Recommended Lubricants. Gehl 283Z

Figure 4-2) located on the right side of the engine.

2. Check the engine oil level using the dipstick (1,

The acceptable oil level is between the maximum and minimum marks on the dipstick.

3. Add oil, if required, through the oil filler neck (2,

Figure 4-2).

4. Drain excess oil if required .

5. Close the engine hood and confirm it is latched securely.

Minimum

Maximum

1 2

Figure 4-2 – Oil Dipstick and Filler Neck

Locations

Printed in U.S.A.

4-9 918254/BP0112

Changing Engine Oil and Filter

1. Position the machine on a level surface.

IMPORTANT

The machine must be positioned on a level surface for the oil to drain completely.

8. Remove the oil filter (1, Figure 4-4), using a filter

wrench as needed.

2. The engine oil drain plug is accessed from underneath the machine. If necessary, rotate and position the cab/canopy so the engine oil drain

access hole (9, Figure 4-3) is accessible.

3. Perform the “Mandatory Safety Shutdown

Procedure” on page 2-2, but do not allow the

engine to fully cool because warm oil will drain more completely.

4. Open the engine hood (see “Accessing the Engine

machine through hole (9, Figure 4-3) at the bottom

5. Access the oil pan drain plug from underneath the

of the engine compartment.

Figure 4-3 – Engine Oil Drain Access

6. Position a waste oil collection container underneath the access hole and engine oil drain plug.

7. Remove the drain plug from the oil pan and allow the oil to drain into the collection container.

IMPORTANT

Dispose of waste engine oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour waste engine oil onto the ground or down a drain.

Figure 4-4 – Oil Filter Location

9. Clean the filter gasket surface on the engine block.

Put a film of clean oil on the filter gasket.

10. Install the new filter and gasket and hand-tighten.

Once hand-tightened, tighten the filter another 1/4 to 1/2 rotation.

11. Reinstall the drain plug.

12. Clean the area around the oil filler cap (2, Figure 4-

2).

13. Remove the oil filler cap and raise the oil dipstick

(2, Figure 4-4) slightly to allow any trapped air to

escape.

14. Add oil to the engine through the oil filler.

Crankcase capacity with filter is 3.5 qts. (3.3 L).

Do NOT fill crankcase above the MAX mark on the dipstick.

15. Reinstall the oil filler cap.

16. Wait about three minutes to allow the oil to settle

and check the oil level according to “Checking

Engine Oil Level” on page 4-9.

17. Start the engine and let it run for several minutes.

Watch the engine oil light on the control panel. The light should turn off after several seconds. If it does not, shut off the engine, determine the cause and fix the problem before restarting the engine.

18. Stop the engine and check for leaks at the oil filter and oil drain plug. If no leaks are found, close the engine hood and confirm it is latched securely.

918254/BP0112 4-10 Printed in U.S.A.

Engine Air Cleaner

Air Cleaner Dust Valve

Squeeze dust valve (6, Figure 4-5) daily to purge accumulated dust from the air cleaner housing.

Early Machines Later Machines

6. Press button (7, Figure 4-6) on air filter restriction

gauge to reset the gauge.

7. Close the engine hood and confirm it is latched securely.

IMPORTANT

Do not knock air filter elements against a solid object to remove dust. The elements may become distorted and damaged.

IMPORTANT

Do not operate engine without the air cleaner components installed or damage to the engine could occur.

Figure 4-5 – Air Filter Dust Valve

Air Filter Element Replacement

To access the engine air cleaner, open the engine hood

(see “Accessing the Engine Compartment” on page 3-

6). The air filter restriction gauge (1, Figure 4-6) will

read “Service” when the elements require replacement.

7 4

Figure 4-6 – Air Filter Restriction Gauge

To service the elements:

2. Release the bow clips (2, Figure 4-7) to remove the

air cleaner cover and gasket (3).

3. Carefully remove the outer air cleaner element (4).

Carefully remove the inner air cleaner element (5).

