Gehl 383Z Operator'S Manual Download

Page: 1 / 112

Compact Excavator

Beginning Serial Number: AE00465

383Z

Form No.

918196

Revision D

Sept. 2013

Oper

or’

s Manual

Summary of Contents for 383Z

Page 2: ...TINUE 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...

Page 3: ...Modifications 2 2 Attachment Precautions 2 2 Mandatory Safety Shutdown Procedure 2 2 Operational Safety 2 2 Exposure to Crystalline Silica 2 5 Parking the Machine 2 5 Travel Controls May Produce Reve...

Page 4: ...the Cab or Canopy 3 10 Throttle Lever 3 11 Optional Auto Idle Feature 3 11 Boom Swivel Pedal 3 12 Dozer Blade 3 12 Operator s Seat Adjustments 3 13 Seat Belt 3 14 Ventilation Cab Only 3 14 Machine Ope...

Page 5: ...ngine 4 10 Changing Engine Oil and Filter 4 11 Air Cleaner 4 12 Fuel System 4 13 Cooling System 4 15 Electrical System 4 16 Battery 4 16 Hydraulic System 4 19 Checking and Adjusting V belt Tension 4 2...

Page 6: ...918196 EP0913 iv Printed in U S A NOTES...

Page 7: ...e nance and use of the machine for purposes for which it was not intended or designed It is essential to have competent and careful operators not physically or mentally impaired who are thor oughly tr...

Page 8: ...ase provide your dealer or the Gehl Company Service Department with the owner s name and current address along with the machine model and serial numbers This will allow the regis tered owner informati...

Page 9: ...Component Names Operator s Seat Boom Dipper Arm Cylinder Boom Light Boom Cylinder Auxiliary Hydraulics Connections Dipper Arm Bucket Cylinder Bucket Swing Cylinder Dozer Blade Track Tension Lubricati...

Page 10: ...ulic Oild d Mobile DTE15M Amoco Rykon 46 BP Energol HLP HD 46 or equivalent HVLP46 according to DIN 51524 section 3 Year round 11 9 gal 45 L Biodegradable Oile e Hydraulic ester oils HEES PANOLIN HLP...

Page 11: ...10 15 seconds Max Inclined Angle engine still supplied with oil 25 in all directions Note This is exceeded by the machine s theoretical climbing ability 30 58 Exhaust Emission Compliance 97 68 EC Tier...

Page 12: ...Swing Speed 8 8 rpm Gradability 30 58 Rubber Track Width 12 300 mm Number of Track Rollers 4 per side Average Ground Pressure 4 8 psi 0 34 kg cm2 Width 68 5 1740 mm Height 13 5 345 mm Maximum Lift Ab...

Page 13: ...Relay Cutoff Solenoid F4 10 Amp Boom Light F5 15 Amp Roof Lights F6 10 Amp s Horn F7 15 Amp Heating Air Conditioning F8 10 Amp Windshield Wiper Interior Light F9 10 Amp Rotating Beacon Radio Drive In...

Page 14: ...nt Halvoline XLC based on ethylene glycol Water Anticorrosion agent Antifreeze agent Up to F C by vol ume in gal cm L by volume by volume 39 4 99 2 6 10 1 14 10 79 20 4 20 65 34 13 25 59 40 22 30 55 4...

Page 15: ...rt Arm 14 10 4530 mm Max digging height w Standard Long Arm 15 3 4660 mm Max dump height w Optional Short Arm 10 7 3220 mm Max dump height w Standard Long Arm 11 0 3350 mm Max digging radius w Optiona...

Page 16: ...lift capacity is exceeded 16 3 5 0 m 13 0 4 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 3 3 1 0 m 0 0 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 9 9 3 0 m 6 6 2 0 m 3 3 1 0 m 0 0 0 m 16 3 5 0 m 13 0 4 0 m 9 9 3 0 m 6 6...

Page 17: ...lift capacity is exceeded 16 3 5 0 m 13 0 4 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 3 3 1 0 m 0 0 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 9 9 3 0 m 6 6 2 0 m 3 3 1 0 m 0 0 0 m 16 3 5 0 m 13 0 4 0 m 9 9 3 0 m 6 6...

