Gehl GE 802 Operator Manual

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GE 802

Crawler

Excavator

OPERATORS MANUAL

Form No.

908147

English

GEHL Warranty

GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl equipment to the Original Retail Purchaser to

be free from defects in material and workmanship for a period of twelve (12) months from the Warranty Start Date.

GEHL WARRANTY SERVICE INCLUDES:

Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer’s business location.

GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT.

GEHL WARRANTY SERVICE DOES NOT INCLUDE:

1. Transportation to selling dealer’s business location or, at the option of the Original Retail Purchaser, the cost of a service call.

2. Used equipment.

3. Components covered by their own non-Gehl warranties, such as tires, trade accessories and engines.

4. Normal maintenance service and expendable, high wear items.

5. Repairs or adjustments caused by: improper use; failure to follow recommended maintenance procedures; use of unauthorized attachments; accident or other casualty.

6. Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment.

No agent, employee or representative of Gehl has any authority to bind Gehl to any warranty except as specifically set forth herein. Any of these limitations excluded by local law shall be deemed deleted from this warranty; all other terms will continue to apply.

Chapter Description Page

INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover

1 GENERAL INFORMATION

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

Machine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Undercarriage and Slewing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Bucket (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

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

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

2 SAFETY INFORMATION

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

Safety Symbols and Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Safety Decal and Sticker Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Safety Decals and Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

3 OPERATION

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Machine Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Outer Cab Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Inner Cab Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Console Controls Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Excavating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Console Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Operator’s Seat Adjustment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Cab Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Checklist Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Starting/Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Moving The Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Mandatory Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Earthmoving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Operating on Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Operating in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Excavator Boom Slewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Grading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 2

Loading Machine for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

PRINTED IN U.S.A. i 908147/0999

TABLE OF CONTENTS (continued)

Chapter Description Page

4 MAINTENANCE

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

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

Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Changing Engine Oil & Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Purging Air from Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Using a Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Track System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Adjusting Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Changing Final Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

5 TROUBLESHOOTING

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Seals & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Travelling Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Bucket, Boom and Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

PRINTED IN U.S.A. ii 908147/0999

Our Dealer network stands by to provide you with any assistance you may require, including genuine GEHL service parts. All service parts should be obtained from your GEHL Dealer. Give complete information about the part and include the model and serial number of your machine. Record the serial number in the space provided on this page, as a handy reference.

Purchased From: Date of Purchase: Model No.: Serial No.:

SERIAL NUMBER LOCATION

The serial plate is located on the inside cab wall next to the throttle lever (Figure 1-1).

GENERAL INFORMATION

The information in this Operator’s Manual was written to give the owner/operator assistance in preparing, adjusting, maintaining and servicing the Crawler Excavator. More importantly, this manual provides an operating plan for safe and proper use of the machine. Major points of safe operation are detailed in Section 2–Safety Information.

The GEHL®Company asks that you read and understand the contents of this manual COMPLETELY and become familiar with your new machine BEFORE attempting to operate it. Consult your GEHL Dealer to obtain extra manuals, or manuals in other languages.

Throughout this manual, information is provided which is set in italic type and introduced by the word NOTE or IMPOR- TANT. Be sure to read carefully and comply with the message. Following this information will improve your operating and maintenance efficiency, help you to avoid breakdown and damage, and extend the machine’s life.

Do not use this machine for any application or purpose other than those described in this manual. If the machine is to be used with special attachments or equipment other than those approved by Gehl, consult your GEHL Dealer. Any person making unauthorized modifications is responsible for the consequences.

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

It is essential to have competent and careful operators, who are not physically or mentally impaired, and who are thoroughly trained in the safe operation of the equipment and the handling of loads. It is recommended that the operator be capable of obtaining a valid motor vehicle operator’s license.

GEHLCompany reserves the right to make changes and improvements in the design and construction of any part without incurring the obligation to install such changes on any unit previously delivered.

INTRODUCTION

IMPORTANT!

Keep these instructions with the machine for future reference.

If the machine changes ownership, be sure this manual accompanies the equipment.

NOTE:

All references to Left-hand or Right-hand are determined from sitting in the operator’s seat and facing forward.

Serial Plate

Figure 1-1. Serial Number Location

PRINTED IN U.S.A. 1-1 908147/0999

MACHINE IDENTIFICATION

Arm Cylinder

Boom

Arm

Left-hand & Right-hand

Travel Levers

Bucket Cylinder

Bucket

Control Lever

Console

Cab

Operator’s

Seat

Engine Hood

Boom

Cylinder

Dozer Blade

PRINTED IN U.S.A. 1-2 908147/0999

Superstructure

Track Frame

SPECIFICATIONS

GE 802

ENGINE

Make Yanmar Model 4TNE98-NSR-Diesel Type 4-Cyl.Water-Cooled Displacement 202 cu. in. (3318 cc) Rated Power Output 62 hp (45.6 kW) @ 2300 rpm Battery 12V (88 Ah) Fuel Tank 23.75 gal. (90 L)

HYDRAULIC SYSTEM

Pumps Double Axial Piston Pump & One Gear Pump Flow Rate 21 gpm (80 L/min)

21 gpm (80 L/min)

13 gpm (50 L/min) Working Pressure 4359 psi (300 bar) Swing System Pressure 3632 psi (250 bar) Oil Cooler Standard Hydraulic Tank 32 gal. (122 L)

UNDER CARRIAGE & SLEWING SYSTEM

Travel Speed-Dual 4 mph (6.4 km/h))

6 mph (9.6 km/h) Ground Clearance 15 in. (335 mm) Slew Speed 9.5 rpm Gradability 30° (= 58%) Rubber Trac k Width 17.7 in. (450 mm) Number of Track Rollers 5 each side Average Ground Pressure 4.27 psi(29.4 kPa)

DOZER BLADE

Width 85 in. (2150 mm) Height 21 in. (540 mm) Maximum Lift Above Ground 21 in. (540 mm) Below Ground 17.7 in. (450 mm)

BUCKET (STANDARD)

Width 129.5 in. (750 mm) Capacity 9 cu. ft. (0.26m

)

NOISE LEVEL

Power Sound 96 dB(A) Pressure Sound 78 dB(A)

PRINTED IN U.S.A. 1-3 908147/0999

GE 802

GENERAL SPECIFICATIONS

Operating Weight w/Cab (SAE) 17,416 lbs. (7900 kg) Height 101 in. (2570 mm) Width 84.6 in. (2150 mm) Length 12.5 ft. (3800 mm) Max. Digging Depth 173.2 in. (4400 mm) Max. Digging Height 284.25 in. (7220 mm) Max. Dump Height 203.9 in. (5180 mm) Max. Digging Radius 285 in. (7240 mm) Bucket Dig Force 10,935 lbs. (48.4 kN) Min.Tail Swing Radius 62.6 in. (1590 mm) Min. Front Swing Radius 65.7 in. (1670 mm) Swing Angle-Left 80° Swing Angle-Right 50°

SPECIFICATIONS (continued)

PRINTED IN U.S.A. 1-4 908147/0999

285"

(7240 mm)

284"

(7220 mm)

204"

(5180 mm)

173"

(4400 mm)

109"

(2780 mm)

21.3"

(540 mm)

17.7"

(450 mm)

101"

(2570 mm)

214"

(5440 mm)

15"

(3800 mm)

59"

(1500 mm)

72.8"

(2150 mm)

17.7"

(450 mm)

62.6"

(1590 mm)

72.8"

(2150 mm)

80˚

50˚

Model GE802

PRINTED IN U.S.A. 1-5 908147/0999

CHECKLISTS

Pre-Delivery Checklist

Delivery Checklist

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

✔✔

CHECK THA T:

❏ Unit has NOT been damaged in shipment. Check for

such things as dents and loose or missing parts; correct or replace components as required.

