Gehl 383Z Operator's Manual

383Z

Compact Excavator

Beginning Serial Number: AE00465

®

Form No.

918196

Revision D

Sept. 2013

© 2013 All Rights Reserved. • Printed in USA

Operator’s Manual

204937/AP0407

GEHL COMPANY

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.

ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL BE DEEMED
DELETED FROM THIS WARRANTY; ALL OTHER TERMS WILL CONTINUE TO
APPLY.

SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE
WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE
LAW.

GEHL WARRANTY 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, batteries,
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.

TABLE OF CONTENTS

Chapter 1 - General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Ownership Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Excavator Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Fluid Capacities/Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Undercarriage and Swing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Fuse Box Under Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Main Fuse Box with Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Coolant Compound Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Sound Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Load Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Chapter 2 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Attachment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Operational Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Exposure to Crystalline Silica. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Travel Controls May Produce Reversed Travel Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Additional Travel Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Snow, Ice and Cold Temperature Operation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Fire Extinguisher Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Additional Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Hydraulic Cylinder Seal Periodic Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

High Pressure Hydraulic Lines Store Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Operator’s Cab and Swing Frame Deck Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Battery Electrolyte and Explosive Gas Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Battery Disconnection Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Jump-starting or Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Lifting the Machine with a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Printed in U.S.A. i 918196/EP0913

Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

New Decal Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

ISO-Style Safety Decal Locations (Serial Numbers AG04058 and Up) . . . . . . . . . . . . . . . . . 2-11

ISO-Style Information Decal Locations (Serial Numbers AG04058 and Up) . . . . . . . . . . . . . 2-14

ANSI-Style Safety Decal Locations (Serial Numbers AG04057 and Before) . . . . . . . . . . . . . 2-16

Chapter 3 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

SAE/ISO Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

SAE Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

ISO Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Tilting the Cab or Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Throttle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Optional Auto-Idle Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Boom Swivel Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Operator’s Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Ventilation – Cab Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Pre-Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Engine Shut-down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Operating on Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Operating in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Operating in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Operating Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Swiveling the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Excavating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Loading Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Grading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Mounting/Removing Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Auxiliary Hydraulics Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Loading and Transporting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Chapter 4 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

General Information

Care and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Care and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

918196/EP0913 ii Printed in U.S.A.

Maintenance Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Maintenance Label Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Check, Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Fluid and Filter Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Changing Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Checking and Adjusting V-belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Checking and Adjusting Air Conditioning V-belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Track System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Windshield Washer Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Before Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

After Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Chapter 5 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Seals and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Traveling Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Bucket, Boom and Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Printed in U.S.A. iii 918196/EP0913

NOTES

918196/EP0913 iv Printed in U.S.A.

CHAPTER 1 – GENERAL

1

2

INFORMATION

INTRODUCTION

This Operator’s Manual is intended to give the owner/
operator assistance in preparing, adjusting, maintaining
and servicing the machine. More importantly, this
manual provides an operating plan for safe and proper
use of the machine. Major points of safe operation are
detailed in Chapter 2 – Safety.

Read and understand the contents of this manual com­pletely and become familiar with the machine before
attempting to operate it. Contact your dealer to obtain
additional manuals.

Throughout this manual, information is introduced by
the word Note or IMPORTANT. Be sure to read the
message carefully and comply with the message. Fol­lowing this information will improve operating and
maintenance efficiency, help to avoid breakdown and
damage and extend the service life of the machine.

Do not use the machine for any application or purpose
other than described in this manual. Consult your
dealer before using special attachments or equipment
not approved for use with the machine. Any person
making unauthorized modifications is responsible for
the consequences.

The Gehl dealer network stands ready to provide any
assistance you may require, including genuine Gehl
service parts. All service parts should be obtained from
your dealer. Give complete information about the part
and include the model and serial number of the
machine. Record the serial number in the following
space, as a handy reference.

Purchased from:______________________________

Date of Purchase: ____________________________

Model No.: _________________________________

Serial No.: __________________________________

Serial Number Location

The machine serial number plate (1, Figure 1-1) is
located on the front frame, below the operator’s cab.
The cab/canopy serial number (2) is located on the right
rear of the frame next to the rear window.

The use of the machine is subject to certain hazards
that cannot be eliminated by mechanical means – only
by exercising intelligence, care and common sense.
Such hazards include, but are not limited to: hillside
operation, overloading, load stability, poor mainte­nance and use of the machine for purposes for which it
was not intended or designed.

It is essential to have competent and careful operators,
not physically or mentally impaired, who are thor­oughly trained in safe operation and proper load han­dling.

It is recommended that operators be capable of obtain­ing a valid motor vehicle operator’s license.

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
secured in the proper operating positions BEFORE
starting the engine to operate the machine.

Manitou Americas, Inc. 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.

Figure 1-1 Serial Number Locations

Printed in U.S.A. 1-1 918196/EP0913

Engine Serial Number Locations

Engine serial number label

Excavators serial numbers AG00573 and up

Engine serial number label

Excavators serial numbers AG00572 and before

The engine serial number label is located on the cylin­der head cover.

Ownership Change

If this machine was purchased “used,” or if the owner’s
address has changed, please provide your dealer or the
Gehl Company Service Department with the owner’s
name and current address, along with the machine
model and serial numbers. This will allow the regis­tered owner information to be updated, so that the
owner can be notified directly in case of an important
product issue, such as a safety update program.

Figure 1-2 Engine Serial Number Location

918196/EP0913 1-2 Printed in U.S.A.

EXCAVATOR COMPONENT IDENTIFICATION

Operator’s Seat

Boom

Dipper Arm Cylinder

Boom Light

Boom Cylinder

Auxiliary Hydraulics

Connections

Dipper Arm

Bucket

Cylinder

Bucket

Swing Cylinder

Dozer Blade

Track Tension

Lubrication Point

Engine

Cover

Track Frame

Travel Drive

Motor

Swing

Frame /

Super-

structure

Figure 1-3 Component Names

Printed in U.S.A. 1-3 918196/EP0913

SPECIFICATIONS

Fluid Capacities/Lubricants

Note: Capacities indicated are approximate.

Component/Applica-

tion

Lubricant Specification Season/Temper-

ature

Capacity

a

SAE 10W-40 (according to

Diesel Engine

Engine Oil

b

DIN 51502); API: CD, CF,

CF-4, CI-4

-4°F (-20°C)

+104°F (+40°C)

7.5 qts. (7.1 L)

SAE E3, E4, E5

Travelling Drive Gear­box Oil

Hydraulic Oil Tank

Gearbox Oil

Hydraulic Oil

c

d

Biodegradable Oil

e

Q8 T 55, SAE80W-90

FINA PONTONIC GLS

SAE80W-90

HVLP46 (according to DIN

51524 section 3)

PANOLIN HLP Synth 46

FINA BIOHYDRAN SE 46

Year-round

About 0.3 gal.