Page 18: ...eeded 16 3 5 0 m 13 0 4 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 3 3 1 0 m 0 0 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 9 9 3 0 m 6 6 2 0 m 3 3 1 0 m 0 0 0 m 16 3 5 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 3 3 1 0 m 0 0...

Page 19: ...city is exceeded 16 3 5 0 m 13 0 4 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 3 3 1 0 m 0 0 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 9 9 3 0 m 6 6 2 0 m 3 3 1 0 m 0 0 0 m 16 3 5 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 3...

Page 20: ...ional 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 I...

Page 21: ...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 I acknowledge the pre...

Page 22: ...918196 EP0913 1 16 Printed in U S A INTENTIONALLY BLANK To be removed as dealer s file copy...

Page 23: ...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 p...

Page 24: ...th non approved attachments Do not use the machine for any application or purpose other than described in this manual Unauthorized Modifications Any machine modification made without authorization fro...

Page 25: ...ompartment 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 belo...

Page 26: ...ifting 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 fir...

Page 27: ...the day plan ahead so that the excavator will be on a firm level sur face away from traffic and away from high walls cliff edges and any area of potential water accumulation or runoff If parking on a...

Page 28: ...ed properly shut down the engine and cycle all controls to release any remain ing hydraulic system pressure Be sure all switches and operating controls are in the OFF position and the left hand consol...

Page 29: ...g 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 tan...

Page 30: ...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...

Page 31: ...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...

Page 32: ...g or illegible they must be replaced promptly Replacements can be obtained from your dealer Refer to the Parts Manual for decal part numbers and ordering information New Decal Application Surfaces mus...

Page 33: ...Decal AVOID INJURY OR DEATH Located on both sides of the boom Keep bystanders away from the machine when it is in use 2 WARNING Hydraulic Reservoir Under Pressure AVOID INJURY OR DEATH Located on the...

Page 34: ...rushing Hazard Decal AVOID SERIOUS INJURY Located on the inside of the front window on cab equipped machines Only open and close the front window using the handles Always lock the front window using b...

Page 35: ...NING Danger Zone Decal AVOID INJURY OR DEATH Located on the back of the swing frame Keep bystanders away from the machine when it is in use 12 WARNING Danger Zone Decal AVOID INJURY OR DEATH Located o...

Page 36: ...locations 5 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 points to secure the machine during tra...

Page 37: ...K KF K KP 0 KF K KF K KF K KF K 7 Maintenance Decal Located on the back window of the cab Provides maintenance intervals quick reference Read the operator s manual before maintenance on the machine Re...

Page 38: ...OID INJURY Read the Operator s Manual before using this machine Be sure all users are instructed on safe use and maintenance Service machine according to the operator s manual Contact dealer or manufa...

Page 39: ...ff engine 3 Lock out controls before exiting 4 Remove key and take it with you WARNING AVOID INJURY Do not loosen lubricator more than 2 3 turns Do not loosen parts other than adjustment fitting Keep...

Page 40: ...esel Fuel Decal inside engine compartment by fuel fill SAE ISO Control Decal front of unit next to swing cylinder WARNING TO AVOID INJURY OR DEATH Read the Operator s Manual before reaching or leaning...

Page 41: ...Printed in U S A 2 19 918196 EP0913 Lubrication Chart Decal cab back window right inside canopy wall...

Page 42: ...918196 EP0913 2 20 Printed in U S A NOTES...

Page 43: ...ions of the machine See Figure 3 1 Figure 3 1 Operator s Left Console in Lock out Position WARNING Read and understand this entire man ual Follow warnings and instructions for operation and maintenanc...

Page 44: ...918196 EP0913 3 2 Printed in U S A Figure 3 2 Equipment and Controls 20 16 11 21 9 10 2 17 4 6 13 24 23 25 26 9 22 5 3 15 1 14 12 7 18 8 19 27...

Page 45: ...ver 3 13 9 Air Vent cab only 10 Radio option 11 Seat Backrest Adjustment 3 13 12 Seat Belt Latch 3 13 13 Cup Holder 14 Bracket storage box for documents 15 Switch Panel 16 Switch Panel 17 Throttle Lev...

