Gehl 503Z, 603 Operator's Manual

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503Z / 603

Compact Excavator

Beginning Serial Number: AC02471

Form No.

918070

Revision F

Aug. 2011

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 Indentification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 in Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

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

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

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

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

503Z General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

603 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Fields of Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Load Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

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

Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

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

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

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

Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Before Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

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

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

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

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

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

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

918070/FP0811 i Printed in U.S.A.

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

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

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

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

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

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

ISO-Style Safety Decal Locations (Serial Numbers AJ02993 and Up) . . . . . . . . . . . . . . . . . . 2-11

ISO-Style Information Decal Locations (Serial Numbers AJ02993 and Up). . . . . . . . . . . . . . 2-14

ANSI-Style Safety Decal Locations (Serial Numbers AH02282 and Before) . . . . . . . . . . . . . 2-16

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

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

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

Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Tilting the Cab or Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

SAE Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

ISO Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Boom Swivel/Auxiliary Hydraulics Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Throttle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Optional Auto-Idle Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Operator’s Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Arm rests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Mounting/Removing Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Auxiliary Hydraulics Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Pre-Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Engine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Operating on Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Operating in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Swiveling the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Grading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Excavating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Loading Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Optional Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Proportional Auxiliary Hydraulic

Joystick Control (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Two-Speed Variable Auxiliary Hydraulic Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Printed in U.S.A. ii 918070/FP0811

Auxiliary Hydraulic Hammer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

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

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

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

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

Cab Functional Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Leakage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

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

Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Changing Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Air Cleaner Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Checking and Adjusting V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Checking and Adjusting Air Conditioning V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Track System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Windshield Washer Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Before Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

After Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

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

Engine Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Error Diagnostic Code Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Engine Diagnostic Codes Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Chapter 6 - index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

918070/FP0811 iii Printed in U.S.A.

NOTES

Printed in U.S.A. iv 918070/FP0811

CHAPTER 1 – GENERAL

INFORMATION

INTRODUCTION

The information in this Operator’s Manual was written

to give the owner/operator assistance in preparing,

adjusting, maintaining and servicing the Compact

Excavator. More important, 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 com-

pletely 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. Fol-

lowing 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, instability of the load, poor

maintenance and using the equipment 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 thor-

oughly trained in safe operation and proper load han-

dling.

It is recommended that operators be capable of obtain-

ing a valid motor vehicle operator’s license.

Some illustrations in this manual may show doors,

guards and shields open or removed for illustrative pur-

poses only. BE SURE all doors, guards and shields are

in their 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 construc-

tion of any part without incurring the obligation to

install such changes on any unit previously delivered.

Figure 1-1 Serial Number Plate Locations

918070/FP0811 1-1 Printed in U.S.A.

Engine Serial Number Location

Engine serial number label

Model 503Z: Serial numbers AH00579 and up

Model 603: Serial numbers AH00645 and up

Engine serial number label

Model 503Z: Serial numbers AH00578 and before

Model 603: Serial numbers AH00644 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 GEHL dealer or 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.

Printed in U.S.A. 1-2 918070/FP0811

Excavator Component Indentification

Dipper Arm Cylinder

Boom

Bucket

Bucket Cylinder

Dipper Arm

Boom Cylinder

Dozer Blade

Track Frame

Travel Drive Motor

Swing Frame/ Superstructure

Hydraulic/Fuel Tank Cover

Counterweight

Operator ’s Seat

Operati o n C o nt rols

Swing Cylinder

Engine Cover

Figure 1-2 Component Names

918070/FP0811 1-3 Printed in U.S.A.

SPECIFICATIONS

Fluid Capacities/Lubricants

Note: Capacities i ndicated are approximate.

Component/Applica-

tion

Diesel Engine

Travelling Drive Gearbox Oil

Hydraulic Oil Tank

Lubricant Specification Season/Temper-

ature

SAE 10W-40 (according to

Engine Oil

DIN 51502); API: CD, CF,

CF-4, CI-4

-4°F (-20°C)

+104°F (+40°C)

SAE E3, E4, E5

Q8 T 55, SAE80W-90

Gearbox Oil

FINA PONTONIC GLS

Year-round

SAE80W-90

HVLP46 (according to DIN

Hydraulic Oil

Biodegradable Oil

51524 section 3)

PANOLIN HLP Synth 46

FINA BIOHYDRAN SE 46

Year-round 11.9 gal. (45 L)

Capacity

Model 503Z: 8.2

qts. (7.8 L)

Model 603: 10.8

qts. (10.2 L)

About 0.3 gal.

(1.3 L) each

BP BIOHYD SE-46

Grease

Grease Fittings

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

FINA Energrease L21M Year-round As Required

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

20.6 gal. (78 L)

1.7 lbs. (750 g)

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

Printed in U.S.A. 1-4 918070/FP0811

Engine

Engine 503Z 603

Engine Model Serial Numbers AH00579 and up:

Yanmar 4TNV88-BPNS

EPA Tier III

S/N AC02471-AH00578:

Yanmar 4TNV88-PNS

EPA Tier II Type Water-cooled 4-stroke, 4 cylinder diesel engine Displacement 134 cu. in. (2.19 L) 202 cu. in. (3.32 L) Bore and Stroke 3.5 x 3.5 in. (88 x 90 mm) 3.9 x 4.3 in. (98 x 110 mm) Horsepower (DIN) 37.8 hp (28.2 kW) @ 2400 rpm 57.0 hp (42.5 kW) @ 2100 rpm Max. Torque 102 lb.-ft. (138 Nm) @ 1100 rpm 184 lb.-ft. (249 Nm) @ 1400 rpm Max. Engine Speed (with no load) 2575 +/- 50 rpm 2275 +/- 50 rpm Idle Engine Speed 1050 +/- 50 rpm Fuel Injection System Direct injection Starting Aid Glow plug (Preheating time 10-15 seconds) Max. Inclined Angle (engine still sup-

plied with oil)

Note: The machine’s theoretical climbing ability

25° in all directions

(30°/ 58%) exceeds this angle!

Exhaust Emission Compliance 97/68 EC; U.S. EPA Engine Oil Capacity 8.2 qts. (7.8 L) 10.7 qts. (10.1 L) Engine Coolant Capacity 7.4 qts. (7.0 L)

Serial Numbers AH00645 and up:

Yanmar 4TNV98-ZVNS

EPA Tier III

S/N AC02513-AH00644:

Yanmar 4TNV98-VNS

EPA Tier II

Hydraulic System

Hydraulic System 503Z 603

Pump Two variable-displacement + two gear pumps Flow Rate 2 x 14.2 gpm + 10.9 gpm + 3.0

gpm @ 2590 rpm

(2 x 53.6 L/min + 41.4 L/min

+11.6 L/min) @ 2590 rpm Operating Pressure (working and driving) 3408 psi (235 bar) 3553 psi (245 bar) Operating Pressure (swing unit) 3336 psi (230 bar) 3480 psi (240 bar) Hydraulic Fluid Cooler Standard Hydraulic Reservoir (system capacity) 21.1 gal. (80 L) Filter Return filter

2 x 15.7 gpm + 11.8 gpm + 2.5

gpm @ 2290 rpm

(2 x 59.6.1 L/min + 44.7 L/min +

9.6 L/min) @ 2130 rpm

918070/FP0811 1-5 Printed in U.S.A.

Undercarriage and Swing System

F10

F5 F6 F7

Serial Numbers to

AH02282

Located on top of right

inside cab/canopy

interior trim.

Serial Numbers

AJ02993 and up

Located on inside of

right cab/canopy

interior trim

Undercarriage and Swing System 503Z 603

Travel Speed

Low Speed 1.7 mph (2.74 km/h) 1.7 mph (2.76 km/h)

High Speed 2.8 mph (4.56 km/h) 3.0 mph (4.76 km/h) Ground Clearance 11.8” (300 mm) 13.2” (335 mm) Swing Speed 8.7 rpm 9.0 rpm Gradability 30

° (58%)

Rubber Track Width 15.7” (400 mm) Number of Track Rollers 4 per side 5 per side Average Ground Pressure

3.84 psi (0.28 kg/cm

)

Dozer Blade

Dozer Blade 503Z 603

Width 78.3” (1990 mm) 78.3” (1990 mm) Height 15.0” (380 mm) 16.7” (425 mm) Maximum Lift Above Ground 15.2” (385 mm) 15.3” (390 mm) Maximum Depth Below Ground 15.4” (390 mm) 15.7” (400 mm)

Electrical System

Alternator 12-V, 55-A Starter 12-V, 2.3-kW Battery 12-V, 88-Ah, BCI group size 49 (93 opt.), 680 CCA Socket 15-A max. - Cigarette lighter

Fuse Box in Instrument Panel

Fuse No.

F3 10 Amp Indicators, cut-off solenoid, relays F4 10 Amp Boom light F5 15 Amp Roof lights F6 10 Amp Valves, horn F7 15 Amp Heating, air conditioning F8 10 Amp Windshield wiper, interior light F9 10 Amp Rotating beacon, radio F10 15 Amp Socket, cigarette lighter

Rated Current

Protected Circuit

Printed in U.S.A. 1-6 918070/FP0811

Main Fuse Box and Relays

F1 F2

Relays

Fuse No. Rated Curren t Protected Circuit

F1 40 Amp Start, preheat, cut-off solenoid F2 50 Amp Main fuse, ignition lock

Relay No. Protected Circuit

K9 Cut-off solenoid K5 Preheating

Relay No. Protected Circuit

K6 Preheating timer K7 Starting relay K8 Cut-off solenoid V1 Diode

918070/FP0811 1-7 Printed in U.S.A.

Sound Levels

503Z 603

Sound Power 96 dB(A) 98 dB(A) Sound Pressure 76 dB(A) 74 dB(A)

Coolant Compound Table

Outside temperature

Up to °F (°C)

39 (4) 99

14 (-10) 79 20

-4 (-20) 65 34

-13 (-25) 59 40

-22(-30) 55 44

Water Anticorrosion agent Antifreeze agent

% by vol-

ume

Coolant: Halvoline XLC (based on ethylene glycol)

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

2.6 (10) 1

–

Printed in U.S.A. 1-8 918070/FP0811

503Z General Specifications

8’2” (2500 mm)

12’ 2” (3097 mm)

8’5” (2570 mm)

6’6” (1990 mm)

1’3”

3’10”

18’4” (5600 mm)

3’3” (995 mm)

11’9” (3583 mm)

8’5” (2570 mm)

1’3” (380 mm)

(400 mm)

(1190 mm)

(400 mm)

1’3”

General Specifications

503Z

Weight 10,582 lbs. (4800 kg) Height 8’5” (2570 mm) Width 6’6” (1990 mm) Transport length 18’4” (5600 mm) Dipper arm length (Standard Arm) 4’9” (1450) mm Dipper arm length (Optional Long Arm) 5’9” (1750 mm) Max. digging depth w/ Standard Arm 11’9” (3570 mm) Max. digging depth w/ Optional Long Arm 12’8” (3870 mm) Max. vertical digging depth w/ Standard Arm 8’8” (2630 mm) Max. vertical digging depth w/ Optional Long Arm 9’7” (2915 mm) Max. digging height w/ Standard Arm 17’5” (5320 mm) Max. digging height w/ Optional Long Arm 18’1” (5500 mm) Max. dump height w/ Standard Arm 12’2” (3720 mm) Max. dump height w/ Optional Long Arm 12’10” (3900 mm) Max. digging radius w/ Standard Arm 19’9” (6030 mm) Max. digging radius w/ Optional Long Arm 20’8” (6300 mm) Max. reach at ground level w/ Standard Arm 19’4” (5900 mm) Max. reach at ground level w/ Optional Long Arm 20’3” (6185 mm) Max. breakout force at bucket tooth 7,599 lbf (33.8 kN) Max. tearout force (Standard Arm) 5,980 lbf (26.6 kN) Max. tearout force (Optional Long Arm) 5,283 lbf (23.5 kN) Min. tail end slewing radius 3’3” (995 mm) Max. tail end lateral projection over tracks 0’0” (0 mm) Max. boom distance to bucket center (right side) 3’1” (960 mm) Max. boom distance to bucket center (left side) 2’11” (895 mm)

Max. boom slew angle (left side) 65° Max. boom slew angle (right side) 61°

3’1”

1°

’

”

(

)

6’6” (1990 mm)

(956 mm)

2’11”

(893 mm)

918070/FP0811 1-9 Printed in U.S.A.