(1.3 L) each

Year-round 11.9 gal. (45 L)

BP BIOHYD SE-46

Grease

Grease Zerks

Battery Terminals

Roller and Friction

Bearings

Open Gear (live ring

gears)

Multipurpose Grease

Acid-proof Grease

FINA Energrease L21M

Year-round As Required

BP Energrease MP-MG2

f

FINA Energrease L21M Year-round As Required

g

FINA Marson L2 Year-round As Required

No. 2-D, DIN 51601 grade Over 39°F (4°C)

Diesel FuelTank Diesel Fuel

Engine and Hydraulic
Oil Cooler

Coolant Water + antifreeze; SP-C Year-round 1.8 gal. (5.5 L)

Refrigerating Agent R134a

Air Conditioning

Compressor Oil Sanden SP10

No. 1-D, DIN 51601 grade

Below 39°F

(4°C)

Year-round

11.6 gal. (44 L)

1.7 lbs. (750 g)

3

7.1 in

(116.5 cm3)

Windshield Washer Cleaning Agent Water + Antifreeze Year-round 5.3 gal. (2 L)

a. Capacities shown are approximate; use only oil level check to determine correct oil level
b. BP Vanellus MG 15W40, BP Vanellus C-Extra 10W30, Chevron Delo 400 15W40 or equivalent; Refer to engine operator’s manual for more

detailed information about recommended oil grade type use depending upon ambient temperature.
c. Hypoid gearbox oil based on basic mineral oil (API GL-4, GL-5)
d. Mobile DTE15M, Amoco Rykon 46, BP Energol HLP-HD 46 or equivalent
e. Hydraulic ester oils (HEES)
f. FINA Energrease 21M, Chevron RPM Heavy-Duty Grease No. 2, Mobilgrease Moly 52, or BP Energrease Moly EP2
g. Standard acid-proof grease

918196/EP0913 1-4 Printed in U.S.A.

Engine

Engine Model Yanmar 3TNV88-PNS

EPA Tier 2

Serial Numbers AE00465-

AG00572

Yanmar 3TNV88-BPNS

EPA Tier 3

Serial Numbers AG00573

and up
Type Water-cooled 3-cylinder Diesel Engine
Displacement 100.2 cu. in. (1.6 L)
Bore and Stroke 3.5 x 3.5 in. (88 x 90 mm)
Horsepower (DIN) 28.8 hp (21.5 kW) @ 2400 rpm
Max. Torque 81 lb.-ft. (110 Nm) @ 1100

rpm

81 lb.-ft. (110 Nm) @ 1000

rpm
Max. Speed (with no load) 2500 +/- 25 rpm
Idle Speed 1100 +/- 50 rpm
Fuel Injection System Direct Injection
Starting Aid Glow Plug (preheating time

10-15 seconds)

Glow Elements (preheating

time 10-15 seconds)

Max. Inclined Angle (engine still supplied with oil) 25° in all directions

Note: This is exceeded by the machine’s theoretical climbing

ability (30°/ 58%)!

Exhaust Emission Compliance 97/68/EC Tier 2; U.S. EPA 97/68/EC Tier 3; U.S. EPA

Tier 4 interim
Engine Oil Capacity 7.5 qts. (7.1 L)
Engine Coolant Capacity 5.8 qts. (5.5 L)

Hydraulic System

Pump Two Variable-capacity + Two Gear Pumps
Flow Rate 2 x 10.6 gpm + 7 gpm + 3.0 gpm at 2500 rpm

(2 x 40 L/min + 26.3 L/min +11.3 L/min) at

2500 rpm
Operating Pressure (working and driving) 3481 +/- 73 psi (240 +/-5 bar)
Operating Pressure (swing unit) 3045 psi (210 bar)
Operating Pressure (boom/bucket/dipper arm) 3481 +/- 44 psi (240 +/-3 bar)
Operating Pressure (dozer blade) 3045 +/- 44 psi (210 +/-3 bar)
Hydraulic Fluid Cooler Standard
Hydraulic Reservoir (system capacity) 11.8 gal. (45 L)
Filter Return Filter

Printed in U.S.A. 1-5 918196/EP0913

Undercarriage and Swing System

Travel Speed

Low Speed 1.7 mph (2.8 km/h)

High Speed 2.9 mph (4.6 km/h)
Ground Clearance 11” (280 mm)
Swing Speed 8.8 rpm
Gradability 30

° (58%)

Rubber Track Width 12” (300 mm)
Number of Track Rollers 4 per side
Average Ground Pressure

4.8 psi (0.34 kg/cm

Dozer Blade

Width 68.5” (1740 mm)
Height 13.5” (345 mm)
Maximum Lift Above Ground 15” (390 mm)
Maximum Depth Below Ground 18” (450 mm)

Electrical System

2

)

Alternator 12-V, 55-A
Starter 12-V, 1.7-kW
Battery 12-V, 71-Ah, Group Size 91; 640 CCA
Socket 15-A max. - Accessory Socket (Cigarette

Lighter)

918196/EP0913 1-6 Printed in U.S.A.

Fuse Box Under Seat

F3

F4

F8

F9

F10

F5 F6 F7

F2

F1

K5

K9

Fuse No. Rated Current Protected Circuit

F3 10 Amp Indicators, Engine Relay, Cutoff

Solenoid
F4 10 Amp Boom Light
F5 15 Amp Roof Lights
F6 10 Amp s, Horn
F7 15 Amp Heating, Air Conditioning
F8 10 Amp Windshield Wiper, Interior Light
F9 10 Amp Rotating Beacon, Radio, Drive Inter-

lock
F10 15 Amp Socket, Cigarette Lighter

Main Fuse Box with Relays

(located in the upper left inside the engine compartment)

Printed in U.S.A. 1-7 918196/EP0913

Fuse No. Rated Current Protected Circuit

F1 40 Amp Start, Preheat, Cutoff Solenoid
F2 50 Amp Main fuse, Ignition Lock

Fuse No. Protected Circuit

K9 Cutoff Solenoid
K5 Preheating

Relays

K7

V1

K6

K81

(located in the upper left inside the engine compartment)

Relay No. Protected Circuit

K6 Preheating Timer
K7 Starting Relay
K8 Cutoff Solenoid
V1 Diode

Coolant Compound Table

Outside temperature

Up to °F (°C)

39 (4) 99

Water Anticorrosion agent Antifreeze agent

% by vol-

ume

Coolant: Halvoline XLC (based on ethylene glycol)

in³/gal (cm³/L) % by volume % by volume

–

14 (-10) 79 20

-4 (-20) 65 34

2.6 (10) 1

-13 (-25) 59 40

-22(-30) 55 44

Sound Levels

Sound Power 95 dB(A)
Sound Pressure 75 dB(A)

Vibration

Effective acceleration value for the upper extremities of the body*

Effective acceleration value for the body*

<2.5 m/s

<0.5 m/s

*Measurements per 2002/44/EC. Machine and attachment operation and maintenance per the Operator’s Manual.

2

2

918196/EP0913 1-8 Printed in U.S.A.