Page 46: ...918196 EP0913 3 4 Printed in U S A Figure 3 3 Instrument Panel Switches and Indicators 39 40 41 42 43 36 31 33 38 37 28 29 30 35 34 37 37 44 45 46 47 32...

Page 47: ...re indicator red Engine oil pressure light comes on when the ignition is turned on and goes off as soon as the engine is running During normal operation this indicator should remain off The indicator...

Page 48: ...ilter 5 Engine oil filter 6 Engine oil dipstick 7 Engine oil fill 2 places 8 Fuel filler cap 9 Hydraulic fluid filler cap 10 Hydraulic fluid level sight gauge 11 Radiator 12 Radiator overflow reservoi...

Page 49: ...ey turned fully clockwise III and held in position the engine will crank start The indicator lights should go out when the engiine starts Release the key after the engine starts the key returns to the...

Page 50: ...e 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 r...

Page 51: ...Note The joystick controls are pilot operated The far ther the controls are moved from center the faster the machine will function ISO Operating Controls ISO boom and bucket functions are controlled...

Page 52: ...lt support 9 from the guide bracket 11 by removing the retention pin and slide the tilt support out of the guide bracket Secure the tilt support into the storage bracket 10 Replace the retention pin b...

Page 53: ...E ISO Selector Throttle Lever The engine speed is controlled by the throttle lever 1 located behind the left joystick See Figure 3 15 Push throttle lever 1 forward to decrease engine speed Pull thrott...

Page 54: ...auxiliary hydraulics pedal 2 swivels the boom to the left Pressing and holding the auxiliary hydraulic changeover button 1 and pressing the back of the auxiliary hydraulics pedal 2 swivels the boom t...

Page 55: ...Adjustment Use the armrest angle adjustment spindle 1 Fig ure 3 20 to change the angle of the armrest Height Adjustment Use the armrest height adjustment 2 to raise lower the armrest as a unit Note Th...

Page 56: ...for ventilation Squeeze turn the latches 1 Figure 3 22 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 Figure...

Page 57: ...older months the operator s cab heater can be operated using the heater control 1 Figure 3 25 on the right of the kick plate below the operator s seat Rotate the control clockwise to reduce the heat c...

Page 58: ...tion WARNING Read and understand this entire man ual Follow warnings and instructions for operation and maintenance Failure to follow instructions can result in injury or death Read and understand all...

Page 59: ...ne 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 engi...

Page 60: ...cted by using the travel speed switch 1 located on the control console See Figure 3 26 The machine uses an Auto2Speed transmission on the drive motors This feature enables the transmission to automati...

Page 61: ...7 The excavator can travel in water as deep as the top of the upper track rollers Be sure that the footing is solid so the machine will not sink Traveling on Slopes Traveling on a slope is hazardous W...

Page 62: ...918196 EP0913 3 20 Printed in U S A Figure 3 28 Traveling Up or Down Slopes 8 12 20 cm 30 cm 8 12 20 cm 30 cm...

Page 63: ...e bucket into the ground and use the weight of the machine to provide additional breakout force IMPORTANT Hydraulic swivel unit brake function is not optimal if the hydraulic system has not reached op...

Page 64: ...ide 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 slop...

Page 65: ...nd 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 pre vent the possibility of a cave in Operating in C...

Page 66: ...ic change over button 1 and pressing the front of the auxiliary hydraulics pedal 2 swiveled the boom to the left Pressing and holding the auxiliary hydraulic change over button 1 and pressing the back...

Page 67: ...he ground to aid machine stability It is best to posi tion the dozer blade on the same side as the excava tion but position the blade on the opposite side of the excavation if the situation prevents t...

Page 68: ...arm toward the excavator b Extend the dipper arm cylinder so the bucket is tilted upward 6 Figure 3 38 c Raise the boom Figure 3 38 Proper Digging Technique Trench Excavating Trench excavating is most...

Page 69: ...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 tr...

Page 70: ...to align the bucket and dipper arm holes ALWAYS verify the bucket is safely locked before starting the engine and resuming operation Removing A Bucket 1 Lower the bucket to the ground with the flat s...