603 General Specifications

8’5” (2570 mm)

19’2” (5800 mm)

8’2” (2500 mm)

10’9” (3280 mm )

13’0” (3967 mm)

4’9” (1465 mm)

1’5” (425 mm)

6’6” (1990 mm)

1’3”

3’10”

(400 mm)

(1190 mm)

8’5” (2570 mm)

1’9”

(535 mm)

6’6” (1990 m m )

2’5”

(745 mm)

(

’

”

)

General Specifications 603

Weight 12,566 lbs. (5700 kg) Height 8’5” (2570 mm) Width 6’6” (1990 mm) Transport length 19’0” (5800 mm) Dipper arm length (Standard Arm) 5’6” (1685 mm) Dipper arm length (Optional Long Arm) 6’6” (1985 mm) Max. digging depth w/ Standard Arm 12’7” (3845 mm) Max. digging depth w/ Optional Long Arm 13’7” (4140 mm) Max. vertical digging depth w/ Standard Arm 9’4” (2855 mm) Max. vertical digging depth w/ Optional Long Arm 10’3” (3135 mm) Max. digging height w/ Standard Arm 18’6” (5660 mm) Max. digging height w/ Optional Long Arm 19’2” (5850 mm) Max. dump height w/ Standard Arm 13’1” (3995 mm) Max. dump height w/ Optional Long Arm 13’8” (4185 mm) Max. digging radius w/ Standard Arm 20’ 4” (6210 mm) Max. digging radius w/ Optional Long Arm 21’3” (6490 mm) Max. reach at ground level w/ Standard Arm 19’11” (6090 mm) Max. reach at ground level w/ Optional Long Arm 20’11” (6380 mm) Max. breakout force at bucket tooth 8,925 lbf (39.7 kN) Max. tearout force (Standard Arm) 6,317 lbf (28.1 kN) Max. tearout force (Optional Long Arm) 5,642 lbf (25.1 kN) Min. tail end slewing radius 4’9” (1465 mm) Max. tail end lateral projection over tracks 1’6” (470 mm) Max. boom distance to bucket center (right side) 2’5” (745 mm) Max. boom distance to bucket center (left side) 1’9” (535 mm)

Max. boom slew angle (left side) 75° Max. boom slew angle (right side) 51°

Printed in U.S.A. 1-10 918070/FP0811

Fields of Applications

Attachment Size Capacity

Heavy-Duty Bucket 10 in. (250 mm)

16 in. (400 mm)

20 in. (500 mm)

24 in. (600 mm)

30 in. (700 mm)

36 in. (900 mm)

Ditching Bucket 48 in. (1000 mm)

Ditch Bucket (503Z only) 48 in. (1000 mm)

55 in. (1400 mm)

Swivel Bucket 48 in. (1200 mm)

55 in. (1400 mm)

2.5 ft

3.3 ft

3.7 ft

6.4 ft

8.8 ft

9.8 ft

5.9 ft

7.0 ft

8.4 ft

5.9 ft

7.0 ft

5.9 ft

(0.070 M3)

(0.093 M3)

(0.104 M3)

(0.181 M3)

(0.249 M3)

(0.278 M3)

(0.167 M3)

(0.196 M3)

(0.238 M3)

(0.167 M3)

(0.198 M3)

(0.167 M3)

918070/FP0811 1-11 Printed in U.S.A.

Load Diagrams

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

-13'0"

(-4.0 m)

16'3"

(5.0 m)

-3'3"

(-1.0 m)

-6'6"

(-2.0 m)

-9'9"

(-3.0 m)

0'0"

(0.0 m)

503Z Load Diagram - Standard Dipper Arm Maximum Permissible Loads

13’0”

(4.0 m)

9’9”

(3.0 m)

6’6”

(2.0 m)

3’3”

(1.0 m)

0’0”

(0.0 m)

-3’3”

(-1.0 m)

-6’6”

(-2.0 m)

2,337*

(1060*)

2,260*

(1025*)

2,304*

(1045*)

2,403*

(1090*)

2,524*

(1145*)

2,668*

(1210*)

2,767*

(1255*)

1,786 (810)

1,290 (585)

1,080 (490)

1,003 (455)

1,014 (460)

1,135 (515)

1,554 (705)

(4.0 m)

2,227*

(1010*)

2,612*

(1185*)

3,120*

(1415*)

3,428*

(1555*)

3,329*

(1510*)

1,720 (780)

1,609 (730)

1,477 (670)

1,378 (625)

1,345 (610)

(3.0 m)

3,483*

(1580*)

4,905

(2225*)

5,368*

(2435*)

5,049*

(2290*)

3,924*

(1780*)

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

9’9”

2,535

(1150)

2,183 (990)

2,028 (920)

2,017 (915)

2,094 (950)

(2.0 m)

8,973*

(4070*)

6,614*

(3000*)

6’6”

3,946

(1790)

4,101

(1860)

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 valves and the hydraulic system's stabilizing features.

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

Printed in U.S.A. 1-12 918070/FP0811

Dozer blade support in drive direction

Dozer blade support 90° to drive direction

503Z Load Diagram - Extended Dipper Arm (Option)

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

-13'0"

(-4.0 m)

16'3"

(5.0 m)

-3'3"

(-1.0 m)

-6'6"

(-2.0 m)

-9'9"

(-3.0 m)

0'0"

(0.0 m)

Maximum permissible loads

13’0”

(4.0 m)

9’9”

(3.0 m)

6’6”

(2.0 m)

3’3”

(1.0 m)

0’0”

(0.0 m)

-3’3”

(-1.0 m)

-6’6”

(-2.0 m)

2,028* (920*)

2,017* (915*)

2,061* (935*)

2,138* (970*)

2,238*

(1015*)

2,348*

(1065*)

2,447*

(1110*)

1,455 (660)

1,102 (500)

937

(425)

871

(395)

882

(400)

970

(440)

1246

(565)

(4.0 m)

1,951* (855*)

1,907* (865*)

2,315*

(1050*)

2,888* (1310)

3,296*

(1495*)

3,340*

(1515*)

2,756*

(1250*)

1,731

(785)

1,720

(780)

1,609

(730)

1,466

(665)

1,345

(610)

1,301

(590)

1,323

(600)

(3.0 m)

2,899*

(1315*)

4,464*

(2025*)

5,258*

(2385*)

5,181*

(2350*)

4,343*

(1970*)

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

9’9”

2,579

(1170)

2,227

(1010)

2,017 (915)

1,962 (890)

2,006 (910)

6’6”

(2.0 m)

10,075* (4570*)

7,915*

(3590*)

3,858

(1750)

3,979

(1805)

918070/FP0811 1-13 Printed in U.S.A.

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

Dozer blade support in drive direction

Dozer blade support 90° to drive direction

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 valves and the hydraulic system's stabilizing features.

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

503Z Load Diagram - Standard Dipper Arm with Counterweight

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

-13'0"

(-4.0 m)

16'3"

(5.0 m)

-3'3"

(-1.0 m)

-6'6"

(-2.0 m)

-9'9"

(-3.0 m)

0'0"

(0.0 m)

Maximum permissible loads

13’0”

(4.0 m)

13’3”

(4.0 m)

9’9”

(3.0 m)

6’6”

(2.0 m)

3’3”

(1.0 m)

0’0”

(0.0 m)

-3’3”

(-1.0 m)

-6’6”

(-2.0 m)

2337*

(1060*)

2260*

(1025*)

2304*

(1045*)

2403*

(1090*)

2524*

(1145*)

2668*

(1210*)

2767*

(1255*)

2017

(915)

1488

(675)

1279

(580)

1202

(545)

1213

(550)

1367

(620)

1830

(830)

2227*

(1010*)

2612*

(1185*)

3120*

(1415*)

3428*

(1555*)

3329*

(1510*)

2006

(910)

1907

(865) 1775

(805) 1676

(760) 1642

(745)

3483*

(1580*)

4905*

(2225*)

5368*

(2435*)

5049*

(2290*)

3924*

(1780*)

Maximum permissible load on standard dipper arm

A Reach from live ring center B Load hook height * Lift capacity limited by hydraulics

9’9”

(3.0 m)

(1345)

(1185)

(1115)

(1110)

(1140)

2965

2612

2458

2447

2513

(2.0 m)

8973*

(4070*)

6614*

(3000*)

6’6”

4751

(2155)

4905

(2225)

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

Printed in U.S.A. 1-14 918070/FP0811

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 valves and the hydraulic system's stabilizing features.

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

Dozer blade support in drive direction

Dozer blade support 90° to drive direction

503Z Load Diagram - Extended Dipper Arm with Counterweight

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

-13'0"

(-4.0 m)

16'3"

(5.0 m)

-3'3"

(-1.0 m)

-6'6"

(-2.0 m)

-9'9"

(-3.0 m)

0'0"

(0.0 m)

Maximum permissible loads

13’0”

(4.0 m)

13’3”

(4.0 m)

9’9”

(3.0 m)

6’6”

(2.0 m)

3’3”

(1.0 m)

0’0”

(0.0 m)

-3’3”

(-1.0 m)

-6’6”

(-2.0 m)

2028*

(920*)

2017*

(915*)

2061*

(935*)

2138*

(970*)

2238*

(1015*)

2348*

(1065*)

2447*

(1110*)

1720

(780)

1323

(600)

1146

(520)

1069

(485)

1080

(490)

1190

(540)

1521

(690)

1885*

(855*)

1907*

(865*)

2315*

(1050*)

2888*

(1310*)

3296*

(1495*)

3340*

(1515*)

2756*

(1250*)

1885*

(855*)

1907*

(865*)

1907*

(865*)

1764

(800) 1642

(745) 1587

(720) 1620

(735)

2899*

(1315*)

4464*

(2025*)

5258*

(2385*)

5181*

(2350*)

4343*

(1970*)

Maximum permissible load on extended dipper arm

A Reach from live ring center B Load hook height * Lift capacity limited by hydraulics

9’9”

(3.0 m)

(1315*)

2899*

2657

(1205)

2447

(1110)

2392

(1085)

2436

(1105)

(2.0 m)

10,075*

(4570*)

7915*

(3590*)

6’6”

4663

(2115)

4663

(2115)

918070/FP0811 1-15 Printed in U.S.A.

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

Dozer blade support in drive direction

Dozer blade support 90° to drive direction

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 valves and the hydraulic system's stabilizing features.

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

603 Load Diagram - Standard Dipper Arm

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

-13'0"

(-4.0 m)

16'3"

(5.0 m)

-3'3"

(-1.0 m)

-6'6"

(-2.0 m)

-9'9"

(-3.0 m)

0'0"

(0.0 m)

Maximum permissible loads (standard arm)

16’0”

(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”

(0.0 m)

-3’3”

(-1.0 m)

-6’6”

(-2.0 m)

2,888*

(1310*)

2,866*

(1300*)

2,911*

(1320*)

2,998*

(1360*)

3,109*

(1410*)

3,230*

(1465*)

3,296*

(1495*)

2,249

(1020)

1,775 (805) 1,565 (710) 1,488 (675) 1,521 (690) 1,676 (760) 2,127 (965)

2,932*

(1330*)

3,164*

(1435*)

3,296*

(1495*)

1,709 (775)

1,654 (750) 1,609 (730)

2,745*

(1245*)

2,789*

(1265*)

3,285*

(1490*)

3,913*

(1775*)

4,343*

(1970*)

4,332*

(1965*)

2,546

(1155)

2,524

(1145)

2,425

(1100)

2,282

(1035)

2,183 (990) 2,138 (970)

Maximum permissible load on standard dipper arm

A Overhang from the center of the turntable B Height of load fixing point * Lifting capacity hydraulically limited

9’9”

(3.0 m)

4,156*

(1885*)

5,765*

(2615*)

6,548*

(2970*)

6,415*

(2910*)

5,401*

(2450*)

3,748

(1700)

3,417

(1550)

3,241

(1470)

3,197

(1450)

3,252

(1475)

6’6”

(2.0 m)

11,045* (5010*)

8829*

(4005*)

6162

(2795)

6294

(2855)

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 valves and the hydraulic system's stabilizing features.

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

Printed in U.S.A. 1-16 918070/FP0811

Dozer blade support in drive direction

Dozer blade support 90° to drive direction

603 Load Diagram - Extended Dipper Arm (Option)

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

-13'0"

(-4.0 m)

16'3"

(5.0 m)

-3'3"

(-1.0 m)

-6'6"

(-2.0 m)

-9'9"

(-3.0 m)

0'0"

(0.0 m)

Maximum permissible loads (extended arm)

16’0”

(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”

(0.0 m)

-3’3”

(-1.0 m)

-6’6”

(-2.0 m)

2,623*

(1190*)

2,623*

(1190*)

2,690*

(1220*)

2789*

(1265*)

2899*

(1315*)

3031*

(1375*)

3142*

(1425*)

2,183 (990)

1,411 (640)

628

(285)

1,168 (530)

1,290 (585)

1,466 (665)

1,819 (825)

2,745*

(1245*)

3,042*

(1380*)

3,274*

(1485*)

1,576 (715)

1,598 (725)

1,554 (705)

2,315*

(1050*)

2,469*

(1120*)

3,031*

(1375*)

3,726*

(1690*)

4,244*

(1925*)

4,387*

(1990*)

1907 (865)

2,326

(1055)

2,392

(1085)

2,271

(1030)

2,161 (980)

2,039 (955)

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

(3.0 m)

3,682*

(1670*)

5,291*

(2400*)

6,184*

(2805*)

6,294*

(2855*)

5,688*

(2580*)

9’9”

3,682

(1670)

3,461

(1570)

3,230

(1465)

3,142

(1425)

3,175

(1440)

6’6”

(2.0 m)

10,075* (4570*)

8,775*

(3980*)

6,140

(2785)

6,173

(2800)

918070/FP0811 1-17 Printed in U.S.A.

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

Dozer blade support in drive direction

Dozer blade support 90° to drive direction

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 valves and the hydraulic system's stabilizing features.

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

603 Load Diagram - Standard Dipper Arm with Counterweight

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

-13'0"

(-4.0 m)

16'3"

(5.0 m)

-3'3"

(-1.0 m)

-6'6"

(-2.0 m)

-9'9"

(-3.0 m)

0'0"

(0.0 m)

Maximum permissible loads (standard dipper w/counterweight)

16’ 3"

(5.0 m)

13’ 0"

(4.0 m)

13’

(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)

2888

(1310*)

2866

(1300*)

2910

(1320*)

2998

(1360*)

3109

(1410*)

3230

(1465*)

3296

(1495*)

2590

(1175)

2061

(935)

1830

(830)

1753

(795)

1786

(810)

1973

(895)

2491

(1130)

2932

(1330*)

3164

(1435*)

3296

(1495*)

1995 (905)

1940 (880) 1874 (850)

2745

(1245*)

2789

(1265*)

3285

(1490*)

3913

(1775*)

4343

(1970*)

4332

(1965*)

2745

(1245*)

2789

(1265*)

2789

(1265)

2657

(1205)

2546

(1155)

2513

(1140)

Maximum permissible load on standard dipper arm

A Reach from live ring center B Load hook height * Lift capacity limited by hydraulics

9’ 9"

(3.0 m)

4156

(1885*)

5766

(2615*)

6548

(2970*)

6445

(2910*)

6504

(2450*)

4156

(1885*)

3957

(1795)

3781

(1715)

3737

(1695)

3792

(1720)

6’ 6"

(2.0 m)

11045

(5010*)

8830

4005*)

(

7165

(3250)

7297

(3310)

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 valves and the hydraulic system's stabilizing features.