❏ Battery is securely mounted and NOT cracked. Make

sure cable connections are tight.

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

loosely connected.

❏ Filters are not damaged, leaking or loosely secured. ❏ Machine is properly lubricated and no grease fittings are

missing or damaged.

❏ Hydraulic system reservoir, engine crankcase and drive

chaincases are filled to their proper levels.

❏ All adjustments are made to comply with settings given

in Section 4–Maintenance of this manual.

❏ All guards, shields and decals are in place and secured. ❏ Model and serial numbers for this unit are recorded in

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

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

✔✔

CHECK THA T:

❏ Drive controls and boom/arm/bucket/swing/pivot

controls operate properly and are not damaged or binding.

❏ Drive controls are properly adjusted for a correct neutral

position.

❏ The parking and travelling gear brake, along with the

blocking devices, are automatically activated with unit stationary (no pilot control pressure).

❏ All hydraulic functions are NOT operational with the

left-hand control console in the pivoted rearward position.

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

Dealership Name

Dealer Representative Name

Date Checklist Filled Out

Model & Serial Number

The following checklist is an important reminder of valuable information that MUST be passed on to the customer at the time of delivery. Check off each item as you explain it to the customer.

✔✔

EXPLAIN:

❏ The Safety Information and Operation chapters of this

manual, regarding the safe operation of this machine.

❏ The Maintenance and Troubleshooting chapters for

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

❏ Give the Operator’s Manual to the customer and instruct

the customer to read and completely understand the contents before operating the unit.

❏ Explain that the customer MUST consult the engine

manual (provided) for related specifications, operating adjustments and maintenance instructions.

❏ Completely fill out the Owner’s Registration, including

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

Customer’s Signature

Date Delivered

Retain for Customer’s Records

PRINTED IN U.S.A. 1-6 908147/0999

Cut along dotted line and retain for Dealer’s records.

CHECKLISTS

Pre-Delivery Checklist

Delivery Checklist

✔✔

CHECK THA T:

❏ Unit has NOT been damaged in shipment. Check for

such things as dents and loose or missing parts; correct or replace components as required.

❏ Battery is securely mounted and NOT cracked. Make

sure cable connections are tight.

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

loosely connected.

❏ Filters are not damaged, leaking or loosely secured. ❏ Machine is properly lubricated and no grease fittings are

missing or damaged.

❏ Hydraulic system reservoir, engine crankcase and drive

chaincases are filled to their proper levels.

❏ All adjustments are made to comply with settings given

in Section 4–Maintenance of this manual.

❏ All guards, shields and decals are in place and secured. ❏ Model and serial numbers for this unit are recorded in

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

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

✔✔

CHECK THA T:

❏ Drive controls and boom/arm/bucket/swing/pivot

controls operate properly and are not damaged or binding.

❏ Drive controls are properly adjusted for a correct neutral

position.

❏ The parking and travelling gear brake, along with the

blocking devices, are automatically activated with unit stationary (no pilot control pressure).

❏ All hydraulic functions are NOT operational with the

left-hand control console in the pivoted rearward position.

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

Dealership Name

Dealer Representative Name

Date Checklist Filled Out

Model & Serial Number

The following checklist is an important reminder of valuable information that MUST be passed on to the customer at the time of delivery. Check off each item as you explain it to the customer.

✔✔

EXPLAIN:

❏ The Safety Information and Operation chapters of this

manual, regarding the safe operation of this machine.

❏ The Maintenance and Troubleshooting chapters for

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

❏ Give the Operator’s Manual to the customer and instruct

the customer to read and completely understand the contents before operating the unit.

❏ Explain that the customer MUST consult the engine

manual (provided) for related specifications, operating adjustments and maintenance instructions.

❏ Completely fill out the Owner’s Registration, including

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

Customer’s Signature

Date Delivered

Retain for Dealer’s Records

PRINTED IN U.S.A 1-7 0908147/0999

This Page Intentionally Blank

PRINTED IN U.S.A. 1-8 908147/0999

• Some illustrations in this manual may show doors, guards and shields open or removed for illustrative purposes only. BE SURE all doors, guards and shields are in their proper operating positions BEFORE starting the engine to operate the machine.

• To ensure safe operation, replace damaged or worn-out parts with genuine Gehl service parts.

• Gehl units are designed and intended to be used ONLY with Gehl Company attachments or approved referral attachments. The Gehl Company cannot be responsible for operator safety if the unit is used with non-approved attachments.

• The terrain, engine speed, load carried, and abrupt control movements can affect machine stability. If misused,

any of the above factors can cause the machine to tip, throwing the operator forward or out of the unit, causing death of serious injury. Therefore, ALWAYS

wear the seatbelt when operating the equipment. Operate the controls smoothly and gradually at an appropriate engine speed which matches the operating conditions.

• For additional stability when operating on inclines or ramps, ALWAYS travel with the bucket and blade towards the top of the incline.

* DO NOT raise or lower a loaded bucket suddenly.

Abrupt movements under load can cause serious instability.

• NEVER attempt to bypass the keyswitch to start the engine. Use only the jump-starting procedure detailed in the Maintenance section of this manual.

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

• Do not operate too close to an excavation or ditch. BE SURE that the surrounding ground has adequate strength to support the weight of the machine and the load.

• DO NOT smoke or have any spark producing equipment in the area while filling the fuel tank or while working on the fuel or hydraulic systems.

SAFETY INFORMATION

The GEHL®Company, in cooperation with the Society of Automotive Engineers, has adopted

this Safety Alert Symbol to pinpoint precautions which, if NOT properly followed, can create a safety hazard. This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! It stresses an attitude of “Heads Up For Safety” and can be found throughout this Operator’s Manual and on the machine.

Before you operate this equipment, read and study the following safety information. In addition, be sure that every individual who operates or works with this equipment, whether family member or employee, is familiar with these safety precautions.

The Gehl Company always considers the operator’s safety when designing its machinery, and guards exposed moving parts for the operator’s protection. However, some areas cannot be guarded or shielded in order to assure proper operation.

The following safety words and symbols are used throughout the manual and on the machine to warn of dangerous situations.

DANGER

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

WARNING

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

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. May also alert against unsafe practices.

GENERAL SAFETY INFORMATION

Safety Symbols & Terminology Safety Reminders

PRINTED IN U.S.A. 2-1 908147/0999

• When driving on or across roads, the machine must be equipped according to the road/traffic laws, and these laws must be observed.

• Adapt working speed to local visibility.

• The driving speed must be adapted to the road and ground conditions.

• Particular attention is required when working on slopes. Angle of inclination of machine for all directions of travel: for brief operation (2-3 minutes)–maximum of 30°; for continuous operation–maximum of 25°.

• Unauthorized personnel must not start-up the machine.

• No one but the operator must be on the machine when in use. PASSENGERS PROHIBITED!

• Use the towing bracket provided for towing the machine.

• The operating area, steps, and grips must be free of oil, dirt, ice and unsecured objects.

• The proper working condition of the lighting system must be checked before and while working in darkness.

• Always keep the windshield and windows clean. Poor visibility can cause accidents.

• Operate the machine from the operator’s seat only. Wear seatbelt which is provided.

• Control the machine cautiously and gradually until you are fully familiar with all the controls and handling.

• Pay attention to all movements of machines and machines in the working area.

• Personnel must not be in the working area. Never operate equipment above people.

• Always wear appropriate protective clothing: hard hat, work gloves, strong work shoes, reflective clothing.

• Make sure you have sufficient knowledge of the working area; location of utility lines (water, gas, electric, etc.) and load bearing capacity of the ground.

• Before working in the area of utility lines, contact the proper authority to determine the measures required for safety.

• Never dig underneath the machine. Support walls properly when excavating or working in, or close to, trenches.