Page 71: ...pper arm holes align flush with the bucket holes 3 Stop the engine 4 Insert the upper securing pin first 3A Figure 3 44 If needed use a hammer and brass punch to gently tap the pin through the hole In...

Page 72: ...ve 2 down in the direction of arrow 5 c Insert the attachment coupling into the corre sponding auxiliary hydraulics connection cou pling d Release lock sleeve 2 so it snaps into place and locks the co...

Page 73: ...e no one is close to the towing apparatus or in between the vehicles The machine may only be towed using suitable tow ing equipment in connection with suit able towing apparatus such as a towing coupl...

Page 74: ...off during loading 2 Load the transporter on solid even ground 3 Engage the transporter parking brake and chock the wheels 4 Determine the direction of the track movement blade facing forward before m...

Page 75: ...e 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 set...

Page 76: ...running unless it is required by the ser vice procedure Avoid contact with leaking hydraulic fluid and diesel fuel under pressure The pressurized flu ids can penetrate the skin and eyes NEVER use your...

Page 77: ...fill with new coolant Engine Check valve clearance adjust if necessary Engine Check the engine oil level Engine Change engine oil Engine Replace the oil filter Engine Check V belt tension Travel drive...

Page 78: ...918196 EP0913 4 4 Printed in U S A Maintenance Label...

Page 79: ...water x x 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 x x Replace cab air filter...

Page 80: ...func tiona x x x Cab canopy tilt lock support compo nentsa x x x Insulating mats in the engine compart ment x x Warning decals and Operator s Manual in place undamaged x x Check air filter restriction...

Page 81: ...ce every 1000 hrs or once every 2 years whichever comes first x x Service Activity Daily Every 50 Hours Every 250 Hours Every 500 Hours Every 1000 Hours Customer Dealer Lights signaling system indicat...

Page 82: ...Figure 4 1 Lubrication Points Service Activity Daily Every 50 Hours Every 250 Hours Every 500 Hours Every 1000 Hours Customer Dealer Dozer blade x x Swivel console x x Boom x x Dipper arm x x Attachme...

Page 83: ...Printed in U S A 4 9 918196 EP0913 Figure 4 2 Lubrication Points continued Lubricate daily at the points indicated...

Page 84: ...ailed specifications Ranges of Applications From 4 F to 104 F 20 C to 40 C outside tem perature Engine Checking Engine Oil Level To check the engine oil the machine must be on a level surface with the...

Page 85: ...l dipstick 2 slightly to allow any trapped air to escape 10 Add new oil through the oil filler cap opening Crankcase capacity with filter is approimately 7 5 qts 7 1 L Do NOT fill crankcase above the...

Page 86: ...Clean the inside of the air cleaner hous ing components with a lint free cloth Clean all contamination dirt and dust from inside the upper and lower air cleaner housing and cover 5 Replace both the in...

Page 87: ...pty The fuel system has to be bled of air whenever the fuel tank is run empty Always fill the fuel tank after use IMPORTANT When using the machine in cold weather it is important to use the proper fue...

Page 88: ...cator ring rises to position 4 Figure 4 8 the bowl will need to be drained Note The water separator is located on the engine below the air cleaner 1 Twist the fuel shut off valve lever 2 on the water...

Page 89: ...h off the engine and bleed the system again as described in this procedure If the engine still does not run smoothly contact your dealer Cooling System Checking Coolant Level Note The engine must be c...

Page 90: ...before replacing the fuse 1 2 WARNING Before servicing the battery or electrical sys tem disconnect battery from the electrical system by turning the battery disconnect switch to the OFF position Exp...

Page 91: ...rame away from the battery Bat teries can create flammable gases Sparks or open flames can cause this gas and the battery to explode DO NOT jump start or charge a frozen battery Warm battery to 60 F 1...

Page 92: ...ond jumper cable to the negative terminal on the booster battery 6 Connect the other end of the same cable to the frame of the machine with the discharged battery Figure 4 13 Jump starting Start the e...

Page 93: ...Slowly open the hydraulic oil filler cap 4 and then remove the cap Note A short hex shaft is included in the tool kit This tool is designed to be used with a standard ratchet wrench to open the filler...