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

Printed in U.S.A. 1-18 918070/FP0811

Dozer blade support in drive direction

Dozer blade support 90° to drive direction

603 Load Diagram - Extended Dipper Arm with Counterweight

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

0'0"

(0.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

16'3"

(5.0 m)

3'3"

(1.0 m)

6'6"

(2.0 m)

9'9"

(3.0 m)

13'0"

(4.0 m)

-13'0"

(-4.0 m)

16'3"

(5.0 m)

-3'3"

(-1.0 m)

-6'6"

(-2.0 m)

-9'9"

(-3.0 m)

0'0"

(0.0 m)

Maximum permissible loads (extended dipper w/counterweight)

16’ 3"

(5.0 m)

13’ 0"

(4.0 m)

13’

(4.0 m)

9’, 9"

(3.0 m)

6,’ 6"

(2.0 m)

3’, 3"

(1.0 m)

(0.0 m)

-3’, 3”

(-1.0 m)

-6’, 6”

(-2.0 m)

2623

(1190*)

2623

(1190*)

2690

(1220*)

2789

(1265*)

0’

2899

(1315*)

3031

(1375*)

3142

(1425*)

2491

(1130)

1676

(760)

871

(395)

1411

(640)

1543

(700)

1731

(785)

2138

(970)

2745

(1245*)

3042

(1380*)

3274

(1485*)

1863

(845)

1874

(850)

1841

(835)

2315

(1050*)

2469

(1120*)

3031

(1375*)

3726

(1690*)

4244

(1925*)

4387

(1990*)

2282

(1035)

2469

(1120*)

2756

(1250)

2646

(1200)

2524

(1145)

2469

(1120)

Maximum permissible load on extended dipper arm

A Reach from live ring center B Load hook height * Lift capacity limited by hydraulics

(3.0 m)

3682

(1670*)

5241

(2400*)

6184

(2805*)

6294

(2855*)

5688

(2580*)

9’ 9"

3682

(1670*)

40011

(1815)

3770

(1710)

3682

(1670)

3715

(1685)

6’ 6"

(2.0 m)

10075

(4570*)

8774

3980*)

(

7143

(3240)

7187

(3260)

918070/FP0811 1-19 Printed in U.S.A.

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

Dozer blade support in drive direction

Dozer blade support 90° to drive direction

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 valves and the hydraulic system's stabilizing features.

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

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.

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 this machine.

 The Maintenance and Troubleshooting chapters for

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

 Give 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.

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.

Printed in U.S.A. 1-20 918070/FP0811

 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

 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.

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 this machine.

 The Maintenance and Troubleshooting chapters for

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

 Give 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.

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.

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 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 DEALER’S RECORDS

INTENTIONALLY BLANK

(To be removed as dealer’s file copy)

Printed in U.S.A. 1-22 918070/FP0811

CHAPTER 2 – SAFETY

DANGER

WARNING

CAUTION

IMPORTANT

SAFETY ALERTS

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:

“IMPORTA NT” is used to draw atten tion to a procedure that must to be followed to prevent machine damage.

GENERAL SAFETY RULES

“CAUTION,” “WARNING,” 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:

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

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

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.

The word “CAUTION” indicates a potentially hazardous situation that, if not avoided. may result in minor or moderate injury.

918070/FP0811 2-1 Printed in U.S.A.

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

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.

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.

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

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.

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.

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OPERATION 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.

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 indica-

tion 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.

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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.

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.

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.

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.

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.

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.

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

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.

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 1-12, 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.

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.

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

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.

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/m 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.

918070/FP0811 2-5 Printed in U.S.A.

as a time-weighted average for up

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

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

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.

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.

ADDITIONAL SAFETY EQUIPMENT

Severe operation may require use of a dditional 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.”

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.

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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.

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 4-15.

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.

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Use warning tag/control lockout procedures during

IMPORTANT

service.

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

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 repai rs 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.

Always use adequate equipment supports and blocking.

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

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

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

Keep your face and body away from the fitting. Refer to “Checking and Adjusting Track Tension” on page 4-24.

Don’t work on hot engi nes , c ool ing or hydraulic systems.

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.

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.

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.

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.

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.

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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 parts—incorrect fastener connections can dangerously

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.

Battery Electrolyte and Explosive Gas Hazard

Flush eyes with water for 10-15 minutes if battery acid is splashed in the face. Anyone who swallows acid must have immediate medical aid. Call the Poison Control center listing in the telephone directory.

Sparks can set off explosive battery gas from incidental contact or static discharge. Turn off all switches and the engine when working on batteries. Keep battery terminals tight. Contact between a loose terminal and post can create an explosive spark.

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. Part numbers for each safety decal and required mounting locations are shown from page 2-10 to page 2-18.

Hydraulic Cylinder Seal Periodic Replacement

Check cylinder drift rate at regular intervals. Maximum allowable rates are included at the end of the Hydraulic section in the Excavator Service Manual. Overhaul seal kits are available through Manitou Americas, Inc..

High Pressure Hydraulic Lines Store Energy

Exposed hydraulic hoses on the arm or boom could react with explosive force if struck by a falling rock, overhead obstacle or other job site hazard. Extra safety

guards may be required. NEVER allow hoses to be hit,

bent or interfered with during operation.

Battery Disconnection Precaution

Remove cable to negative terminal first when disconnecting a battery. Connect positive terminal cable first when installing a battery.

Jump-starting or Charging the Battery

Turn off all electrical equipment before connecting leads to the battery, including electrical switches on the battery charger or jump-starting equipment.

When jump-starting from another machine or vehicle, do not allow the machines to touch. Wear safety glasses or goggles while battery connections are made.

Batteries contain acid and produce explosive gases. Keep sparks, flames and lit cigarettes away from batteries at all times.

Connect positive cable first when installing jumper cables. The final cable connection, at the metal frame of the machine being charged or jump-started, should be as far away from the batteries as possible.

Disconnect the negative cable first when removing the jumper cables. For specific model instructions refer to Page 4-16 in the Maintenance chapter of this manual.

LIFTING THE MACHINE WITH A

Operator’s Cab and Swing Frame Deck Maintenance

Cleaning off accumulations of grease and dirt helps extend equipment service life. Cleaning also provides an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems result.

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CRANE

Only lift the machine according to the following guidelines:

• The crane and rigging equipment must have sufficient capacity. See “Lifting the Machine” on page 3-39.

• Lift the machine according to “Lifting the Machine” on page 3-39.

• Secure the machine against unintentional movement. Use taglines as needed.

• Do not lift the machine with persons on or in the machine.

• Any person guiding the crane operator must be within sight or sound of the crane operator.

SAFETY DECALS

The machine has decals shown on the following pages that provide safety information and precautions. These decals must be kept legible. If missing or illegible, they must be replaced promptly. Replacements can be obtained from your dealer.

• Lift the machine only with the standard bucket installed, the bucket empty and in the transport position.

• Persons must stay clear of and not under the machine when it is lifted.

• Fasten the rigging equipment so the machine is horizontal when it is lifted.

• Do not lift the machine by the eye hooks on the cab. Attach the rigging equipment only at the lift points identified by this symbol:

TRANSPORTING

Obey state and local over-the-road regulations. Check state and local restrictions regarding weight, width and length of a load. The hauling vehicle, trailer and load must all be in compliance with local regulations. See “Loading and Transporting” on page 3-40.

Refer to the Parts Manual for decal part numbers and ordering information.

New Decal Application

Surfaces must be free of dirt, dust, grease and foreign material before applying the decal. Remove the smaller portion of the decal backing paper and apply the exposed adhesive to the clean surface, maintaining proper position and alignment. Peel the rest of the backing paper and apply hand pressure to smooth out the decal surface. Refer to the following pages for proper decal locations.

If replacing a part that has a decal on it, ensure that the replacement part has the same decal.

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ISO-Style Safety Decal Locations (Serial Numbers AJ02993 and Up)

WARNING! Stay Clear Decal

AVOID INJURY OR DEATH!

Located next to the track tension grease fitting on both sides of the machine.

WARNING! Grease is under high pressure. Keep your face and body away from the fitting.

Do not loosen the fitting more than two turns. Do not loosen parts other than the fitting.

Refer to the operator’s manual for track adjustment procedure.

WARNING! Danger Zone Decal

AVOID INJURY OR DEATH! Located on both sides of the boom. Keep bystanders away fr om t h e machine when it

is in use.

WARNING! Hydraulic Reservoir Under Pressure

AVOID INJURY OR DEATH!

Located on the hydraulic system accumulator bulb inside the engine compartment .

Relieve hydraulic pressur e before servicing machine. Removed hydraulic reservoir cap slowly.

Refer to the maintenance section in the opera tor’s manual before servicin g the mach in e .

WARNING! Hot Surfaces Decal

AVOID SERIOUS INJURY!

Located inside the engin e compartment.

Stop the engine and wait for all parts to cool before opening the engine compartment. Hot surfaces can cause sev er e bur ns.

Read the operator’s manual before performing any maintenance on the machine.

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WARNING! Rotat ing and Hot

Components Decal

AVOID SERIOUS INJURY!

Located on the fan shroud inside the engine compartment.

Stop the engine and wait for all parts to cool before opening the engine compartment. Rotating parts can cause severe injury. Hot surfaces and liquid s can cause severe burns.

Read the operator’s manual before performing any maintenance on the machine.

WARNING! Read Operator’s

Manual

AVOID INJURY OR DEATH!

Located on the door pillar inside the cab.

Read the operator’s manual before operating or performing any maintenance on the machine.

WARNING! Rotating Components! Danger of

Entanglement! Decal

AVOID SERIOUS INJURY! Located below the engin e cover latch. Stop the engine before opening the engine

compartment. Rotating parts can cause severe injury.

WARNING! Crushing Hazard Decal

AVOID SERIOUS INJUR Y !

Located on the inside of the front window on cabequipped machines.

Only open and close the front window using the handles.

Always lock the front window using both locks.

WARNING! Decal

AVOID INJURY OR DEATH!

Located on the door pillar inside the cab.

No riders! Never use work tool as work platform.

Operate only from operator’s seat. ALWAYS wear seatbelt. WARNING: Avoid Overturn Side stability is reduced when: 1)

turning; 2) operating on rough terrain or side slopes; and 3) carrying load raised.

Carry load low. Do not exceed Rated Operating Capacity .

Avoid steep slopes and high speed turns.

Travel up and down slopes with heavy end uphill.

Read the operator’s manual before operating the machine .

WARNING! Hot Components Decal

AVOID SERIOUS INJURY!

Located next to the hydraulic system filler cap.

Stop the engine and wait for all parts to stop and cool before. Hot surfaces and liquids can cause seve re burns.

Read the operator’s manual before performing any maintenance on th e machine.

Printed in U.S.A. 2-12 918070/FP0811

WARNING! Mandatory Safety

Shutdown Decal

AVOID INJURY OR DEATH!

Before leaving the machine, or performing any servic e on t he machine, perform the “M andatory Safety Shutdown Procedure” on page 2-2..

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

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

3. Turn the key fully counterclockwise to shut off the engin e.

4. Lock out controls by raising left control console.

5. Remove the ignition key and take it with you.

WARNING! Danger Zone Decal

AVOID INJURY OR DEATH! Located on the back of the swing frame. Keep bystanders away fr om t h e machine when it

is in use.

WARNING! Danger Zone Decal

AVOID INJURY OR DEATH! Located on both sides of the boom swivel bracket. Swiveling boom can cause cr ushing. Keep

bystanders away from the machine when it is in use.

WARNING! Danger Zone Decal

AVOID INJURY OR DEATH! Located next to the boom swi vel br ack et . Keep bystanders away fr om t h e machine when it

is in use. Read the operator’s manual before operating the machine.

918070/FP0811 2-13 Printed in U.S.A.

ISO-Style Information Decal Locations (Serial Numbers AJ02993 and Up)

Track Front Decal

Located near the front of the track frame on both sides of the machine

Indicates the front of the track frame.

Lift Point Decal

Located on both sides of the boom on the dipper arm cylinder bracket, and on both ends of the dozer blade.

Apply lift hooks only in these locations.

Tie-Down Point Decal

Located on both ends of the dozer blade and near the rear end of the track frame on both sides of the machine.

Only use tie-down p oints to secure the machine during transport.

Diesel Fuel Decal

USE DIESEL FUEL ONLY! Located next to the fuel filler neck.

Hydraulic Fluid Decal

Located next to the hydraulic system filler cap.

USE HYDRAULIC FLUID ONLY!

Operator Controls Decal Located on the ceiling inside the cab. Provides quick-reference fo r the SAE operator’s

control option inside the cab. Read the operator’s manual before operating the

machine. Refer to the ope rator’s manual for details about the operator’s controls.

Printed in U.S.A. 2-14 918070/FP0811

Maintenance Decal Located on the back window of the cab. Provides main t enance intervals quick-refer ence. Read the operator’s manual before maintenan ce on

the machine. Refer to “Ma in te n ance Schedule” on page 4-5..

Operator Controls Decal Located on the ceiling inside the cab. Provides quick-referenc e fo r th e I S O operator’s

control option inside the cab. Read the operator’s manual before operating the

machine. Refer to the ope rator’s manual for details about the operator’s controls.

918070/FP0811 2-15 Printed in U.S.A.

ANSI-Style Safety Decal Locations (Serial Numbers AH02282 and Before)

PN 161985

PN 161966

PN 161986

Danger Zone Warning Decal

To Avoid Injury Warning Decal

Hydraulic Oil Warning Decal

Printed in U.S.A. 2-16 918070/FP0811

Cab Ceiling Decals To Avoid Injury Warning Decal (Cab Only)

PN 177443 PN 177444

PN 163976 PN 163973

PN 164854

PN 163975 BOTH SIDES

Warning Avoid Injury or Death Decal

918070/FP0811 2-17 Printed in U.S.A.

