorized service center Machine will not travel straight Obstruction jamming track mechanism Remove object forward or backward Unequal track tension Adjust track tension;...
  • Page 107 Index Short Dipper Arm with Counterweight .........1-13 Air Conditioning ........4-7 Loading and Transporting .......3-32 Auto-Idle ..........3-11 Long-Term Storage .........4-27 Auxiliary Hydraulics Connections ..3-30 Lubrication ..........4-7 Auxiliary Hydraulics Operation ....3-23 Machine Orientation .........3-1 Battery .............4-16 Boom Swivel Pedal ......3-12 Battery Disconnect Switch ....3-7 Cab Door Latch .........3-15 Jump-start Procedure ......4-18 Dozer Blade Lever ......3-12...
  • Page 108 Index Travel ..........3-18 Seals/Hoses .........5-3 Water Operation ........3-23 Traveling Gear ........5-4 Operational Safety ........2-2 Ownership Change ........1-2 Using the Excavator ........3-31 Pilot Valve ..........4-20 Pilot Control Valve Filter/Restrictor .4-20 Windshield ..........3-14 Pre-Operation Checklist ......3-16 Windshield Washer Fluid ......4-27 Relays ............1-8 SAE/ISO Controls SAE/ISO Selector Valve ....3-11 Safety ............2-1...
  • Page 110 TORQUE SPECIFICATIONS Note: Use these torque values when tightening Gehl 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.
  • Page 111 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) 10 (14)
  • Page 112 If you have any questions on proper operation, adjustment or mainte- nance of the 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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