Page 94: ...aks or dam age Pilot Valve Checking Pilot Control Valve Filter 1 Position the machine on a level surface 2 Fully extend the bucket and boom retract the arm and position as shown in Figure 4 14 3 Lower...

Page 95: ...fitting filter screen C for contamination dirt and clean if necessary Replace the filter restrictor if it is damaged 10 Replace filter restrictor fitting B back into the valve and reconnect hose to th...

Page 96: ...pressurized oil can have enough force to pierce the skin and cause seri ous injury Obtain immediate medical attention if pressurized oil pierces the skin Failure to obtain prompt medical assistance c...

Page 97: ...cool down 4 Press the engine cover release button and raise the engine cover Carefully inspect the V belt 1 for damage If the V belt 1 is damaged have it replaced by your dealer 5 Press on the center...

Page 98: ...ol down 4 Press the engine cover release button and raise the engine cover Carefully inspect the air conditioning V belt 1 for damage If the V belt 1 is damaged have it replaced by your dealer 5 Press...

Page 99: ...si tion in Figure 4 21 2 Shut off the engine Remove the ignition key and take it with you Lock out the controls by raising left control console 3 Open both plugs and drain the oil into a suitable cont...

Page 100: ...controls by raising left control console 4 Measure the clearance of the raised track at the sec ond track roller from the drive gear Deflection should be between 3 4 1 20 25 mm 5 Using a grease gun p...

Page 101: ...nge the engine oil and filter according to Changing Engine Oil and Filter on page 4 11 4 Add a fuel stabilizer to the fuel system according to the fuel supplier s recommendations 5 Remove and fully ch...

Page 102: ...Check all fluid levels and top off as necessary 5 Start the engine Observe all indicators If all indi cators are functioning properly and reading nor mally move the machine outside 6 When outside park...

Page 103: ...rter pinion contact authorized ser vice center Glow plug system not working Repair glow plug system contact authorized service center Rough running engine Incorrect fuel grade Replace fuel with proper...

Page 104: ...clination too high 15 maximum inclination up and across slopes 25 maximum inclination down slopes Incorrect engine oil SAE grade Replace engine oil with proper grade see Fluid Capacities Lubricants on...

Page 105: ...Adjusting Air Conditioning V belt Tension on page 4 24 Air filter contaminated Service air filter see Air Cleaner on page 4 12 Coolant system malfunction Service cooling system contact authorized serv...

Page 106: ...Add hydraulic fluid see Checking Hydraulic Oil Level on page 4 19 Low engine power See Engine troubleshooting on page 5 1 contact authorized service center Engine to pump coupling or hydraulic pump d...

Page 107: ...ipper Arm 1 12 Short Dipper Arm with Counterweight 1 13 Loading and Transporting 3 32 Long Term Storage 4 27 Lubrication 4 7 M Machine Orientation 3 1 Boom Swivel Pedal 3 12 Cab Door Latch 3 15 Dozer...

Page 108: ...els 1 8 Specifications 1 4 Dimensions 1 9 Dozer Blade 1 6 Electrical System 1 6 Engine 1 5 Fluid Capacities Lubricants 1 4 Fuse Box 1 7 General Specifications 1 9 Hydraulic System 1 5 Main Fuse Box 1...

Page 109: ......

Page 110: ...66 90 133 180 74 100 103 140 1 0 in 26 44 mm G1A 111 150 229 310 118 160 140 190 1 3 in 33 25 mm G1 1 4A 177 240 332 450 155 210 266 360 1 7 in 41 91 mm G1 1 2A 214 290 398 540 192 260 398 540 1 9 in...

Page 111: ...42 870 922 1250 M30 1047 1420 1482 2010 1770 2400 885 1200 1254 1700 With fine pitch thread All torque values are in lb ft Nm unless marked otherwise Thread Threads according to DIN 912 DIN 931 DIN 93...

Page 112: ...on proper operation adjustment or mainte nance of the machine contact your dealer or the Gehl Company Service Department before starting or continuing operation California Proposition 65 Warnings Dies...

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Gehl 383Z, Operator'S Manual

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