Entanglement Hazard, Rotating Fan, and Hot

PN 163977

PN 163978

PN 161987

PN 177441

PN 161965

Surface Decals

To Avoid Injury or Death Decal

Diesel Warning Decal

Printed in U.S.A. 2-18 918070/FP0811

CHAPTER 3 – OPERATION

WARNING

OPERATING CONTROLS

• Read and understand this entire manual. Follow warnings and instructions for operation and maintenance. Failure to follow instructions can result in injury or death.

• Read and understand all safety decals before operating the machine. DO NOT operate the machine unless all factoryinstalled guards and shields are in place.

• Be sure you are familiar with all safety devices and controls before operating the machine.

• Know how to stop the machine before starting.

• Use only with GEHL Company approved accessories or referral attachments. GEHL Company cannot be responsible for safety if the unit is used with nonapproved attachments.

Machine Orientation

Guards and Shields

Whenever possible, guards and shields are used to protect potentially hazardous areas on the machine. In many places, decals are also provided to warn of potential hazards or to display special operating procedures. See Chapter 2 – Safety.

The left operator’s console should be raised to enter and exit the cab. In the raised position, the console locks out all hydraulic functions of the machine. See Figure 3-1.

• Check for correct function after adjustments or maintenance.

Figure 3-1 Operator’s Left Console in Lock-out Position

918070/FP0811 3-1 Printed in U.S.A.

Figure 3-2 Equipment and Controls

Model 503Z/603 -- Serial Numbers AJ02993 and Up

Printed in U.S.A. 3-2 918070/FP0811

Pos.

Description For more information see page

1 Auxiliary Hydraulics Pedal Cover............................................................................................................................................................3-18

2 Auxiliary Hydraulics Pedal....................................................................................................................................................................... 3-18

3 Joystick (left)...........................................................................................................................................................................................3-17

4 Joystick (right) - optional proportional auxiliary hydraulic joystick shown................................................................................................3-17

5 Control Lever Base (left) 6 Control Lever Base (right) 7 Armrest (left) 8 Armrest (right)

9 Seat Horizontal Adjustment Lever...........................................................................................................................................................3-19

10 Air Vent (cab only, rear window / left) 11 Air Vent (cab only, rear window / right) 12 Radio (option)

13 Seat Backrest Adjustment.......................................................................................................................................................................3-19

14 Seat Belt Latch........................................................................................................................................................................................3-19

15 Cup Holder 16 Document Storage Box

17 Switch Panel.............................................................................................................................................................................................. 3-9

18 Throttle Lever..........................................................................................................................................................................................3-18

19 Fuse Box...................................................................................................................................................................................................1-6

20 Preheating/Ignition Switch.......................................................................................................................................................................3-13

21 Accessory Power Outlet 22 Instrument Cluster

23 Drive Pedal (left)......................................................................................................................................................................................3-14

24 Drive Pedal (right) ...................................................................................................................................................................................3-14

25 Drive Lever (left)......................................................................................................................................................................................3-14

26 Drive Lever (right).................................................................................................................................................................................... 3-14

27 Dozer Blade Pedal/Lever ........................ ............. ...................................................................................................................................3-18

28 Heater Control (cab only) ........................................................................................................................................................................3-24

918070/FP0811 3-3 Printed in U.S.A.

Figure 3-3 Equipment and Controls

Model 603 -- Serial Numbers AH00579 to AH02282

Printed in U.S.A. 3-4 918070/FP0811

Figure 3-4 Equipment and Controls

Model 503Z -- Serial Numbers up to AH02282; Model 603 -- Serial Numbers AH00578 and Before

918070/FP0811 3-5 Printed in U.S.A.

Pos.

Description For more information see page

1 Auxiliary Hydraulics Pedal Cover.............................................................................................................................................................3-18

2 Auxiliary Hydraulics Pedal .......................................................................................................................................................................3-18

4 Joystick (right) - optional proportional auxiliary hydraulic joystick shown................................................................................................3-17

5 Control Lever Base (left) 6 Control Lever Base (right) 7 Armrest (left) 8 Armrest (right)

9 Seat Horizontal Adjustment Lever ...........................................................................................................................................................3-19

10 Air Vent (cab only, rear window, on the left) 11 Air Vent (cab only, rear window, on the right) 12 Radio (option)

13 Seat Backrest Adjustment........................................................................................................................................................................3-19

15 Cup Holder 16 Bracket (storage box for documents)

20 Preheating/Ignition Switch .......................................................................................................................................................................3-13

21 Accessory Power Outlet 22 Coolant Temperature Indicator 23 Instrument Cluster

24 Drive Pedal (left)......................................................................................................................................................................................3-14

25 Drive Pedal (right)....................................................................................................................................................................................3-14

26 Drive Lever (left) ......................................................................................................................................................................................3-14

27 Drive Lever (right)....................................................................................................................................................................................3-14

28 Dozer Blade Pedal/Lever.......................................... ............. ............. .....................................................................................................3-18

29 Heater Control (cab only).........................................................................................................................................................................3-24

Printed in U.S.A. 3-6 918070/FP0811

Figure 3-5 Instrument Panel, Switches and Indicat ors

Model 503Z/603 -- Serial Numbers AJ02993 and Up

3PD

2PD

DP1

KMH

MPH

01PD

8PD

7PD

6PD

5PD

4PD

51PD

61P

71PD

81PD

91PD

02P

12PD

22P

32PD

DP24

918070/FP0811 3-7 Printed in U.S.A.

Pos.

Description

30 Hydraulic oil filter indicator (red) – Hydraulic oil filter indicator light comes on when hydraulic oil filter is too restricted. 31 Air filter indicator (red) – Air filter indicator light comes on when air filter is too dirty. 32 Battery charge fault indicator (red) – Battery charge indicator light comes on when the ignition is turned on and goes off when the engine

starts. If the indicator light comes on while the engine is running, the battery is not charging, indicating a faulty charging circuit in the alternator or problems with the V-belt. NOTE: a faulty V-belt affects cooling pump operation, which can lead to overheating and more serious engine problems. Shut off the engine IMMEDIATELY and determine the cause if this indicator comes on when the engine is running.

33 Engine oil pressure indicator (red) – Engine oil pressure light comes on when the ignition is turned on, and goes out when the engine

starts. During normal operation, this indicator should remain off. The indicator will light if the engine oil pressure drops too low. If this occurs,

shut the engine off IMMEDIATELY and determine the cause of the pressure drop. 34 Coolant temperature indicator (red) – Coolant temperature indicator light comes on when coolant temperature is too high. 35 Glow plug indicator (yellow) – Glow plug indicator light comes on when the ignition key is in the glow plug activation position. Indicator will

go out when the glow plugs have heated sufficiently to start the engine. 36 Hourmeter – Indicates the total operating hours of the machine. Use the hourmeter to track maintenance in the maintenance log. 37 Fuel level gauge – The fuel level gauge shows the amount of fuel in the tank. 38 Indicator light – Not assigned. 39 Hydraulic oil temperature indicator light – Hydraulic oil temperature indicator light comes on when hydraulic oil is too hot. 40 Coolant temperature gauge – Displays coolant temperature. 41 High-speed switch (transport speed) – Pressing the switch will enable high travel speed. 42 Windshield wiper switch (cab models only) – Pressing the two-position switch to the first position turns on the windshield wiper. Pressing

and holding the switch in the second position activates the washer fluid pump. 43 Work light switch – Press switch to the ON position to turn on the boom work light. 44 Roof lights (option) – Press switch to the ON position to turn on the roof light lights. 45 Rotating beacon (option) – Press switch to the ON position to turn on the rotating beacon. 46 Ventilation fan (two-speed) – Press the two-position switch to turn on the ventilation fan. Pressing switch to the first position is the low fan

speed position, and the second position is the high fan speed position. If the Summer/Winter operation valve is OPEN (HEATING position),

this switch will function as the cab heater ON/OFF switch. The Summer/Winter operation valve is located under the hood on top of the engine

behind the radiator. 47 Air conditioning (option) – Press the switch to turn on the air conditioning. 48 Proportional control status indicator (option) – One flash indicates precision mode; two flashes indicate power mode. 49 Not assigned 50 High-speed indicator (option) – Indicates high-speed is enabled. 51 Engine error indicator – Indicates a “check engine” condition. See page 5-6. 52 Auto-idle switch (option) – Enables optional auto-idle feature. See page 3-19.

Printed in U.S.A. 3-8 918070/FP0811

Figure 3-6 Instrument Panel, Switches and Indicat ors

41 42

43 44 45

49 49

Model 603 -- Serial Numbers AH00579 to AH02282

3PD

2PD

DP1

KMH

MPH

01PD

8PD

7PD

6PD

5PD

4PD

51PD

61P

71PD

81PD

91PD

02P

12PD

22P

32PD

DP24

918070/FP0811 3-9 Printed in U.S.A.

Figure 3-7 Instrument Panel, Switches and Indicat ors

41 42

43 44 45

46 47

48 49

Model 503Z -- Serial Numbers up to AH02282; Model 603 -- Serial Numbers AH00578 and Before

Printed in U.S.A. 3-10 918070/FP0811

Pos.

Description

33 Engine oil pressure indicator (red) – Engine oil pressure light comes on when the ignition is turned on, and goes out when the engine

starts. During normal operation, this indicator should remain off. The indicator will light if the engine oil pressure drops too low. If this occurs,

speed position, and the second position is the high fan speed position. If the Summer/Winter operation valve is OPEN (HEATING position),

this switch will function as the cab heater ON/OFF switch. The Summer/Winter operation valve is located under the hood on top of the engine

918070/FP0811 3-11 Printed in U.S.A.

Excavator Components

1. Fuel water separator

2. Battery disconnect switch (All Model 603; Model 503Z - serial numbers AH00579 and up)

3. Air cleaner

4. Fuel filter

5. Engine oil filter

6. Engine oil dipstick

7. Engine oil fill

8. Heater on/off valve (cab only serial numbers AD04650 and before)

9. Locking fuel filler cap

10. Hydraulic fluid filler cap

11. Hydraulic fluid level sight gauge

12. Radiator

13. Radiator overflow reservoir

14. Radiator cap

15. Windshield washer reservoir (cab only)

16. Hydraulic oil cooler

17. Air conditioning condenser (option, cab only)

18. Battery (503Z up to serial numbers AH02282 shown; Model 603 and 503Z machines with serial numbers AJ02993 and up battery is located under cab)

Figure 3-8 Excavator Components

Printed in U.S.A. 3-12 918070/FP0811

Ignition Key Switch

III

Model 503Z -- Serial Numbers AH00579 to AH02282

Model 603 -- Serial Num bers AH00579 and up

Model 503Z -- Serial Numbers A J 02993 and up

Model 603 -- Serial Numbers AH00578 and before

Battery Disconnect Switch

Note: The engine can only be started if the left control lever console is pivoted down into the operation position.

With the key in the fully counter-clockwise “P” position, all power is shut off. The key can be inserted or removed when the switch is in this position.

With the key in the “0” position, power to the accessory circuit is turned on. The key can be inserted or removed when the switch is in this position.

With the key in the “I” position, power is turned on to all controls and electrical circuits. The battery charge indicator light and the oil pressure indicator light will come on.

With the key in the “II” position, the glow plug indicator will come on while the glow plugs warm intake air in cold weather.

With the key turned fully clockwise “III” and held in position, the engine will crank/start and the indicator lights should go out. Release the key after the engine starts (the key returns to the “I” position when it is released after starting the engine).

A battery disconnect switch is located in the engine compartment under the hood. The switch allows electrical lock out of all functions of the excavator. See Figure 3-10. To disconnect battery and lock out all electrical functions, turn key (1) of the battery disconnect switch to position (2) and remove it. To reconnect battery and turn on all electrical functions, insert key (1) into the battery disconnect switch and turn down to the notched position (3).

Note: The key must always be returned to the “I” position between attempts to start the engine in order to activate the glow plug system.

Figure 3-9 Ignition Key Switch

918070/FP0811 3-13 Printed in U.S.A.

Figure 3-10 Battery Disconnect Switch

Travel Controls

WARNING

• Levers and controls should return to neutral position when released.

• Be sure the levers and controls are in the neutral (middle) position before starting the engine.

• Operate controls gradually and smoothly. Excessive speed and quick control movements without regard for conditions and circumstances are hazardous and could cause an accident.

Be sure that the dozer blade is “in front.” When the operator’s cab is facing forward, the blade will be visible and travel controls will operate as expected. If the dozer blade is not visible, the operator’ s cab is facing to the rear, and the travel controls will operate in reverse.

Figure 3-11 Travel Controls Spin Turn

Move the levers in opposite directions to spin the machine on its axis. To spin turn left, move the right control lever forward while pulling the left control lever to the rear; to spin turn right, move the left control lever forward while pulling the right control lever to the rear. See Figure 3-11.

Forward Travel

Push both travel control levers or pedals forward. The farther these are moved, the faster the machine will travel. See Figure 3-11.

Reverse Travel

Pull both travel control levers or pedals back. The farther these are moved, the faster the machine will travel. See Figure 3-11.

Turning During Travel

Move one control lever or pedal farther than the other one. To turn left while moving forward, move the right control lever farther forward; to turn right while moving forward, move the left control lever farther forward. See Figure 3-11.

Printed in U.S.A. 3-14 918070/FP0811

Tilting the Cab or Canopy

WARNING

• Always tighten cab lock-down nuts before driving or using the machine.

• Always close the cab door before tilting the cab.

• Stay clear from underneath the cab as it is tilted.

• Always secure the tilt rod in the support position the when cab is tilted.

5. Reinstall the cab lock-down nuts (2) and (3).

6. Place the jack handle tubes (4) back in the tool kit.

Refer to items 1—10 in Figure 3-12 to safely complete the following procedure.

Tilting the cab or canopy up:

1. Follow “Mandatory Safety Shutdown Procedure” on page 2-2.

2. Raise the floor mat (1) on the right, front of the cab and remove cab lock-down nut (2). Remove cab lock-down nut (3) at the right rear of the cab.

