GEHL GE 502, GE 602 Crawler Excavator Operator’s Manual

®
GE 502/GE 602
Crawler
Excavator
Form No.
906931
English
OPERATOR’S MANUAL
GEHL Warranty
GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl equipment to the Original Retail Purchaser to
be free from defects in material and workmanship for a period of twelve (12) months from the Warranty Start Date.
GEHL WARRANTY SERVICE INCLUDES:
Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer’s business location.
GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE),
EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT.
GEHL WARRANTY SERVICE DOES NOT INCLUDE:
1. Transportation to selling dealer’s business location or, at the option of the Original Retail Purchaser, the cost of
a service call.
2. Used equipment.
3. Components covered by their own non-Gehl warranties, such as tires, trade accessories and engines.
4. Normal maintenance service and expendable, high wear items.
5. Repairs or adjustments caused by: improper use; failure to follow recommended maintenance procedures; use
of unauthorized attachments; accident or other casualty.
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. Any of these limitations excluded by local law shall be deemed deleted from this warranty; all other
terms will continue to apply.
TABLE OF CONTENTS
Chapter
1
2
3
PRINTED IN U.S.A.
Description
Page
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover
GENERAL INFORMATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Machine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Undercarriage and Slewing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Bucket (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
SAFETY INFORMATION
General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Safety Symbols and Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Safety Decal and Sticker Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Safety Decals and Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
OPERATION
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Machine Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Outer Cab Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Inner Cab Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Console Controls Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Excavating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Console Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Operator’s Seat Adjustment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Cab Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Checklist Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Starting/Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Moving The Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Mandatory Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Earthmoving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Operating on Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Operating in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Excavator Boom Slewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Grading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Loading Machine for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
i
906931/0999
TABLE OF CONTENTS (continued)
Chapter
4
5
PRINTED IN U.S.A.
Description
Page
MAINTENANCE
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Care and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Changing Engine Oil & Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Purging Air from Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Using a Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Track System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Adjusting Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Changing Final Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
TROUBLESHOOTING
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Seals & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Travelling Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Bucket, Boom and Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
ii
906931/0999
GENERAL INFORMATION
INTRODUCTION
The information in this Operator’s Manual was written to
give the owner/operator assistance in preparing, adjusting,
maintaining and servicing the Crawler Excavator. More
importantly, this manual provides an operating plan for safe
and proper use of the machine. Major points of safe operation are detailed in Section 2–Safety Information.
Our Dealer network stands by to provide you with any assistance you may require, including genuine GEHL service
parts. All service parts should be obtained from your GEHL
Dealer. Give complete information about the part and
include the model and serial number of your machine.
Record the serial number in the space provided on this page,
as a handy reference.
The GEHL® Company asks that you read and understand the
contents of this manual COMPLETELY and become familiar
with your new machine BEFORE attempting to operate it.
Consult your GEHL Dealer to obtain extra manuals, or manuals in other languages.
Purchased From:
Date of Purchase:
Model No.:
Throughout this manual, information is provided which is set
in italic type and introduced by the word NOTE or IMPORTANT. Be sure to read carefully and comply with the message. Following this information will improve your operating and maintenance efficiency, help you to avoid breakdown
and damage, and extend the machine’s life.
Serial No.:
SERIAL NUMBER LOCATION
The serial plate is located on the inside cab wall next to the
throttle lever (Figure 1-1).
Do not use this machine for any application or purpose other
than those described in this manual. If the machine is to be
used with special attachments or equipment other than those
approved by Gehl, consult your GEHL Dealer. Any person
making unauthorized modifications is responsible for the
consequences.
Serial Plate
The use of this equipment is subject to certain hazards that
cannot be eliminated by mechanical means, but only by exercising intelligence, care and common sense. Such hazards
include, but are not limited to, hillside operation, overloading, instability of the load, poor maintenance and using the
equipment for a purpose for which it is not intended or
designed.
It is essential to have competent and careful operators, who
are not physically or mentally impaired, and who are thoroughly trained in the safe operation of the equipment and the
handling of loads. It is recommended that the operator be
capable of obtaining a valid motor vehicle operator’s license.
Figure 1-1. Serial Number Location
GEHL Company reserves the right to make changes and
improvements in the design and construction of any part
without incurring the obligation to install such changes on
any unit previously delivered.
NOTE: All references to Left-hand or Right-hand are determined from sitting in the operator’s seat and facing forward.
IMPORTANT! Keep these instructions with the machine for future reference.
If the machine changes ownership, be sure this manual accompanies the equipment.
PRINTED IN U.S.A.
1-1
906931/0999
MACHINE IDENTIFICATION
Arm Cylinder
Boom
Arm
Left-hand & Right-hand
Travel Levers
Bucket Cylinder
Cab
Operator’s
Seat
Bucket
Engine Hood
Boom
Cylinder
Control Lever
Console
Dozer
Blade
PRINTED IN U.S.A.
Superstructure
1-2
Track Frame
906931/0999
SPECIFICATIONS
GE 502
GE 602
Yanmar
4TNE88-NSW-Diesel
4-Cyl. Water-Cooled
134 cu. in. (2190 cc)
40 hp (30 kW)
@ 2500 rpm
12V (88 Ah)
14.5 gal. (55 L)
Yanmar
4TNE98-NSR-Diesel
4-Cyl. Water-Cooled
202 cu. in. (3318 cc)
64 hp (47.5 kW)
@ 2300 rpm
12V (88 Ah)
19.8 gal. (75 L)
Double Variable Cap.
& One Gear Pump
14 gpm (52 L/min)
14 gpm (52 L/min)
8 gpm (31 L/min)
3343 psi (230 bar)
2616 psi (180 bar)
Standard
26.4 gal. (100 L)
Double Variable Cap.
& One Gear Pump
17 gpm (64 L/min)
17 gpm (64 L/min)
13 gpm (48 L/min)
3561 psi (245 bar)
2616 psi (180 bar)
Standard
31.7 gal. (120 L)
1.6 mph (2.5 km/h)
2.8 mph (4.5 km/h)
13 in. (335 mm)
9 rpm
30° (= 58%)
16 in. (400 mm)
5 each side
3.84 psi (26.5 kPa)
1.9 mph (3.0 km/h)
3.4 mph (5.5 km/h)
13 in. (335 mm)
10 rpm
30° (= 58%)
16 in. (400 mm)
5 each side
4.27 psi (29.4 kPa)
DOZER BLADE
Width
Height
Maximum Lift Above Ground
Below Ground
73
17
15
16
73
17
16
17
BUCKET (STANDARD)
Width
Capacity
19.7 in. (500 mm)
4.5 cu. ft. (130 L)
19.7 in. (500 mm)
4.5 cu. ft. (130 L)
NOISE LEVEL
Power Sound
Pressure Sound
94 dB(A)
80 dB(A)
96 dB(A)
78 dB(A)
ENGINE
Make
Model
Type
Displacement
Rated Power Output
Battery
Fuel Tank
HYDRAULIC SYSTEM
Pumps
Flow Rate
Working Pressure
Swing System Pressure
Oil Cooler
Hydraulic Tank
UNDER CARRIAGE & SLEWING SYSTEM
Travel Speed-Dual
Ground Clearance
Slew Speed
Gradability
Rubber Track Width
Number of Track Rollers
Average Ground Pressure
PRINTED IN U.S.A.
in. (1850 mm)
in. (425 mm)
in. (381 mm)
in. (400 mm)
1-3
in. (1850 mm)
in. (425 mm)
in. (400 mm)
in. (432 mm)
906931/0999
SPECIFICATIONS (continued)
GENERAL SPECIFICATIONS
Operating Weight w/Cab (SAE)
Height
Width
Length
Transport Length
Max. Digging Depth w/Std. Arm
Max. Digging Depth w/Long Arm
Max. Digging Height w/Std. Arm
Max. Digging Height w/Long Arm
Max. Dump Height w/Std. Arm
Max. Dump Height w/Long Arm
Max. Digging Radius w/Std. Arm
Max. Digging Radius w/Long Arm
Bucket Dig Force
Min. Tail Swing Radius
Min. Front Swing Radius
Swing Angle-Right/Left
Standard Arm
Optional Long Arm
PRINTED IN U.S.A.
GE 502
GE 602
10,395 lbs. (4960 kg)
96 in. (2435 mm)
73 in. (1850 mm)
12 ft. (3665 mm)
19.7 ft. (6000 mm)
146.1 in. (3710 mm)
157.9 in. (4010 mm)
215.7 in. (5480 mm)
223.6 in. (5680 mm)
157.5 in. (4000 mm)
165.4 in. (4200 mm)
236.6 in. (6010 mm)
247.6 in. (6290 mm)
7540 lbs. (3420 kg)
57.9 in. (1470 mm)
74 in. (1880 mm)
80° / 45°
59.1 in. (1500 mm)
70.9 in. (1800 mm)
12,566 lbs. (5700 kg)
96 in. (2435 mm)
73 in. (1850 mm)
12.5 ft. (3800 mm
20.2 ft. (6150 mm)
152 in. (3860 mm)
163.8 in. (4160 mm)
219.7 in. (5580 mm)
227.6 in. (5780 mm)
161.2 in. (4095 mm)
169.1 in. (4295 mm)
242.5 in. (6160 mm)
254.3 in. (6460 mm)
8025 lbs. (3640 kg)
62.6 in. (1590 mm)
75.6 in. (1920 mm)
80° / 45°
65 in. (1650 mm)
76.8 in. (1950 mm)
1-4
906931/0999
Model GE 502 (w/optional long arm)
157.48"
(4000 mm)
70.86"
(1800 mm)
144.29"
(3665 mm)
215.74"
(5480 mm)
59.05"
(1500 mm)
167.32"
(4250 mm)
95.86"
(2435 mm)
72.83"
(1850 mm)
15.35"
(390 mm)
15.74"
(400 mm)
45˚
15.75"
(400 mm)
146"
(3710 mm)
98.8"
(2510 mm)
72.83"
(1850 mm)
80
˚
236.6"
(6010 mm)
57.87"
(1470 mm)
Model GE 602 (w/optional long arm)
157.48"
(4000 mm)
70.86"
(1800 mm)
144.29"
(3665 mm)
215.74"
(5480 mm)
64.96"
(1650 mm)
167.32"
(4250 mm)
95.86"
(2435 mm)
72.83"
(1850 mm)
15.75"
(400 mm)
15.74"
(400 mm)
98.8"
(2510 mm)
45˚
17.12"
(435 mm)
151.96"
(3710 mm)
72.83"
(1850 mm)
80˚
57.87"
(1470 mm)
242.51"
(6159 mm)
PRINTED IN U.S.A.
1-5
906931/0999
CHECKLISTS
I acknowledge that pre-delivery procedures were performed
on this unit as outlined on this page.
Pre-Delivery Checklist
The following checklist is an important reminder of valuable
information and inspections which MUST be made before
delivering the machine to the customer. Check off each item
after prescribed action is taken.
Dealership Name
✔ CHECK THAT:
Dealer Representative Name
❏ Unit has NOT been damaged in shipment. Check for
❏
❏
❏
❏
❏
❏
❏
❏
such things as dents and loose or missing parts; correct
or replace components as required.
Battery is securely mounted and NOT cracked. Make
sure cable connections are tight.
Cylinders, hoses and fittings are not damaged, leaking or
loosely connected.
Filters are not damaged, leaking or loosely secured.
Machine is properly lubricated and no grease fittings are
missing or damaged.
Hydraulic system reservoir, engine crankcase and drive
chaincases are filled to their proper levels.
All adjustments are made to comply with settings given
in Section 4–Maintenance of this manual.
All guards, shields and decals are in place and secured.
Model and serial numbers for this unit are recorded in
the space provided on this page and on page 1-1.
Date Checklist Filled Out
Model & Serial Number
Delivery Checklist
The following checklist is an important reminder of valuable
information that MUST be passed on to the customer at the
time of delivery. Check off each item as you explain it to the
customer.
✔ EXPLAIN:
❏ The Safety Information and Operation chapters of this
IMPORTANT: Start the engine and test run the unit
while checking that all controls operate properly.
❏
✔ CHECK THAT:
❏ Drive controls and boom/arm/bucket/swing/pivot
❏
❏
❏
❏
controls operate properly and are not damaged or
binding.
Drive controls are properly adjusted for a correct neutral
position.
The parking and travelling gear brake, along with the
blocking devices, are automatically activated with unit
stationary (no pilot control pressure).
All hydraulic functions are NOT operational with the
left-hand control console in the pivoted rearward
position.
❏
❏
manual, regarding the safe operation of this machine.
The Maintenance and Troubleshooting chapters for
information regarding the proper maintenance of this
machine. Explain that regular lubrication and maintenance is required for continued safe operation and long
machine life.
Give the Operator’s Manual to the customer and instruct
the customer to read and completely understand the contents before operating the unit.
Explain that the customer MUST consult the engine
manual (provided) for related specifications, operating
adjustments and maintenance instructions.
Completely fill out the Owner’s Registration, including
customer’s signature and return it to the Gehl Company.
Customer’s Signature
Date Delivered
Retain for Customer Records
PRINTED IN U.S.A.
1-6
906931/0999
CHECKLISTS
I acknowledge that pre-delivery procedures were performed
on this unit as outlined on this page.
Pre-Delivery Checklist
The following checklist is an important reminder of valuable
information and inspections which MUST be made before
delivering the machine to the customer. Check off each item
after prescribed action is taken.
Dealership Name
✔ CHECK THAT:
Dealer Representative Name
❏ Unit has NOT been damaged in shipment. Check for
❏
❏
Cut along dotted line and retain for Dealer’s records.
❏
❏
❏
❏
❏
❏
such things as dents and loose or missing parts; correct
or replace components as required.
Battery is securely mounted and NOT cracked. Make
sure cable connections are tight.
Cylinders, hoses and fittings are not damaged, leaking or
loosely connected.
Filters are not damaged, leaking or loosely secured.
Machine is properly lubricated and no grease fittings are
missing or damaged.
Hydraulic system reservoir, engine crankcase and drive
chaincases are filled to their proper levels.
All adjustments are made to comply with settings given
in Section 4–Maintenance of this manual.
All guards, shields and decals are in place and secured.
Model and serial numbers for this unit are recorded in
the space provided on this page and on page 1-1.
Date Checklist Filled Out
Model & Serial Number
Delivery Checklist
The following checklist is an important reminder of valuable
information that MUST be passed on to the customer at the
time of delivery. Check off each item as you explain it to the
customer.
✔ EXPLAIN:
❏ The Safety Information and Operation chapters of this
manual, regarding the safe operation of this machine.
IMPORTANT: Start the engine and test run the unit
while checking that all controls operate properly.
❏ The Maintenance and Troubleshooting chapters for
✔ CHECK THAT:
❏ Drive controls and boom/arm/bucket/swing/pivot
❏
❏
❏
❏
controls operate properly and are not damaged or
binding.
Drive controls are properly adjusted for a correct neutral
position.
The parking and travelling gear brake, along with the
blocking devices, are automatically activated with unit
stationary (no pilot control pressure).
All hydraulic functions are NOT operational with the
left-hand control console in the pivoted rearward
position.
❏
❏
information regarding the proper maintenance of this
machine. Explain that regular lubrication and maintenance is required for continued safe operation and long
machine life.
Give the Operator’s Manual to the customer and instruct
the customer to read and completely understand the contents before operating the unit.
Explain that the customer MUST consult the engine
manual (provided) for related specifications, operating
adjustments and maintenance instructions.
Completely fill out the Owner’s Registration, including
customer’s signature and return it to the Gehl Company.
Customer’s Signature
Date Delivered
Retain for Dealer’s Records
PRINTED IN U.S.A
1-7
06931/0899
This Page Intentionally Blank
PRINTED IN U.S.A.
1-8
906931/0999
SAFETY INFORMATION
GENERAL SAFETY INFORMATION
Safety Symbols & Terminology
Safety Reminders
The GEHL® Company, in cooperation with the
Society of Automotive Engineers, has adopted
this Safety Alert Symbol to pinpoint precautions
which, if NOT properly followed, can create a safety hazard. This symbol means ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED! It stresses an
attitude of “Heads Up For Safety” and can be found
throughout this Operator’s Manual and on the machine.
•
Some illustrations in this manual may show doors,
guards and shields open or removed for illustrative purposes only. BE SURE all doors, guards and shields are
in their proper operating positions BEFORE starting the
engine to operate the machine.
•
To ensure safe operation, replace damaged or worn-out
parts with genuine Gehl service parts.
Before you operate this equipment, read and study the
following safety information. In addition, make sure that
every individual who operates or works with this equipment, whether family member or employee, is familiar
with these safety precautions.
•
Gehl units are designed and intended to be used ONLY
with Gehl Company attachments or approved referral
attachments. The Gehl Company cannot be responsible
for operator safety if the unit is used with non-approved
attachments.
The Gehl Company always considers the operator’s safety
when designing its machinery, and guards exposed moving
parts for the operator’s protection. However, some areas cannot be guarded or shielded in order to assure proper operation.
•
The terrain, engine speed, load carried, and abrupt control movements can affect machine stability. If misused,
any of the above factors can cause the machine to tip,
throwing the operator forward or out of the unit,
causing death of serious injury. Therefore, ALWAYS
wear the seatbelt when operating the equipment.
Operate the controls smoothly and gradually at an appropriate engine speed which matches the operating conditions.
•
For additional stability when operating on inclines or
ramps, ALWAYS travel with the bucket and blade
towards the top of the incline.
*
DO NOT raise or lower a loaded bucket suddenly.
Abrupt movements under load can cause serious instability.
•
NEVER attempt to bypass the keyswitch to start the
engine. Use only the jump-starting procedure detailed in
the Maintenance section of this manual.
•
NEVER use your hands to search for hydraulic fluid
leaks; use a piece of paper or cardboard. Escaping fluid
under pressure can be invisible and can penetrate the
skin and cause serious injury. If any fluid is injected
into your skin, see a doctor at once. Injected fluid MUST
be surgically removed by a doctor or gangrene may
result.
•
Do not operate too close to an excavation or ditch. BE
SURE that the surrounding ground has adequate strength
to support the weight of the machine and the load.
•
DO NOT smoke or have any spark producing equipment
in the area while filling the fuel tank or while working
on the fuel or hydraulic systems.
The following safety words and symbols are used throughout
the manual and on the machine to warn of dangerous situations.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. May also alert
against unsafe practices.
PRINTED IN U.S.A.
2-1
906931/0999
•
When driving on or across roads, the machine must be
equipped according to the road/traffic laws, and these
laws must be observed.
Never drive across the incline on sloping ground.
Extreme caution is required when working across an
incline or changing direction.
•
Never use the weight of the machine to obtain more
force when excavating. There is a risk overturning.
•
Adapt working speed to local visibility.
•
•
The driving speed must be adapted to the road and
ground conditions.
Before starting up the machine or setting it in motion,
warn any personnel in the area.
•
Attach a clearly visible, legible OUT OF SERVICE sign
when repair and adjustments are being performed on the
machine.
•
Unless necessary for servicing the engine, the engine
hood must not be opened while the engine is running.
Safety Reminders (continued)
•
•
Particular attention is required when working on slopes.
Angle of inclination of machine for all directions of travel: for brief operation (2-3 minutes)–maximum of 30°;
for continuous operation–maximum of 25°.
•
Unauthorized personnel must not start-up the machine.
•
Be familiar with the machine safety devices.
•
No one but the operator must be on the machine when in
use. PASSENGERS PROHIBITED!
•
The machine is not to be used to lift equipment or transport personnel.
•
Use the towing bracket provided for towing the machine.
•
•
The operating area, steps, and grips must be free of oil,
dirt, ice and unsecured objects.
The excavator arm is not a ramming tool. Never attempt
to use the working equipment to drive piles or similar
items into the ground, or to flatten the ground.
•
The proper working condition of the lighting system
must be checked before and while working in darkness.
•
•
Always keep the windshield and windows clean. Poor
visibility can cause accidents.
Never excavate while the machine is travelling. Never
move the machine to dig. Never slew with lowered
working equipment and never move the machine when
the working equipment is resting on the ground.
•
Operate the machine from the operator’s seat only. Wear
seatbelt which is provided.
Fire Prevention
•
Control the machine cautiously and gradually until you
are fully familiar with all the controls and handling.
•
Pay attention to all movements of machines and
machines in the working area.
•
Personnel must not be in the working area. Never operate equipment above people.
•
Always wear appropriate protective clothing: hard hat,
work gloves, strong work shoes, reflective clothing.
•
Make sure you have sufficient knowledge of the working
area; location of utility lines (water, gas, electric, etc.)
and load bearing capacity of the ground.
•
Before working in the area of utility lines, contact the
proper authority to determine the measures required for
safety.
•
Never dig underneath the machine. Support walls properly when excavating or working in, or close to, trenches.
•
The machine has several components that operate at high
temperature under normal operating conditions, primarily the
engine and exhaust systems. Also, the electrical system, if
not properly maintained or is damaged, can arc or produce
sparks. These conditions make it extremely important to
avoid conditions where explosive dust or gasses can be ignited by arcs, sparks or heat.
The machine must be cleaned on a regular basis to avoid the
buildup of flammable debris such as leaves, straw, etc.
Accumulated debris, particularly in the engine compartment,
poses a fire hazard.
The spark arrestor muffler is designed to control the emission
of hot particles from the engine and exhaust system, but the
muffler system still gets hot during operation. For this reason, it is extremely important not to operate the machine in
an area where explosive dust or gasses can contact the hot
exhaust.
Never drive long distances with the working equipment
fully raised. Lowering the working equipment produces
improved visibility and improved weight distribution.
PRINTED IN U.S.A.
2-2
•
Do not use the machine where explosive gasses or dust
can be ignited by arcs, sparks, hot components or
exhaust gasses.
•
The operator cab, engine compartment and engine cooling system must be inspected every day and cleaned if
necessary to remove any flammable debris.
906931/0999
•
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged parts.
•
Check fuel and hydraulic tubes, hoses and fittings for
damage and leakage. Tighten or replace any parts that
show leakage. Always clean fluid spills.
•
Always the clean the machine before performing any
welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine
when welding.
•
Mandatory Safety Shutdown Procedure
Before leaving the vehicle:
1.
Lower the working equipment to the ground and support
it securely.
2.
Reduce throttle and turn off the engine.
3.
Lock out controls by raising left control console.
4.
Remove the ignition key and take it with you.
Stop the engine and let it cool before adding fuel.
SAFETY DECAL & STICKER LOCATIONS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
WARNING: Danger zone. Keep away! (both sides
of the boom)
Direction arrow (left and right on track frames)
Hydraulic Oil
WARNING–Hydraulic reservoir under pressure
Diesel
WARNING: Do not open when engine is running
Lower boom, raise boom, close bucket, open
bucket (on windshield)
Lower dozer blade, raise dozer blade (on windshield)
Travel right, forward, reverse (on windshield)
Travel left, forward, reverse (on windshield)
Bucket arm out, bucket arm in, superstructure left,
superstructure right (on windshield)
Environmental symbol (blue angel) (on windshield)
Nameplate
Warning. TO AVOID INJURY: Read the Operator’s
Manual before using the machine. Be sure all
user’s are instructed on safe use and maintenance. Service the machine per the manual.
Contact dealer (or manufacturer) for information
and service parts.
LWA 96
LPA 78
CE symbol
Lifting point for lifting the excavator (left and right
on boom and dozer blade)
Tie down point (left and right on dozer blade and
chassis
1
18
14
18,19
2
8 9 10 11
7
12
23
14
13,17
5
3
4
6
18
15,16
PRINTED IN U.S.A.
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SAFETY DECAL & STICKER LOCATIONS
20.
21.
22.
23.
24.
25.
26.
27.
28.
WARNING: TO AVOID INJURY:
Load and transport unit properly. Inspect job-site
for hazards.
Operate only from operator’s seat. Fasten seatbelt.
Keep people out of DANGER ZONE.
Operate within stability limit of machine. DO NOT
OVERLOAD. Use only approved attachments.
WARNING: Mandatory Safety Shutdown
Procedure:
1. Lower all equipment to ground.
2. Reduce throttle; shut off engine.
3. Lock out controls before exiting.
4. Remove key and take it with you.
WARNING: TO AVOID INJURY: Always hold handle
when closing front window. When opening window, be sure to lock both sides.
WARNING: TO AVOID INJURY OR DEATH: Do not
loosen lubricator more than 2 turns. Do not
loosen parts other than lubricator. Grease is
under high pressure.
Lubrication hours
Engine cover release latch
Valve cover release latch
Throttle speed
Hydraulic Breaker
1
18
14
18,19
2
8 9 10 11
7
12
23
14
13,17
5
3
4
6
18
15,16
PRINTED IN U.S.A.
2-4
906931/0999
SAFETY DECALS
WARNING
DANGER ZONE
Keep away!
1
HYDRAULIC OIL
2
3
D
WARNING
HYDRAULIC RESERVOIR
UNDER PRESSURE
WARNING
DO NOT OPEN WHILE
ENGINE IS RUNNING
DIESEL
4
5
BOOM DOWN
6
TRAVEL RIGHT
TRAVEL LEFT
FORWARD
FORWARD
REVERSE
REVERSE
DOZER BLADE DOWN
BUCKET
OPEN
BUCKET
CLOSED
7
DOZER BLADE UP
BOOM UP
8
ARM OUT
BOOM LEFT
SWING
LEFT
BOOM RIGHT
WARNING
10
TO AVOID INJURY:
SWING
RIGHT
Read the Operator's Manual before
using this machine.
Be sure all users are instructed on
safe use and maintenance.
Service machine per the Manual.
Contact dealer (or manuafacturer) for
information and service parts.
ARM IN
11
PRINTED IN U.S.A.
9
14
2-5
906931/0999
SAFETY DECALS (continued)
1.
WARNING
2.
TO AVOID INJURY:
3.
1. Load and transport unit properly.
Inspect job-site for hazards.
4.
2. Operate only from operator's seat.
Fasten seatbelt.
3. Keep people out of DANGER ZONE.
4. Operate within stability limit of
machine. DO NOT OVERLOAD.
Use only approved attachments.
18
1.
19
20
WARNING
2.
STOP
WARNING
MANDATORY SAFETY
SHUTDOWN PROCEDURE:
3.
4.
TO AVOID INJURY:
1. Lower all equipment to ground.
ALWAYS hold handle
when closing front
window.
When opening window be
sure to lock both sides
2. Reduce throttle; shut off engine.
3. Lock out controls before exiting.
4. Remove key and take it with you.
21
22
WARNING
10
AVOID INJURY OR DEATH
Do not loosen lubricator more
than 2 turns
Do not loosen parts other than lubricator.
Grease is under high presure.
50
23
24
25
26
A+B
A+T
HYDRAULIC BREAKER
28
27
PRINTED IN U.S.A.
2-6
906931/0999
OPERATION
GENERAL INFORMATION
WARNING
Guards & Shields
Whenever possible, guards and shields are used to protect
potentially hazardous areas on the machine. In many places,
decals are also provided to warn of potential dangers and/or
to display special operating procedures (see Safety Decals
Locations in Section 2).
Make sure you are familiar with all safety
devices and controls before operating the
machine. Know how to stop before starting.
This GEHL® Company machine is designed for
use only with GEHL® Company approved
accessories or referral attachments. The
GEHL® Company cannot be responsible for
operator safety if the unit is used with nonapproved attachments.
The operator’s seat left-hand console must be raised in order
to exit the cab. In the raised position, the left-hand console
locks out all hydraulic functions of the machine (Figure 3-1).
WARNING
Armrest Lever
Instructions are necessary before operating
the machine. Read and understand this entire
manual. Follow warnings and instructions for
operation and maintenance. Check for correct
function after adjustments or maintenance.
Failure to follow instructions can result in
injury or death.
Left-Hand Console
In Raised Position
WARNING
Read and thoroughly understand all safety
decals before operating the machine. DO NOT
operate the machine unless all factory installed
guards and shields are in place.
Figure 3-1. Left-Hand Console Raised
PRINTED IN U.S.A.