4. Clean all contamination (dust) inside the air cleaner housing and cover.

5. Replace the filter elements as required and/or

according to “Maintenance Schedule” on page 4-5.

Install both elements (4 and 5), gasket and air cleaner cover (3). Fasten bow clips (2). Ensure dust valve (6, Figure 4-5) points down.

Printed in U.S.A.

4-11

Figure 4-7 – Air Filter Service

918254/BP0112

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.

IMPORTANT

Unless draining fuel tank for servicing, never operate the machine until the fuel tank is completely empty. The fuel system has to be bled of air whenever the fuel tank is run empty. Always fill the fuel tank after use.

The fuel gauge on the cab console indicates the fuel level in the tank.

1. To fill the tank, swivel lock cover (7, Figure 4-8)

on fuel filler cap (5) and unlock cap (5) using key

(7). Remove cap.

2. Check fuel filler screen (8) for debris, and clean if necessary. Replace screen (8) back into the fuel filler neck.

3. Fill the fuel tank using only high-grade diesel fuel

(rated 1-D or 2-D ASTM D975-94).

4. After fueling, re-install and lock the fuel cap.

Figure 4-8 – Fuel Filler

IMPORTANT

When using the machine in cold weather, make sure to use the proper fuel blend to prevent the fuel filters from “jelling” up. If this happens, the fuel filter and water separator elements will have to be replaced, and the fuel will have to be replaced with the proper fuel.

DANGER

When handling fuel, there is a high risk of fire. Never work on the fuel system around open flames or sparks. DO NOT smoke when working on the fuel system or refueling. Before refueling, turn off the engine and remove the ignition key. Do not refuel in closed rooms. Wipe up fuel spills immediately. Keep the machine clean to reduce the risk of fire.

Fuel Filter

Note: For fuel filter location, see “Engine Compartment

Components” on page 3-6.

cool.

3. Turn fuel shut-off valve lever (1, Figure 4-9) on the

fuel filter to the “OFF” position.

4. Loosen retaining ring (2, Figure 4-9) until the cup

(3, Figure 4-9) can be removed.

918254/BP0112 4-12 Printed in U.S.A.

5. Carefully remove cup (3). Discard any fuel in the cup according to environmental laws. DO NOT pour fuel onto the ground or down a drain.

6. Wash the inside of the cup. Inspect the O-ring (not shown) and replace it if required.

7. Remove and discard the old fuel filter properly.

8. Install a new fuel filter in the cup. Install the cup onto the mounting flange and tighten retaining ring

(2). Hand tighten only.

9. Turn the fuel shut-off valve on the fuel filter to the

“ON” position.

10. Close the engine hood and confirm it is latched securely.

11. Purge air (bleed) from the fuel system according to

“Purging Air from the Fuel System” on page 4-14.

IMPORTANT

Do not turn the ignition key to the start position before bleeding/priming the fuel system. Damage to the starter motor, coils, pinion or ring gear could result.

Water Separator

Note: For water separator location, see “Engine Compart- ment Components” on page 3-6.

The water separator contains a red indicator ring that will float on top of any accumulated water. Under normal conditions, this ring sits at the bottom of the separator. If the red ring is somewhere between the

bottom and the white ring (5, Figure 4-10), then the

accumulated water must be drained.

OFF

Figure 4-9 – Fuel Filter

12. Start the engine and run for one minute. Check the fuel filter for leaks and repair/tighten as necessary.

Figure 4-10 – Water Separator

cool.

3. Turn the fuel shut-off valve lever (4, Figure 4-10)

on the water separator to the “OFF” position.

4. Drain plug (6, Figure 4-10) has a hose connected to

it. Place a container underneath this hose to collect the water. Loosen plug (6) until water begins draining out through the hose. Allow water to drain until the red indicator ring returns to the bottom of the water separator.