3. Securely close the cab door.

4. Locate the jack handle tubes (4) from the tool kit in the engine compartment, insert them into the jack (5) and jack to the limit. The cab will be raised as far as the jack (5) will travel.

5. Pull on handle (7) until the cab is completely tilted and supported by the safety cable (8).

6. Remove the tilt rod (9) from the storage bracket (10) and slide the tilt rod (9) into the guide bracket (11) and secure with the retention pin.

Tilting the cab or canopy down:

1. Remove the tilt rod (9) from the guide bracket (11) by removing the retention pin and slide the tilt rod (10) out of the guide bracket (9) and secure with the retention pin back in the storage bracket (10).

2. Use handle (7) to slowly lower the cab back onto the jack (5).

3. Remove jack handle tubes (4) from the jack (5) and insert the opposite end of the jack handle tubes (4) onto the release pin (6). Slowly turn release pin (6) counter-clockwise until the cab is lowered.

4. Turn the release pin (6) clockwise.

Figure 3-12 Tilting the cab or canopy

918070/FP0811 3-15 Printed in U.S.A.

CAUTION

Check tilt rod (9), the retention pin and

safety cable (8) at regular intervals for cracks and cuts. Replace defective parts immediately.

SAE/ISO Operating Controls Selector Valve

Located on the lower left side of the chassis, under the cab, is the SAE/ISO Selector Valve. See (1), Figure 3-

13. The SAE/ISO valve can be accessed through a cutout on the left side of the chassis at location (2). This machine has been set at the factory for SAE standard operation shown at position (3). If ISO operation is desired, loosen wing nut (5) and rotate valve to position (4) and retighten wing nut (5).

Figure 3-13 SAE/ISO Selector Valve

Printed in U.S.A. 3-16 918070/FP0811

SAE Operating Controls

ISO Operating Controls

SAE boom and bucket functions are controlled by the right and left joystick control levers located on the seat consoles.

SAE Left Joystick – see Figure 3-14.

1 – Arm extend 2 – Arm retract 3 – Swing left 4 – Swing right

Figure 3-14 SAE Left Joystick

ISO boom and bucket functions are controlled by the right and left joystick control levers located on the seat consoles.

ISO Left Joystick – see Figure 3-16.

1 – Boom lower 2 – Boom raise 3 – Swing left 4 – Swing right

Figure 3-16 ISO Left Joystick

SAE Right Joystick – see Figure 3-15.

5 – Boom lower 6 – Boom raise 7 – Curl bucket in 8 – Curl bucket out

Figure 3-15 SAE Right Joystick

Note: The joystick controls are pilot-operated. The farther the controls are moved from center, the faster the machine will function.

ISO Right Joystick – see Figure 3-17.

5 – Arm extend 6 – Arm retract 7 – Curl bucket in 8 – Curl bucket out

Figure 3-17 ISO Right Joystick

Note: The joystick controls are pilot-operated. The farther the controls are moved from center, the faster the machine will function.

918070/FP0811 3-17 Printed in U.S.A.

Boom Swivel/Auxiliary Hydraulics

Serial Numbers AH 02282 and earlier shown -- later

serial numbers simila r

Serial Numbers AJ02993 and up

Serial Numbers to AH02 282

Pedal

The boom can be swiveled without moving the swing frame by pressing and holding the auxiliary hydraulic/ changeover valve button (1) on top of the left joystick, and then pressing the auxiliary hydraulics pedal (2) left or right. See Figure 3-18. Pressing and holding the auxiliary hydraulic/changeover valve button (1) and pressing the auxiliary hydraulics pedal (2) to the left with your toe swivel the boom to the left. Pressing and holding the auxiliary hydraulic/changeover valve button (1) and pressing the auxiliary hydraulics pedal (2) to the right with your toe swivels the boom to the right.

The auxiliary hydraulics pedal (2) allows use/control of front end attachments. Action will vary depending on the attachment and how it is connected.

Dozer Blade

The dozer blade is controlled by the dozer control pedal/lever (1) located next to the travel controls. See Figure 3-19.

• Push control pedal/lever forward to lower the blade.

• Pull control pedal/lever rearward to raise the blade.

Figure 3-19 Dozer Blade Controls

Figure 3-18 Boom Swivel

Printed in U.S.A. 3-18 918070/FP0811

Throttle Lever

Models 503Z/603 -- S er ia l Numbers AH00578 and before

Model 603 -- Serial Numbers A H 0 0579 to AH02282

Models 503Z/603 -- Serial Numbers AJ02993 and Up

Model 503Z/603 -- Seri al N umbers AJ02993 and Up

Model 503Z/603 -- Serial Nu m bers AH00611 to AH02282

Optional Auto-Idle Feature

The engine speed is controlled by the throttle lever (1) In machines with serial numbers AJ02993 and up. the throttle is located behind the left armrest; in machines up to serial numbers AH02282, the throttle is located next to the right joystick. See Figure 3-20.

• Push throttle lever (1) forward to decrease engine speed.

• Pull throttle lever (1) rearward to increase engine speed.

Model 603 Standard; Model 503Z Option Serial Numbers AH00645 and Up

Press switch (1) to enable the auto-idle feature.

When the auto-idle feature is enabled, engine speed is automatically lowered to idle when no hydraulic functions occur for five seconds. Engine speed resumes when a hydraulic function is activated.

Figure 3-20 Throttle Lever

Figure 3-21 Auto-Idle Switch

918070/FP0811 3-19 Printed in U.S.A.

Operator’s Seat Adjustments

Model 503Z/603 -- Serial Numbers AJ02993 and up

shown -- earlier serial num bers similar

Serial Numbers to

AH02282

Serial Numbers AJ02993 and up

4. Backrest Adjustment

Note: The operator’s seat left console must be raised

in order to exit the cab. In the lowered or work position, all operational functions are activated, and operator exit is blocked by the Warning Arm/Lever. In the raised position, the all hydraulic functions of the machine are locked out.

Note: Not all serial number machines are equipped with all seat adjustment options

The backrest adjustment lever (5) allows the operator to move the backrest forward and rearward.

5. Headrest Adjustment

The headrest adjustment (6) allows the operator to move the headrest up and down.

6. Seat Height Adjustment

The seat height adjustment allows the operator to move the seat height up and down. To raise the seat height, grasp the seat and lift up until you hear an audible click. To lower the seat, raise the seat to the highest position and then lower the seat to its lowest position.

7. Horizontal Suspension

When horizontal suspension is turned on, shocks from travel motion are absorbed by the seat suspension.

Arm rests

Serial Numbers AJ02993 and Up: To adjust, hold armrest (2, Figure 3-23) and pull out latch (3). Move the armrest to the desired position and release latch (3). Make sure latch (3) locks securely into a detent in the armrest.

Figure 3-22 Seat Adjustment – Cab Shown

1. Seat Suspension Adjustment

Rotate the knob (1) to adjust the seat suspension for the operator’s weight. An indicator on the front of the seat base shows the weight adjustment in kilograms. (1 kg = 2.2 lbs.) Adjust the seat suspension correctly to ensure a comfortable ride. See Figure 3-22.

2. Horizontal Seat Adjustment

The seat adjustment lever (2) allows the operator to move only the seat forward and rearward.

3. Horizontal Seat & Control Adjustment

move both the seat and the controls forward and

The seat adjustment lever (3) allows the operator to

rearward.

Printed in U.S.A. 3-20 918070/FP0811

Serial Numbers AH02282 and before: To adjust, turn the adjustment wheel (4).

Note: The rear of the left armrest has a turnbuckle that may need to be adjusted to allow the left armrest to rotate out of the way when the left console is raised. Use the turnbuckle to adjust the armrest so it does not contact the left control lev er wh en rais ing t he left console to the lock-out position.

Figure 3-23 Armrests

Seat Belt

WARNING

CAUTION

Ventilation

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

Keep the seat belt clean because dirt can impair seat belt operation. Check seat belt condition regularly and have damaged or worn belts immediately repaired by an authorized workshop.

After an accident the seat belt strap is stretched and must be replaced with a new strap installed by an authorized workshop.

Make sure the seat belt is not twisted when it is fastened, and that it is fastened over the hips and not the stomach.

Fasten the seat belt tightly and securely. Remove hard, edged or fragile objects from your pockets or clothes that might lie between the seatbelt and your body.

Never use ether starting aids. Glow plugs are used for cold weather star ting. The glow plug can cause ether or other starting fluid to detonate, causing injury.

Windshield – Optional Cab

When the windshield is opened, be sure both latches are locked. When closing the windshield, keep hands on the handles and away from path of the windshield.

The windshield can be opened for ventilation. Squeeze/ turn latches (1, Figure 3-25) located at the upper corners of the windshield. Grasp the handles (2) and pull the windshield up until the latches lock in the open position.

Serial Numbers AJ02993 and Up

Fastening/Unfastening the Seat Belt

Fasten the seat belt around your hips and waist and insert tab (A, Figure 3-24) into buckle (B) until it clicks securely in place. Slack in the seat belt should automatically retract into seat belt spool (D).

Unfasten the seat belt by pressing button (C).

Figure 3-24 Seat Belt

The windshield can opened for ventilation. Squeeze latches (1, Figure 3-25) located at the upper corners of the windshield, pull/push the top of the windshield backwards/forward and release latches. Pull/push the top of the window until the catch locks the top of the windshield securely in place.

To close the windshield, squeeze/turn the latches and then lower the windshield. Lock the latches in the closed position.

Support the windshield when releasing it from the ceiling catches to avoid possible head injury.

For additional ventilation, the lower portion of the windshield can be removed and securely stored in the glass holder (3) located on the rear window.

918070/FP0811 3-21 Printed in U.S.A.

Before closing the windshield, first re-install (if

Serial Numbers AC02975 and before

Serial Numbers AC02976 and up

removed) and lower the bottom windshield (See “Movable Bottom Window – Optional Cab” on page 3-22). Close the windshield by squeezing/turning the latches, and then lower the windshield and lock the latches in the closed position.

Figure 3-26 Side Window Operation Movable Bottom Window – Optional Cab

Serial Numbers AJ02993 and Up

Squeeze both latches (1, Figure 3-27) on the left and right and slide the window at both latches to open or close. Release latches and make sure the window locks securely open/closed.

Figure 3-25 Windshield Latches Side Window – Optional Cab

Squeeze button (1, Figure 3-26) and slide the window to open. Release button (1) when the window is in the desired position. Make sure the window lock securely in one of the recesses.

Printed in U.S.A. 3-22 918070/FP0811

Figure 3-27 Lower Front Window Operation

Note: If the lower front window is raised all the way into the wind shield frame, it will move with the windshield as a unit if the windshield is raised for ventilation.

Serial Numbers up to AH02282

The lower front window can be removed and securely

IMPORTANT

Model 503Z/603 -- Serial Numbers AH02282 and earlier

shown -- later serial numbers similar

stored in the glass holder (3, Figure 3-25) located on the rear window.

Re-install the lower window before lowering the windshield.

Cab Door Latch Release – Optional Cab

When fully opened, the left cab door will lock in position to the side of the cab. To release the latch, use the black knob (1) located on the inside of the door. See Figure 3-28.

Figure 3-28 Cab Door Latch Release Interior Light

The interior light is located on the back of the cab above the rear window. Press the switch to the right or left to turn the light ON. Move the switch to the center position to turn the light OFF.

Figure 3-29 Interior Light Tool Kit and Cab Jack Handle

The machine tool kit and the cab jack handle are located in the storage area under the hood in the engine compartment.

918070/FP0811 3-23 Printed in U.S.A.

Cab Heat Control – Optional Cab

During the colder months, the operator’s cab heater can be turned on by rotating the dial near the vent (Figure 3-30). On older models, turn on the cab heater by opening the heater valve located under the hood on top of the engine behind the radiator (Figure 3-31). Rotate the lever to either the “heat on” or “heat off” position as required.

Note: The recirculated air mode vent is a storage compartment on the canopy model machines.

Recirculated Air Mode

When heating or cooling the cab, the recirculated air mode can be utilized to heat or cool only the air in the cab with no fresh air supply from the outside. Sliding the plate to the left will turn ON the recirculated air mode by closing the vent. Sliding the plate to the right will turn OFF the recirculated air mode by opening the vent. Figure 3-32 shows the unit with recirculated air mode turned OFF.

Figure 3-32 Recirculated Air Mode

Figure 3-30 Cab Heat Control - SN AD04651 and Up

Figure 3-31 Cab Heat Control - SN AD04650 and Before

Printed in U.S.A. 3-24 918070/FP0811

Preheated Fresh Air

WARNING

IMPORTANT

Selection of “cold” or “preheated” fresh air in winter.

Mounting/Removing Buckets

ALWAYS wear protective goggles, helmets, gloves,

steel-toed shoes, etc.

DO NOT service the bucket while the engine is

running.

DO NOT stand behind the bucket when removing the

pins.

DO NOT use your hands or fingers to align the bucket

and dipper arm holes.

ALWAYS verify the bucket is safely locked before

starting the engine and resuming operation.

Figure 3-33 Fresh Air

A deflector plate on the heater baffle can be set to two different positions:

• Fresh air-heater takes in air from outside the cab. See Figure 3-33.

• Preheated fresh air-heater takes in air from the chassis. See Figure 3-34.

Figure 3-34 Preheated Fresh Air

• DO NOT use a hammer directly on a securing pin to loosen it. The pounding may cause splintering, which may lead to serious injury.

• The bucket can crush hands or feet. DO NOT use your hands or feet as substitutes for the correct equipment.

Removing A Bucket

1. Lower the bucket to the ground with the flat side facing down (1, Figure 3-35).

Place the bucket against the ground with minimum pressure. More pressure increases resistance, which will make it more difficult to remove the pins.

2. Stop the engine.

Change from fresh air to preheated fresh air as follows:

• Tilt the cab. See “Tilting the cab or canopy” on page 3-15. The deflector plate is located on the heater under the cab.