3-1
906931/0999
OPERATOR CONTROLS
Outer Cab Layout
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
2
1
Fuel Filler
Hydraulic Reservoir
Hydraulic Valves
Diesel Pump (Option)
Hydraulic Oil Filler
Hydraulic Oil Filter
Hydraulic Oil Sight Gauge
Battery
Hydraulic Reservoir Drain
Fuel Tank Drain
Fuel Tank
Engine Hood
Door Latches–Engine and
Hydraulic Valves Compartment
3
4
+
5
-
6
13
7
8
12
10
11
9
Inner Cab Layout
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Auxiliary Hydraulics Pedal
Left-Hand Travel Lever w/Foot Pedal
Seat Suspension Adjustment Lever
Right-Hand Travel Lever w/Foot Pedal
Seat Adjustment Lever
Footrest
Dozer Blade Control Lever w/Foot Pedal
Ventilation Controls
Cab Light
Windshield Washer Reservoir
Throttle Lever
Valve Cover Latch Lever
Engine Cover Latch Lever
Right-Hand Control Lever for Boom, Bucket
Cylinder and Horn
Ashtray
Console Controls (see next page)
Radio (optional)
Stereo Speaker
Ignition Key Switch
Armrest
Storage Shelf
Fuse Panel (see next page)
Heater
Left-Hand Control Lever for Rotating/Slewing
Bucket Arm; Control Button for Boom Swing when
used with Auxiliary Hydraulics Pedal (#1)
Armrest Lever (for folding back the armrest which
disables the hydraulic controls)
Seat and Console Adjustment Lever
PRINTED IN U.S.A.
1
2
4 5
3
6
7
8
8
9
26
+
10
-
25
11
24
14
13
15
12
23
20
18
22 21
3-2
20
19
17
18
16
906931/0999
Console Controls Layout
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Fuel Level Gauge
Coolant Temperature Indicator
Battery Voltage Indicator
Engine Oil Pressure Indicator
Glow Plug Indicator
Engine Air Filter Indicator
Hydraulic Oil Level Indicator
Low Fuel Indicator
Work Lights ON Indicator
Hour Meter
Heater Control
2-Speed Travel Switch
Light Switch–Cab Front Work Light
Ignition Key Switch
Light Switch–Boom Work Light
Light Switch–Rear Work Light (optional)
3
4
- +
2
5
6
7
9
8
1
00000000
HOURS
10
11
17
16
12
15
13
14
Fuse Panel
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Overdrive (Tilt Switch and Drive Lever) (7.5 Amp)
Windshield Wiper and Washer (7.5 Amp)
Turn Engine Off (Stop Solenoid) (3.0 Amp)
Switch Lighting, Instrument Panel and Lighting (7.5 Amp)
Front Work Lights (15 Amp)
Heating, Horn (15 Amp)
Safety (turning) Light, Free (10 Amp)
Cabin Lighting, Socket, Radio (Optional) (10 Amp)
Alternator, Starter (10 Amp)
Fuel Pump, Free (15 Amp)
Changeover Valve, Safety Solenoid Valve (10 Amp)
!
"
PRINTED IN U.S.A.
3-3
'
#
$
%
&
906931/0999
OPERATOR CONTROLS (continued)
Left-Hand Lever w/Foot Pedal
Right-Hand Lever w/Foot Pedal
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 lever controls gradually and smoothly. Excessive speed
and quick handle movements without regard
for conditions and circumstances is hazardous
and could cause an accident.
Dozer Lever
w/Foot Pedal
Travel Controls
NOTE: Moving the handles equally in the same direction will result in travelling straight forward or straight
backward.
Figure 3-2. Travel Controls
Boom Swing
Control (used with
Auxiliary Hydraulic Pedal)
FORWARD TRAVEL
Push both levers (Figure 3-2) straight forward, slowly the
same distance.
Left-Hand Control
REVERSE TRAVEL
Pull both levers straight backward, slowly the same distance.
TURNING DURING TRAVEL
Horn
Move one lever farther than the other one. To turn left while
moving forward, move the right lever farther forward; to turn
right while moving forward, move the left lever farther forward.
Right-Hand
Control
Figure 3-3. Boom & Bucket Controls
PIVOTING
Move the levers in opposite directions to pivot the machine
on its axis. To pivot left, move the right lever farther forward
while pulling the left lever to the rear; to pivot right, move
the left lever forward while pulling the right lever to the rear.
Right-Hand Control
7
5
5
Excavating Controls
6
8
8
7
The boom and bucket are controlled by the right- and lefthand levers on the seat consoles (Figure 3-3).
6
The superstructure or “house” is slewed by moving the lefthand lever left or right (Figure 3-4).
Left-Hand Control
3
The bucket can be slewed without moving the cab by pressing the auxiliary hydraulics pedal left or right (Figure 3-5)
while pressing the boom swing switch on the left-hand control lever.
1
2
The boom and bucket are moved using the right-hand control
lever. The button located on the right-hand lever sounds the
horn (Figure 3-3).
4
3
4
2
The dozer is controlled by the dozer lever (Figure 3-2).
PRINTED IN U.S.A.
1
Figure 3-4. Boom and Bucket Controls
3-4
906931/0999
LEFT-HAND CONTROL LEVER (FIGURE 3-3)
1. Move the left-hand lever forward to move bucket arm
away from the machine.
2.
Move the left-hand lever to the rear to move the arm
towards the machine.
3.
Move the left-hand lever to the left to slew superstructure to the left.
4.
Move the left-hand lever to the right to slew superstructure to the right.
RIGHT-HAND CONTROL LEVER (FIGURE 3-4)
5. Move the right-hand lever forward to lower the boom.
6.
Move the right-hand lever to the rear to raise the boom.
7.
Move the right-hand lever to the left to close the bucket
(bucket moves up and to the front).
8.
Must use with Boom Swing Switch on Left-Hand Control
Figure 3-5. Auxiliary Hydraulics Pedal
Move the right-hand lever to the right to open the bucket
(bucket moves down and to the rear).
3
AUXILIARY HYDRAULICS PEDAL (FIGURE 3-5)
Lift the protective shield, then depress the pedal left or right
while depressing the switch located on top of the left-hand
control lever to slew only the bucket (superstructure will
remain stationary).
DOZER BLADE
The dozer blade is raised and lowered by the dozer lever
w/foot pedal (Figure 3-2). Push the lever forward to lower
the blade; pull the lever to the rear to raise the dozer blade.
- +
4
2
5
6
7
9
8
1
00000000
HOURS
10
Console Controls (Figure 3-6)
11
17
1. FUEL LEVEL GAUGE
The fuel gauge shows the level of fuel in the tank.
16
12
2. COOLANT TEMPERATURE INDICATOR
Indicator light comes on when coolant temperature is too
high.
15
13
3. BATTERY VOLTAGE INDICATOR
Indicator light comes on when battery voltage is too low.
14
4. ENGINE OIL PRESSURE INDICATOR
During normal operation, this indicator light should remain
off. The indicator will light if the engine oil pressure drops
too low. If this occurs, shut off the engine IMMEDIATELY
and determine the cause of the pressure drop.
Figure 3-6. Console Controls
7. HYDRAULIC OIL LEVEL INDICATOR
Indicator light comes on when hydraulic oil level is too low.
Shut off engine and add oil.
5. GLOW PLUG INDICATOR
Indicator light comes on when the ignition key is turned on.
Indicator will go out when glow plugs have heated sufficiently to start the engine.
8. LOW FUEL INDICATOR
Indicator light comes on when fuel level is too low.
9. WORK LIGHTS INDICATOR
Indicator light comes on when work lights are turned on.
6. ENGINE AIR FILTER INDICATOR
Indicator light comes on when engine air filter is too dirty.
PRINTED IN U.S.A.
3-5
906931/0999
OPERATOR CONTROLS (continued)
Console Controls (continued) (Figure 3-6)
Armrest Lever
10. HOUR METER
Indicates total operating hours of the machine. Use the hour
meter to log maintenance time in the log located in
Section 4–Maintenance.
Left-Hand Console
In Raised Position
11. HEATER CONTROL SWITCH
Turns on the cab heater and controls the fan speed.
12. 2-SPEED TRAVEL CONTROL SWITCH
Turn the switch on to engage a higher travel speed. With
switch on, machine can only move straight forward or rearward. It will not steer to either side.
13. CAB FRONT WORKING LIGHT SWITCH
Turns the working light on the front of the cab on and off.
The switch has two positions; the first position operates the
low beam; the second position operates the high beam.
14. IGNITION KEYSWITCH
With the key in the OFF (vertical) position, power from the
battery is disconnected to the controls and console. This is
the only position that the key can be inserted or removed
from the switch.
Figure 3-7. Operator’s Seat with Left-Hand
Console Raised
Seat Adjustment Lever
With the key turned one position clockwise (RUN) from the
vertical position, power from the battery is supplied to all
controls and electrical circuits.
With the key turned fully clockwise (START) and held in
position, the electric starter energizes and starts the engine
when the glow plug indicator goes out. Release the key after
the engine starts.
Seat/Console
Adjustment Lever
NOTE: The key must always be returned to the OFF
position between attempts to start the engine in order to
activate the glow plug system.
Seat Suspension
Adjustment Lever
15. BOOM WORKING LIGHT SWITCH
Turns the boom working light on and off.
Figure 3-8. Operator’s Seat Adjustment Controls
16. REAR WORKING LIGHT SWITCH (Optional)
Turns the optional rear working light on and off.
SEAT SUSPENSION ADJUSTMENT LEVER
Turn the lever (Figure 3-8) to adjust the seat suspension for
the operator’s weight. An indicator on the front of the seat
base shows the weight adjustment.
17. WINDSHIELD WIPER SWITCH
Pushing the switch to the first position turns the windshield
wiper on. Pushing and holding the switch in the second position activates the washer fluid pump.
SEAT/CONSOLE ADJUSTMENT LEVER
The seat/console lever (Figure 3-8) allows the operator to
move the seat and console forward or rearward as a unit.
Operator’s Seat Adjustment Controls
SEAT ADJUSTMENT LEVER
The seat adjustment lever (Figure 3-8) allows the operator to
move the seat only (without console) forward or rearward.
NOTE: The operator’s seat left-hand console must be
raised in order to exit the cab. In the raised position,
the left-hand console locks out all hydraulic functions of
the machine (Figure 3-7).
PRINTED IN U.S.A.
3-6
906931/0999
Ventilation
WINDSHIELD
The windshield can be opened for ventilation. Turn the latch
(Figure 3-9) located at the upper corners of the windshield.
Grasp the handles and pull the windshield up until latches
lock in position.
Latch
To close the windshield, turn the latches then lower the windshield until the latches lock in position.
Handle
SIDE WINDOW
The side window can be opened for ventilation. Squeeze the
latch (Figure 3-10) located on the window, then slide window
to desired position and release latch.
Figure 3-9. Windshield
VENTS
There are two side vents located underneath the side window
(Figure 3-10. Open the slats for better ventilation.
Cab Latches
CAB DOOR LATCH
When fully opened, the cab door will lock in position to the
side of the cab. To release the latch, pull the black knob
located on the right side of the door jamb.
Latch
Vents
ENGINE AND HYDRAULIC VALVE COVER LATCHES
The engine cover and hydraulic valve cover latches are located just inside the door next to the operator’s seat (Figure 311).
To unlock a cover, pull the respective latch handle. The
cover can then be opened.
Figure 3-10. Side Window
Engine
Valve
Figure 3-11. Engine and Valve Cover Latches
PRINTED IN U.S.A.
3-7
906931/0999
MACHINE OPERATION
Starting/Stopping the Engine
WARNING
Instructions are necessary before operating or
servicing the machine. Read this entire manual and all decals on the machine. Follow all
warnings and instructions. Failure to follow all
instructions can cause injury or death.
SAFETY DEVICES
When the machine is stationary (no pilot control pressure),
the parking and travelling gear brake along with the blocking
devices, are automatically activated.
Checklist Before Operation
The brakes and blocking devices are not released until a travel lever or control lever is operated.
All hydraulic functions are inoperable with the operator’s
seat left-hand console in the raised position.
Check the following items before each day of operation:
•
Seat belt and mounting hardware.
•
Decals. Replace as required.
•
Air cleaner and intake hoses. Clear any obstructions.
•
Engine coolant level and system for leaks.
•
Clean engine area of any flammable materials.
•
Check engine oil level and fill if required.
•
Check hydraulic system for leaks and check hydraulic
fluid level.
NORMAL STARTING/STOPPING PROCEDURE
1. Adjust the operator’s seat to desired settings.
DANGER
See the list of recommended lubricants in
Section 4–Maintenance for proper grade of
engine oil and hydraulic oil. Only use oils of
specified on the list or serious injury or death
could occur.
•
Check all pivot points for proper operation.
•
Check track tension.
•
Check for broken and loose parts, and repair.
•
Check fuel tank.
Be sure all levers and controls are in neutral positions.
3.
Insert ignition key into switch and turn clockwise to the
first position. Indicators for oil pressure and battery
voltage will light.
4.
Turn the key fully clockwise and hold in position until
glow plug indicator goes out (approximately 10 seconds
when engine is cold).
5.
When engine starts, release the key.
6.
Allow engine to warm-up for approximately 5 minutes
to warm the hydraulic fluid.
7.
Turn the key fully counterclockwise to turn the engine
off.
IMPORTANT: Do not engage the starter motor for
longer than 10 seconds at each starting attempt. If
the engine does not start, wait 30 seconds, turn the
key fully off, then attempt to start the engine again.
WARNING
When an engine is running in an enclosed
area, fresh air must be added to avoid concentration of exhaust fumes. If the machine is stationary, vent the exhaust outside. Exhaust
fumes contain odorless, invisible gases which
can kill without warning.
IMPORTANT: Never operate machine until fuel tank
is empty or fuel system must be bled of air. Always
fill tank after use.
Engines have hot parts and hot exhaust gas.
Keep flammable materials away from engine.
WARNING
Do not use ether with glow plugs (preheat) systems. Explosion can result which can cause
injury or damage.
PRINTED IN U.S.A.
2.
Do not use machine in atmosphere containing
explosive gas.
3-8
906931/0999
Throttle Lever
Starting/Stopping The Engine (continued)
IMPORTANT: Indicator lamps must go out when
engine starts. If they do not, turn off the engine
IMMEDIATELY until cause has been determined and
fixed.
COLD WEATHER STARTING PROCEDURE
1. Install an engine heater.
2.
Be sure engine oil is correct type and viscosity for the
ambient temperature.
3.
Be sure battery is fully charged.
4.
Push the throttle lever (Figure 3-12) fully forward.
5.
Follow all steps under Normal Starting Procedure.
6.
As the engine warms up and engine speed increases,
move the throttle lever to the idling position.
Figure 3-12. Throttle Lever
Left-Hand Lever w/Foot Pedal
Right-Hand Lever w/Foot Pedal
Travel Speed
Switch
NEW MACHINE BREAK-IN PROCEDURE
A new machine requires careful operation during the first 100
hours to properly break-in various parts. If the machine is
subjected to hard use during the break-in period, the performance and service life will be reduced.
Perform the following when operating a new machine:
•
After starting, let the engine idle for 5 minutes so all the
components can warm-up.
•
Avoid operation with heavy loads or at high speeds.
Figure 3-13. Travel Levers & Speed Switch
•
Avoid sudden starting and stopping or abrupt motions.
3.
Moving the Excavator
1.
To turn right, pull the right-hand lever back and push the
left-hand lever forward.
Set the travel speed using the travel speed switch on the
console:
Slow Speed Maximum = 1.6 mph (2.6 km/h)
Fast Speed Maximum = 3.7 mph (5.3 km/h)
4.
Mandatory Safety Shutdown Procedure
Before leaving the machine:
Push or pull the travel levers w/foot pedals to move the
machine (Figure 3-13).
1.
Lower the working equipment to the ground and support
it securely.
2.
Reduce throttle and turn off the engine.
3.
Lock out controls by raising left control console.
4.
Remove the ignition key and take it with you.
Push both levers forward to move forward.
Pull both levers rearward to travel in reverse.
NOTE: If the superstructure has been rotated 180°
(dozer blade at the rear), travel levers will work in the
opposite manner. Pushing levers forward will cause the
machine to travel in reverse and pulling levers to the
rear will move the machine forward.
PRINTED IN U.S.A.
To stop travelling, return levers to neutral (middle) position.
NOTE: When released, levers and controls return to the
neutral position automatically.
NOTE: If the travel speed switch on the console
(Figure 3-6) is in the fast speed position, machine will
not turn right or left. It will only go straight forward or
rearward.
2.
To turn left, pull the left-hand travel lever back and push
the right-hand lever forward.
3-9
906931/0999
EARTHMOVING
Operating On Slopes
WARNING
Do not travel up or across a slope steeper than
15°. Do not travel down a slope steeper than
25°. Keep boom centered while travelling.
Keep attachments as low as possible when
travelling on slopes or rough terrain.
Operating on a slope is inherently dangerous. It is recommended to level the work area as shown in Figure 3-14. If
this is not possible, use the following guidelines.
•
When going down a slope, control the speed with the
travelling levers and the the throttle lever.
•
When going down grades that exceed 15°, put the
machine in the position shown in Figure 3-15. Run the
engine slowly.
•
Operate as slowly as possible and avoid sudden changes
in direction.
•
Avoid travelling over objects such as rocks, trees,
stumps, etc.
•
Stop the machine travel before moving the bucket or
dozer controls.
•
Slow down the work cycle. Take your time.
•
Avoid working with the tracks positioned across the
slope. Position the machine with the blade downhill and
lowered.
Figure 3-14. Levelling the Work Site on a Slope
12" m
imu
Max mm)
(304
25 Maximum
•
•
Figure 3-15. Travelling on a Slope Exceeding 15°
Avoid swinging or extending the bucket farther than necessary in a downhill direction. When you must swing
the bucket downhill, keep the boom low and skid the
bucket along the ground.
When working with the bucket on the uphill side, keep
the bucket as close to the ground as possible. Unload far
enough away from the trench or hole to prevent the possibility of a cave-in.
•
Do not operate or immerse the machine in water higher
than the tracks.
•
Properly grease the machine if it has been operated or
immersed in water for a period of time.
IMPORTANT: Never operate machine until fuel tank
is empty or fuel system must be bled of air. Always
fill tank after use.
Operating in Water
•
Mud and water should be removed from the machine
before parking. If possible, park the machine on boards
or concrete to prevent the track or undercarriage from
freezing to the ground and preventing machine movement.
PRINTED IN U.S.A.
3-10
906931/0999
Excavator Boom Slewing
WARNING
Always ensure adequate stability when working with the machine. Particularly when working with equipment slewed to the side.
Changing the working equipment alters the
stability (weight) of the machine.
The excavator boom can be slewed 45° to the right and 80°
to the left from the basic front position. This allows excavation of trenches along walls, fences, etc.
Digging
Figure 3-16. Proper Excavating
OPTIMAL STABILITY WHEN DIGGING
• Use the dozer blade to support the excavator on the
ground.
•
Grading
WARNING
Always ensure adequate stability when working near trenches. Be aware of conditions that
could cause the earth to collapse resulting in
risk of injury or death.
•
•
The boom must be fully raised and the bucket tilted in
(up) when grading.
•
When grading, the material may be pushed away to the
front or the side.
•
Raise the dozer blade slightly if excessive resistance
occurs.
Never dig under the machine. Support the walls properly when excavating or working close to trenches.
To obtain maximum digging performance, avoid fully
extending the excavator arm. Excavate using long, flat
pulling movements of the arm (Figure 3-16).
PRINTED IN U.S.A.
3-11
906931/0999
TRANSPORTING
Lifting Machine
Loading Machine for Transport
•
Use only transport machines that are in proper working
order and are approved for use on public roads.
•
When using ramps to load machine onto the transport
machine:
- Do not exceed an incline of 18°.
- Ramp width must be at least 1½ times the
width of the track.
- Clean dirt, mud, ice and snow from the
ramps and tracks.
•
CAUTION
Use lifting device with sufficient capacity for
the weight of the machine plus any attachments.
Maintain center of gravity and balance when
lifting.
Do not swing boom or cab.
Use metal loading ramps with a slip-resistant surface.
Never lift machine with operator aboard.
NOTE: The ends of the ramps should be beveled to
prevent damage to the rubber tracks (Figure 3-17).
•
Attach ramps securely to the transport machine to prevent them from slipping off during loading.
•
Load the machine on solid, even ground.
•
When loading, apply the transport machine parking
brake and chock the wheels.
•
Determine the direction of the track movement (blade
facing forward) before moving the machine onto the
ramps.
•
After the machine is on the transport machine, lower the
dozer blade and the bucket onto the loading surface
(Figure 3-17). Turn off the engine.
•
Lock the cab.
•
Place chocks under machine tracks and secure machine
to prevent slipping, overturning and moving on the transport machine.
•
Use the points on the excavator indicated by decals for
tie down.
•
Secure the lifting fixture sling to the lifting points on the
machine (Figure 3-18).
•
Install spreader bar above the cab to prevent lifting fixture from rubbing on the machine.
•
Do not exceed rated load capacity.
Spreader
Bar
Lifting
Point
Lifting
Point
Figure 3-18. Machine Tie Down Points
Beveled Ramps
Figure 3-17. Transporting the Machine
PRINTED IN U.S.A.
3-12
906931/0999
MAINTENANCE
GENERAL INFORMATION
Care and Servicing
WARNING
Instructions are necessary before operating
and servicing the machine. Read and understand this entire manual. Follow warnings and
instructions for operation and maintenance.
Check for correct function after adjustments or
maintenance. Failure to follow instructions can
result in injury or death.
WARNING
Be sure you are familiar with all safety devices
and controls before operating or servicing the
machine. Know how to stop before starting.
This GEHL® Company machine is designed for
use only with GEHL® Company approved
accessories or referral attachments. The
GEHL® Company cannot be responsible for
operator safety if the unit is used with nonapproved attachments.
Care and servicing have a significant influence on the
readiness for operation and service life of the machine.
•
For additional servicing work regarding the engine, see
the engine manual provided with the machine.
•
Use of lubricants which do not correspond to the manufacturer’s recommendations may invalidate warranty
claims.
•
More frequent servicing, other than the recommended
intervals, may be required under extreme operating conditions.
•
Always dispose of waste lubricating oils and hydraulic
fluids according to local regulations or take to a recycling center for proper disposal. DO NOT pour fluids
onto the ground or down a drain.
Maintenance Safety
WARNING
Read and thoroughly understand all safety
decals before operating the machine. DO NOT
operate the machine unless all factory installed
guards and shields are in place.
CALIFORNIA PROPOSITION
65 WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects and other reproductive harm.
WARNING
Hydraulic reservoir is under pressure. Avoid
contact with leaking hydraulic fluid or diesel
fuel under pressure. It can penetrate the skin
or eyes.
PRINTED IN U.S.A.
•
4-1
•
Never service the machine without reading the
applicable instructions.
•
Always lower bucket and dozer blade to the
ground before performing any maintenance.
•
Use correct procedures to lift and support the
machine. Always lift the blade fully before
installing jackstands.
•
Cleaning and maintenance are required daily.
•
Keep engine cover and valve cover closed
except for service. Close and latch covers
before operating the machine.
•
Be sure to have area properly ventilated when
grinding or welding parts. Wear dust mask.
•
Vent exhaust to outside when engine must be
run for service. Exhaust system must be tightly
sealed. Exhaust fumes can kill without warning.
•
Never modify equipment or add attachments
not approved by Gehl Company.
•
Stop engine and let cool, then clean engine of
any flammable materials before checking fluid
levels.
906931/0799
GENERAL INFORMATION (continued)
Maintenance Safety (continued)
•
Never service or adjust machine with the engine
running unless service procedure calls for the
engine to be running.
•
Avoid contact with leaking hydraulic fluid or
diesel fuel under pressure. It can penetrate the
skin or eyes. NEVER use your hands to search
for hydraulic fluid leaks; use a piece of paper or
cardboard. Escaping fluid under pressure can
be invisible and can penetrate the skin and
cause serious injury. If any fluid is injected into
your skin, see a doctor at once. Injected fluid
MUST be surgically removed by a doctor or
gangrene may result.
•
The operating pressure settings of the hydraulic
system should only be set by trained, qualified
personnel. If malfunctions are caused by unauthorized alteration of operating pressure settings, all warranty responsibilities on the part of
the manufacturer are automatically invalidated.
PRINTED IN U.S.A.
4-2
•
Never fill fuel tank with engine running, while
smoking or when near open flame.
•
Keep body, jewelry and clothing away from moving parts, electrical contacts, hot parts and
exhaust.
•
Wear eye protection when servicing the
machine.
•
Lead acid batteries produce flammable and
explosive gas. Keep arcs, sparks, flames and
lighted tobacco away from batteries.
•
Batteries contain acid which burns eyes and
skin on contact. Wear protective clothing. If
acid contacts body, flush well with water. For
eye contact, flush well with water and get immediate medical attention.
906931/0799
MAINTENANCE SCHEDULE
IMPORTANT: Maintenance work must be done at regular intervals. Failure to perform scheduled maintenance
work will result in excessive wear and early machine failures. The following service schedule is a recommended guide for servicing the machine.
Engine
Service Activity
Daily
Clean air filter
✔
Check oil level
✔
Check fuel level
✔
Check for leakage
✔
Perform visual check
✔
Check engine oil
Check coolant
✔
✔
Weekly
Every
50
Hours
Every
125-250
Hours
Every
500
Hours
Every
1000
Hours
✔
Check engine mounting bolts
✔
Check V-belt condition and tension
✔
Clean cooler fins
✔
Check fuel filter
✔
Check exhaust system
✔
Change engine oil and filter
✔*
Annually
✔
✔
✔
Change fuel filter
✔
✔
Check engine speed regulation
✔
Check valve clearance
✔
Check cooling system and hoses
✔
Check electrical connections
✔
Check pre-glow system
✔
Check coolant thermostat
✔
Check generator & starter
✔
Clean fuel tank
✔
Check water pump
✔
* First change only.
PRINTED IN U.S.A.
4-3
906931/0799
MAINTENANCE SCHEDULE (continued)
Hydraulic System
Service Activity
Daily
Check hydraulic oil level
✔
Check system for leakage
✔
Weekly
Check hydraulic pump bolts
✔
Clean cooler fins
✔
Change filter
✔*
Change hydraulic oil
✔*
Every
50
Hours
Every
125-250
Hours
Every
500
Hours
Every
1000
Hours
✔
Check filter
✔
Check hydraulic oil
Check primary & secondary
pressure limiting valves
Check breather filter &
filling strainer
✔
Annually
✔
✔
✔
✔
✔
* First change only.
Electrical System
Service Activity
Check indicator lights
Daily
Weekly
Every
50
Hours
Every
125-250
Hours
Every
500
Hours
Every
1000
Hours
Annually
Every
125-250
Hours
Every
500
Hours
Every
1000
Hours
Annually
✔
✔
Check system function
✔
Check connections
Travelling Gear
Service Activity
Check track after work shift
Check track tension
Daily
Weekly
Every
50
Hours
✔
✔
Check bearing play of track
rollers, track carrier rollers &
front idlers.
PRINTED IN U.S.A.
✔
4-4
906931/0799
Travelling Gear Unit
Service Activity
Daily
Weekly
Every
50
Hours
Every
125-250
Hours
Every
500
Hours
Every
1000
Hours
Annually
✔*
✔
✔
Every
500
Hours
Every
1000
Hours
Annually
✔
Check for leakage
Change final drive gear oil
* First change only.
Gear Ring
Service Activity
Daily
Weekly
Every
50
Hours
Every
125-250
Hours
✔
Change gear ring
✔
Check bearing system
✔
Cab Heating System
Service Activity
Daily
Check fan
✔
Check function
✔
Check heating circuit
for leaks
✔
Check seals
✔
Weekly
Every
50
Hours
Every
125-250
Hours
Every
500
Hours
Every
1000
Hours
Annually
Every
500
Hours
Every
1000
Hours
Annually
Bucket, Boom & Dozer Blade
Service Activity
Daily
Lubricate all points
✔
Check bucket teeth for wear
✔
Check pin fastening
✔
Check line fastenings
✔
Check piston rods
✔
Weekly
Every
50
Hours
Every
125-250
Hours
Check hydraulic cylinder
under load
✔
✔
Check bearing play
PRINTED IN U.S.A.
4-5
906931/0799
MAINTENANCE SCHEDULE (continued)
General
Service Activity
Daily
Check hydraulic system
✔
Check bolts
✔
Check lights
✔
Weekly
Every
125-250
Hours
Every
500
Hours
Every
1000
Hours
Annually
✔
Check windshield wiper system
Check for leaks
Every
50
Hours
✔
LUBRICATION
Lubrication Points
Green Caps–lubricate weekly (points marked with a “W”)
Blue Caps–lubricate daily
W
Superstructure bearing system (W)
W
PRINTED IN U.S.A.
W
W
4-6
906931/0799
ENGINE OIL
BP Vanellus FE, APISF-CD + SAE 10W 40
EXCAVATOR ARM
BP Energrease L 21 M
Gleitmo 805 (for initial lubrication of pins and tension bushings)
HYDRAULIC OIL
BP Energol SHF 46
ALL LUBRICATION POINTS
BP Energrease L 21 M
SLEWING RING
• Gearing: BP Energrease OG
• Ball Bearing: BP Energrease L 21 M
RANGES OF APPLICATIONS
1. from -77°F to +104°F (-25°C to +40°C)
outside temperature
TRAVELLING GEAR UNIT
Gearoil EP 90 API GL 4
2.
SLEWING GEAR UNIT
Gearoil EP 90 API GL 4
NOTE: All listed greases are suitable for
-77°F to +104°F (-25°C to +40°C).
Recommended Lubricants
from -59°F to +104°F (-15°C to +40°C)
outside temperature
ENGINE
NOTE: Be sure to read the engine manual supplied with
this machine.
Checking Engine Oil Level
IMPORTANT: See the lubricant list for engine oil
grade. Only use engine oil specified, or of equivalent quality and grade, or damage to the engine
could occur.
Engine
Valve
The machine must be on a level surface and the engine
turned off.
1.
Run the engine until it is at operating temperature, then
turn the engine off.
2.
Pull the engine cover latch lever (Figure 4-1) and raise
the engine cover.
3.
Check the engine oil level using the dipstick located on
rear of the engine (Figure 4-2).
4.
Add oil if required.
Figure 4-1. Engine Cover Latch Lever
NOTE: The marks on the dipstick indicate the minimum
and maximum oil levels.
Dipstick
Figure 4-2. Engine Oil Dipstick
PRINTED IN U.S.A.
4-7
906931/0799
ENGINE (continued)
Changing Engine Oil & Filter
1.
Place the machine on a level surface. Run the engine
until it is at operating temperature, then turn the engine
off.
2.
Pull the engine cover latch lever (Figure 4-1) and raise
the engine cover.
3.
Remove the drain plug from the oil pan underneath the
engine and allow oil to drain into a container.
4.
Remove the oil filter using a filter wrench.
5.
Clean the filter housing surface. Put a film of clean oil
on the filter gasket. Install the new filter with gasket and
hand tighten.
6.
Reinstall the drain plug.
7.
Remove the oil fill cap from the engine (Figure 4-3).
Pour in new oil. Crankcase capacity is 6.1 qts. (5.7 L).
Reinstall oil fill cap.
8.
Start the engine and let it run for several minutes. Stop
the engine and check for leaks at the oil filter and oil
drain plug.
9.
Check the oil level again and add oil if necessary.
Oil Fill
Oil Filter
Figure 4-3. Engine Oil Fill and Filter
Bolt
Air Cleaner Service
1.
The air cleaner is located under the valve cover. Pull the
valve cover latch lever (Figure 4-1) and raise the valve
cover.
2.
Turn the air cleaner cover bolt (Figure 4-4) to remove
the air cleaner cover and gasket.
3.
Remove the wingnut (Figure 4-5) and remove air cleaner
element.
4.
Clean air cleaner element with compressed air
(Figure 4-5) (300-450 kPa).
5.
Reinstall air cleaner element, wingnut, gasket, and air
cleaner cover. Tighten cover bolt.
6.
Figure 4-4. Engine Air Filter
Air Cleaner Cover
Gasket
Wingnut
Close valve cover.
IMPORTANT: Do not knock the element against
solid object to remove dust. The element may
become distorted and damaged.
Compressed Air
Do not operate engine without the air cleaner element installed or damage to the engine could occur.
Figure 4-5. Servicing Engine Air Filter
PRINTED IN U.S.A.
4-8
906931/0799
FUEL SYSTEM
Filling the Fuel Tank
- +
WARNING
Stop and cool the engine before adding fuel.
NO SMOKING! Failure to obey warnings can
cause an explosion or fire.
Low Fuel
Indicator Light
Fuel Gauge
The fuel level in the tank is indicated by the fuel gauge on
the console (Figure 4-6).
00000000
HOURS
NOTE: When the fuel level reaches 2.5 gal. (2.3 L) the
low fuel indicator light (Figure 4-6) will come on to alert
the operator.
Figure 4-6. Fuel Gauge and Low Fuel Indicator
Injection Pump
Priming Lever
To fill the tank, remove the fuel filler cover located on top of
the valve cover. Fill using diesel fuel with a cetane rating of
over 45. Re-install fuel cap.
NOTE: Never allow fuel tank to run dry or it will be necessary to purge the fuel system of air.
Fuel
Filter
Valve
WARNING
Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around combustibles can cause explosion or fire, which
can result in injury or death.
Fuel Filter
Plastic
Housing
Fuel Filter
Water Separator
Unscrew the clear plastic housing (Figure 4-9) to change the
filter element and clean dirt from the housing. Clean around
the filter housing. Put oil on the seal of the new filter element. Install the fuel filter and hand tighten.
Figure 4-7. Fuel Filter
A B
The fuel system must be purged of air after changing the fuel
filter, or if the fuel tank has been run dry.
Purging Air from the Fuel System
1.
Turn the fuel filter valve (Figure 4-7) to the open position (vertical).
2.
While operating the priming lever on the fuel injector
pump, loosen the air bleeding screw (A, Figure 4-8) on
the fuel filter. When fuel starts flowing from the bleeder
valve (A) without any air, tighten the bleeder screw (A).
3.
E
Fuel Filter Injection
Pump
C
Repeat step 2 for bleeder screws B, C, D and E
(Figure 4-8).
D
Water
Separator
Figure 4-8. Bleeding Air from Fuel System
PRINTED IN U.S.A.
4-9
906931/0799
COOLANT SYSTEM
Checking Coolant Level
1.
Pull the engine cover latch lever (Figure 4-1) and raise
the engine cover.
2.
Check the coolant level in the expansion reservoir
(Figure 4-9).
3.
Full
If low, slowly remove cap and fill reservoir to FULL
line.
Low
WARNING
Engine must be cold. Be careful to avoid
burns when removing the cap. Keep face away
from cap. Cover cap with a cloth, turn cap
slowly to release pressure.
Figure 4-9. Checking Coolant Level
Refer to the engine manual for correct coolant
mixture for your engine.
ELECTRICAL SYSTEM
Fuses
The fuse panel is located on the right arm console
(Figure 4-10).
To replace a fuse, remove the panel cover and pull the old
fuse from the socket. Install a new fuse and re-install the
fuse panel cover.
Fuse Panel
Refer to page 3-3 in Section 3 for fuse identification.
Battery
Figure 4-10. Fuse Panel
WARNING
Batteries contain acid which burns eyes and
skin on contact. Wear safety goggles and protective clothing to keep acid off body.
In case of acid contact, wash immediately with
water for several minutes. In case of eye contact, get medical attention immediately.
The battery is located under the valve cover. To access the
battery, pull the valve cover latch lever (Figure 4-1) and open
the valve cover.
The battery cables must be clean and tight. Remove any acid
or corrosion from the battery and cables using a sodium
bicarbonate and water solution. Cover the battery terminals
and cable ends with battery saver grease.
Battery
Figure 4-11. Battery
The battery is maintenance-free and requires no other service.
PRINTED IN U.S.A.
4-10
906931/0799
IMPORTANT: Damage to the alternator can
occur if:
• Engine is operated with battery cables disconnected.
Using a Booster Battery (Jump Starting)
WARNING
Keep arcs, sparks, flames and lighted tobacco
away from batteries. When jump starting from
booster battery, make final connection (negative) at engine frame.
• Battery cables are connected when using a
fast charger or when welding on the
machine. Remove both cables from the battery.
DO NOT jump start or charge a frozen battery.
Warm battery to 60°F (16°C) before connecting
to a charger. Unplug charger before connecting or disconnecting cables to battery.
• Extra battery cables (booster cables) are
incorrectly connected.
Be very careful when jump starting the machine. Booster
battery must be 12 volt.
1. Turn ignition key to the off position.
Battery gas can explode and cause serious
injury.
IMPORTANT: When jump starting from another
machine, be sure the second machine is not running while using the glow plugs. High voltage
spikes from a running machine can burn out the
glow plugs.
PRINTED IN U.S.A.
4-11
2.
Pull the valve cover latch lever (Figure 4-1) and open
the valve cover.
3.
Connect one end of the cable to the positive (+) terminal on the booster battery. Connect the other end of the
same cable to the positive (+) terminal on the machine
battery.
4.
Connect one end of the second cable to the negative (-)
terminal on the booster battery. Connect the other end of
the same cable to the machine frame.
5.
Start the machine engine. Once the engine is running,
remove the cable connected to the frame first.
Disconnect the other cable from the machine battery
positive (+) terminal.
906931/0799
HYDRAULIC SYSTEM
WARNING
Hydraulic reservoir is under pressure. Avoid
contact with leaking hydraulic fluid or diesel
fuel under pressure. It can penetrate the skin
or eyes and cause severe injury.
Checking Hydraulic Oil Level
1.
Position the machine on a level surface.
2.
Fully extend the bucket and boom. Lower bucket and
dozer blade to the ground (Figure 4-12). Turn off the
machine.
3.
Pull the valve cover latch lever (Figure 4-1) and open
the valve cover to expose the hydraulic oil level indicator (Figure 4-12).
4.
Check the hydraulic oil level indicator (Figure 4-12).
Oil level should be between black and red marks on
sight glass. If hydraulic oil is required, proceed to
step 5.
5.
Remove access panel located on top of valve cover
(Figure 4-13) to expose the hydraulic oil cap.
6.
Slowly open the cap to relieve pressure.
7.
Add hydraulic oil until oil level is between red and black
marks on indicator (Figure 4-12).
8.
Re-install hydraulic tank cap and tighten securely.
9.
Start engine and let idle for a few minutes to build up
pressure.
Black
Mark
Red
Mark
Figure 4-12. Checking Hydraulic Oil Level
10. Check hydraulic functions. Recheck hydraulic oil level.
Figure 4-13. Hydraulic Oil Cap Access Panel
11. Reinstall access panel.
Changing Hydraulic Oil
1.
Position the machine on a level surface.
2.
Fully extend the bucket and boom. Lower bucket and
dozer blade to the ground (Figure 4-12). Turn off the
machine.
3.
Remove access panel located on top of valve cover
(Figure 4-13) to expose the hydraulic oil cap.
4.
Slowly open the cap to relieve pressure (Figure 4-14).
Remove cap and clean strainer of any debris.
Hydraulic Tank Cap w/Strainer
Figure 4-14. Hydraulic Oil Cap w/Strainer
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906931/0799
5.
Open the drain plug (Figure 4-15) and drain oil into a
suitable container. Re-install drain plug and tighten
securely.
Filter
Gasket
IMPORTANT: Always dispose of hydraulic fluids
according to local regulations or take to a recycling
center for proper disposal. DO NOT pour fluids
onto the ground or down a drain.
6.
Remove four bolts and filter cover (Figure 4-15).
Remove and discard old filter. Put clean hydraulic fluid
on the filter gasket and install gasket and new filter into
tank.
7.
Reinstall filter cover and bolts.
8.
Fill tank with hydraulic oil until oil level is between red
and black marks on indicator (Figure 4-12).
9.
Re-install hydraulic tank cap and tighten securely.
Filter Cover
Cap w/Strainer
Filter
10. Start engine and let idle for a few minutes to build up
pressure.
11. Check hydraulic functions. Recheck hydraulic oil level.
12. Reinstall access panel.
Drain Plug
Figure 4-15. Hydraulic Oil Tank
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4-13
906931/0799
TRACK SYSTEM
Changing Final Drive Oil
1.
Position the machine on a level surface with final drive
plugs positioned as shown in POSITION A, Figure 4-16.
Turn off the engine.
2.
Open both plugs and drain oil into a suitable container.
Re-install plugs.
3.
Turn the engine on and move the machine slightly until
plugs are positioned as shown in POSITION B, Figure
4-16. Turn off the engine.
4.
Remove both screw plugs. Pour fresh oil (Gearoil EP 90
API GL 4) into the top hole until oil starts to run out of
the bottom hole.
5.
Re-install both plugs securely.
POSITION A
Screw Plugs in position
for draining oil
POSITION B
Screw Plugs in position
for Filling oil
Figure 4-16 Changing Final Drive Oil
IMPORTANT: Always dispose of oil according to
local regulations or take to a recycling center for
proper disposal. DO NOT pour fluids onto the
ground or down a drain.
Side Plate
Adjusting Track Tension
1.
Position the machine on a level surface.
2.
Use the bucket and dozer blade to lift the unit up until
tracks are just clear of the ground. Turn off the engine.
3.
Remove the side plate from the left track to expose the
adjustment fitting (Figure 4-17).
4.
Using a grease gun, pump grease into the fitting until the
idler wheel is equidistant as shown in Figure 4-17.
Grease Gun
Adjustment
Fitting
Wrench
NOTE: A grease gun is supplied with machine tool kit.
5.
Install side plate.
6.
Repeat steps 4 & 5 for right side track.
7.
Start the engine. Lower the unit to the ground.
Distance Should
Be Equal
Figure 4-17. Track Adjustment
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4-14
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MAINTENANCE LOG
DATE
PRINTED IN U.S.A.
HOURS
SERVICE PROCEDURE
4-15
906931/0799
MAINTENANCE LOG
DATE
PRINTED IN U.S.A.
HOURS
SERVICE PROCEDURE
4-16
906931/0799
TROUBLESHOOTING
GENERAL INFORMATION
WARNING
WARNING
Make sure you are familiar with all safety
devices and controls before operating or servicing the machine. Know how to stop before
starting. This GEHL® Company machine is
designed for use only with GEHL® Company
approved accessories or referral attachments.
The GEHL® Company cannot be responsible for
operator safety if the unit is used with nonapproved attachments.
Read and thoroughly understand all safety
decals before operating the machine. DO NOT
operate the machine unless all factory installed
guards and shields are in place.
CALIFORNIA PROPOSITION
65 WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects and other reproductive harm.
WARNING
Instructions are necessary before operating
and servicing the machine. Read and understand this entire manual. Follow warnings and
instructions for operation and maintenance.
Check for correct function after adjustments or
maintenance. Failure to follow instructions can
result in injury or death.
PRINTED IN U.S.A.
WARNING
Hydraulic reservoir is under pressure. Avoid
contact with leaking hydraulic fluid or diesel
fuel under pressure. It can penetrate the skin
or eyes.
5-1
906931/0999
ENGINE
PROBLEM
Engine will not start.
Insufficient engine power.
POSSIBLE CAUSE
CORRECTIVE ACTION
No fuel.
Add fuel to tank.
Battery power insufficient.
Charge battery or replace if necessary.
Fuel filter contaminated.
Clean fuel filter.
Pre-glow system not working.
Replace pre-glow system (contact authorized
repair center.).
Fuel line leakage.
Replace fuel line.
Air filter contaminated.
Clean air filter.
Engine not at operating temperature.
Warm up the engine.
Engine overheated.
Check cooling system.
INDICATOR LAMPS
PROBLEM
POSSIBLE CAUSE
CORRECTIVE ACTION
Engine oil pressure indicator
light comes on during operation.
Oil pressure too low.
Stop engine immediately. Check oil level and
add oil if necessary. If oil level is correct, oil
pump may be inoperative.
Water temperature display light
comes on during operation.
Oil level too low.
Add oil.
Coolant level too low.
Add coolant.
Fan blades rotate too slowly.
Adjust V-belt tension.
Air filter contaminated.
Clean air filter.
Battery voltage light comes on
during operation.
Alternator not charging properly.
Adjust V-belt tension.
Fuel light comes on.
Insufficient fuel.
Add fuel.
SEALS & HOSES
PROBLEM
POSSIBLE CAUSE
CORRECTIVE ACTION
Oil or fuel leakage under
engine.
Loose hose connections.
Tighten hose connections.
Seals or hoses damaged.
Change seals or hoses and check engine oil level.
Add engine oil if required.
Oil losses from hydraulic
system.
Loose hose fittings.
Tighten hose fittings. Check hydraulic oil level.
Add hydraulic oil if required.
Seals, hoses or lines damaged.
Change seals, hoses and/or lines.
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906931/0999
TRAVELLING GEAR
PROBLEM
POSSIBLE CAUSE
CORRECTIVE ACTION
Machine will not travel in any
direction.
Foreign body jammed in track.
Remove foreign body.
Gears not operative.
Repair gears (contact authorized repair center).
Machine will not travel straight
ahead.
Foreign body jammed in track.
Remove foreign body.
Track tension unequal.
Adjust track tension.
Travel valves damaged.
Repair/replace valves (contact authorized repair
center).
BUCKET, BOOM AND DOZER BLADE
PROBLEM
Slewing chassis is difficult or
impossible.
Equipment does not work or
works only at a low performance level.
Hydraulic cylinders lower too
quickly.
Hydraulic lines overheat.
PRINTED IN U.S.A.
POSSIBLE CAUSE
CORRECTIVE ACTION
Brakes do not release.
Contact authorized repair center.
Insufficient lubrication.
Lubricate slewing ring hose connections.
Slewing motor not operating.
Contact authorized repair center.
Insufficient hydraulic oil.
Fill hydraulic oil reservoir.
Insufficient engine power.
Contact authorized repair center.
Coupling or pump damaged.
Contact authorized repair center.
Pressure limiting valves set too low.
Contact authorized repair center.
Hydraulic cylinder damaged.
Contact authorized repair center.
Control valves damaged.
Contact authorized repair center.
Seals contaminated or damaged.
Contact authorized repair center.
Heavy leakage at control spools.
Contact authorized repair center.
Secondary cartridges damaged.
Contact authorized repair center.
Hydraulic oil filter blocked.
Clean or replace filter.
Insufficient hydraulic oil in oil reservoir.
Fill hydraulic oil reservoir.
Secondary cartridges set too low.
Contact authorized repair center.
Cooling system not in working order.
Clean oil cooler.
5-3
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NOTES
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5-4
906931/0999
®
Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 U.S.A.
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects and other reproductive harm.
906931/0999
© 1999 Gehl Company
All Rights Reserved
PRINTED IN U.S.A.
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