General Specifications

8’2” (2500 mm)

1’2”

6’10” (2075 mm)

9’0” (2725 mm)

8’2” (2500 mm)

5’9” (1740 mm)

3’9” (1140 mm)

15’9” (4800 mm)

2’10”

10’4” (3158 mm)

(345 mm)

(870 mm)

1’0”
(300 mm)

1’0”

(300 mm)

Weight (with cab) 8003 lbs. (3630 kg)
Weight (with canopy) 7826 lbs. (3550 kg)
Height 8’2” (2500 mm)
Width 5’8” (1740 mm)
Transport length 15’9” (4800 mm)
Dipper arm length (Optional Short Arm) 4’7” (1400) mm
Dipper arm length (Standard Long Arm) 5’5” (1650 mm)
Max. digging depth w/ Optional Short Arm 10’2” (3110 mm)
Max. digging depth w/ Standard Long Arm 11’0” (3360 mm)
Max. vertical digging depth w/ Optional Short Arm 8’0” (2430 mm)
Max. vertical digging depth w/ Standard Long Arm 8’9” (2670 mm)
Max. digging height w/ Optional Short Arm 14’10” (4530 mm)
Max. digging height w/ Standard Long Arm 15’3” (4660 mm)
Max. dump height w/ Optional Short Arm 10’7” (3220 mm)
Max. dump height w/ Standard Long Arm 11’0” (3350 mm)
Max. digging radius w/ Optional Short Arm 17’5” (5300 mm)
Max. digging radius w/ Standard Long Arm 18’2” (5540 mm)
Max. reach at ground level w/ Optional Short Arm 17’5” (5300 mm)
Max. reach at ground level w/ Standard Long Arm 17’10” (5430 mm)
Max. breakout force at bucket tooth 5778 lbf (25.7 kN)
Max. tearout force (Optional Short Arm) 4923 lbf (21.9 kN)
Max. tearout force (Standard Long Arm) 4383 lbf (19.5 kN)
Min. tail end swiveling radius 2’10” (870 mm)
Max. tail end lateral projection over tracks 0’0” (0 mm)
Max. boom distance to bucket center (right side) 2’5” (739 mm)
Max. boom distance to bucket center (left side) 1’11” (590 mm)
Max. boom swivel angle (left side) 70°
Max. boom swivel angle (right side) 55°

1'11"

(590 mm)

55°

70°

5'9"

(1740 mm)

2'5"

(739 mm)

R2'10"

(87

0 mm)

Printed in U.S.A. 1-9 918196/EP0913

Load Diagrams

Maximum permissible loads (standard long dipper arm)

All table values are in lbs. (kg) and for a machine in a horizontal position on
firm ground without bucket.

If equipped with a bucket or other implements, lift capacity or tilt load is
reduced by bucket or implement weight.

Calculation basis: According to ISO 10567.

The excavator's lift capacity is restricted by the settings of the pressure relief
s and the hydraulic system's stabilizing features.

Neither 75% of the static tilt load nor 87% of the hydraulic lift capacity is
exceeded.

16'3"

(5.0 m)

13'0"

(4.0 m)

13'0"

(4.0 m)

9'9"

(3.0 m)

6'6"

(2.0 m)

3'3"

(1.0 m)

0'0"

(0 m)

-3'3"

(-1.0 m)

-6'6"

(-2.0 m)

9'9"

(3.0 m)

9'9"

(3.0 m)

6'6"

(2.0 m)

3'3"

(1.0 m)

0'0"

(0 m)

16'3"

(5.0 m)

13'0"

(4.0 m)

9'9"

(3.0 m)

6'6"

(2.0 m)

3'3"

(1.0 m)

0'0"

(0 m)

14’9”

(4.5 m)

11’6”

(3.5 m)

8’2”

(2.5 m)

9’9”

(3.0 m)

6’6”

(2.0 m)

1554*

(705*)

937

(425)

1477*

(670*)

1422

(645)

3’3”

(1.0 m)

1664*

(755*)

794

(360)

1742*

(790)

904

(410)

2127*

(965*)

1323

(600)

3351*

(1520*)

2172

(985)

0’0”

(0.0 m)

1653*

(750*)

772

(350)

1863*

(845*)

871

(395)

2579*

(1170*)

1246

(565)

4354*

(1975*)

2006

(910)

-3’3”

(-1.0 m)

2590*

(1175*)

1213

(550)

4233*

(1920*)

1973

(895)

-6’6”

(-2.0 m)

3461*

(1570*)

2017

(915)

Maximum permissible load on extended dipper arm
A Overhang from the center of the turntable
B Height of load fixing point
* Lifting capacity hydraulically limited

Dozer blade support in drive direction

Dozer blade support 90° to drive direction

MAX

B

A

Figure 1-4 Standard Long Dipper Arm
Load Diagram

918196/EP0913 1-10 Printed in U.S.A.

Figure 1-5 Standard Long Dipper Arm

Max. permissible loads (long dipper arm / counterweight)

All table values are in lbs. (kg) and for a machine in a horizontal position on
firm ground without bucket.

If equipped with a bucket or other implements, lift capacity or tilt load is
reduced by bucket or implement weight.

Calculation basis: According to ISO 10567.

The excavator's lift capacity is restricted by the settings of the pressure relief
s and the hydraulic system's stabilizing features.

Neither 75% of the static tilt load nor 87% of the hydraulic lift capacity is
exceeded.

16'3"

(5.0 m)

13'0"

(4.0 m)

13'0"

(4.0 m)

9'9"

(3.0 m)

6'6"

(2.0 m)

3'3"

(1.0 m)

0'0"

(0 m)

-3'3"

(-1.0 m)

-6'6"

(-2.0 m)

9'9"

(3.0 m)

9'9"

(3.0 m)

6'6"

(2.0 m)

3'3"

(1.0 m)

0'0"

(0 m)

16'3"

(5.0 m)

13'0"

(4.0 m)

9'9"

(3.0 m)

6'6"

(2.0 m)

3'3"

(1.0 m)

0'0"

(0 m)

14’9”

(4.5 m)

11’6”

(3.5 m)

8’2”

(2.5 m)

9’9”

(3.0 m)

6’6”

(2.0 m)

1554*

(705*)

1047

(475)

1477*

(670*)

1477*
(670*)

3’3”

(1.0 m)

1664*

(755*)

893

(405)

1742*

(790*)

1014

(460)

2127*

(965*)

1477

(670)

3351*

(1520*)

2414

(1095)

0’0”

(0.0 m)

1653*

(750*)

882

(400)

1863*

(845*)

981

(445)

2579*

(1170*)

1400

(635)

4354*

(1975*)

2249

(1020)

-3’3”

(-1.0 m)

2590*

(1175*)

1367

(620)

4233*

(1920*)

2216

(1005)

-6’6”

(-2.0 m)

3461*

(1570*)

2260

(1025)

Maximum permissible load on extended dipper arm
A Overhang from the center of the turntable
B Height of load fixing point
* Lifting capacity hydraulically limited

Dozer blade support in drive direction

Dozer blade support 90° to drive direction

MAX

B

A

with Counterweight Load Diagram

Printed in U.S.A. 1-11 918196/EP0913

Figure 1-6 Optional Short Dipper Arm

Maximum permissible loads (short dipper arm)

All table values are in lbs. (kg) and for a machine in a horizontal position on
firm ground without bucket.