• Loosen both attachment screws.

• Reposition and fit the deflector plate back on again.

• Tilt the cab back down again and secure it.

918070/FP0811 3-25 Printed in U.S.A.

3. Remove the two lynch pins (2A and 2B, Figure 3-

35).

Attaching A Bucket

WARNING

IMPORTANT

1. Grease the dipper arm and bucket holes.

2. Since the bucket is on the ground and stationary, maneuver the machine until the dipper arm holes align flush with the bucket holes.

DO NOT use your hands or fingers to align the bucket and dipper arm holes.

3. Stop the engine.

4. Insert the upper securing pin first (3A, Figure 3-

35). If needed, use a hammer and brass punch to gently tap the pin through the hole. Insert a lynch pin (2A, Figure 3-35) through the hole in the pin and lock.

Figure 3-35 Bucket Removal/Mounting

4. Remove the lower securing pin first (3B, Figure 3-

35) and then the other (3A). Carefully remove the pins with a hammer and brass punch if they are stuck. Once pin 3B is removed, pin 3A might have more pressure applied against it, making it difficult to remove. If this happens:

a. Start the engine.

b. Slightly raise and lower the boom to relieve

c. Turn off the engine.

d. Try removing the pin again, using a hammer

pressure from the pin.

and brass punch if needed.

The flat side of each securing pin head must align with the flat guide on each side of the hole; see 3A and 3B in Fi gure 3-27 for how the pins look when properly installed.

5. Insert the lower securing pin (3B, Figure 3-35). If needed, use a hammer and brass punch to gently tap the pin through the hole. Insert a lynch pin (2B, Figure 3-35) through the hole in the pin. Lock the lynch pin securely in place.

6. Verify the bucket is locked and secure before starting the engine and resuming operation.

Printed in U.S.A. 3-26 918070/FP0811

Auxiliary Hydraulics Connections

IMPORTANT

Follow the instructions in the operator’s manual from the attachment manufacturer for connecting the attachment to the machine’s auxiliary hydraulics machine’s auxiliary hydraulics.

Figure 3-36 shows the three quick connections on the dipper arm meant for auxiliary hydraulics, which are for the following:

• 1: Pressure line (male connector)

• 2: Large return line (female connector)

• 3: Pressure line (female connector)

7. To connect each coupling:

a. If necessary, rotate lock sleeve (2, Figure 3-37)

so notch (3) aligns with lock ball (4).

b. Pull lock sleeve (2) down in the direction of

arrow (5).

c. Insert the attachment coupling into the corre-

sponding auxiliary hydraulics connection coupling.

d. Release lock sleeve (2) so it snaps into place

and locks the couplings together. Verify the lock sleeve (2) is snapped closed and the coupling is securely locked together.

e. Twist lock sleeve (2) so notch (3) is NOT

aligned with lock ball (4), to help prevent accidental de-coupling.

Disconnecting the Quick Couplings

1. Perform steps 1 through 6 in “Connecting the Quick Couplings” on page 3-27 before proceeding to the next step.

Figure 3-36 Auxiliary Hydraulics Connections Connecting the Quick Couplings

1. Park the machine on firm and level ground.

2. Extend the dipper arm cylinder halfway and position the boom/dipper arm so the auxiliary hydraulic connectors are positioned as shown in Figure 3-36.

3. Stop the engine.

4. Turn the ignition key to position 1.

2. To disconnect each coupling:

a. Pull lock sleeve (2, Figure 3-37) down in the

direction of arrow (5).

b. Listen for the hissing sound to verify that any

pressure has been released from the connection.

c. Twist lock sleeve (2) so notch (3) is aligned

with lock ball (4).

d. Push lock sleeve (2) up in the direction of

arrow (6) to disconnect the coupling.

5. Release pressure from the bucket cylinder by moving the left control lever to the left and right.

6. Lift the left control lever base as a safety precaution.

918070/FP0811 3-27 Printed in U.S.A.

Figure 3-37 Quick Coupling Connections

MACHINE OPERATION

WARNING

IMPORTANT

WARNING

• Read and understand this entire manual. Follow warnings and instructions for operation and maintenance. Failure to follow instructions can result in injury or death.

• Read and understand all safety decals before operating the machine. DO NOT operate the machine unless all factory installed guards and shields are in place.

• Be sure you are familiar with all safety devices and controls before operating the machine.

• Know how to stop the machine before starting.

• Use only with approved accessories or referral attachments. Manitou Americas, Inc. cannot be responsible for safety if the unit is used with nonapproved attachments..

• Clean engine area of any flammable materials.

• Engine oil level (fill as required) (page 4-9)

• Hydraulic system for leaks

• Hydraulic oil level (fill as required) (page 4-9)

• Pivot points for proper operation

• Track tension and condition (page 4-23)

• Windshield washer reservoir level (cab machines only) (page 4-26)

• Lights, signals, indicators warning lights and indicator lights

• Attachment safely locked onto machine and attachment condition

• V-belt condition and tension (page 4-22)

• Lubrication points lubricated

• Broken and loose parts (repair as required)

• Engine cover securely latched

• Fuel level (page 4-11)

• Check for correct function after adjustments or maintenance.

Pre-Operation Checklist

See the list of recommended lubricants in “Fluid Capacities/Lubricants” on page 1-4 for proper grade of engine oil and hydraulic oil. Only use oils specified on the list. specified on the list .

Check the following items at the beginning of each work day or every 12 working hours:

• Seat belt and mounting hardware

• Safety decals (replace as required) (page 2-10)

• Air cleaner and intake hoses (page 4-10)

• Engine coolant level and system for leaks (page 4-

14)

Do not run the engine until the fuel tank is completely empty. If this happens, air will enter the fuel system, and the fuel system will have to be bled. Always fill the tank with fuel at the end of the working day. with fuel at the end of the working day.

Never use ether starting aids. Glow plugs are used for cold weather star ting. The glow plug can cause ether or other starting fluid to detonate, causing injury.

Engine Start and Stop

Note: When all machine controls are stationary (no pilot control pressure), the swing motor and travel motor brakes are automatically applied. When any control is activated, the appropriate brake is automatically released.

Note: All hydraulic functions are locked out with the operator’s seat left console in the raised position.

Printed in U.S.A. 3-28 918070/FP0811

Engine Start Procedure

DANGER

WARNING

IMPORTANT

DO NOT run the engine in an enclosed area without proper ventilation. Be sure there is adequate fresh air if running the machine in an enclosed area.

Indicator lamps should go out when the engine starts. If they do not, turn the engine off IMMEDIATELY. Do not use machine until the problem has been identified and repaired.

7. Allow engine to warm up at idle speed for approximately 10 - 15 minutes to fully warm up all systems.

Ensure that bystanders are a safe distance away from the machine before starting the engine.

1. Adjust the operator’s seat to desired settings.

2. Fasten the seat belt.

3. Be sure all levers and controls are in the neutral positions.

4. Make sure no one is dangerously close to the machine.

5. Insert the ignition key into the switch and turn it clockwise to the (II) position. Indicators for oil pressure and battery voltage should light. In cold weather, the glow plug indicator will come on while the glow plugs warm the engine.

6. Turn the key fully clockwise and hold it until the engine starts, and then release the key.

Note: The key must be returned to the (I) position between attempts to s tart the eng ine in order to activat e the glow pl ug system.

8. Test the drive pedals and control levers and check for proper operations before working with the machine.

Cold Weather Engine Starting Procedure

Note: Install an in-block or tank style engine heater that will keep engine block and oil warm for easier cold weather starting.

Note: Be sure engine oil is correct type and viscosity for the ambie nt (air) tempera ture.

Note: Be sure battery is fully charged.

1. Follow all steps under “Engine Start Procedure” above.

2. Advance the throttle to 1/4 engine speed for a faster warm up.

3. As the engine warms up, move the throttle lever to the idle position.

After Starting/During Operation

Check the following after startup and during operation. Stop the engine and fix problems before continuing operation.

Do not activate the starter motor for longer than 20 seconds during each starting attempt. If the engine does not start, turn the key fully counter-clockwise, wait 30 seconds, and then attempt to start the engine again.

918070/FP0811 3-29 Printed in U.S.A.

1. Warning indicator lights on?

2. Travel drive/steering operating properly?

3. Boom, dipper, cab rotation and bucket controls operating properly?

4. Engine exhaust excessively smoky?

Engine Shut Down

WARNING

Mandatory Safety Shutdown Procedure

Before leaving the machine:

Travel

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.

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

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.

New Machine Break-in Procedure

A new machine requires reduced operational speed during the first 50 operating hours to properly break in various parts. If the machine is subjected to hard use during the break-in period, damage to operating systems may occur.

Perform the following when operating a new machine:

• Before operating the travel levers, be sure that you know in which direction the machine is pointing. If the dozer blade is not visible from the operator’s cab, you are looking at the rear of the machine and the travel controls will be the reverse of normal operation.

• Before moving, be sure that ther e are no personnel in the way of the machine. Sound the horn to alert workers that you are about to move the machine.

• Be sure the path is clear during travel.

• Use extreme caution when reversing travel. Be sure there is a clear path behind the machine.

• Operate the travel control levers smoothly to avoid sudden starts and stops.

• Before leaving the operator’s seat, be sure to lock out all control systems and shut down the engine to avoid accidental activation.

• Perform all steps in “Pre-Operation Checklist” on page 3-28.

• Start engine and let it idle for 10 - 15 minutes so all components and systems can warm up.

• Operate machine at about 80% of maximum loads and speed.

• At the end of the first 100 operational hours, drain and replace the engine oil and engine oil filter.

Printed in U.S.A. 3-30 918070/FP0811

Travel Speed Selection

CAUTION

Two travel speed ranges can be selected by using the Travel Speed Switch (1) located on the control console. See Figure 3-38. The 503Z and 603 units use an Auto2-Speed transmission on the drive motors. This feature enables the transmission to automatically switch from high to low speed when it senses a load.

Travel speeds are:

• Slow Speed Maximum = 1.7 mph (2.8 km/h)

• High Speed Maximum = 2.9 mph (4.7 km/h)

The slow-speed setting should be selected to prevent automatic up-shifts if conditions warrant.

3. Travel straight up and down slopes; never travel across the slope. See Figure 3-39. Extend arm and lower boom to keep the bucket about 12” (300 mm) off the ground. If the machine starts to slide or becomes unstable, lower the bucket to regain control. If the engine stalls, lower the bucket, make sure that all controls are in the neutral position and restart the engine. See “Operating on Slopes” on page 3-33 for more information about operating the machine on slopes.

Figure 3-38 Travel Speed Selection General Travel Instructions

1. Avoid sudden movements and sharp turns.

2. Travel slowly on rough, frozen, or uneven terrain.

Figure 3-39 Travel Down Slopes

4. To travel straight, push both travel control levers (or pedals) forward (or rearward). The farther the levers (or pedals) are moved, the faster the travel speed.

5. Pivot (or wide) turns are made by rotating only one track forward (or rearward). The machine will pivot on the stationary track.

6. Spin turns are made by rotating one track forward and one track rear. The machine will spin around its mid-point.

7. The excavator can travel in water that comes up to the top of the upper track rollers. Be sure that the footing is solid so that the machine will not sink.

918070/FP0811 3-31 Printed in U.S.A.

Machine Operation

IMPORTANT

DANGER

WARNING

Joystick Controls

Extending and retracting the cylinders (boom, arm and bucket) are controlled by the joysticks located on the consoles attached to the operator’s seat. See page 3-17 for control configurations.

Note: The joystick controls are pilot-operated. The farther the controls are moved from center, the faster the machine will function.

Hydraulic Swivel Unit Brake

Swing frame rotation is sufficiently braked by moving the control lever back to the initial position. Moving the control lever in the opposite direction brakes the swing frame with full hydraulic pressure.

Hydraulic swivel unit brake function is not optimal if the hydraulic system has not reached operating temperature.

The upper carriage’s rotation is sufficiently braked by moving the control lever back to the initial position. Moving the control lever in the opposite direction brakes the upper carriage with full hydraulic pressure.

Operating Precautions

• DO NOT elevate the front end of the tracks by use of downward pressure on the dozer blade. This will cause the machine to become unstable.

• DO NOT excavate underneath the machine.

• Always be sure that there is adequate support underneath the machine. Be aware of conditions that could cause the earth or foundation to collapse, resulting in risk of injury or death.

• Do not position the machine directly underneath structures during demolition. Falling objects or structure collapse could cause severe damage or personal injury.

• Be sure that there is the proper clearance from overhead electrical lines.

• Be sure that all underground electrical power and gas supply lines are clearly marked and avoided.

Mechanical Stop Brake

A multi-disc brake integrated into the rotation drive has an additional mechanical brake effect with a time delay. This brake is used to stop the swivel unit from rotating in any position.

Printed in U.S.A. 3-32 918070/FP0811

• DO NOT rest your feet on the travel pedals during normal machine operation. Unexpected machine movement could occur.

• On Model 603 machines, make sure there are no obstacles in the immediate area before rotating the swing frame because the rear section of the swing frame protrudes over the undercarriage.

• When working close to an excavated edge, be sure that the ground the machine is sitting on is solid. Keep the travel motors to the rear. See Figure 3-40.

DO NOT use machine travel or swing to provide addi-

tional breakout force when the bucket is in the ground.

DO NOT jam bucket into the ground and use machine

IMPORTANT

WARNING

weight to provide additional breakout force.

When working on soft or muddy ground, be sure that the machine is not sinking.

DO NOT use the bucket as a hammer or ramming

device.

When digging at maximum excavation depth, BE SURE that the dozer blade does not contact the boom cylinder. Damage to the boom cylinder may occur if it contacts the dozer blade.