5. Tighten the drain plug and discard fuel/water according to environmental laws. DO NOT pour the fuel/water onto the ground or down a drain.

6. Turn the fuel shut-off valve lever (4) on the water separator to the “ON” position.

7. Close the engine hood and confirm it is latched securely.

Printed in U.S.A.

4-13 918254/BP0112

Purging Air from the Fuel System

IMPORTANT

DO NOT bleed/prime the fuel system if the engine is hot. Spilled fuel can cause a fire.

Trapped air must be removed (bled) from the fuel system if the following conditions exist:

• the fuel tank has run dry

• any component in the fuel system was replaced, including the fuel filter element

• the machine has not been operated in a long time

To bleed air from the fuel system:

1. Fill the fuel tank.

2. Verify the fuel shut-off valve levers (1, Figure 4-9 and 4, Figure 4-10) on the fuel filter and the water

separator are both in the “ON” position.

3. Turn the ignition key to the “I” (ON) position.

4. Wait five minutes.

5. Start the engine.

If the engine runs smoothly and then stops, or if it does not run smoothly, switch off the engine and repeat steps 1 through 6. If the engine still does not run smoothly, contact your dealer.

Cooling System

Checking Coolant Level

cool.

Note: The engine must be cold in order to accurately check the coolant level.

Figure 4-11), remove the reservoir cap (1).

3. Check the coolant level in the expansion reservoir.

If the coolant level is at or below the low line (3,

4. Carefully loosen the radiator cap to allow the coolant system to vent. Fill reservoir to FULL line

(2). Refer to “Fluid Capacities/Lubricants” on page 1-4 for the correct coolant type and to

“Coolant Compound Table” on page 1-7 for the

correct coolant mixture. Replace the reservoir cap.

Tighten the radiator cap

5. Close the engine hood and confirm it is latched securely.

Figure 4-11 – Coolant Expansion Reservoir

918254/BP0112 4-14 Printed in U.S.A.

Hydraulic System

WARNING

The hydraulic reservoir is under pressure.

Never use your hands to search for hydraulic fluid leaks; use a piece of paper or cardboard to find leaks. Escaping fluid under pressure can be invisible and can penetrate the skin, causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this procedure, or gangrene may result.

g. Cycle all hydraulic functions and check the oil level at the sight glass. Repeat steps “a” through “f” (excluding b) if oil must be added.

h. Once oil is at the correct level (3, Figure 4-12),

replace the hydraulic valve cover (5) and tighten the hardware securely.

5. Close the engine hood and confirm it is latched securely.

Checking Hydraulic Oil Level

1. Position the machine on a level surface.

2. For an accurate reading, fully extend the bucket and boom. Retract the dipper arm and lower the bucket and dozer blade to the ground. Refer to

Figure 4-12.

Note: See “Engine Compartment Components” on page 3-6

to locate the sight gauge and breather cap described below.

3. Check the hydraulic oil level sight gauge (2, Figure

4-12). Oil level should be approximately at point

(3).

4. If the hydraulic oil level is low:

a. Slowly loosen the breather cap (4, Figure 4-12)

to relieve pressure in the hydraulic system. Retighten the breather cap after relieving pressure.

b. Remove the hydraulic valve cover on the rear

of the machine (5, Figure 4-12) to access the

hydraulic oil filler cap (6).

c. Slowly open and remove the hydraulic oil filler cap (6).

d. Add hydraulic oil until it is at the ideal level

registered at the sight glass (2, Figure 4-12).

e. Replace and tighten the oil filler cap (6).

f. Start the engine and let it idle for a few minutes.

MAX

MIN

Figure 4-12 – Hydraulic Reservoir

Printed in U.S.A.

4-15 918254/BP0112

Changing Hydraulic Oil

1. Position the machine on a level surface. Fully extend the bucket and boom, retract the arm and

position as shown in Figure 4-12.

2. Lower the bucket and dozer blade to the ground.

Perform the “Mandatory Safety Shutdown

3. Open the engine hood (see “Accessing the Engine

4. Slowly loosen the breather cap (3, Figure 4-12) to

relieve pressure in the hydraulic system. Re-tighten the breather cap after relieving pressure.

5. Remove the hydraulic valve cover on the rear of the machine to access the hydraulic oil filler cap.

6. Slowly open and remove the hydraulic oil filler cap

(4, Figure 4-13). Cover the hydraulic oil filler

opening with a clean cloth to prevent contamination.

IMPORTANT

Protect the area from spilled or dripping hydraulic fluid.

7. Open the hydraulic reservoir drain plug and drain the oil into a suitable container. Once drained, reinstall the drain plug and tighten securely.

IMPORTANT

Always dispose of hydraulic fluids according to environmental laws or take to a recycling center for proper disposal. DO

NOT pour onto the ground or down a drain.

Figure 4-13 – Hydraulic System Filter

9. Remove the cloth from the hydraulic oil filler opening and add hydraulic oil until it is at the

correct level (3, Figure 4-12) indicated at the sight

glass.

10. Replace and tighten the hydraulic oil filler cap (4,

Figure 4-13).

11. Start the engine and let it idle for a few minutes.

12. Cycle all hydraulic functions and check the oil level at the sight glass. If oil must be added, repeat the preceding steps except for steps 5 and 7.

13. Replace the hydraulic valve cover. Tighten hardware securely.

14. Close the engine hood and confirm it is latched securely.

Hydraulic Cooling System

See “Engine Compartment Components” on page 3-6

for the hydraulic cooler location. Inspect the cooler for leaks or damage.

8. Remove the hydraulic system filter cover (1, Figure 4-13). Remove and discard old filter. Put clean

hydraulic fluid onto the gasket on a new filter and install the new filter into the filter reservoir.

Replace and tighten filter cover (1).

918254/BP0112 4-16 Printed in U.S.A.

Pilot Valve

IMPORTANT

Hydraulic oil contamination can damage pilot valve control spools. Check the pilot control valve filter/restrictor every 1000 hours and clean if necessary. Replace the filter/restrictor if it is damaged in any way.

Checking Pilot Control Valve Filter:

1. Fully extend the bucket and boom, retract the arm

and position as shown in Figure 4-12.

2. Lower the bucket and dozer blade to the ground.

Perform the “Mandatory Safety Shutdown Procedure” on page 2-2.

3. Open the engine hood (see “Accessing the Engine

4. Slowly loosen the breather cap (4, Figure 4-12) to

relieve pressure in the hydraulic system. Re-tighten the breather cap after relieving pressure.

5. Disconnect the hose connected to the pilot control filter/restrictor fitting (B, Figure 4-14) on the right joystick control valve.

IMPORTANT

Hydraulic oil will leak during this procedure. Place absorbent material under valve to catch leaking oil. Always dispose of hydraulic fluids according to environmental laws or take to a recycling center for proper disposal.

B D

Figure 4-14 Pilot Control Filter/Restrictor

7. Check the filter/restrictor fitting filter screen (C) for contamination/dirt and clean if necessary.

Replace the filter/restrictor if it is damaged.

8. Replace filter/restrictor fitting (B) back into the valve, and reconnect hose to the filter/restrictor

(C). Tighten securely.

9. Repeat steps 5-8 for the left joystick control valve,

checking the filter/restrictors (D).

6. Disconnect the pilot control filter/restrictor fitting

(B) from the valve.

Printed in U.S.A.

4-17 918254/BP0112

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 be immediately repaired or replaced by an authorized service center.

• Never use your hands to check for suspected hydraulic leaks. Always use a piece of wood or cardboard.

• Leaks from hydraulic hoses or pressurized components can be difficult to see, but pressurized oil can have enough force to pierce the skin and cause serious injury.

• Obtain immediate medical attention if pressurized oil pierces the skin. Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

• Always relieve hydraulic system pressure before performing any maintenance on the machine. Do not tighten leaking connections when the hydraulic system is under pressure.

• Never weld or solder damaged or leaking pressure lines and/or screw connections. Always replace damaged hydraulic components.

• Hydraulic hoses must be replaced every six years from the date of manufacture, even if they do not appear damaged.

The date of manufacture (month or quarter and year) is indicated on hydraulic hoses. See Figure 4-15.

Figure 4-15 Hydraulic Hose Manufacture Date

918254/BP0112 4-18 Printed in U.S.A.

Electrical System

Fuses

1. Open the engine hood (see “Accessing the Engine

2. See “Fuses” on page 1-6 to locate and identify the

fuses.

3. To replace a fuse:

a. Perform the “Mandatory Safety Shutdown Procedure” on page 2-2. Wait for the engine to

cool.

b. Remove the panel cover. c. Remove the old fuse from the socket. d. Install a new fuse of the same rating.

IMPORTANT

Determine what caused the fuse to blow and repair the problem before replacing the fuse.

WARNING

Never lay a metal object on top of a battery, because a short circuit can result. Battery acid is harmful to skin and fabrics. If acid spills, follow these first-aid tips:

Immediately remove any clothing on which acid spill.

• If acid contacts skin, rinse the affected area with running water for 10 to 15 minutes.

• If acid contacts eyes, flood eyes with running water for 10 to 15 minutes. See a doctor at once. Never use any medication or eye drops unless prescribed by the doctor.

• To neutralize acid spilled on the floor, use one of the following mixtures:

• 0.5 kg (1 lbs.) of baking soda in 4 L (4 qts.) of water.

• 0.5 L (0.5 qts.) of household ammonia in

4 L (4 qts.) of water.

4. Replace the fuse panel cover.

5. Close the engine hood and confirm it is latched securely.

Battery

WARNING

Before servicing the battery or electrical system, disconnect the negative cable from the negative battery terminal, or if the machine is equipped with a battery disconnect switch, turn the switch to the “OFF” position.

Explosive gas is produced while a battery is in use or being charged. Keep flames or sparks away from the battery area. ALWAYS charge the battery in a well ventilated area.

Do not jump-start a frozen battery, or it may explode. A discharged battery can freeze at

14°F (10°C).

Note: See “Engine Compartment Components” on page 3-6

to locate the battery.

Battery cables must be clean and tight. Remove any acid or corrosion from the battery and cables with a sodium bicarbonate and water solution. Cover the battery terminals and cable ends with battery-saver grease.

Note: The battery is maintenance-free and requires no other service.

IMPORTANT

Damage to the alternator can occur if:

• the engine is operated with the battery cables disconnected,

• the battery cables are connected when using a fast charger or when welding on the machine (When welding on the machine, remove both cables from the battery and ground the welder to the machine frame near the repair area), or

• extra battery cables (booster cables) are connected incorrectly.

Printed in U.S.A.

4-19 918254/BP0112

Using a Booster Battery (Jump-Starting)

WARNING

• Keep arcs, sparks, flames and lighted tobacco away from batteries. When jump-starting from a booster battery, make final connection (negative) at engine frame away from the battery.

Batteries can create flammable gases.

Sparks or open flames can cause this gas, and the battery, to explode.

• 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.

7. Connect the other end of the same cable to the frame of the machine with the discharged battery.

8. Start the engine of the machine with the discharged battery.

9. Once the engine is running, remove the cable connected to the frame first.

10. Disconnect the other cable from the positive (+) terminal on the discharged battery.

11. Remove the cables from the booster battery.

IMPORTANT

DO NOT allow the booster cable ends to touch together when removing them from the batteries. Arcs and direct short circuits can cause severe damage to the electrical systems.

12. Close the engine hood and confirm it is latched securely.

IMPORTANT

When jump-starting from another machine, be sure the second machine is not running if pre-heating the unstarted machine. High voltage spikes from a running machine can burn out the engine pre-heating system.

IMPORTANT

The booster battery must be 12 volt.

III

Discharged

Battery

12 V

1. Turn the ignition key on the machine with the discharged battery to the “P” position (see Figure

4-16).

3. Stop the engine of the machine with the booster battery.

4. Connect one end of a jumper cable to the positive

(+) terminal on the booster battery.

5. Connect the other end of the same cable to the positive (+) terminal on the discharged battery.

6. Connect one end of the second jumper cable to the negative (-) terminal on the booster battery.

Figure 4-16 – Jump-starting

12 V

Booster

Battery

918254/BP0112 4-20 Printed in U.S.A.

Checking & Adjusting V-belt Tension

cool.

3. Inspect the V-belt (1, Figure 4-17) for damage. If

the V-belt is damaged, have it replaced by your dealer.

4. Press on the V-belt to check deflection. The belt should deflect no more than 5/16" (8 mm).

5. If deflection is more than 5/16" (8 mm):

a. Loosen the adjustment bolt (2, Figure 4-17)

and rotate the alternator (3) as necessary until

V-belt tension is correct.

b. Tighten bolt (2) and re-check V-belt tension.

Windshield Washer Fluid

other track. See Figure 4-19.

3. Open the windshield washer reservoir cover (1,

Figure 4-18) and fill the tank with windshield washer fluid.

4. Close the windshield washer tank cover securely.

5. Close the engine hood and confirm it is latched securely.

1 approx. 5/16" (8 mm)

Figure 4-18 – Fluid Reservoir

Figure 4-17 – V-belt Tension

Printed in U.S.A.

4-21 918254/BP0112

Track System

Track Cleaning

If dirt or mud builds up in the track frame, raise the track frame using the boom and dipper arm and then operate the elevated track to clean it. Be sure that the build-up has been cleared from the track. Repeat for the

Position track so drain plugs align vertically

Figure 4-19 – Track Cleaning

Checking the Drive Oil

1. Position the machine on a level surface with drive

plugs positioned as shown in Figure 4-20.

2. Perform the “Mandatory Safety Shutdown

3. Remove the top and center plugs (1 and 2, Figure

4-20).

4. If a slight amount of oil does not flow out of the opening for center plug (2), add oil (Chevron Delo

Gear 80W-90 or BP Transgear 80W-90) into the top opening (1) until oil flows out of center plug opening (2).

5. Re-install plugs (1) and (2).

6. Wipe off any oil that has flowed out and properly dispose of the soiled towel(s).

Figure 4-20 – Plugs for Drive Oil Check/

Change

Changing the Drive Oil

1. Position the machine on a level surface with final

drive plugs positioned as shown in Figure 4-20.

2. Perform the “Mandatory Safety Shutdown

the bottom drain plug (3, Figure 4-20).

3. Place a container to catch draining oil underneath

4. Remove the center plug (2, Figure 4-20).

5. Remove the bottom plug (3) to drain oil into the container. Once all oil has drained, re-install the bottom plug (3).

6. Remove the top drain plug (1, Figure 4-20).

7. Add oil (Chevron Delo Gear 80W-90 or BP

Transgear 80W-90) into top plug (1) until oil begins to flow out of center plug hole(2).

8. Re-install plugs (1) and (2).

9. Wipe off any oil that has flowed out and properly dispose of the soiled towel(s) and drained oil in the container.

IMPORTANT

Always dispose of oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain.

918254/BP0112 4-22 Printed in U.S.A.

Checking and Adjusting Track Tension

1. Position the machine on a level surface.

2. Locate the mark (1, Figure 4-22) on the rubber

track. Move the machine until this mark is at top

center, midway between points A and B (2, Figure

4-22).

3. Use the bucket and dozer blade to lift the unit up until the track is just clear of the ground as shown

in Figure 4-21.

4. Perform the “Mandatory Safety Shutdown