If equipped with a bucket or other implements, lift capacity or tilt load is
reduced by bucket or implement weight.

Calculation basis: According to ISO 10567.

The excavator's lift capacity is restricted by the settings of the pressure relief
s and the hydraulic system's stabilizing features.

Neither 75% of the static tilt load nor 87% of the hydraulic lift capacity is
exceeded.

16'3"

(5.0 m)

13'0"

(4.0 m)

13'0"

(4.0 m)

9'9"

(3.0 m)

6'6"

(2.0 m)

3'3"

(1.0 m)

0'0"
(0 m)

-3'3"

(-1.0 m)

-6'6"

(-2.0 m)

9'9"

(3.0 m)

9'9"

(3.0 m)

6'6"

(2.0 m)

3'3"

(1.0 m)

0'0"

(0 m)

16'3"

(5.0 m)

13'0"

(4.0 m)

9'9"

(3.0 m)

6'6"

(2.0 m)

3'3"

(1.0 m)

0'0"

(0 m)

14’9”

(4.5 m)

11’6”

(3.5 m)

8’2”

(2.5 m)

9’9”

(3.0 m)

1455*

(660*)

1455*
(660*)

6’6”

(2.0 m)

1742*

(790*)

937

(425)

1731*

(785*)

1411

(640)

3’3”

(1.0 m)

1819*

(825*)

871

(395)

1852*

(840)

904

(410)

2315*

(1050*)

1323

(600)

3825*

(1735*)

2150

(975)

0’0”

(0.0 m)

1775*

(805*)

849

(385)

1885*

(855*)

882

(400)

2668*

(1210*)

1257

(570)

4464*

(2025*)

2039

(925)

-3’3”

(-1.0 m)

2557*

(1160*)

1246

(565)

4134*

(1875*)

2017

(915)

-6’6”

(-2.0 m)

3175*

(1440*)

2083

(945)

Maximum permissible load on extended dipper arm
A Overhang from the center of the turntable
B Height of load fixing point
* Lifting capacity hydraulically limited

Dozer blade support in drive direction

Dozer blade support 90° to drive direction

MAX

B

A

Load Diagram

918196/EP0913 1-12 Printed in U.S.A.

Figure 1-7 Optional Short Dipper Arm

Max. permissible loads (short dipper arm / counterweight)

All table values are in lbs. (kg) and for a machine in a horizontal position on
firm ground without bucket.

If equipped with a bucket or other implements, lift capacity or tilt load is
reduced by bucket or implement weight.

Calculation basis: According to ISO 10567.

The excavator's lift capacity is restricted by the settings of the pressure relief
s and the hydraulic system's stabilizing features.

Neither 75% of the static tilt load nor 87% of the hydraulic lift capacity is
exceeded.

16'3"

(5.0 m)

13'0"

(4.0 m)

13'0"
(4.0 m)

9'9"

(3.0 m)

6'6"

(2.0 m)

3'3"

(1.0 m)

0'0"

(0 m)

-3'3"

(-1.0 m)

-6'6"

(-2.0 m)

9'9"

(3.0 m)

9'9"

(3.0 m)

6'6"

(2.0 m)

3'3"

(1.0 m)

0'0"

(0 m)

16'3"

(5.0 m)

13'0"

(4.0 m)

9'9"

(3.0 m)

6'6"

(2.0 m)

3'3"

(1.0 m)

0'0"

(0 m)

14’9”

(4.5 m)

11’6”

(3.5 m)

8’2”

(2.5 m)

9’9”

(3.0 m)

1455*

(660*)

1455

(660)

6’6”

(2.0 m)

1742*

(790*)

1058

(480)

1731*

(785*)

1576

(715)

3’3”

(1.0 m)

1819*

(825*)

992

(450)

1852*

(840*)

1025

(465)

2315*

(1050*)

1488

(675)

3825*

(1735*)

2414

(1095)

0’0”

(0.0 m)

1715*

(805*)

970

(440)

1885*

(855*)

1003

(455)

2668*

(1210*)

1422

(645)

4464*

(2025*)

2293

(1040)

-3’3”

(-1.0 m)

2557*

(1160*)

1411

(640)

4134*

(1875*)

2282

(1035)

-6’6”

(-2.0 m)

3175*

(1440*)

2337

(1060)

Maximum permissible load on extended dipper arm
A Overhang from the center of the turntable
B Height of load fixing point
* Lifting capacity hydraulically limited

Dozer blade support in drive direction

Dozer blade support 90° to drive direction

MAX

B

A

with Counterweight Load Diagram

Printed in U.S.A. 1-13 918196/EP0913

IMPORTANT

CHECKLISTS

Pre-Delivery Checklist

The following checklist is an important reminder of
valuable information and inspections that MUST be
made before delivering the machine to the customer.
Check off each item after the prescribed action is taken.

 CHECK THAT:

 Machine 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. Be sure

cable connections are tight.

 Cylinders, hoses and fittings are not damaged, leaking or

loosely connected.

 Coolant/radiator hoses and fittings are not damaged,

leaking or loosely connected. Coolant system is filled to
the proper level and has proper antifreeze protection.

 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

motors are filled to their proper levels.

 All adjustments are made to comply with settings

provided in Chapter 4 – Maintenance of this manual.

 All guards, shields and decals are in place and secured.

 Model and serial numbers for the machine are recorded

in the space provided on this page and on page 1-1.

Start the engine and test run the unit while
checking that all controls operate properly.

I acknowledge the pre-delivery procedures were performed
on this unit as outlined on this page.

________________________________________________

Dealership’s Name

________________________________________________

Dealer Representative’s Name

________________________________________________

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 and Operation chapters of this manual,

regarding the safe operation of the machine.

 The Maintenance and Troubleshooting chapters for

information regarding the proper maintenance of the
machine. Explain that regular lubrication and
maintenance is required for continued safe operation and
long machine life.

 Give this Operator’s Manual and the AEM Compact

Excavator Safety Manual to the customer and instruct
the customer to read and completely understand the
contents before operating the machine.

 Complete the Owner’s Registration, including

customer’s signature and return it to Manitou Americas,
Inc..



CHECK THAT:

 Drive controls and boom/arm/bucket/dozer blade/swing/

pivot controls operate properly and are not damaged or
binding.

 Drive controls are properly adjusted for correct neutral

position.

 The parking and travelling gear brake, along with the

lock-out devices, are activated with the machine
stationary (no pilot control pressure).

 All hydraulic functions are NOT operational with the

left control console in the raised lock-out position.

 All instrument panel gauges, indicator lights, etc.

function properly and all installed lights, such as work
lights, function properly.

918196/EP0913 1-14 Printed in U.S.A.

 Explain that a copy of the product warranty is included

on the inside front cover of this Operator’s Manual.

________________________________________________

Customer’s Signature

________________________________________________

Date Delivered

RETAIN FOR CUSTOMER’S RECORDS

IMPORTANT

CHECKLISTS

Remove dealer’s file copy at perforation.

Pre-Delivery Checklist

The following checklist is an important reminder of
valuable information and inspections that MUST be
made before delivering the machine to the customer.
Check off each item after the prescribed action is taken.

 CHECK THAT:

 Machine 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. Be sure

cable connections are tight.

 Cylinders, hoses and fittings are not damaged, leaking

or loosely connected.

 Coolant/radiator hoses and fittings are not damaged,

leaking or loosely connected. Coolant system is filled to
the proper level and has proper antifreeze protection.

 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

motors are filled to their proper levels.

 All adjustments are made to comply with settings

provided in Chapter 4 – Maintenance of this manual.

 All guards, shields and decals are in place and secured.

 Model and serial numbers for the machine are recorded

in the space provided on this page and on page 1-1.

Start the engine and test run the unit while
checking that all controls operate properly.



CHECK THAT:

I acknowledge the pre-delivery procedures were performed
on this unit as outlined on this page.

_______________________________________________

Dealership’s Name

_______________________________________________

Dealer Representative’s Name

_______________________________________________

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 and Operation chapters of this manual,

regarding the safe operation of the machine.

 The Maintenance and Troubleshooting chapters for

information regarding the proper maintenance of the
machine. Explain that regular lubrication and
maintenance is required for continued safe operation
and long machine life.

 Give this Operator’s Manual and the AEM Compact

Excavator Safety Manual to the customer and instruct
the customer to read and completely understand the
contents before operating the machine.

 Completely fill out the Owner’s Registration, including

customer’s signature and return it to the Gehl Company.

 Explain that a copy of the product warranty is included

on the inside front cover of this Operator’s Manual.

 Drive controls and boom/arm/bucket/dozer blade/swing/

pivot controls operate properly and are not damaged or
binding.

 Drive controls are properly adjusted for correct neutral

position.

 The parking and travelling gear brake, along with the

lock-out devices, are activated with the machine
stationary (no pilot control pressure).

 All hydraulic functions are NOT operational with the

left control console in the raised lock-out position.

 All instrument panel gauges, indicator lights, etc.

function properly and all installed lights, such as work
lights, function properly.

Printed in U.S.A. 1-15 918196/EP0913

_______________________________________________

Customer’s Signature

_______________________________________________

Date Delivered

RETAIN FOR DEALER’S RECORDS

INTENTIONALLY BLANK

(To be removed as dealer’s file copy)

918196/EP0913 1-16 Printed in U.S.A.

CHAPTER 2 – SAFETY

DANGER

WARNING

CAUTION

IMPORTANT

GENERAL SAFETY
INFORMATION

Manitou Americas, Inc, in cooperation with the Society
of Automotive Engineers (SAE), has adopted this

safety alert symbol: This warning symbol, used
with a “signal word,” indicates situations or conditions
that can cause injury or death if precautions are not fol­lowed. The signal words used with the safety alert sym­bol are:

“IMPORTANT” is used to draw attention to
a procedure that must to be followed to pre­vent machine damage.

GENERAL SAFETY RULES

“CAUTION,” “WA R N IN G ,” and “DANGER,”
which indicate the level of risk and severity of hazards.
All three levels indicate that safety is involved.
Observe the precautions whenever you see the safety
alert symbol, no matter which signal word is used.

The following signal words are used throughout this
manual and on decals on the machine to warn of
potential hazards:

“DANGER” indicates an imminently hazard­ous situation, which, if not avoided, will
result in death or serious injury.

“WARNING” indicates a potentially hazard­ous situation, which, if not avoided, could
result in death or serious injury.

Before operating the machine, first read and study the
safety information in this manual. Be sure that anyone
who operates or works on the machine is familiar with
the safety precautions. This includes providing
translations of the warnings and instructions for
operators who are not fluent in reading English.

It is essential that operators be thoroughly trained in the
safe operation of the machine and handling loads.
Operators must not be physically or mentally impaired.
Do not allow minors or unqualified personnel to
operate the machine, or to be near the machine unless
they are properly supervised. It is recommended that
the operator be capable of obtaining a valid motor
vehicle operator’s license.

Only trained and authorized personnel, with a full
awareness of safe procedures, should be allowed to
operate or perform maintenance or service on the
excavator.

Read the operator’s manual provided with each
attachment before using it.

Use of the machine is subject to certain hazards that
cannot be eliminated by mechanical means, but only by
exercising intelligence, care and common sense. Such
hazards include: hillside operation, overloading, load
instability, poor maintenance, and using the machine
for a purpose for which it was not intended or designed.

“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 918196/EP0913

Manitou Americas, Inc. always takes operator’s safety
into consideration during the design process. Guards
and shields are provided, which protect the operator
and bystanders from moving parts and other hazards.
Operators must be alert, however, because some areas
cannot be guarded or shielded without preventing or
interfering with proper operation.

Different applications may require optional safety
equipment. Users must evaluate the worksite hazards
and equip the machine and the operator as necessary.
The information in this manual does not replace any
applicable safety rules and laws. Before operating the
machine, learn the rules and laws for the local area.
Make sure the machine is equipped as required
according to these rules/laws.

Remember that some risks to your health may not be
immediately apparent. Exhaust gases and noise
pollution may not be visible, but these hazards can
cause permanent injuries.

Some photographs in this manual may show doors,
guards and shields open or removed for the purposes of
illustration only. Be sure all doors, guards, shields and
panels are in the proper operating positions before
starting the engine to operate the machine.

Do not modify the Falling Object Protective Structure
(“FOPS”) unless instructed to do so in approved instal­lation instructions. Modifications, such as welding,
drilling or cutting, can weaken the structure and reduce
the protection it provides. A damaged protective struc­ture cannot be repaired – it must be replaced.

For safety reasons, use only genuine replacment ser­vice parts. For example, using incorrect fasteners could
lead to a condition in which the safety of critical
assemblies is dangerously compromised.

For safety reasons, use only genuine replacement ser­vice parts. For example, using incorrect fasteners could
lead to a condition in which the safety of critical
assemblies is dangerously compromised.

Attachment Precautions

Optional kits are available through your dealer. Contact
your dealer or the Manitou Americas, Inc. service
department for information on available one-way (sin­gle-acting) and two-way (double-acting) piping/valv­ing/auxiliary control kits. Because Manitou Americas,
Inc. cannot anticipate, identify and test all of the attach­ments that owners may want to install on their
machines, please contact Manitou Americas, Inc. for
information on approval of attachments, and their com­patibility with optional kits.

MANDATORY SAFETY SHUTDOWN
PROCEDURE

Before leaving the machine:

1. Bring the machine to a complete stop on a level
surface. Avoid parking on an incline or a hillside,
but if this is not possible, park across the slope;
place chocks under the tracks to prevent the
machine from moving.

2. Lower the working equipment to the ground and
support it securely.

The machine is designed and intended to be used only
with approved attachments. To avoid possible personal
injury, equipment damage or performance problems,
use only attachments that are approved for use on and
within the rated operating capacity of the machine.
Contact your dealer or the Manitou Americas, Inc. ser­vice department for information about attachment
approval and compatibility with specific machine mod­els. Manitou Americas, Inc. cannot be responsible if
the machine is used with non-approved attachments.

Do not use the machine for any application or purpose
other than described in this manual.

Unauthorized Modifications

Any machine modification made without authorization
from Manitou Americas, Inc. could create a safety haz­ard, for which the machine owner would be responsi­ble.

3. Run the engine at idle speed for a few minutes to
allow systems to cool after operation at full speed.

4. Turn the key fully counter-clockwise to shut off the
engine. Wait for all movement to stop.

5. Move the joysticks in all directions to verify the
hydraulic system is de-pressurized.

6. Lock out controls by raising left control console.

7. Remove the ignition key and take it with you. Exit
the machine using the hand-holds.

OPERATIONAL SAFETY

Before Operation

Contact the proper local authorities for utility line loca­tions BEFORE starting to dig. In North America, con­tact the North American One-Call Referral System at
8-1-1 in the U.S., or 1-888-258-0808 in the U.S. and
Canada.

918196/EP0913 2-2 Printed in U.S.A.

Remove all trash and debris from the machine every
day, especially in the engine compartment, to minimize
the risk of fire.

The operator’s area, steps and hand holds must be kept
free of oil, dirt, ice and unsecured objects.

Never use ether starting aids. Glow plugs are used for
cold weather starting. Glow plugs can cause ether or
other starting fluid to detonate, causing injury or dam­age.

Walk around the machine and inspect it before using it.
Look for damage, loose or missing parts, leaks, etc.
Repair as required before using the machine.

Check the tracks for damage at regular intervals.
Repair or replace as necessary.

Warn all nearby personnel before starting the machine.

Below-ground hazards also include water mains, tun­nels and buried foundations. Know what is underneath
the work site before starting to dig.

Before working near power lines (either above-ground
or buried cable-type), always contact the power utility
and establish a safety plan with them.

Be aware of height obstacles. Any object in the vicinity
of the boom could represent a potential hazard, or
cause the operator to react suddenly and cause an acci­dent. Use a spotter or signal person when working near
bridges, phone lines, work site scaffolds, or other
obstructions.

Depending upon the voltage in the line and atmo­spheric conditions, strong current shocks can occur if
the boom or bucket is closer than 10 ft. (3 m) to the
power line. Very high voltage and rainy weather can
further increase the safe operating distance.

If a lighting system is installed, check its operation
before working in darkness.

Use warning tag/control lockout procedures during ser­vice. Alert others that service or maintenance is being
performed by tagging the operator’s controls — and
other machine areas if required — with a warning
notice. NEVER start the engine if there is any indica­tion that maintenance or service work is in progress, or
if a warning tag is attached to controls in the cab.

Replace damaged safety decals and a lost or damaged
operator’s manual. Always store this operator’s manual
in the storage compartment provided for it inside the
cab.

Work crew members should observe and monitor all
terrain and soil conditions at the work site, along with
traffic, weather-related hazards and any above- or
below-ground obstacles and hazards.

If the machine is equipped with a cab, keep the wind­shield, mirrors and windows clean. If equipped, adjust
the rearview mirrors to provide the best view to the rear
of the machine. Poor visibility can cause accidents.

Adjust the seat to allow complete and comfortable
access to the controls. Never adjust the seat during
machine operation.

Stop the engine and lock out the controls by raising left
control console before mounting attachments. Check
that attachments are securely fastened to the excavator
before using them.

Before working on or with the machine, remove jew­elry, tie back long hair, and do not wear loose fitting
garments, such as, scarves, ties, unzipped jackets, etc.,
which could become caught in the moving parts of the
machine and cause injury.

Do not use the machine when maintenance is sched­uled to be performed. Postponing maintenance can
result in a serious reduction of the service life of the
machine, more serious and costly equipment failures,
and contribute to unsafe operating conditions.

During Operation

ALWAYS fasten the seat belt securely and properly.
Never operate the machine without the seat belt fas­tened around the operator.

Operate ONLY while seated in the operator’s seat.
Never reach in through a window to work a control. Do
not try to operate the excavator unless you’re in the
operator’s position, seated at the controls. Stay alert
and focused on your work at all times.

Always keep hands and feet inside the operator’s com­partment while operating the machine.

Control the machine cautiously and gradually until
fully familiar with all the controls and handling. Avoid
high-voltage lines. Serious injury or death can result
from contact or proximity to high-voltage electric lines.
The bucket or boom does not have to make physical
contact with power lines for current to be transmitted.

Use care on loose ground. Working heavy loads over
loose, soft ground or uneven, broken terrain can cause
dangerous side-load conditions and possible tip over
and injury. Traveling with a suspended load or an
unbalanced load can also be hazardous.

Printed in U.S.A. 2-3 918196/EP0913

Stay away from ditches and other weak support sur­faces. Be sure the surrounding ground has adequate
strength to support the weight of the machine and the
load.

If temperatures are changing, be cautious of dark and
wet patches when working or traveling over frozen
ground.

Stay away from ditches, overhangs and other weak
support surfaces. Halt work and install support mats or
blocking if work is required in an area of poor track
support.

Overhangs are hazardous. Digging under an overhang
is dangerous. Know the height and reach limits of the
excavator and plan ahead while working. Avoid creat­ing dangerous situations caused by moving around the
work site while making excavations. Move to another
digging area before large overhangs are formed. Work­ing around deep pits or along high-walls or trenches
may require support blocks, especially after heavy rain­falls or during spring thaws. Park the excavator away
from overhangs.

Exposed hydraulic hoses could react with explosive
force if struck by falling or overhead items. NEVER
allow hoses to be hit, bent or interfered with during
operation. Extra guards may be required. Replace any
damaged hoses.

To avoid tipping, travel with the bucket or attachment
as low as possible: 8–12 inches (200–300 mm) from
the ground. In an emergency, lower the attachment
immediately to the ground to aid stopping the machine.

Sloping terrain requires caution. Dig evenly around the
work site whenever possible, trying to gradually level
any existing slope. If it is not possible to level the area
or avoid working on a slope, reduce the size and
cycling rate of the load.

If the machine becomes unstable and starts to tip, keep
the seat belt fastened, hold on firmly and brace your­self. Lean away from the point of impact and stay with
the machine. If tipping occurs, DO NOT jump from the
machine. The machine is equipped with rollover pro­tection, which can only protect the operator while in
the operator’s seat. Trying to escape from a tipping
machine can result in death or serious personal injury.

Stay alert for people moving through the work area.
When loading a truck you should always know where
the driver is.

Avoid loading over the cab of a truck, even if the driver
is in a safe spot, because someone else could have gone
inside.

Slow down the work cycle and use slower travel speeds
in congested or populated areas. Use commonly under­stood signals so that other members of the work crew
can warn the operator to slow or halt work in a poten­tially hazardous situation.

Use a signal person if you can’t see the entire work
area clearly.

Use a spotter and hand signals to keep away from
power lines not clearly visible to the operator.

All personnel at the work site should be aware of
assigned individual responsibilities. Communication
and hand signals used should be understood by every­one.

Terrain and soil conditions at the job site, approaching
traffic, weather-related hazards and any above-or
below-ground obstacles or hazards should be observed
and monitored by all work crew members.

Be aware that attachments affect the handling and bal­ance of the machine. Adjust the operation of the
machine as necessary when using attachments.

On sloping surfaces, use caution when positioning the
excavator prior to starting a work cycle. Stay alert for
instability situations. For example, always avoid work­ing the bucket over the downhill crawler tracks when
parked perpendicular to the slope. Slow all downhill
swing movements and avoid full extensions of the
bucket in a downhill direction. Lifting the bucket too
high, too close to the machine, while the excavator is
turned uphill can also be hazardous.

918196/EP0913 2-4 Printed in U.S.A.

Before coupling or uncoupling the hydraulic lines for
the attachment, stop the engine and release the pressure
in the hydraulic system by moving the joysticks in all
directions a couple of times.

DO NOT raise or lower a loaded bucket suddenly.
Abrupt movements under load can cause serious insta­bility.

Make sure that no one comes inside the swing radius of
the machine. Anyone standing near the track frames,
swing frame or the attachment is at risk of being caught
between moving parts of the machine.

Do not use the machine to lift or transport people.
Never carry riders. Do not allow others to ride on the
machine or attachments, because they could fall or
cause an accident.

Unless necessary for servicing the engine, the engine
hood must not be opened while the engine is running.

After the machine has been parked properly, shut down
the machine according to the “Mandatory Safety Shut­down Procedure” on page 2-2.

Travel Controls May Produce Reversed
Travel Operations

Engine exhaust gases can cause unconsciousness and
fatalities. Ensure adequate ventilation before starting
the engine in an enclosed area.

Operators should also be aware of any open windows,
doors or ductwork into which exhaust gases may be
carried, exposing others to danger.

Do not overload the machine. See “Load Diagrams”,
starting on page 1-10, for load limits.

If the machine becomes damaged or malfunctions, stop
the machine immediately and lock and tag it. Repair
the damage or malfunction before using the machine.

Never jump off the machine. Always leave the machine
using the steps and hand-holds. Never get on or off a
moving machine.

Exposure to Crystalline Silica

Exposure to crystalline silica (found in sand, soil and
rocks) has been associated with silicosis, a debilitating
and often fatal lung disease. A Hazard Review (Pub.
No. 2002-129) by the U.S. National Institute for Occu­pational Safety and Health (NIOSH) indicates that a
significant risk (at least 1 in 100) of chronic silicosis
for workers exposed to inhaled crystalline silica over a
working lifetime. NIOSH recommends an exposure
limit of 0.05 mg/m3 as a time-weighted average for up
to a 10-hr workday during a 40-hr workweek. NIOSH
also recommends substituting less hazardous materials
when feasible, using respiratory protection, and regular
medical examinations for exposed workers.

Before starting the machine, always check to see which
end of the track frame is under the operator’s cab. In
the normal travel configuration, travel motors are at the
rear of the machine, under the engine, and with the
dozer blade to the front.

If the operator rotates the swing frame 180º, travel
motors will be underneath the operator’s cab, and oper­ating travel will be reversed.

Use caution in reverse travel and swing frame rotation.

Use a signal person in high traffic areas and whenever
the operator’s view is not clear, such as when traveling
in reverse.

Additional Travel Precautions

Swing frame control levers should not be operated
while traveling.

Do not change selected travel mode (FAST/SLOW)
while traveling.

Fold in work equipment so that the outer end of the
boom is as close to the machine as possible, and is as
low as possible (8”—12” [200 mm—300 mm]) to the
ground.

Never travel over obstacles or slopes that will cause the
machine to tilt severely. Travel around any slope or
obstacle that would cause a tilt greater than 10º.

Snow, Ice and Cold Temperature
Operation Precautions

Parking the Machine

When shutting down the machine for the day, plan
ahead so that the excavator will be on a firm, level sur­face away from traffic and away from high-walls, cliff
edges and any area of potential water accumulation or
runoff. If parking on an incline is unavoidable, block
the crawler tracks to prevent movement. Lower the
bucket and dozer blade to the ground. There should be
no possibility of unintended or accidental machine
movement.

Printed in U.S.A. 2-5 918196/EP0913

In cold weather, avoid sudden travel movements and
stay away from even very slight slopes. The machine
can slide sideways on icy slopes.

Snow accumulation can hide potential hazards. Use
care while operating and while using the machine to
clear snow.

FIRE HAZARDS

ADDITIONAL SAFETY

The machine has several components that operate at
high temperature under normal operation conditions,
primarily the engine and exhaust systems. Also, the
electrical system, if not properly maintained or if dam­aged, can arc or produce sparks. These conditions
make it extremely important to avoid circumstances
where explosive dust or gases 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.

Add fuel, oil, antifreeze and hydraulic fluid to the
machine only in a well ventilated area. The machine
must be parked with controls, lights and switches
turned off. The engine must be turned off before refuel­ing or service checks are performed.

Static electricity can produce dangerous sparks at the
fuel-filling nozzle. In very cold, dry weather or other
conditions that could produce static discharge, keep the
tip of the fuel nozzle in constant contact with the filler
neck of the fuel tank, to provide a ground. Make sure
that the static line is connected from the excavator to
the service truck before fueling begins.

Keep fuel and other fluid reservoir caps tight and do
not start the engine until caps have been secured.

Do not smoke while filling the fuel tank, while working
on the fuel or hydraulic systems, or while working
around the battery.

Take care to avoid spilling combustible fluids, such as
oil or fuel, on a hot engine.

EQUIPMENT

Severe operation may require use of additional
safety equipment

Work in mines, tunnels, deep pits or on loose or wet
surfaces could produce the hazard of falling rock, roll
over or falling objects.

Any operator protective system installed on the
machine must comply with applicable safety standards
and carry appropriate labeling and rating information.
For example, the cab of an excavator used in applica­tions with falling object hazards must meet Society of
Automotive Engineers Standard SAE J1356, “Perfor­mance Criteria for Falling Object Guards for Excava­tors.”

Never attempt to alter or modify the protective struc­ture, by drilling holes, welding or re-locating fasteners.
Any serious impact or damage to the system requires a
complete integrity re-evaluation, and the replacement
of the system may be necessary.

Install additional safety equipment if conditions
require.

When working with a hydraulic breaker, a front guard
over the windshield may be required.

Laminated glass or polycarbonate protection for the
front, side or rear windows may also be recommended
depending upon particular work conditions.

Contact your dealer for available safety guards and/or
recommendations if there is any risk of being hit by
objects that could strike the operator’s cab.

Fire Extinguisher Recommendation

It is recommended that a 5 lb. (2.27 kg) or larger,
multi-purpose “A/B/C” fire extinguisher be mounted in
the cab. Check the fire extinguisher periodically and be
sure that work crew members are trained in its use.

After the machine has been parked properly, shut down
the engine and cycle all controls to release any remain­ing hydraulic system pressure. Be sure all switches and
operating controls are in the OFF position and the left­hand console is raised, locking out the hydraulic func­tions.

918196/EP0913 2-6 Printed in U.S.A.

Eye Protection and Safety Clothing

Wear full eye protection, ear and head protection,
safety shoes, gloves and any other protective clothing
or equipment as needed while operating the machine.

Safety Equipment Maintenance

Machinery guards and body panel covers must be in
place at all times. Keep clear of rotating parts, such as
cooling fan and alternator belts, which could catch hair,
jewelry or loose clothing.

All safety equipment must be maintained so it is
always in good condition.

Safety-critical parts must be periodically replaced.
Replace the following potentially fire-sensitive compo­nents as soon as they begin to show signs of deteriora­tion:

• Fuel system flexible hoses, fuel tank overflow
drain hose and the fuel filler cap.

• Hydraulic system hoses, especially the pump outlet
lines.

Keep mounting brackets and hose and cable routing
straps tight. Hose routing should have gradual bends.

Breathing Masks and Ear Protection

Remember that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollu­tion may not be visible, but these hazards can cause
permanent injuries.

MAINTENANCE SAFETY

Only trained and authorized personnel, with a full
awareness of safe procedures, should be allowed to
operate or perform maintenance or service on the
machine.

Use solid support blocking. Never rely on jacks or
other inadequate supports when maintenance work is
being done. Block tracks front and back to prevent any
movement.

Keep fuel and other fluid reservoir caps tight. Do not
start the engine until caps have been secured.

Never attempt to bypass the keyswitch to start the
engine. Use only the proper jump-starting procedure
according to See “Using a Booster Battery (Jump­Starting)” on page 4-17.

Never use hands to search for hydraulic fluid leaks.
Instead, 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.

Always wear safety glasses with side shields when
striking metal against metal. In addition, it is recom­mended that a softer (chip-resistant) material be used to
cushion the blow, otherwise, serious injury to the eyes
or other parts of the body could result.

Use care when seating retainer pins — retainer pins can
fly out or splinter when struck and could cause injury.

Do not smoke or have any spark- or flame-producing
equipment or materials in the area while filling the fuel
tank or working on the fuel or hydraulic systems.

Do not attempt to loosen or disconnect any hydraulic
lines, hoses, fittings, covers or caps without first reliev­ing hydraulic circuit pressure. Relieve hydraulic pres­sure by performing the “Mandatory Safety Shutdown
Procedure” on page 2-2. Be careful not to touch any
hydraulic components that have been in recent opera­tion, because they can be hot and cause burns.

Refer to the parts manual for information about assem­bly of components. Always use the correct parts and
the proper torques — incorrect fastener connections
can dangerously weaken assemblies.

Do not run the engine if repairs are being performed
alone. There should always be at least two people
working together if the engine must be run during ser­vice. Both persons must maintain visual contact with
each other. Keep a safe distance away from all rotating
and moving parts.

Always use the proper tools while working on the
machine. Inappropriate tools could break or slip, caus­ing injury, or they may not adequately perform
intended functions.

Unless necessary for servicing the machine, do not
open the engine cover while the engine is running.

Keep mounting brackets and hose and cable routing
straps tight. Hose routing should have gradual bends.

After cleaning the machine, examine all fuel, lubricant
and hydraulic oil lines for leaks, chafe marks and dam­age. Tighten any loose connections and repair or
replace parts as necessary.

Use warning tag/control lockout procedures during
service.

Alert others that service or maintenance is being per­formed and tag operator’s cab controls — and other
machine areas if required — with a warning notice.

Don’t run the engine if repairs or work is being per­formed alone.

Do not run the engine if repairs or work is performed
alone. There should always be at least two people
working together if the engine must be run during ser­vice.

Printed in U.S.A. 2-7 918196/EP0913

Always use adequate equipment supports and

IMPORTANT

blocking.

Lower bucket to the ground before leaving the opera­tor’s seat. Don’t work under any equipment supported
solely by a lift jack.

Pressurized hydraulic oil leaks can be hazardous.

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

Track tension adjustments require caution.
NEVER fully remove the track tension grease fitting.

To release pressure from the crawler frame track ten­sion assembly, you should loosen the grease fitting
slightly, no more than two turns.

Keep your face and body away from the fitting. Refer
to “Checking and Adjusting Track Tension” on page 4-

26.

Don’t work on hot engines, cooling or hydraulic sys­tems.

Wait for the engine to cool after normal operation. Park
the excavator on a firm, level surface and lower all
equipment before shutting down and switching off con­trols. When engine lube oil, gearbox lubricant or other
fluids require changing, wait for fluid temperatures to
decrease to a moderate level before removing drain
plugs.

Temperatures below 120°F (49°C) will reduce the
chances of scalding exposed skin while allowing the
fluid to drain quickly and completely. However, do not
let the fluid to fully cool, because drain time will be
substantially increased.

Cool-down is required prior to radiator or hydrau­lic reservoir checks.

Stop the engine and allow it to cool before performing
service on the engine radiator or hydraulic reservoir.
Both assemblies have pressure vents at the filler cap for
venting pressure. LOOSEN CAPS SLOWLY. Vent the
pressure before removing the filler caps.

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

Use correct replacement fasteners tightened to
proper torque.

Refer to the Parts Manual for information on torques
and assembly of components.

Always use the correct, original-equipment
parts. Incorrect fastener connections can
dangerously weaken assemblies.

Dispose of all petroleum-based oils and fluids prop­erly.

Dispose of all petroleum-based oils and fluids properly.
Used motor oil may pose a health risk. Wipe oil from
your hands promptly and wash off any residue. Used
motor oil is an environmental contaminant and may
only be disposed of at approved collection facilities.
Never drain any petroleum-based product on the
ground or dispose of used oil in municipal waste col­lection containers, or in metropolitan sewer systems or
landfills. Check state and local regulations for other
requirements.

Release hydraulic system pressure by cycling con­trols and releasing hydraulic reservoir pressure
before removing hydraulic reservoir access cover.

The hydraulic reservoir is pressurized. Vent the system
pressure by rotating the filler cap. LOOSEN CAP
SLOWLY prior to removal.

Make sure to release any hydraulic pressure stored in
the lines by cycling the operator’s controls in each
direction after the engine has been shut down.

918196/EP0913 2-8 Printed in U.S.A.

When handling oil, grease and other chemical sub­stances, follow the product-related safety requirements
(Material Safety Data Sheet (MSDS) carefully to pre­vent burning or scalding yourself or other persons.

Safety Decals

Safety decals must be replaced if they become unread­able. Safety decal mounting locations are shown start­ing on page 2-11.