Figure 3-40 Machine Position for Excavating

Figure 3-41 Level Work Area on Slope

• Travel straight up and down slopes; never travel across the slope. See Figure 3-39. Extend arm and lower boom to keep the bucket about 12” (305 mm) off the ground. If the machine starts to slide or becomes unstable, lower the bucket to regain control. If the engine stalls, lower the bucket, be sure that all controls are in the neutral position and restart the engine.

• When traveling down a slope, put the machine in the position shown in Figure 3-42, control the speed with the travel levers and the throttle controls, and reduce engine RPM.

Operating on Slopes

• Do not travel up or across a slope steeper than 15°. Do not travel down a slope steeper than 25°. Keep boom centered while traveling.

• Keep attachments as low as possible when traveling on slopes or rough terrain.

Operating on a slope is hazardous. It is recommended to level the work area as shown in Figure 3-41. If this is not possible, use the following guidelines:

918070/FP0811 3-33 Printed in U.S.A.

Figure 3-42 Travel Down Slope

• To achieve the best stability while excavating, lower the dozer blade to the ground.

• Operate as slowly as possible and avoid sudden changes in direction.

• Avoid traveling over objects such as rocks, trees, stumps, etc.

• Stop the machine travel before moving the bucket or dozer controls.

• Slow the work cycle. Take your time.

• Avoid working with the tracks positioned across the

WARNING

Serial Numbers AJ02993 and after

slope. Position the machine with the blade downhill and lowered.

• Avoid swinging or extending the bucket farther than necessary in a downhill direction. If you must swing the bucket downhill, keep the boom low and skid the bucket along the ground.

• When working with the bucket on the uphill side, keep the bucket as close to the ground as possible. Unload far enough away from the excavation to prevent the possibility of a cave-in.

Cold Weather Operation

In cold weather, mud should be removed from the machine before parking. See “Track Cleaning” on page 4-23 for cleaning mud off of the tracks. If possible, park the machine on solid ground, or on wood planks, to prevent the track or undercarriage from freezing to the ground.

Operating in Water

Do not operate or immerse the machine in water higher than the top of the upper track rollers.

Thoroughly grease the machine if it has been operated in deep water.

Swiveling the Boom

Working with the boom swiveled to the side reduces lifting capacity.

Overloading the bucket can cause an unstable condition and increases the possibility of tipping the machine.

The excavator boom can be swiveled from the front position 61º to the right and 65º to the left on the 503Z, and 51º to the right and 75º to the left on the 603. This allows excavation of trenches along walls, fences, etc. See Figure 3-43.

Figure 3-43 Boom Swivel Control

Press and hold the auxiliary control button, located on top of the left joystick. Then press the auxiliary hydraulics pedal (2, Figure 3-43) with your toe or heel. Pressing the pedal down to the left swivels the boom to the left. Pressing the pedal down to the right swivels the boom to the right.

Bucket controls do not change when swiveling the boom.

Printed in U.S.A. 3-34 918070/FP0811

Grading

WARNING

Model 503Z/603 -- Serial N um b e rs AJ02993 and Up

Model 503Z/603 -- Serial Numbers to AH02282

Bulldozing

• Be sure there is proper clear ance for the front end attachments when bulldozing.

• Be sure that the front end attachments do not contact any overhead power lines or obstructions during bulldozing.

• DO NOT drive machine into the excavation or onto loose soil, which can cause an unstable condition, and possible tipping of the machine.

1. Raise or lower the dozer blade using the control lever/pedal located to the right of the travel levers/ pedals. See Figure 3-44. Move the control forward to lower the dozer blade, rearward to raise the dozer blade.

2. The boom must be fully raised and the bucket curled in (up) when grading.

3. When grading, the material may be pushed away to the front or the side.

4. Raise the dozer blade slightly if excessive resistance occurs.

5. When the blade is in position, use the travel controls to move the machine as in normal travel.

Figure 3-44 Dozer Blade Control

918070/FP0811 3-35 Printed in U.S.A.

Excavation

IMPORTANT

The following section applies to an excavator with a standard bucket, which is used mainly for digging into the ground to loosen, excavate and load loose or solid material.

Never use the excavator bucket to perform actions other than digging, grading, loadi ng and excavating. Damage to the excavator could result.

• Do not use the swiveling force of the excavator so the bucket serves as a hammer or battering ram (1, Figure 3-

45).

• Do not lower the bucket into the ground while rotating the upper carriage or driving the excavator (2, Figure 3-46).

• When excavating, lower the dozer blade to the ground to aid machine stability. Whenever possible, it is best to position the dozer blade on the same side as the excavation.

• Do not support the weight of the machine on one side of the dozer blade.

• Do not use the falling force of the dipper arm so the bucket serves as a hammer or pile-driver (3).

• Do not cause the excavator to tip, bounce or fall to amplify digging or excavating (4) force.

• Use caution when retracting the bucket to prepare for driving or transport. Hitting the bucket into the dozer blade might damage either attachment, especially the bucket teeth.

• The dozer blade is intended for grading only; using it as a battering ram risks serious damage to the blade, its cylinder and connections.

Figure 3-45 Machine Operation Exclusions

Printed in U.S.A. 3-36 918070/FP0811

Figure 3-46 Machine Operation Exclusions

Excavating

IMPORTANT

1 2 3

4 5 5

4. After the bucket is sufficiently filled:

Proper Bucket Position

Move the flat side of the bucket so it is parallel to the ground (Figure 3-47).

Positions 2 and 3 in Figure 3-47 show improper bucket orientations while excavating. Position 2 forces the bucket downward into the ground, slowing down work and subjecting the engine and hydraulic pump to overloading. Position 3 forces the bucket upward toward the ground surface, reducing productivity because of reduced bucket loads.

a. Continue moving the dipper arm toward the

excavator.

b. Extend the dipper arm cylinder so the bucket is

tilted upward (6, Figure 3-48).

c. Raise the boom.

Figure 3-48 Proper Digging Technique Trench Excavating

Trench excavating is most efficient when the machine tracks are parallel to the line of the trench (Figure 3-

49). For larger trenches, excavate each side first and then the center.

Figure 3-47 Proper and Improper Bucket Orientations

Proper Digging Technique

1. Lower the bucket into the ground (4, Figure 3-48).

2. After the bucket penetrates the ground, adjust it so its flat side is parallel to the ground (5, Figure 3-

48).

3. Pull the bucket towards the excavator by:

a. Moving the dipper arm toward the excavator,

and

b. Lowering the boom.

918070/FP0811 3-37 Printed in U.S.A.

Figure 3-49 Efficient Trench Excavating

When excavating in confined areas, excavate by

WARNING

rotating the upper carriage and swiveling the boom (Figure 3-50).

Figure 3-50 Excavating Trenches Sideways

• Working alongside trenches and deep excavation are two applications where the dozer blade might restrict bucket movement. When working alongside trenches, lower and place the dozer blade on the ground to avoid damage to the boom cylinder. When deep excavating, position the machine so the lowered dozer blade is on the opposite side of the excavation (Figure 3-51).

Placing the dozer blade on the opposite side of the excavation decreases machine stability. Always consider operator safety when operating the machine, especially under less-than-ideal working conditions.

Loading Vehicles

When loading vehicles, consider the following:

• Whenever loading in a confined area with a limited range of motion, position the truck so maximum visibility is ensured for the excavator operator.

• When work conditions permit, position the truck so the excavator can load material at the rear of the truck instead of the sides (1, Figure 3-52). The most effective way to load into the rear of the truck is when the truck and excavator form a 45° angle (2, Figure 3-52).

• Raise the boom and dipper arm to dump height just before rotating toward the truck.

• Whenever possible, dump upwind to keep dust and airborne debris away from the operator, and the excavator air filters and fans.

Figure 3-51 Dozer Blade Positioning

Printed in U.S.A. 3-38 918070/FP0811

Figure 3-52 Loading Vehicles

Transporting

WARNING

Towing

• When towing the machine, make sure no one is close to the towing apparatus, or in between the vehicles. The machine may only be towed using suitable towing equipment, in connection with suitable towing apparatus, such as a towing coupling, hooks and eyes.

• Do not use a towing apparatus that is kinked, twisted, or otherwise damaged.

• Do not apply high loads abruptly to the retrieval apparatus. The towing bracket has a maximum admissible load of 6992 lbf (3110 daN).

• The towing bracket is designed for retrieving the machine only. Do not use the excavator to tow other vehicles.

• Do not tow the machine if the travel drive is damaged. Damage to the machine cause by towing is not covered under warranty.

The Excavator can be towed by using the towing bracket (1). Secure a towing shackle, shackle pin and lock (2) of adequate size to the towing bracket (1) as shown in Figure 3-53. Tow the machine slowly and only short distances.

Lifting the Machine

• Use a lifting device and rigging with sufficient capacity for the weight of the machine plus any attachments

• While lifting, maintain the center-ofgravity and balance points on the machine. See Figure 3-54.

• Do not swing the boom.

• Never lift the machine with the anyone on-board.

Secure the lifting fixture sling to the lifting points (1) as shown.

• Model 503Z: length L1 on the lifting sling for the

boom must be 5’, 7” (1.70 m) long; length L2 on the lifting sling must be 12’, 11” (3.93 m) long. See Figure 3-54.

• Model 603: length L1 on the lifting sling for the

boom must be 6’, 7” (2.0 m) long; length L2 on the lifting sling must be 15’, 0” (4.6 m) long. See Figure 3-54.

• Do not exceed rated load capacity of the lifting machine. See “503Z General Specifications” on page 1-9 and “603 General Specifications” on page 1-10 for excavator weights.

Figure 3-53 Towing

918070/FP0811 3-39 Printed in U.S.A.

Figure 3-54 Machine Lifting Points

Loading and Transporting

WARNING

Use only transport machines that are in proper working order and are approved for use on public roads.

• Do not exceed the transport vehicle’s gross weight rating and the gross axle weight rating when loading and transporting the machine.

• The transport vehicle must have sufficient capacity for the size and weight of the machine. See “503Z General Specifications” on page 1-9 and “603 General Specifications” on page 1-10.

• Make sure the load does not fall short of the minimum axle load of the steering axle of the transport vehicle, otherwise the transport vehicle’s steering could be seriously affected.

6. Slowly and carefully drive the machine onto the transport vehicle. Do not change direction while driving on the ramps. Instead, drive down off of the ramps, and re-align the machine with the ramps.

7. After the machine is on the transport machine, lower the dozer blade and the bucket onto the loading surface and turn of the engine. See Figure 3-55.

8. Perform the Mandatory Safety Shutdown Procedure on page 2-2.

9. Lock the cab. Do not allow anyone to stay in the machine.

10. Place chocks under the machine tracks and secure the machine to prevent slipping, overturning and moving on the transport machine.

11. Use the tie down points (1) identified by decals for securing to the transport machine. See Figure 3-55. Securely tie the excavator to the transport vehicle at the front, rear and the sides.

• Adjust transport speed to the load, to the road/traffic conditions and to the handling of the transport vehicle. Consider all possible transport conditions such as: heavy braking, evasive maneuvers, and uneven or rough roadways.

When using ramps to load the machine:

• Do not exceed an incline of 17° (30%). See Figure 3-55.

• Clean dirt, mud, ice and snow from the ramps and tracks.

• Use metal loading ramps with a slip-resistant surface, and with beveled ends to prevent damage to rubber tracks.

1. Attach ramps securely to the transport machine to prevent them from slipping off during loading.

2. Load the machine on solid, even ground.

3. Apply the transport machine parking brake and chock the wheels.

4. Determine the direction of the track movement (dozer blade facing forward) before moving the machine onto the ramps.

5. Raise the bucket and dozer blade on the excavator high enough so they will not touch the ramps during loading.

Printed in U.S.A. 3-40 918070/FP0811

Figure 3-55 Loading and Transporting

Secure the machine properly so it cannot slip, slide,

Serial Numbers AJ02993 and after

roll, tip over or fall, or cause the transport vehicle to tip over under transport conditions. Use anti-slip bases and linings, load-securing straps and chains, clamping beams, protective paddings, nets, edge protectors, etc. as needed to properly secure the load. Consider all possible transport conditions such as: heavy braking, evasive maneuvers, and uneven or rough roadways. Make sure the load does not exceed the authorized maximum height.

OPTIONAL CONTROLS

Proportional Auxiliary Hydraulic Joystick Control (Option)

The proportional auxiliary hydraulic joystick control enables the following new functions:

• Selectable two-speed variable auxiliary hydraulic mode at startup (precision or power).

• Auxiliary hydraulic control moved to the right joystick thumb control.

• Auxiliary hammer operation is enabled for the right joystick trigger button control.

Note: With proportional auxiliary hydraulic joystick control , the auxiliary hydraulic / ch ange over valve button (A, Figure 3-56) is not functional . Pedal (B) always controls boom swivel and does not change to control the auxiliary hydraulics if button (A) is pressed. The auxiliary hydraulics are instead controlled using the thumb and trigger switches installed on the new right joystick.

918070/FP0811 3-41 Printed in U.S.A.

Figure 3-56 Auxiliary Hydraulic Changeover Valve Button/Boom Swivel Pedal

Two-Speed Variable Auxiliary

Hold Switch

to the Right

During

Startup for

Power

Mode

Hold Switch

to the Left

During

Startup for

Precision

Mode

Model 503Z/603 -- Serial Numbers AJ02993 and Up

Model 503Z/603 -- Serial Numbers to AH02282

Hydraulic Mode Selection

Upon startup, the auxiliary hydraulic system can be placed into either the power mode, or the precision mode. Select the appropriate mode depending upon the job requirements.

1. Shut down the excavator.

2. To set the auxiliary hydraulics to power mode, slide and hold the thumb switch (C, Figure 3-57) on the right joystick to the right and start the excavator.

3. To set the auxiliary hydraulics to precision mode, slide and hold the thumb switch (C, Figure 3-57) on the right joystick to the left and start the excavator.

4. Continue holding thumb switch (C) until the proportional control indicator (D, Figure 3-58) flashes. It will flash once when starting in precision mode; twice when starting in power mode.