• Never drive long distances with the working equipment fully raised. Lowering the working equipment produces improved visibility and improved weight distribution.

Safety Reminders (continued)

• Never drive across the incline on sloping ground. Extreme caution is required when working across an incline or changing direction.

• Never use the weight of the machine to obtain more force when excavating. There is a risk overturning.

• Before starting up the machine or setting it in motion, warn any personnel in the area.

• Attach a clearly visible, legible OUT OF SERVICE sign when repair and adjustments are being performed on the machine.

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

• Be familiar with the machine safety devices.

• The machine is not to be used to lift equipment or transport personnel.

• The excavator arm is not a ramming tool. Never attempt to use the working equipment to drive piles or similar items into the ground, or to flatten the ground.

• Never excavate while the machine is travelling. Never move the machine to dig. Never slew with lowered working equipment and never move the machine when the working equipment is resting on the ground.

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

The machine must be cleaned on a regular basis to avoid the buildup of flammable debris such as leaves, straw, etc. Accumulated debris, particularly in the engine compartment, poses a fire hazard.

The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the muffler system still gets hot during operation. For this reason, it is extremely important not to operate the machine in an area where explosive dust or gasses can contact the hot exhaust.

• Do not use the machine where explosive gasses or dust can be ignited by arcs, sparks, hot components or exhaust gasses.

• The operator cab, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to remove any flammable debris.

Fire Prevention

PRINTED IN U.S.A. 2-2 908147/0999

Mandatory Safety Shutdown Procedure

Before leaving the machine:

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

2. Reduce throttle and turn off the engine.

3. Lock out controls by raising left control console.

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

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged parts.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Tighten or replace any parts that show leakage. Always clean fluid spills.

• Always the clean the machine before performing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding.

• Stop the engine and let it cool before adding fuel.

SAFETY DECAL & STICKER LOCATIONS

18,19

13,17

15,16

20, 21

25, 26

1. WARNING: Danger zone . Keep away! (both sides of the boom)

2. Direction arrow (left and right on track frames)

3. Hydraulic Oil

4. WARNING–Hydraulic reservoir under pressure

5. Diesel

6. WARNING: Do not open when engine is running

7. Lower boom, raise boom, close bucket, open bucket (on windshield)

8. Lower dozer blade, raise dozer blade (on windshield)

9. Travel right, forward/reverse (on windshield)

10. Travel left, forward/reverse (on windshield)

11. Bucket arm out, bucket arm in, superstructure left, superstructure right (on windshield)

12. Environmental symbol (blue angel) (on windshield)

13. Nameplate

14. Warning. TO AVOID INJURY: Read the Operator’s Manual before using the machine. Be sure all user’s are instructed on safe use and maintenance. Service the machine per the manual. Contact dealer (or manufacturer) for information and service parts.

15. L

16. LPA78

17. CE symbol

18. Lifting point for lifting the excavator (left and right on boom and dozer blade)

19. Tie down point (left and right on dozer blade and chassis

PRINTED IN U.S.A. 2-3 908147/0999

SAFETY DECAL & STICKER LOCATIONS

18,19

13,17

15,16

20, 21

25, 26

20. WARNING: TO AVOID INJURY: Load and transport unit properly. Inspect job-site for hazards. Operate only from operator’s seat. Fasten seatbelt. Keep people out of DANGER ZONE. Operate within stability limit of machine. DO NOT OVERLOAD. Use only approved attachments.

21. WARNING: Mandatory Safety Shutdown Procedure:

1. Lower all equipment to ground.

2.Reduce throttle; shut off engine.

3.Lock out controls before exiting.

4.Remove key and take it with you.

22. WARNING: TO AVOID INJURY: Always hold handle when closing front window. When opening window, be sure to lock both sides.

23. WARNING:TO AVOID INJURY OR DEATH: Do not loosen lubricator more than 2 turns. Do not loosen parts other than lubricator. Grease is under high pressure.

24. Lubrication hours

25. Engine cover release latch

26. Hydraulic valve cover release latch

27. Throttle speed

28. Hydraulic breaker

29. Keep hands away from fan blade

PRINTED IN U.S.A. 2-4 908147/0999

SAFETY DECALS

WARNING

DANGER ZONE

Keep away!

HYDRAULIC OIL

WARNING

HYDRAULIC RESERVOIR

UNDER PRESSURE

DIESEL

WARNING

DO NOT OPEN WHILE

ENGINE IS RUNNING

DOZER BLADE DOWN

DOZER BLADE UP

BOOM DOWN

BUCKET CLOSED

BUCKET

OPEN

TRAVEL RIGHT

FORWARD

REVERSE

TRAVEL LEFT

FORWARD

REVERSE

ARM OUT

SWING

LEFT

SWING

RIGHT

ARM IN

BOOM LEFT

BOOM RIGHT

WARNING

TO AVOID INJURY:

Read the Operator's Manual before using this machine.

Be sure all users are instructed on safe use and maintenance.

Service machine per the Manual.

Contact dealer (or manuafacturer) for information and service parts.

12 3

456

910

BOOM UP

PRINTED IN U.S.A. 2-5 908147/0999

SAFETY DECALS (continued)

18 19

WARNING

TO AVOID INJURY:

Load and transport unit properly. Inspect job-site for hazards.

Operate only from operator's seat. Fasten seatbelt.

Keep people out of DANGER ZONE.

Operate within stability limit of machine. DO NOT OVERLOAD. Use only approved attachments.

WARNING

MANDATORY SAFETY

SHUTDOWN PROCEDURE:

1. Lower all equipment to ground.

2. Reduce throttle; shut off engine.

3. Lock out controls before exiting.

4. Remove key and take it with you.

STOP

WARNING

AVOID INJURY OR DEATH

Do not loosen lubricator more than 2 turns

Do not loosen parts other than lubricator. Grease is under high presure.

25 26

WARNING

TO AVOID INJURY:

ALWAYS hold handle when closing front window. When opening window be sure to lock both sides

A + B

A + T

HYDRAULIC BREAKER

PRINTED IN U.S.A. 2-6 908147/0999

OPERATION

WARNING

Be sure you are familiar with all safety devices and controls before operating the machine. Know how to stop before starting. This GEHL

Company machine is designed for use only with GEHL®Company approved accessories or referral attachments. The GEHL®Company cannot be responsible for operator safety if the unit is used with non-approved attachments.

GENERAL INFORMATION

WARNING

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

Guards & Shields

Whenever possible, guards and shields are used to protect potentially hazardous areas on the machine. In many places, decals are also provided to warn of potential hazards and/or to display special operating procedures (see Safety Decals Locations in Section 2).

The operator’s seat left-hand console must be raised in order to exit the cab. In the raised position, the left-hand console locks out all hydraulic functions of the machine (Figure 3-1).

WARNING

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

Armrest Lever

Left-Hand Console In Raised Position

Figure 3-1. Left-Hand Console Raised

PRINTED IN U.S.A. 3-1 908147/0999

OPERATOR CONTROLS

45 6 7

12, 13

1. Auxiliary Hydraulics Pedal

2. Left-Hand Travel Lever w/Foot Pedal

3. Seat Suspension Adjustment Lever

4. Right-Hand Travel Lever w/Foot Pedal

5. Seat Adjustment Lever

6. Footrest

7. Dozer Blade Control Lever w/Foot Pedal

8. Ventilation Controls

9. Cab Light

10. Windshield Washer Reservoir

11. Throttle Lever

12. Hydraulic Valve Cover Latch Lever

13. Engine Cover Latch Lever

14. Right-Hand Control Lever for Boom, Bucket

Cylinder and Horn

15. Ashtray

16. Console Controls (see next page)

17. Radio

18. Stereo Speaker

19. Ignition Key Switch

20. Armrest

21. Storage Shelf

22. Fuse Panel (see next page)

23. Heater

24. Left-Hand Control Lever for Rotating/Slewing

Bucket Arm; Control Button for Boom Swing when used with Auxiliary Hydraulics Pedal (#1)

25. Armrest Lever (for folding back the armrest which

disables the hydraulic controls)

26. Seat and Console Adjustment Lever

1. Fuel Filler

2. Hydraulic Reservoir

3. Hydraulic Valves

4. Diesel Pump (Option)

5. Hydraulic Oil Filler

6. Hydraulic Oil Filter

7. Hydraulic Oil Sight Gauge

8. Battery

9. Hydraulic Reservoir Drain

10. Fuel T ank Drain

11. Fuel T ank

12. Engine Hood

13. Fire Extinguisher in Tool Box

Inner Cab Layout

Outer Cab Layout

PRINTED IN U.S.A. 3-2 908147/0999

HOURS

1. Fuel Level Gauge

2. Coolant Temperature Indicator

3. Battery V oltage Indicator

4. Engine Oil Pressure Indicator

5. Glow Plug Indicator

6. Engine Air Filter Indicator

7. Hydraulic Oil Level Indicator

8. Low Fuel Indicator

9. Work Lights ON Indicator

10. Hour Meter

11. Heater Control

12. 2-Speed T ravel Switch

13. Light Switch–Cab Front Work Light

14. Ignition Key Switch

15. Light Switch–Boom Work Light

16. Light Switch–Rear Work Light (optional)

Console Controls Layout

5 6 7

1. Fast Speed (Tilt Switch and Drive Lever) (7.5 Amp)

2. Windshield Wiper and Washer (7.5 Amp)

3. Turn Engine Off (Stop Solenoid) (3.0 Amp)

4. Switch Lighting, Instrument Panel and Lighting (7.5 Amp)

5. Front Work Lights (15 Amp)

6. Heating, Horn (15 Amp)

7. Safety (turning) Light, Free (10 Amp)

8. Cabin Lighting, Socket, Radio (Optional) (10 Amp)

9. Alternator, Starter (10 Amp)

10. Fuel Pump, Free (15 Amp)

11. Changeover Valve, Safety Solenoid Valve (10 Amp)

Fuse Panel

PRINTED IN U.S.A. 3-3 908147/0999

OPERATOR CONTROLS (continued)

Left-Hand Lever w/Foot Pedal

Right-Hand Lever w/Foot Pedal

Dozer Lever w/Foot Pedal

Left-Hand Control

Horn

Right-Hand Control

Boom Swing Control (used with Auxiliary Hydraulic Pedal)

Figure 3-2. Travel Controls; Dozer Control

Figure 3-3. Boom & Bucket Controls

Left-Hand Control

Right-Hand Control

Figure 3-4. Boom and Bucket Controls

NOTE: Moving the handles equally in the same direction will result in travelling straight forward or straight backward.

FORW ARD TRA VEL

Push both levers (Figure 3-2) straight forward, slowly the same distance.

REVERSE TRA VEL

Pull both levers straight backward, slowly the same distance.

TURNING DURING TRAVEL

Move one lever farther than the other one. To turn left while moving forward, move the right lever farther forward; to turn right while moving forward, move the left lever farther forward.

PIVOTING

Move the levers in opposite directions to pivot the machine on its axis. To pivot left, move the right lever farther forward while pulling the left lever to the rear; to pivot right, move the left lever forward while pulling the right lever to the rear.

The boom and bucket are controlled by the right- and lefthand levers on the seat consoles (Figure 3-3).

The superstructure or “house” is slewed (swung) by moving the left-hand lever left or right (Figure 3-4).

The boom can be slewed (swung) without moving the cab by pressing the auxiliary hydraulics pedal left or right (Figure 3-

5) while pressing the boom swing switch on the left-hand control lever.

The boom and bucket are moved using the right-hand control lever. The button located on the right-hand lever sounds the horn (Figure 3-3).

The dozer is controlled by the dozer lever (Figure 3-2).

WARNING

Levers and controls should return to neutral position when released. Be sure the levers and controls are in the neutral (middle) position before starting the engine. Operate lever controls gradually and smoothly. Excessive speed and quick handle movements without regard for conditions and circumstances is hazardous and could cause an accident.

Travel Controls

Excavating Controls

PRINTED IN U.S.A. 3-4 908147/0999

Figure 3-5. Auxiliary Hydraulics Pedal

HOURS

Figure 3-6. Console Controls

LEFT-HAND CONTROL LEVER (FIGURE 3-3)

1. Move the left-hand lever forward to move bucket arm away from the machine.

2. Move the left-hand lever to the rear to move the arm towards the machine.

3. Move the left-hand lever to the left to slew superstructure to the left.

4. Move the left-hand lever to the right to slew superstructure to the right.

RIGHT-HAND CONTROL LEVER (FIGURE 3-4)

5. Move the right-hand lever forward to lower the boom.

6. Move the right-hand lever to the rear to raise the boom.

7. Move the right-hand lever to the left to close the bucket (bucket moves up and toward the boom).

8. Move the right-hand lever to the right to open the bucket (bucket moves down and away from the boom).

AUXILIARY HYDRAULICS PEDAL (FIGURE 3-5)

Lift the protective shield, then depress the pedal left or right while depressing the switch located on top of the left-hand control lever to slew only the bucket (superstructure will remain stationary).

DOZER BLADE

The dozer blade is raised and lowered by the dozer lever w/foot pedal (Figure 3-2). Push the lever forward to lower the blade; pull the lever to the rear to raise the dozer blade.

1. FUEL LEVEL GAUGE

The fuel gauge shows the level of fuel in the tank.

2. COOLANT TEMPERATURE INDICAT OR

Indicator light comes on when coolant temperature is too high.

3. BA TTER Y V OL TAGE INDICA T OR

Indicator light comes on when battery voltage is too low.

4. ENGINE OIL PRESSURE INDICATOR

During normal operation, this indicator light should remain off. The indicator will light if the engine oil pressure drops too low. If this occurs, shut off the engine IMMEDIATELY and determine the cause of the pressure drop.

5. GLOW PLUG INDICATOR

Indicator light comes on when the ignition key is turned on. Indicator will go out when glow plugs have heated sufficiently to start the engine.

6. ENGINE AIR FILTER INDICATOR

Indicator light comes on when engine air filter is too dirty.

Console Controls (Figure 3-6)

7. HYDRAULIC OIL LEVEL INDICATOR

Indicator light comes on when hydraulic oil level is too low. Shut off engine and add oil.

8. LOW FUEL INDICATOR

Indicator light comes on when fuel level is too low.

9.WORK LIGHTS INDICATOR

Indicator light comes on when work lights are turned on.

Must use with Boom Swing Switch on Left-Hand Control

PRINTED IN U.S.A. 3-5 908147/0999

OPERATOR CONTROLS (continued)

10. HOUR METER

Indicates total operating hours of the machine. Use the hour meter to log maintenance time in the log located in Section 4–Maintenance.

11. HEATER CONTROL SWITCH

Turns on the cab heater and controls the fan speed.

12. 2-SPEED TRAVEL CONTROL SWITCH

Turn the switch on to engage a higher travel speed. With switch on, machine can only move straight forward or rearward. It will not steer to either side.

13. CAB FRONT WORKING LIGHT SWITCH

Turns the working light on the front of the cab on and off. The switch has two positions; the first position operates the low beam; the second position operates the high beam.

14. IGNITION KEYSWITCH

With the key in the OFF (vertical) position, power from the battery is disconnected to the controls and console. This is the only position that the key can be inserted or removed from the switch.

With the key turned one position clockwise (RUN) from the vertical position, power from the battery is supplied to all controls and electrical circuits.

With the key turned fully clockwise (START) and held in position, the electric starter energizes and starts the engine when the glow plug indicator goes out. Release the key after the engine starts.

NOTE:

The key must always be returned to the OFF position between attempts to start the engine in order to activate the glow plug system.

15. BOOM WORKING LIGHT SWITCH

Turns the boom working light on and off.

16. REAR WORKING LIGHT SWITCH (Optional)

Turns the optional rear working light on and off.

17.WINDSHIELD WIPER SWITCH

Pushing the switch to the first position turns the windshield wiper on. Pushing and holding the switch in the second position activates the washer fluid pump.

NOTE:

The operator’s seat left-hand console must be raised in order to exit the cab. In the raised position, the left-hand console locks out all hydraulic functions of the machine (Figure 3-7).

Console Controls (continued) (Figure 3-6)

Operator’s Seat Adjustment Controls

Armrest Lever

Left-Hand Console In Raised Position

Figure 3-7. Operator’s Seat with Left-Hand Console Raised

Seat/Console Adjustment Lever

Seat Suspension Adjustment Lever

Seat Adjustment Lever

Figure 3-8. Operator’s Seat Adjustment Controls

SEAT SUSPENSION ADJUSTMENT LEVER

Turn the lever (Figure 3-8) to adjust the seat suspension for the operator’s weight. An indicator on the front of the seat base shows the weight adjustment.

SEAT/CONSOLE ADJUSTMENT LEVER

The seat/console lever (Figure 3-8) allows the operator to move the seat and console forward or rearward as a unit.

SEAT ADJUSTMENT LEVER

The seat adjustment lever (Figure 3-8) allows the operator to move the seat only (without console) forward or rearward.

PRINTED IN U.S.A. 3-6 908147/0999

Ventilation

Cab Latches

Handle

Latch

Figure 3-9.Windshield

Latch

Vents

Figure 3-10. Side Window

WINDSHIELD

The windshield can be opened for ventilation. Turn the latch (Figure 3-9) located at the upper corners of the windshield. Grasp the handles and pull the windshield up until latches lock in position.

To close the windshield, turn the latches then lower the windshield until the latches lock in position.

SIDE WINDOW

The side window can be opened for ventilation. Squeeze the latch (Figure 3-10) located on the window, then slide window to desired position and release latch.

VENTS

There are two side vents located underneath the side window (Figure 3-10. Open the slats for better ventilation.

CAB DOOR LATCH

When fully opened, the cab door will lock in position to the side of the cab. To release the latch, pull the black knob located on the right side of the door jamb.

ENGINE AND HYDRAULIC VALVE COVER LATCHES

The engine cover and hydraulic valve cover latches are located next to the operator’s seat, on the right-hand side.

To unlock a cover, pull the respective latch handle. The cover can then be opened.

WARNING

When opening windshield, be sure to lock both latches. When closing windshield, keep hands on handle and away from path of window.

PRINTED IN U.S.A. 3-7 908147/0999

MACHINE OPERATION

Checklist Before Operation

Check the following items before each day of operation:

• Seat belt and mounting hardware.

• Decals. Replace as required.

• Air cleaner and intake hoses.

• Engine coolant level and system for leaks.

• Clean engine area of any flammable materials.

• Check engine oil level and fill if required.

• Check hydraulic system for leaks and check hydraulic fluid level.

• Check all pivot points for proper operation.

• Check track tension.

• Check for broken and loose parts, and repair.

• Check fuel tank.

IMPORTANT: Never operate machine until fuel tank is completely empty. If this occurs, the fuel system will have to be bled of air. Always fill tank after use.

Starting/Stopping the Engine

WARNING

Instructions are necessary before operating or servicing the machine. Read this entire manual and all decals on the machine. Follow all warnings and instructions. Failure to follow all instructions can cause injury or death.

WARNING

See the list of recommended lubricants in

Section 4–Maintenance

for proper grade of engine oil and hydraulic oil. Only use oils of specified on the list or serious injury or death could occur.

SAFETY DEVICES

When the machine is stationary (no pilot control pressure), the parking and travelling gear brake are automatically activated.

All hydraulic functions are inoperable with the operator’s seat left-hand console in the raised position.

The brakes are not released and hydraulic functions activated until a travel lever or control lever is operated.

NORMAL STARTING/STOPPING PROCEDURE

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

2. Be sure all levers and controls are in neutral positions.

3. Insert ignition key into switch and turn clockwise to the first position. Indicators for oil pressure and battery voltage will light.

4. Turn the key fully clockwise and hold in position until glow plug indicator goes out (approximately 10 seconds when engine is cold).

5. When engine starts, release the key.

6. Allow engine to warm-up for approximately 5 minutes to warm the hydraulic fluid.

7. Turn the key fully counterclockwise to turn the engine off.

IMPORTANT: Do not engage the starter motor for longer than 10 seconds at each starting attempt. If the engine does not start, wait 30 seconds, turn the key fully off, then attempt to start the engine again.

WARNING

Do not use ether with glow plugs (preheat) systems. Explosion can result which can cause injury or damage.

WARNING

When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the machine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.

Engines have hot parts and hot exhaust gas. Keep flammable materials away from engine.

Do not use machine in atmosphere containing explosive gas.

PRINTED IN U.S.A. 3-8 908147/0999

Starting/Stopping the Engine (continued)

Mandatory Safety Shutdown Procedure

COLD WEATHER STARTING PROCEDURE

1. Install an engine heater.

2. Be sure engine oil is correct type and viscosity for the ambient temperature.

3. Be sure battery is fully charged.

4. Push the throttle lever (Figure 3-11) fully forward.

5. Follow all steps under Normal Starting Procedure on previous page.

6. As the engine warms up and engine speed increases, move the throttle lever to the idling position.

NEW MACHINE BREAK-IN PROCEDURE

A new machine requires careful operation during the first 100 hours to properly break-in various parts. If the machine is subjected to hard use during the break-in period, the performance and service life will be reduced.

Perform the following when operating a new machine:

• After starting, let the engine idle for 5 minutes so all the components can warm-up.

• Avoid operation with heavy loads or at high speeds.

• Avoid sudden starting and stopping or abrupt motions.

1. Set the travel speed using the travel speed switch on the console: Slow Speed Maximum = 4 mph (6.4 km/h) Fast Speed Maximum = 6 mph (9.6 km/h)

NOTE:

If the travel speed switch on the console (Figure 3-12) is in the fast speed position, machine will not turn right or left. It will only go straight forward or rearward.

2. Push or pull the travel levers w/foot pedals to move the machine (Figure 3-12).

Push both levers forward to move forward. Pull both levers rearward to travel in reverse.

NOTE:

If the superstructure has been rotated 180° (dozer blade at the rear), travel levers will work in the opposite manner.Pushing levers forward will cause the machine to travel in reverse and pulling levers to the rear will move the machine forward.

Throttle Lever

Figure 3-11.Throttle Lever

Left-Hand Lever w/Foot Pedal

Right-Hand Lever w/Foot Pedal

Travel Speed Switch

Figure 3-12.Travel Levers & Speed Switch

IMPORTANT: Indicator lamps must go out when engine starts. If they do not, turn off the engine IMMEDIATELY until cause has been determined and fixed.

Before leaving the machine:

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

2. Reduce throttle and turn off the engine.

3. Lock out controls by raising left control console.

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

Moving the Excavator

3. To turn left, pull the left-hand travel lever back and push the right-hand lever forward.

To turn right, pull the right-hand lever back and push the left-hand lever forward.

4. To stop travelling, return levers to neutral (middle) position.

NOTE:

When released, levers and controls return to the

neutral position automatically.

PRINTED IN U.S.A. 3-9 908147/0999

Operating on Slopes

EARTHMOVING

Operating on a slope is inherently dangerous. It is recommended to level the work area as shown in Figure 3-13. If this is not possible, use the following guidelines.

• When going down a slope, control the speed with the travelling levers and the the throttle lever.

• When going down grades that exceed 15°, put the machine in the position shown in Figure 3-14. Run the engine slowly.

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

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

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

• Slow down the work cycle. Take your time.

• Avoid working with the tracks positioned across the slope. Position the machine with the blade downhill and lowered.

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

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

• Mud and water should be removed from the machine before parking. If possible, park the machine on boards or concrete to prevent the track or undercarriage from freezing to the ground and preventing machine movement.

WARNING

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

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

Figure 3-13. Levelling the Work Site on a Slope

12"

Maximum

(305 m

25 Maximum

Figure 3-14.Travelling on a Slope Exceeding 15°

Operating in Water

• Do not operate or immerse the machine in water higher than the tracks.

• Properly grease the machine if it has been operated or immersed in water for a period of time.

IMPORTANT: Never operate machine until fuel tank is completely empty. If this occurs, the fuel system will have to be bled of air. Always fill tank after use.

PRINTED IN U.S.A. 3-10 908147/0999

The excavator boom can be slewed 45° to the right and 80° to the left from the basic front position. This allows excavation of trenches along walls, fences, etc.

OPTIMAL STABILITY WHEN DIGGING

• Use the dozer blade to support the excavator on the ground.

• Never dig under the machine. Support the walls properly when excavating or working close to trenches.

• To obtain maximum digging performance, avoid fully extending the excavator arm. Excavate using long, flat pulling movements of the arm (Figure 3-15).

WARNING

Always ensure adequate stability when working with the machine. Particularly when working with equipment slewed to the side. Changing the working equipment alters the stability (weight) of the machine.

WARNING

Always ensure adequate stability when working near trenches. Be aware of conditions that could cause the earth to collapse resulting in risk of injury or death.

Figure 3-15. Proper Excavating

Excavator Boom Slewing

Digging

Grading

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

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

• Raise the dozer blade slightly if excessive resistance occurs.

PRINTED IN U.S.A. 3-11 908147/0999

Loading Machine for Transport

TRANSPORTING

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

• When using ramps to load machine onto the transport machine:

- Do not exceed an incline of 18°.

- Ramp width must be at least 1½ times the

width of the track.

- Clean dirt, mud, ice and snow from the

ramps and tracks.

• Use metal loading ramps with a slip-resistant surface.

NOTE:

The ends of the ramps should be beveled to

prevent damage to the rubber tracks (Figure 3-16).

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

• Load the machine on solid, even ground.

• When loading, apply the transport machine parking brake and chock the wheels.

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

• After the machine is on the transport machine, lower the dozer blade and the bucket onto the loading surface (Figure 3-16). Turn off the engine.

• Lock the cab.

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

• Use the points on the excavator indicated by decals for tie down.

Beveled Ramps

Figure 3-16.Transporting the Machine

Lifting Point

Spreader Bar

Figure 3-17. Machine Lifting Points

Lifting Machine

• Secure the lifting fixture sling to the lifting points on the machine (Figure 3-17).

• Install spreader bar above the cab to prevent lifting fixture from rubbing on the machine.

• Do not exceed rated load capacity.

WARNING

Use lifting device with sufficient capacity for the weight of the machine plus any attachments.

Maintain center of gravity and balance when lifting.

Do not swing boom or cab. Never lift machine with operator aboard.

PRINTED IN U.S.A. 3-12 908147/0999

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

• For additional servicing work regarding the engine, see the engine manual provided with the machine.

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

• More frequent servicing, other than the recommended intervals, may be required under extreme operating conditions.

• Always dispose of waste lubricating oils and hydraulic fluids according to local regulations or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain.

MAINTENANCE

WARNING

Be sure you are familiar with all safety devices and controls before operating or servicing the machine. Know how to stop before starting. This Gehl®Company machine is designed for use only with Gehl®Company approved accessories or referral attachments. The Gehl

Company cannot be responsible for operator safety if the unit is used with non-approved attachments.

GENERAL INFORMATION

WARNING

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

Care and Servicing

• Never service the machine without reading the applicable instructions.

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

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

• Cleaning and maintenance are required daily.

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

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

• Vent exhaust to outside when engine must be run for service. Exhaust system must be tightly sealed. Exhaust fumes can kill without warning.

• Never modify equipment or add attachments not approved by Gehl Company.

• Stop engine and let cool, then clean engine of any flammable materials before checking fluid levels.

WARNING

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

WARNING

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

CALIFORNIA PROPOSITION

65 W ARNING

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

Maintenance Safety

PRINTED IN U.S.A. 4-1 908147/0999

GENERAL INFORMATION (continued)

Maintenance Safety (continued)

• Never service or adjust machine with the engine running unless service procedure calls for the engine to be running.

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

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

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

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

• Wear eye protection when servicing the machine.

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

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

PRINTED IN U.S.A. 4-2 908147/0999

Engine

MAINTENANCE SCHEDULE

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

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000

Hours Hours Hours Hours

Check air filter ✔✔✔ Check engine oil level ✔ Check fuel level ✔ Check for leakage ✔ Perform visual check ✔

Check coolant level ✔ Check engine mounting bolts ✔ Check V-belt condition and tension ✔ Clean radiator fins ✔ Check fuel filter ✔ Check exhaust system ✔ Change engine oil and filter ✔* ✔✔ Change fuel filter ✔✔ Check engine speed regulation ✔ Check valve clearance ✔ Check cooling system and hoses ✔ Check electrical connections ✔ Check pre-glow system ✔ Check coolant thermostat ✔ Check alternator & starter ✔ Clean fuel tank ✔ Check water pump ✔

* First change only.

PRINTED IN U.S.A. 4-3 908147/0999

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000

Hours Hours Hours Hours

Check track after work shift ✔ Check track tension ✔ Check bearing play of track

rollers, track carrier rollers & front idlers. ✔

Hydraulic System

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000

Hours Hours Hours Hours

Check hydraulic oil level ✔ Check system for leakage ✔ Check hydraulic pump bolts ✔ Clean cooler fins ✔ Change filter ✔* Change hydraulic oil ✔* ✔✔ Check filter ✔ Check hydraulic oil ✔✔✔

Check primary & secondary pressure limiting valves ✔ Check breather filter & filling strainer ✔

Electrical System

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000

Hours Hours Hours Hours

Check indicator lights ✔ Check system function ✔ Check connections ✔

MAINTENANCE SCHEDULE (continued)

* First change only.

Travelling Gear

PRINTED IN U.S.A. 4-4 908147/0999

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000

Hours Hours Hours Hours

Check fan ✔ Check function ✔ Check heating circuit

for leaks ✔ Check seals ✔

* First change only.

Travelling Gear Unit

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000

Hours Hours Hours Hours

Check for leakage ✔ Change final drive gear oil ✔* ✔✔

Slewing Gear Ring

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000

Hours Hours Hours Hours

Change gear ring ✔ Check bearing system ✔✔

Cab Heating System

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000

Hours Hours Hours Hours

Lubricate all points ✔ Check bucket teeth for wear ✔ Check pin fastening ✔ Check hydraulic line connections ✔ Check piston rods ✔ Check hydraulic cylinder

under load ✔ Check bearing play ✔

Bucket, Boom & Dozer Blade

PRINTED IN U.S.A. 4-5 908147/0999

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000

Hours Hours Hours Hours

Check hydraulic system ✔ Check bolts ✔ Check lights ✔ Check windshield wiper system ✔ Check for leaks ✔

General

Lubrication Points

MAINTENANCE SCHEDULE (continued)

LUBRICATION

Superstructure bearing system (W)

Green Caps–lubricate weekly (points marked with a “W”) Blue Caps–lubricate daily

Figure 4-1. Lubrication Points

PRINTED IN U.S.A. 4-6 908147/0999

Checking Engine Oil Level

ENGINE

Figure 4-2. Engine Oil Dipstick

IMPORTANT: See the lubricant list for engine oil grade. Only use engine oil specified, or of equivalent quality and grade, or damage to the engine could occur.

The machine must be on a level surface and the engine turned off.

1. Run the engine until it is at operating temperature, then turn the engine off.

2. Pull the engine cover latch lever (located next the right side of the operator’s seat) and raise the engine cover.

3. Check the engine oil level using the dipstick located on rear of the engine (Figure 4-2).

4. Add oil if required.

NOTE:

The marks on the dipstick indicate the minimum

and maximum oil levels.

Dipstick

NOTE:

Be sure to read the engine manual supplied with

this machine.

Recommended Lubricants

ENGINE OIL

A diesel engine oil conforming to SAE grade 10W 30 or 15W 40, and API classification CD (or higher, e.g., CH-4), such as BP Vanellus MG 15W 40, BP Vanellus C-Extra 10W 30, or Chevron Delo 400 15W 40

HYDRAULIC OIL

A hydraulic oil with anti-wear,anti-foam, and anti-oxidation additives that conforms to ISO Viscosity Grade 46, such as, Mobil DTE 15M, Amoco Rykon 46, or BP Energol HLP-HD 46.

SLEWING RING

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

TRAVELLING GEAR UNIT

An EP grade gear oil that conforms to API GL 5, such as Chevron Delo Gear 80W 90 or BP Transgear 80W 90

SLEWING GEAR UNIT

An EP grade gear oil that conforms to API GL 5, such as Chevron Delo Gear 80W 90 or BP Transgear 80W 90

EXCAVATOR ARM

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

ALL LUBRICATION POINTS

A heavy-duty lithium complex grease with 3% molybdenumdisulfide, 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

NOTE:

All listed greases are suitable for

-13°F to +104°F (-25°C to +40°C).

PRINTED IN U.S.A. 4-7 908147/0999

Bolt

Changing Engine Oil & Filter

ENGINE (continued)

1. Place the machine on a level surface. Run the engine until it is at operating temperature, then turn the engine off.

2. Pull the engine cover latch lever (located next the right side of the operator’s seat) and raise the engine cover.

3. Remove the drain plug from the oil pan underneath the engine and allow oil to drain into a container.

4. Remove the oil filter using a filter wrench.

5. Clean the filter housing surface. Put a film of clean oil on the filter gasket. Install the new filter with gasket and hand tighten.

6. Reinstall the drain plug.

7. Remove the oil fill cap from the engine (Figure 4-3). Pour in new oil. Crankcase capacity is 6.1 qts. (5.7 L). Reinstall oil fill cap.

8. Start the engine and let it run for several minutes. Stop the engine and check for leaks at the oil filter and oil drain plug.

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

1. The air cleaner is located under the side cover. Pull the side cover latch lever (located on the right-side of the operator’s seat) and raise the side cover.

2. Turn the air cleaner cover bolt (Figure 4-4) to remove the air cleaner cover and gasket.

3. Remove the wingnut (Figure 4-5) and remove air cleaner element.

4. Clean air cleaner element with compressed air 30 psi

(200 kPa) (Figure 4-5).

5. Reinstall air cleaner element, wingnut, gasket, and air cleaner cover. Tighten cover bolt.

6. Close valve cover.

IMPORTANT: Do not knock the element against solid object to remove dust. The element may become distorted and damaged.

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

Figure 4-3. Engine Oil Fill and Filter

Oil Filter

Oil Fill

Figure 4-4. Engine Air Filter

Figure 4-5. Servicing Engine Air Filter

Air Cleaner Service

Air Cleaner Cover

Gasket

Compressed Air

Wingnut

PRINTED IN U.S.A. 4-8 908147/0999

Fuel Filter Valve

Fuel Filter Plastic Housing

Water Separator

Injection Pump Priming Lever

Figure 4-7. Fuel Filter

Figure 4-8. Bleeding Air from Fuel System

Fuel Filter

Injection Pump

Water Separator

The fuel level in the tank is indicated by the fuel gauge on the console (Figure 4-6).

NOTE:

When the fuel level reaches 2.5 gal.(2.3 L) the low fuel indicator light (Figure 4-6) will come on to alert the operator.

To fill the tank, remove the fuel filler cover located on the right-side of the machine. Fill using diesel fuel with a cetane rating of over 45. Re-install fuel cap.

IMPORTANT: Never operate machine until fuel tank is completely empty. If this occurs, the fuel system will have to be bled of air. Always fill tank after use.

Unscrew the clear plastic housing (Figure 4-9) to change the filter element and clean dirt from the housing. Clean around the filter housing. Put oil on the seal of the new filter element. Install the fuel filter and hand tighten.

The fuel system must be purged of air after changing the fuel filter, or if the fuel tank has been run dry.

1. Turn the fuel filter valve (Figure 4-7) to the open position (vertical).

2. While operating the priming lever on the fuel injector pump, loosen the air bleeding screw (A, Figure 4-8) on the fuel filter. When fuel starts flowing from the bleeder valve (A) without any air, tighten the bleeder screw (A).

3. Repeat step 2 for bleeder screws B, C, D and E (Figure 4-8).

Filling the Fuel Tank

Fuel Filter

Purging Air from the Fuel System

FUEL SYSTEM

Figure 4-6. Fuel Gauge and Low Fuel Indicator

HOURS

Fuel Gauge

Low Fuel Indicator Light

WARNING

Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.

WARNING

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire, which can result in injury or death.

PRINTED IN U.S.A. 4-9 908147/0999

Checking Coolant Level

Fuses

COOLANT SYSTEM

ELECTRICAL SYSTEM

Figure 4-9. Checking Coolant Level

Full

Low

1. Pull the engine cover latch lever (located next the right side of the operator’s seat) and raise the engine cover.

2. Check the coolant level in the expansion reservoir (Figure 4-9).

3. If low, slowly remove cap and fill reservoir to FULL line.

WARNING

Engine must be cold. Be careful to avoid burns when removing the cap. Keep face away from cap. Cover cap with a cloth, turn cap slowly to release pressure.

Refer to the engine manual for correct coolant mixture for your engine.

The fuse panel is located on the right arm console

(Figure 4-10).

To replace a fuse, remove the panel cover and pull the old fuse from the socket. Install a new fuse and re-install the fuse panel cover.

Refer to page 3-3 in Section 3 for fuse identification.

The battery is located under the side cover, below the air cleaner. To access the battery, pull the side cover latch lever (located on the right-hand side of the operator’s seat) and open the valve cover.

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

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

Figure 4-10. Fuse Panel

Fuse Panel

Figure 4-11. Battery

Battery

WARNING

Batteries contain acid which burns eyes and skin on contact. Wear safety goggles and protective clothing to keep acid off body.

In case of acid contact, wash immediately with water for several minutes. In case of eye contact, g et medical attention immediately.

PRINTED IN U.S.A. 4-10 908147/0999

Using a Booster Battery (Jump Starting)

WARNING

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

DO NOT jump start or charge a frozen battery. Warm battery to 60°F (16°C) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

Battery gas can explode and cause serious injury.

IMPORTANT:When jump starting from another machine, be sure the second machine is not running while using the glow plugs. High voltage spikes from a running machine can burn out the glow plugs.

IMPORTANT: Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a fast charger or when welding on the machine. Remove both cables from the battery.

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

Be very careful when jump starting the machine. Booster battery must be 12 volt.

1. Turn ignition key to the off position.

2. Pull the valve cover latch lever (Figure 4-1) and open

the valve cover.

3. Connect one end of the cable to the positive (+) termi-

nal on the booster battery. Connect the other end of the same cable to the positive (+) terminal on the machine battery.

4. Connect one end of the second cable to the negative (-)

terminal on the booster battery. Connect the other end of the same cable to the machine frame.

5. Start the machine engine. Once the engine is running,

remove the cable connected to the frame first. Disconnect the other cable from the machine battery positive (+) terminal.

PRINTED IN U.S.A. 4-11 908147/0999

HYDRAULIC SYSTEM

1. Position the machine on a level surface.

2. Fully extend the bucket and boomas shown (Figure 4-

12). Lower bucket and dozer blade to the ground. Turn off the machine.

3. Remove the hydraulic valve cover as shown (Figure 4-

12).

3. Check the hydraulic oil level indicator. Oil level should be between black and red marks on sight glass. If hydraulic oil is required, proceed to step 4.

4. Slowly open the hydraulic oil cap to relieve pressure, then remove cap.

5. Add hydraulic oil until oil level is between red and black marks on indicator (Figure 4-12).

6. Re-install hydraulic tank cap and tighten securely.

7. Start engine and let idle for a few minutes.

8. Check hydraulic functions. Recheck hydraulic oil level.

Checking Hydraulic Oil Level

Figure 4-12. Checking Hydraulic Oil Level

Sight Glass

WARNING

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

PRINTED IN U.S.A. 4-12 908147/0999

Figure 4-13. Hydraulic Oil Tank

Filter Gasket

Filter

Filter Cover

Drain Plug

Cap w/Strainer

1. Position the machine on a level surface.

2. Fully extend the bucket and boom. Lower bucket and dozer blade to the ground (Figure 4-12). Turn off the machine.

3. Slowly open the cap to relieve pressure (Figure 4-14). Remove cap and clean strainer of any debris.

4. Open the drain plug (Figure 4-13) and drain oil into a suitable container. Re-install drain plug and tighten securely.

IMPORTANT: Always dispose of hydraulic fluids according to local regulations or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain.

5. Remove bolts and filter cover (Figure 4-13). Remove and discard old filter. Put clean hydraulic fluid on the filter gasket and install gasket and new filter into tank.

6. Reinstall filter cover and bolts.

7. Fill tank with hydraulic oil until oil level is between red and black marks on indicator (Figure 4-12).

8. Re-install hydraulic tank cap and tighten securely.

9. Start engine and let idle for a few minutes.

10. Check hydraulic functions. Recheck hydraulic oil level.

11. Reinstall access panel.

Changing Hydraulic Oil

PRINTED IN U.S.A. 4-13 908147/0999

Changing Final Drive Oil

TRACK SYSTEM

1. Position the machine on a level surface with final drive plugs positioned as shown in POSITION A, Figure 4-14. Turn off the engine.

2. Open both plugs and drain oil into a suitable container. Re-install plugs.

3. Turn the engine on and move the machine slightly until plugs are positioned as shown in POSITION B, Figure 4-14. Turn off the engine.

4. Remove both screw plugs. Pour fresh oil (Gearoil EP 90 API GL 4) into the top hole until oil starts to run out of the bottom hole.

5. Re-install both plugs securely.

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

1. Position the machine on a level surface.

2. Use the bucket and dozer blade to lift the unit up until tracks are just clear of the ground. Turn off the engine.

3. Remove the side plate from the left track to expose the adjustment fitting (Figure 4-15).

4. Using a grease gun, pump grease into the fitting until the idler wheel is centered as shown in Figure 4-17.

NOTE:

A grease gun is supplied with machine tool kit.

5. Install side plate.

6. Repeat steps 4 and 5 for right side track.

7. Start the engine. Lower the unit to the ground.

POSITION A Screw Plugs in position for draining oil

POSITION B Screw Plugs in position for Filling oil

Figure 4-14 Changing Final Drive Oil

Figure 4-15. Track Adjustment

Adjusting T rack T ension

Side Plate

Grease Gun

Adjustment Fitting

Wrench

Idler wheel should be centered in this opening

PRINTED IN U.S.A. 4-14 908147/0999

MAINTENANCE LOG

DATE HOURS SERVICE PROCEDURE

PRINTED IN U.S.A. 4-15 908147/0999

MAINTENANCE LOG

DATE HOURS SERVICE PROCEDURE

PRINTED IN U.S.A. 4-16 908147/0999

TROUBLESHOOTING

WARNING

Be sure you are familiar with all safety devices and controls before operating or servicing the machine. Know how to stop before starting. This GEHL®Company machine is designed for use only with GEHL®Company approved accessories or referral attachments. The GEHL®Company cannot be responsible for operator safety if the unit is used with nonapproved attachments.

GENERAL INFORMATION

WARNING

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

WARNING

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

PRINTED IN U.S.A. 5-1 908147/0999

Engine will not start.

Insufficient engine power.

No fuel. Battery power insufficient. Fuel filter contaminated. Pre-glow system not working.

Fuel line leakage. Air filter contaminated. Engine not at operating temperature. Engine overheated.

Add fuel to tank; bleed fuel system. Charge battery or replace if necessary. Clean fuel filter. Replace pre-glow system (contact authorized

repair center.). Replace fuel line. Clean air filter. Warm up the engine. Check cooling system.

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

ENGINE

Engine oil pressure indicator light comes on during operation.

Water temperature display light comes on during operation.

Battery voltage light comes on during operation.

Fuel light comes on.

Engine oil pressure too low.

Engine oil level too low. Coolant level too low. Fan blades rotate too slowly. Air filter contaminated. Alternator not charging properly.

Low fuel.

Stop engine immediately. Check oil level and add oil if necessary. If oil level is correct, oil pump may be inoperative.

Add oil. Add coolant. Adjust V-belt tension. Clean air filter. Adjust V-belt tension.

Add fuel.

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

INDICATOR LAMPS

Oil or fuel leakage under engine.

Oil losses from hydraulic system.

Loose hose connections. Seals or hoses damaged.

Loose hose fittings.

Seals, hoses or lines damaged.

Tighten hose connections. Change seals or hoses and check engine oil level.

Add engine oil if required. Tighten hose fittings. Check hydraulic oil level.

Add hydraulic oil if required. Change seals, hoses and/or lines.

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

SEALS & HOSES

PRINTED IN U.S.A. 5-2 908147/0999

Machine will not travel in any direction.

Machine will not travel straight ahead.

Foreign body jammed in track. Gears not operative. Foreign body jammed in track. Track tension unequal. Travel valves damaged.

Remove foreign body. Repair gears (contact authorized repair center). Remove foreign body. Adjust track tension. Repair/replace valves (contact authorized repair

center).

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

TRAVELLING GEAR

Slewing chassis is difficult or impossible.

Equipment does not work or works only at a low performance level.

Hydraulic cylinders lower too quickly.

Hydraulic lines overheat.

Brakes do not release. Insufficient lubrication. Slewing motor not operating. Insufficient hydraulic oil. Insufficient engine power. Coupling or pump damaged. Pressure limiting valves set too low. Hydraulic cylinder damaged. Control valves damaged. Seals contaminated or damaged. Heavy leakage at control spools. Secondary cartridges damaged. Hydraulic oil filter blocked. Insufficient hydraulic oil in oil reservoir. Secondary cartridges set too low. Cooling system not in working order.

Contact authorized repair center. Lubricate slewing ring hose connections. Contact authorized repair center. Fill hydraulic oil reservoir. Contact authorized repair center. Contact authorized repair center. Contact authorized repair center. Contact authorized repair center. Contact authorized repair center. Contact authorized repair center. Contact authorized repair center. Contact authorized repair center. Clean or replace filter. Fill hydraulic oil reservoir. Contact authorized repair center. Clean oil cooler.

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

BUCKET, BOOM AND DOZER BLADE

PRINTED IN U.S.A. 5-3 908147/0999