Figure 3-57 Right Joystick

Figure 3-58 Proportional Control Indicator

Note: After the excavator is started, it must be shut down and restarted in order to change between auxiliary hydraulic modes.

Printed in U.S.A. 3-42 918070/FP0811

Auxiliary Hydraulics Proportional

Joystick Control

When the excavator is running, use the thumb switch (C, Figure 3-59) on the right joystick to control the auxiliary hydraulics.

Figure 3-59 Auxiliary Hydraulics Control

Slide thumb switch (C) to the right to move the auxiliary hydraulics in one direction; slide thumb switch (C) to the left to move the auxiliary hydraulics in the opposite direction.

Auxiliary Hydraulic Hammer Operation

Note: Use the power mode (refer to “Two-Speed Variable Auxiliary Hydraulic Mode Selection”) when operating a hydraulic hammer attachment. Maximum performance of hammer attachments is only possible using the power mode.

To operate an auxiliary hydraulic hammer attachment, press and hold trigger button (D, Figure 3-60) on the right joystick. The hammer will operate continuously until button (D) is released.

Figure 3-60 Hammer Operation

918070/FP0811 3-43 Printed in U.S.A.

NOTES

Printed in U.S.A. 3-44 918070/FP0811

CHAPTER 4 – MAINTENANCE

WARNING

GENERAL INFORMATION

Instructions are necessary before operating or servicing the machine. Read and understand this entire manual. Follow warnings and instructions for operation and maintenance. Check for correct function after adjustments or maintenance. Failure to follow instructions can result in injury or death.

Be sure you are familiar with all safety devices and controls before operating or servicing the machine. Know how to stop before starting. This machine is designed for use only with approved accessories or referral attachments. Manitou Americas, Inc. cannot be responsible for safety if the unit is used with non-approved attachments.

Care and Servicing

Care and servicing have a significant influence on the readiness for operation and service life of the machine.

For additional service information about the engine, see the service manual provided with the machine.

Use of lubricants that do not correspond to the manufacturer’s recommendations may invalidate warranty claims.

More frequent servicing, other than the recommended intervals, may be required under extreme operational conditions (extremely dusty or hot conditions).

Always dispose of waste lubrication oils and hydraulic fluids according to local regulations or take to a recy-

cling center for proper disposal. DO NOT pour fluids

onto the ground or down a drain.

DO NOT power wash the main hydraulic pumps and

controls, throttle solenoids and sealed bearings. High pressure water can be forced through seals and trapped within these components, causing premature failure.

The operating pressure settings of the hydraulic system should only be adjusted by trained, qualified personnel. If malfunctions are caused by unauthorized alteration of operating pressure settings, all warranty responsibilities of the manufacturer are invalidated.

Hydraulic reservoir is under pressure. Avoid contact with leaking hydraulic fluid and diesel fuel under pressure. It can penetrate the skin and eyes.

918070/FP0811 4-1 Printed in U.S.A.

Maintenance Safety

• Never service the machine without reading the applicable instructions.

• Always lower bucket and dozer blade to the ground before performing any maintenance.

• Use correct procedures to lift and support the machine. Always lift the blade fully before installing jackstands.

• Keep engine cover and hydraulic valve cover closed except for service. Close and latch covers before operating the machine.

• Be sure to have area properly ventilated when grinding or welding parts. Wear a dust mask.

• Exhaust fumes can kill. Exhaust system must be tightly sealed. If working in an enclosed area, vent exhaust to outside when engine must be run for service.

• Never modify equipment or add unapproved attachments.

• Before checking fluid levels, stop engine and let cool, and then clean any flammable materials from the engine and engine compartment.

• Never service or adjust machine with the engine running unless the service procedure requires it.

• Avoid contact with leaking hydraulic fluid and diesel fuel under pressure, which can penetrate the skin and eyes. NEVER use your hands to search for hydraulic fluid leaks; use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and can penetrate skin and cause serious injury. If any fluid is injected into your skin, get immediate medical attention. Injected fluid MUST be surgically removed or gangrene may result.

• Never fill fuel tank with engine running, while smoking or when near open flame.

• Wipe up fuel spills immediately.

• Keep body, jewelry and clothing away from moving parts, electrical contacts, hot parts and exhaust.

• Wear eye protection when servicing the machine.

• Lead-acid batteries produce flammable and explosive gas. Keep arcs, sparks, flames and lighted tobacco away from batteries.

• Batteries contain acid, which burns eyes and skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact, flush well with water and get immediate medical attention.

Printed in U.S.A. 4-2 918070/FP0811

Maintenance Label Symbols

Symbol Assembly Explanation

General Visual check

General Lubrication instructions

Fuel system Drain condensation water

Fuel system Replace the fuel filter; clean the fuel pre-filter

Radiator Check the coolant level

Radiator Change coolant

Engine Check valve clearance; adjust if necessary

Engine Check engine oil level

Engine Change engine oil

Engine Replace oil filter

Engine Check V-belt tension

Travel drive Change final drive oil

Travel drive Check final drive oil level

Undercarriage Check track tension

Hydraulic system Check hydraulic oil level

Hydraulic system Change hydraulic oil

Hydraulic system Replace hydraulic oil filter; replace hydraulic reservoir breather filter

Radiator fins Clean radiator fins

Heating, air conditioning

918070/FP0811 4-3 Printed in U.S.A.

Replace the cab air filter

Maintenance Label

Printed in U.S.A. 4-4 918070/FP0811

MAINTENANCE SCHEDULE

The following service schedule is a recommended. Maintenance work must be done at regular intervals. Failure to perform scheduled maintenance work will result in excessive wear and early machine failures. The following service schedule is a recommended.

Check, Clean and Inspect

Service Activity Daily Every 50

Hours

Engine oil level x x Engine coolant level x x Hydraulic oil level x x Inspect engine/hydraulic oil radiator

and air conditioning condenser for dirt/ debris; clean if necessary

Inspect cooling system, heating and hoses for leaks and pressure (visual check)

Inspect air filter for damage x x Inspect water separator pre-filter; drain

water Check V-belt condition and tension x x Check exhaust system for damage x x Gearbox oil level x x Check battery electrolyte; fill with dis-

tilled water if necessary Clean battery x x Replace cab air fi lter fo r heatin g and air

conditioning Empty diesel fuel tank

Clean water separator x x Inspect alternator, sta rter a nd electrical

connections, bearing play and function Preheating system and electrical con-

nections Check engine valve clearance; set if

necessary Fuel injection pump, injection and pres-

sure, injection nozzles and valves Inspect pilot control valve filter/restric-

tor; clean/replace if necessary Clean drain holes in cab/canopy x x

Every 250

Hours

Every 500

Hours

Every

1000

Hours

Customer Dealer

a. After emptying the tank, water must be removed and air must be purged from the fuel system before use. See “Fuel

Shut-off Valve and Water Separator” on page 4-13 and “Purging Air from the Fuel System” on page 4-13.

918070/FP0811 4-5 Printed in U.S.A.

Check, Clean & Inspect (Cont.)

Service Activity Daily Every 50

Hours

Every 250

Hours

Every 500

Hours

Every

1000

Customer Dealer

Hours

Check tracks for cracks or cuts x x Check track tension ; adjus t if ne cess ary x x Inspect cylinder piston rods for damage x x Ensure bucket and at tachment pins ar e

secure and locked Inspect hydraulic line clamps for tight-

ness/damage Clean hydraulic couplings/dirt build-up

on the hydraulic system dust caps Grease central lubrication system x x Inspect engine cover gas strut x x Ensure warning decals and Operator’s Manual are in place

Check primary relief valve pressure Check fasteners for tightness

Check indicator lights for correct func-

tion Inspect cab/canopy tilt lock/support components

Inspect insulating mats in the eng ine compartment

Check bearing play on tread rollers,

xxxx

xx x xx x xx x

xx x

track carrier rollers and front idlers Check air filter restriction indicator x x

a. Check after first 50 hrs; every 500 hrs thereafter.

Fluid and Filter Changes

Service Activity Daily Every 50

Hours

Engine oil Engine oil filter Fuel filter Hydraulic oil filter insert Gearbox oil

x x x x

x Hydraulic oil xx Breather-hydraulic oil tank x x Engine coolant xx Air filter element when indicator light

comes on

a. Change after first 50 hrs; every 500 hrs thereafter. b. Dusty work environment, high temperature, high rate of hammer use, and similar intensive use conditions. c. Change after first 50 hrs; every 500 hrs thereafter. d. Change after first 50 hrs; every 1000 hrs thereafter.

a a c c d

Every 250

Hours

Every 500

Hours

Every

1000

Customer Dealer

Hours

xx xx

Printed in U.S.A. 4-6 918070/FP0811

Cab Air Conditioning

Service Activity Daily Every 50

Hours

Test air conditioning function x x Check dehumidifier for corrosion x x Replace cab air filter x x Check refrigerant x x

Replace dehumidifie r

Replace compressor oil

Every 250

Hours

Every 500

Hours

Every

1000

Hours

xx xx

Customer Dealer

a. Replace every 1000 hrs or once every 2 years, whichever comes first.

Cab Functional Checks

Service Activity Daily Every 50

Lights, signaling system, audible warning system

Heating function

a. Operate weekly.

Hours

Every 250

Hours

Every 500

Hours

Every

1000

Hours

Customer Dealer

Leakage Checks

Service Activity Daily Every 50

Hours

Inspect hydraulic lines/hoses for tightness, leaking, or chafing

Engine and hydraulic system components

Cooling and heating circuit components x x Traveling drive components x x

Every 250

Hours

Every 500

Hours

Every

1000

Hours

Customer Dealer

918070/FP0811 4-7 Printed in U.S.A.

Lubrication

D = Daily W = Weekly

D D

(See Figure 4-1).

Service Activity Daily Every 50

Hours

Dozer blade x x Swivel console x x Boom x x Dipper arm x x Attachments x x Chassis (front of undercarriage) x x

Every 250

Hours

Every 500

Hours

Every

1000

Hours

Customer Dealer

Figure 4-1 Lubrication Points

Printed in U.S.A. 4-8 918070/FP0811

Recommended Lubricants

IMPORTANT

max min

Engine Oil

Engine

Be sure to read the service manual supplied

Be sure to read the engine manual supplied with this machine for detailed engine specifications.

See “Fluid Capacities/Lubricants” on page 1-4 for engine oil specifications.

Hydraulic Oil

See “Fluid Capacities/Lubricants” on page 1-4 for hydraulic oil specifications.

Swing Ring

Lubricate with a heavy-duty lithium complex grease with 3% molybdenum disulfide, such as Chevron RPM Heavy Duty Grease No. 2, Mobilgrease Moly 52 or BP Energrease Moly EP2.

Final Drive Unit

An EP grade gear oil that conforms to API GL5, such as Chevron Delo Gear 80W-90 or BP Transgear 80W90 is required.

Swing Gear Unit

An EP grade gear oil that conforms to API GL5, such as Chevron Delo Gear 80W-90 or BP Transgear 80W90 is required.

Checking Engine Oil Level

See “Fluid Capacities/Lubricants” on page 1-4 for engine oil grade. To prevent damage to the engine, only use the engine oils specified, or oils of equivalent quality and grade could occur.

To check the engine oil, the machine must be on a level surface with the engine turned off. Check the oil level before starting the engine or at least five minutes after shutting off the engine.

1. Open the engine cover.

2. Check the engine oil level using the dipstick (1) located at front of the engine. See Figure 4-2.

3. Add oil if required through the oil filler neck (3). See Figure 4-2.

4. Drain excess oil if required. See “Changing Engine Oil and Filter” on page 4-10.

Lubrication Points

See Figure 4-1.

Grease all lubrications points using a heavy-duty lithium complex grease with 3% molybdenum disulfide, such as Chevron RPM Heavy Duty Grease No. 2, Mobilgrease Moly 52 or BP Energrease Moly EP2.

Ranges of Applications

From –13° F to +104° F (-25° C to + 40° C) outside temperature.

918070/FP0811 4-9 Printed in U.S.A.

Figure 4-2 Oil Dipstick and Filter Locations

Note: The marks on the dipstick indicate the minimum and maximum oil levels.

Changing Engine Oil and Filter

IMPORTANT

Air Cleaner Service

1. Perform the “Mandatory Safety Shutdown Procedure” on page 2-2, but do not allow the engine to fully cool; warm oil will drain more completely..

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

2. Open the engine cover.

3. Position waste oil collection container under engine oil pan.

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

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.

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

2. The air cleaner is located under the engine cover. Press the engine cover release button and raise the engine cover.

3. Release the bow clips (1) to remove the air cleaner cover and gasket (2). See Figure 4-3.

4. Carefully remove outer air cleaner element (3). See Figure 4-3. Carefully remove inner air cleaner element (3). Clean the inside of the air cleaner housing components with a lint-free cloth. Clean all contamination (dust) from inside the upper and lower air cleaner housing and cover with a clean, lint-free cloth.

5. Replace both the inner and outer air cleaner elements when the indicator light comes on or according to the maintenance schedule.

6. Reinstall air cleaner elements (3, 4), gasket and air cleaner cover (2). Fasten bow clips (1).

7. Close and secure engine cover.

5. Remove the oil filter (2, Figure 4-2), using a filter wrench as necessary.

6. Clean the filter housing surface. Put a film of clean oil on the filter gasket. Install the new filter and tighten 1/2 rotation past where the filter contacts the filter mounting surface.

7. Reinstall the drain plug.

8. Clean the area around the oil filler cap.

9. Remove the oil fill cap from the engine. Pour in new oil. Crankcase capacity is 8.2 qts. (7.8 L). Do NOT fill crankcase above the MAX mark on the dipstick.

10. Reinstall oil filler cap.

11. 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 engine and determine cause.

12. Stop the engine and check for leaks at the oil filter and oil drain plug.

13. Check the oil level again and add oil if necessary.

Printed in U.S.A. 4-10 918070/FP0811

Figure 4-3 Air Filter Service

Gehl 503Z, 603 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual