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Gehl 503Z Operator'S Manual Download Page 5

918070/FP0811

iii

Printed in U.S.A.

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

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

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

Care and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Maintenance Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Maintenance Label Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-3
Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-4

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

Check, Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-5
Fluid and Filter Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-6
Cab Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-7
Cab Functional Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-7
Leakage Checks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-7
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Recommended Lubricants  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-9
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-9
Changing Engine Oil and Filter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-10
Air Cleaner Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-10
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-11
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-14
Electrical System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-14
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-15
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-17
Checking and Adjusting V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Checking and Adjusting Air Conditioning V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-22
Track System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-23
Windshield Washer Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-26

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

Before Storage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-26
After Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-27

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

Engine   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1
Indicator Lamps  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-3
Seals and Hoses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-3
Traveling Gear  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Bucket, Boom and Dozer Blade   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-4
Engine Error Codes  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-5

Error Diagnostic Code Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-5
Engine Diagnostic Codes Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-6

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

Summary of Contents for 503Z

Page 1: ...Compact Excavator Beginning Serial Number AC02471 503Z 603 Form No 918070 Revision F Aug 2011 Operator s Manual 2011 All Rights Reserved Printed in USA ...

Page 2: ...NTINUE TO APPLY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW GEHL WARRANTY DOES NOT INCLUDE 1 Transportation to selling dealer s business location or at the option of the Original Retail Purchaser the cost of a service call 2 Used equipment 3 Components covered by their own non Gehl warranties such as tires batteries...

Page 3: ...ty 2 1 Safety Alerts 2 1 General Safety Rules 2 1 Unauthorized Modifications 2 2 Attachment Precautions 2 2 Mandatory Safety Shutdown Procedure 2 2 Operation Safety 2 2 Before Operation 2 2 During Operation 2 3 Exposure to Crystalline Silica 2 5 Parking the Machine 2 5 Travel Controls May Produce Reversed Travel Operations 2 5 Additional Travel Precautions 2 5 Snow Ice and Cold Temperature Operati...

Page 4: ...ng the Cab or Canopy 3 15 SAE Operating Controls 3 17 ISO Operating Controls 3 17 Boom Swivel Auxiliary Hydraulics Pedal 3 18 Dozer Blade 3 18 Throttle Lever 3 19 Optional Auto Idle Feature 3 19 Operator s Seat Adjustments 3 20 Arm rests 3 20 Seat Belt 3 21 Ventilation 3 21 Mounting Removing Buckets 3 25 Auxiliary Hydraulics Connections 3 27 Machine Operation 3 28 Pre Operation Checklist 3 28 Engi...

Page 5: ...Engine 4 9 Changing Engine Oil and Filter 4 10 Air Cleaner Service 4 10 Fuel System 4 11 Cooling System 4 14 Electrical System 4 14 Battery 4 15 Hydraulic System 4 17 Checking and Adjusting V Belt Tension 4 22 Checking and Adjusting Air Conditioning V Belt Tension 4 22 Track System 4 23 Windshield Washer Fluid 4 26 Long Term Storage 4 26 Before Storage 4 26 After Storage 4 27 Chapter 5 Troubleshoo...

Page 6: ...Printed in U S A iv 918070 FP0811 NOTES ...

Page 7: ...the load poor maintenance and using the equipment for purposes for which it was not intended or designed It is essential to have competent and careful operators not physically or mentally impaired who are thor oughly trained in safe operation and proper load han dling It is recommended that operators be capable of obtain ing a valid motor vehicle operator s license Some illustrations in this manua...

Page 8: ...t with the owner s name and current address along with the machine model and serial numbers This will allow the registered owner information to be updated so that the owner can be notified directly in case of an important product issue such as a safety update program Engine serial number label Model 503Z Serial numbers AH00579 and up Model 603 Serial numbers AH00645 and up Engine serial number lab...

Page 9: ...Figure 1 2 Component Names Dipper Arm Cylinder Boom Bucket Bucket Cylinder Dipper Arm Boom Cylinder Dozer Blade Track Frame Travel Drive Motor Swing Frame Superstructure Hydraulic Fuel Tank Cover Counterweight Operator s Seat Operation Controls Swing Cylinder Engine Cover ...

Page 10: ...lic Oil Tank Hydraulic 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 Synth 46 FINA BIOHYDRAN SE 46 BP BIOHYD SE 46 Grease Roller and Friction Bearings FINA Energrease L21M Year round As Required Open Gear live ring gears BP Energrease MP MG2 Grease Fi...

Page 11: ...d 1050 50 rpm Fuel Injection System Direct injection Starting Aid Glow plug Preheating time 10 15 seconds Max Inclined Angle engine still sup plied with oil 25 in all directions Note The machine s theoretical climbing ability 30 58 exceeds this angle Exhaust Emission Compliance 97 68 EC U S EPA Engine Oil Capacity 8 2 qts 7 8 L 10 7 qts 10 1 L Engine Coolant Capacity 7 4 qts 7 0 L Hydraulic System...

Page 12: ...ht 15 0 380 mm 16 7 425 mm Maximum Lift Above Ground 15 2 385 mm 15 3 390 mm Maximum Depth Below Ground 15 4 390 mm 15 7 400 mm Alternator 12 V 55 A Starter 12 V 2 3 kW Battery 12 V 88 Ah BCI group size 49 93 opt 680 CCA Socket 15 A max Cigarette lighter Fuse No Rated Current Protected Circuit F3 10 Amp Indicators cut off solenoid relays F4 10 Amp Boom light F5 15 Amp Roof lights F6 10 Amp Valves ...

Page 13: ...d Current Protected Circuit F1 40 Amp Start preheat cut off solenoid F2 50 Amp Main fuse ignition lock Relay No Protected Circuit K9 Cut off solenoid K5 Preheating Relay No Protected Circuit K6 Preheating timer K7 Starting relay K8 Cut off solenoid V1 Diode K9 K5 F1 F2 K7 K6 K8 V1 ...

Page 14: ...und Power 96 dB A 98 dB A Sound Pressure 76 dB A 74 dB A Outside temperature Coolant 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 44 ...

Page 15: ...d Arm 17 5 5320 mm Max digging height w Optional Long Arm 18 1 5500 mm Max dump height w Standard Arm 12 2 3720 mm Max dump height w Optional Long Arm 12 10 3900 mm Max digging radius w Standard Arm 19 9 6030 mm Max digging radius w Optional Long Arm 20 8 6300 mm Max reach at ground level w Standard Arm 19 4 5900 mm Max reach at ground level w Optional Long Arm 20 3 6185 mm Max breakout force at b...

Page 16: ...8 6 5660 mm Max digging height w Optional Long Arm 19 2 5850 mm Max dump height w Standard Arm 13 1 3995 mm Max dump height w Optional Long Arm 13 8 4185 mm Max digging radius w Standard Arm 20 4 6210 mm Max digging radius w Optional Long Arm 21 3 6490 mm Max reach at ground level w Standard Arm 19 11 6090 mm Max reach at ground level w Optional Long Arm 20 11 6380 mm Max breakout force at bucket ...

Page 17: ... 0 093 M3 20 in 500 mm 3 7 ft3 0 104 M3 24 in 600 mm 6 4 ft3 0 181 M3 30 in 700 mm 8 8 ft3 0 249 M3 36 in 900 mm 9 8 ft3 0 278 M3 Ditching Bucket 48 in 1000 mm 5 9 ft3 0 167 M3 Ditch Bucket 503Z only 48 in 1000 mm 55 in 1400 mm 7 0 ft3 0 196 M3 8 4 ft3 0 238 M3 Swivel Bucket 48 in 1200 mm 5 9 ft3 0 167 M3 7 0 ft3 0 198 M3 55 in 1400 mm 5 9 ft3 0 167 M3 ...

Page 18: ... m 9 9 3 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 13 0 4 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 0 0 0 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 13 0 4 0 m 2 337 1060 1 786 810 9 9 3 0 m 2 260 1025 1 290 585 2 227 1010 1 720 780 6 6 2 0 m 2 304 1045 1 080 490 2 612 1185 1 609 730 3 483 1580 2 535 1150 3 3 1 0 m 2 403 1090 1 003 455 3 120 1415 1 477 670 4 905 2225 2 183 990 ...

Page 19: ...4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 13 0 4 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 0 0 0 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 13 0 4 0 m 2 028 920 1 455 660 1 951 855 1 731 785 9 9 3 0 m 2 017 915 1 102 500 1 907 865 1 720 780 6 6 2 0 m 2 061 935 937 425 2 315 1050 1 609 730 2 899 1315 2 579 1170 3 3 1 0 m 2 138 970 871 395 2 888 1310 1 466 665 4 464 2025 2 227 1010 0 0 0 ...

Page 20: ...5 0 m 0 0 0 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 13 0 4 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 0 0 0 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 13 3 4 0 m 2337 1060 2017 915 9 9 3 0 m 2260 1025 1488 675 2227 1010 2006 910 6 6 2 0 m 2304 1045 1279 580 2612 1185 1907 865 3483 1580 2965 1345 3 3 1 0 m 2403 1090 1202 545 3120 1415 1775 805 4905...

Page 21: ... 3 1 0 m 6 6 2 0 m 9 9 3 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 13 0 4 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 0 0 0 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 13 3 4 0 m 2028 920 1720 780 1885 855 1885 855 9 9 3 0 m 2017 915 1323 600 1907 865 1907 865 6 6 2 0 m 2061 935 1146 520 2315 1050 1907 865 2899 1315 2899 1315 3 3 1 0 m 2138 970 1069 485 2888 1310 1764 800 4464 202...

Page 22: ... m 9 9 3 0 m 13 0 4 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 0 0 0 0 m 16 0 5 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 13 0 4 0 m 2 888 1310 2 249 1020 2 745 1245 2 546 1155 9 9 3 0 m 2 866 1300 1 775 805 2 789 1265 2 524 1145 6 6 2 0 m 2 911 1320 1 565 710 2 932 1330 1 709 775 3 285 1490 2 425 1100 4 156 1885 3 748 1700 3 3 1 0 m 2 998 1360 1 488 675 3 164 1435 1 654 750 3 913 1775 2 282...

Page 23: ... 6 2 0 m 9 9 3 0 m 13 0 4 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 0 0 0 0 m 16 0 5 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 13 0 4 0 m 2 623 1190 2 183 990 2 315 1050 1907 865 9 9 3 0 m 2 623 1190 1 411 640 2 469 1120 2 326 1055 6 6 2 0 m 2 690 1220 628 285 2 745 1245 1 576 715 3 031 1375 2 392 1085 3 682 1670 3 682 1670 3 3 1 0 m 2789 1265 1 168 530 3 042 1380 1 598 725 3 726 1690 2 271...

Page 24: ...2 0 m 9 9 3 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 13 0 4 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 0 0 0 0 m 16 3 5 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 13 4 0 m 2888 1310 2590 1175 2745 1245 2745 1245 9 9 3 0 m 2866 1300 2061 935 2789 1265 2789 1265 6 6 2 0 m 2910 1320 1830 830 2932 1330 1995 905 3285 1490 2789 1265 4156 1885 4156 1885 3 3 1 0 m 2998 1360 1753 795 31...

Page 25: ...2 0 m 9 9 3 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 13 0 4 0 m 13 0 4 0 m 16 3 5 0 m 3 3 1 0 m 6 6 2 0 m 9 9 3 0 m 0 0 0 0 m 16 3 5 0 m 13 0 4 0 m 9 9 3 0 m 6 6 2 0 m 13 4 0 m 2623 1190 2491 1130 2315 1050 2282 1035 9 9 3 0 m 2623 1190 1676 760 2469 1120 2469 1120 6 6 2 0 m 2690 1220 871 395 2745 1245 1863 845 3031 1375 2756 1250 3682 1670 3682 1670 3 3 1 0 m 2789 1265 1411 640 304...

Page 26: ...th 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 acknowledge the pre delivery procedures were performed on this unit as outlined on this page _______________________________________________ Dealership s Name _______________________________________________ D...

Page 27: ...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 delivery procedures were performed on this unit as outlined on this page _______________________________________________ Dealership s Name _______________________________________________ Dealer Representative...

Page 28: ...Printed in U S A 1 22 918070 FP0811 INTENTIONALLY BLANK To be removed as dealer s file copy ...

Page 29: ...ess they are properly supervised It is recommended that the operator be capable of obtaining a valid motor vehicle operator s license Only trained and authorized personnel with a full awareness of safe procedures should be allowed to operate or perform maintenance or service on the excavator Read the operator s manual provided with each attach ment before using it Use of the machine is subject to ...

Page 30: ...ble if the machine is used with non approved attachments Do not use the machine for any application or purpose other than described in this manual Unauthorized Modifications Any machine modification made without authorization from Manitou Americas Inc could create a safety haz ard for which the machine owner would be responsi ble For safety reasons use only genuine replacement ser vice parts For e...

Page 31: ... Replace damaged safety decals and a lost or damaged operator s manual Always store this operator s manual in the storage compartment provided for it inside the cab Work crew members should observe and monitor all terrain and soil conditions at the work site along with traffic weather related hazards and any above or below ground obstacles and hazards If the machine is equipped with a cab keep the...

Page 32: ...cling rate of the load On sloping surfaces use caution when positioning the excavator prior to starting a work cycle Stay alert for instability situations For example always avoid work ing the bucket over the downhill crawler tracks when parked perpendicular to the slope Slow all downhill swing movements and avoid full extensions of the bucket in a downhill direction Lifting the bucket too high to...

Page 33: ...exposed to inhaled crystalline silica over a working lifetime NIOSH recommends an exposure limit of 0 05 mg m3 as a time weighted average for up to a 10 hr workday during a 40 hr workweek NIOSH also recommends substituting less hazardous materials when feasible using respiratory protection and regular medical examinations for exposed workers Parking the Machine When shutting down the machine for t...

Page 34: ...or while working around the battery Take care to avoid spilling combustible fluids such as oil or fuel on a hot engine Fire Extinguisher Recommendation It is recommended that a 5 lb 2 27 kg or larger multi purpose A B C fire extinguisher be mounted in the cab Check the fire extinguisher periodically and be sure that work crew members are trained in its use After the machine has been parked properl...

Page 35: ...an penetrate the skin and cause serious injury If any fluid is injected into your skin see a doctor at once Injected fluid must be surgically removed by a doctor or gangrene may result Always wear safety glasses with side shields when striking metal against metal In addition it is recom mended that a softer chip resistant material be used to cushion the blow otherwise serious injury to the eyes or...

Page 36: ...posed skin while allowing the fluid to drain quickly and completely However do not let the fluid to fully cool because drain time will be substantially increased Cool down is required prior to radiator or hydrau lic reservoir checks Stop the engine and allow it to cool before performing service on the engine radiator or hydraulic reservoir Both assemblies have pressure vents at the filler cap for ...

Page 37: ...des an opportunity to inspect equipment Minor damage can be repaired or corrected before major problems result Battery Electrolyte and Explosive Gas Hazard Flush eyes with water for 10 15 minutes if battery acid is splashed in the face Anyone who swallows acid must have immediate medical aid Call the Poison Con trol center listing in the telephone directory Sparks can set off explosive battery gas...

Page 38: ...gth of a load The hauling vehicle trailer and load must all be in compliance with local regulations See Loading and Transporting on page 3 40 SAFETY DECALS The machine has decals shown on the following pages that provide safety information and precautions These decals must be kept legible If missing or illegible they must be replaced promptly Replacements can be obtained from your dealer Refer to ...

Page 39: ...ecal 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 hydraulic system accumulator bulb inside the engine compartment Relieve hydraulic pressure before servicing machine Removed hydraulic reservoir cap slowly Refer to the maintenance section in the operat...

Page 40: ...Crushing 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 both locks 9 WARNING Decal AVOID INJURY OR DEATH Located on the door pillar inside the cab No riders Never use work tool as work platform Operate only from operator s seat ALWAYS wear seatbelt WARNING...

Page 41: ...ff the engine 4 Lock out controls by raising left control console 5 Remove the ignition key and take it with you 11 WARNING 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 on both sides of the boom swivel bracket Swiveling boom can cause crushing Keep by...

Page 42: ... 19 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 transport 18 Diesel Fuel Decal USE DIESEL FUEL ONLY Located next to the fuel filler neck 17 Hydraulic Fluid Decal Located next to the hydraulic system filler cap USE HYDRAULIC FLUID ONLY 20 Operator Controls Dec...

Page 43: ...e Read the operator s manual before maintenance on the machine Refer to Maintenance Schedule on page 4 5 22 Operator Controls Decal Located on the ceiling inside the cab Provides quick reference for the ISO operator s control option inside the cab Read the operator s manual before operating the machine Refer to the operator s manual for details about the operator s controls ...

Page 44: ...in U S A 2 16 918070 FP0811 ANSI Style Safety Decal Locations Serial Numbers AH02282 and Before Danger Zone Warning Decal Hydraulic Oil Warning Decal To Avoid Injury Warning Decal PN 161985 PN 161966 PN 161986 ...

Page 45: ...918070 FP0811 2 17 Printed in U S A Cab Ceiling Decals To Avoid Injury Warning Decal Cab Only Warning Avoid Injury or Death Decal PN 177443 PN 177444 PN 163976 PN 163973 PN 164854 PN 163975 BOTH SIDES ...

Page 46: ...Printed in U S A 2 18 918070 FP0811 Entanglement Hazard Rotating Fan and Hot Surface Decals To Avoid Injury or Death Decal Diesel Warning Decal PN 163977 PN 163978 PN 161987 PN 177441 PN 161965 ...

Page 47: ...rator s Left Console in Lock out Position 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 safety decals before operating the machine DO NOT operate the machine unless all factory installed guards and shields are in place Be sure you are familiar with a...

Page 48: ...Printed in U S A 3 2 918070 FP0811 Figure 3 2 Equipment and Controls Model 503Z 603 Serial Numbers AJ02993 and Up 9 1 2 23 25 24 26 27 22 20 4 19 21 28 8 17 14 12 11 15 16 15 10 13 18 7 3 6 5 ...

Page 49: ...ht 9 Seat Horizontal Adjustment Lever 3 19 10 Air Vent cab only rear window left 11 Air Vent cab only rear window right 12 Radio option 13 Seat Backrest Adjustment 3 19 14 Seat Belt Latch 3 19 15 Cup Holder 16 Document Storage Box 17 Switch Panel 3 9 18 Throttle Lever 3 18 19 Fuse Box 1 6 20 Preheating Ignition Switch 3 13 21 Accessory Power Outlet 22 Instrument Cluster 23 Drive Pedal left 3 14 24...

Page 50: ...Printed in U S A 3 4 918070 FP0811 Figure 3 3 Equipment and Controls Model 603 Serial Numbers AH00579 to AH02282 4 8 17 13 11 6 12 14 1 3 2 5 10 9 7 15 16 25 24 26 27 23 21 19 20 18 28 29 ...

Page 51: ...3 5 Printed in U S A Figure 3 4 Equipment and Controls Model 503Z Serial Numbers up to AH02282 Model 603 Serial Numbers AH00578 and Before 4 8 7 13 11 6 12 14 1 3 2 5 10 9 7 15 16 25 24 26 27 22 23 21 19 20 18 28 29 ...

Page 52: ...t Lever 3 19 10 Air Vent cab only rear window on the left 11 Air Vent cab only rear window on the right 12 Radio option 13 Seat Backrest Adjustment 3 19 14 Seat Belt Latch 3 19 15 Cup Holder 16 Bracket storage box for documents 17 Switch Panel 3 9 18 Throttle Lever 3 18 19 Fuse Box 1 6 20 Preheating Ignition Switch 3 13 21 Accessory Power Outlet 22 Coolant Temperature Indicator 23 Instrument Clust...

Page 53: ...ndicators Model 503Z 603 Serial Numbers AJ02993 and Up MPH KM H DP1 2 P D 3 P D 4 P D 5 P D 6 P D 7 P D 8 P D 9 P D 0 1 P D DP24 3 2 P D 2 2 P D 1 2 P D 0 2 P D 9 1 P D 8 1 P D 7 1 P D 6 1 P D 5 1 P D 32 31 35 30 38 34 40 51 38 50 38 36 37 38 33 41 42 43 44 45 46 47 49 49 48 52 ...

Page 54: ...e the hourmeter to track maintenance in the maintenance log 37 Fuel level gauge The fuel level gauge shows the amount of fuel in the tank 38 Indicator light Not assigned 39 Hydraulic oil temperature indicator light Hydraulic oil temperature indicator light comes on when hydraulic oil is too hot 40 Coolant temperature gauge Displays coolant temperature 41 High speed switch transport speed Pressing ...

Page 55: ...Indicators Model 603 Serial Numbers AH00579 to AH02282 MPH KM H DP1 2 P D 3 P D 4 P D 5 P D 6 P D 7 P D 8 P D 9 P D 0 1 P D DP24 3 2 P D 2 2 P D 1 2 P D 0 2 P D 9 1 P D 8 1 P D 7 1 P D 6 1 P D 5 1 P D 32 31 35 30 38 34 40 51 38 50 38 36 37 38 33 41 42 43 44 45 46 47 48 49 49 52 ...

Page 56: ...10 918070 FP0811 Figure 3 7 Instrument Panel Switches and Indicators Model 503Z Serial Numbers up to AH02282 Model 603 Serial Numbers AH00578 and Before 33 34 35 39 38 30 31 32 37 36 40 38 38 41 42 43 44 45 46 47 48 49 49 ...

Page 57: ...e the hourmeter to track maintenance in the maintenance log 37 Fuel level gauge The fuel level gauge shows the amount of fuel in the tank 38 Indicator light Not assigned 39 Hydraulic oil temperature indicator light Hydraulic oil temperature indicator light comes on when hydraulic oil is too hot 40 Coolant temperature gauge Displays coolant temperature 41 High speed switch transport speed Pressing ...

Page 58: ...l fill 8 Heater on off valve cab only serial numbers AD04650 and before 9 Locking fuel filler cap 10 Hydraulic fluid filler cap 11 Hydraulic fluid level sight gauge 12 Radiator 13 Radiator overflow reservoir 14 Radiator cap 15 Windshield washer reservoir cab only 16 Hydraulic oil cooler 17 Air conditioning condenser option cab only 18 Battery 503Z up to serial numbers AH02282 shown Model 603 and 5...

Page 59: ...nk start and the indicator lights should go out Release the key after the engine starts the key returns to the I position when it is released after starting the engine Note The key must always be returned to the I posi tion between attempts to start the engine in order to activate the glow plug system Figure 3 9 Ignition Key Switch Battery Disconnect Switch A battery disconnect switch is located i...

Page 60: ...n the machine on its axis To spin turn left move the right control lever forward while pulling the left control lever to the rear to spin turn right move the left control lever forward while pulling the right control lever to the rear See Figure 3 11 WARNING Levers and controls should return to neutral position when released Be sure the levers and controls are in the neutral middle position before...

Page 61: ...et 11 and secure with the retention pin Tilting the cab or canopy down 1 Remove the tilt rod 9 from the guide bracket 11 by removing the retention pin and slide the tilt rod 10 out of the guide bracket 9 and secure with the retention pin back in the storage bracket 10 2 Use handle 7 to slowly lower the cab back onto the jack 5 3 Remove jack handle tubes 4 from the jack 5 and insert the opposite en...

Page 62: ...a cut out on the left side of the chassis at location 2 This machine has been set at the factory for SAE standard operation shown at position 3 If ISO operation is desired loosen wing nut 5 and rotate valve to position 4 and retighten wing nut 5 Figure 3 13 SAE ISO Selector Valve CAUTION Check tilt rod 9 the retention pin and safety cable 8 at regular intervals for cracks and cuts Replace defectiv...

Page 63: ...stick 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 by the right and left joystick control levers located on the seat consoles ISO Left Joystick see Figure 3 16 1 Boom lower 2 Boom raise 3 Swing left 4 Swing right Figure 3 16 ISO Left Joystick ISO Right Joystick se...

Page 64: ...xiliary hydraulic changeover valve button 1 and pressing the auxiliary hydraulics pedal 2 to the right with your toe swivels the boom to the right The auxiliary hydraulics pedal 2 allows use control of front end attachments Action will vary depending on the attachment and how it is connected Figure 3 18 Boom Swivel Dozer Blade The dozer blade is controlled by the dozer control pedal lever 1 locate...

Page 65: ...3 20 Throttle Lever Optional Auto Idle Feature Model 603 Standard Model 503Z Option Serial Numbers AH00645 and Up Press switch 1 to enable the auto idle feature When the auto idle feature is enabled engine speed is automatically lowered to idle when no hydraulic func tions occur for five seconds Engine speed resumes when a hydraulic function is activated Figure 3 21 Auto Idle Switch Models 503Z 60...

Page 66: ...ard and rearward 5 Headrest Adjustment The headrest adjustment 6 allows the operator to move the headrest up and down 6 Seat Height Adjustment The seat height adjustment allows the operator to move the seat height up and down To raise the seat height grasp the seat and lift up until you hear an audible click To lower the seat raise the seat to the highest position and then lower the seat to its lo...

Page 67: ...forward and release latches Pull push the top of the window until the catch locks the top of the windshield securely in place To close the windshield squeeze turn the latches and then lower the windshield Lock the latches in the closed position For additional ventilation the lower portion of the windshield can be removed and securely stored in the glass holder 3 located on the rear window WARNING ...

Page 68: ...ired position Make sure the window lock securely in one of the recesses Figure 3 26 Side Window Operation Movable Bottom Window Optional Cab Serial Numbers AJ02993 and Up Squeeze both latches 1 Figure 3 27 on the left and right and slide the window at both latches to open or close Release latches and make sure the window locks securely open closed Figure 3 27 Lower Front Window Operation Note If t...

Page 69: ...re 3 28 Cab Door Latch Release Interior Light The interior light is located on the back of the cab above the rear window Press the switch to the right or left to turn the light ON Move the switch to the center position to turn the light OFF Figure 3 29 Interior Light Tool Kit and Cab Jack Handle The machine tool kit and the cab jack handle are located in the storage area under the hood in the engi...

Page 70: ...ir mode vent is a storage compartment on the canopy model machines Figure 3 30 Cab Heat Control SN AD04651 and Up Figure 3 31 Cab Heat Control SN AD04650 and Before Recirculated Air Mode When heating or cooling the cab the recirculated air mode can be utilized to heat or cool only the air in the cab with no fresh air supply from the outside Sliding the plate to the left will turn ON the recirculat...

Page 71: ...ALWAYS wear protective goggles helmets gloves steel toed shoes etc DO NOT service the bucket while the engine is running DO NOT stand behind the bucket when removing the pins DO NOT use your hands or fingers to align the bucket and dipper arm holes ALWAYS verify the bucket is safely locked before starting the engine and resuming operation Removing A Bucket 1 Lower the bucket to the ground with the...

Page 72: ...ipper arm holes align flush with the bucket holes 3 Stop the engine 4 Insert the upper securing pin first 3A Figure 3 35 If needed use a hammer and brass punch to gently tap the pin through the hole Insert a lynch pin 2A Figure 3 35 through the hole in the pin and lock 5 Insert the lower securing pin 3B Figure 3 35 If needed use a hammer and brass punch to gently tap the pin through the hole Inser...

Page 73: ...e 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 couplings together Verify the lock sleeve 2 is snapped closed and the cou pling is securely locked together e Twist lock sleeve 2 so notch 3 is NOT aligned with lock ball 4 to help prevent acci dental de coupling Disc...

Page 74: ...e locked out with the operator s seat left console in the raised position 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 safety decals before operating the machine DO NOT operate the machine unless all factory installed guards and shields are in place...

Page 75: ... sure engine oil is correct type and viscosity for the ambient air temperature Note Be sure battery is fully charged 1 Follow all steps under Engine Start Procedure above 2 Advance the throttle to 1 4 engine speed for a faster warm up 3 As the engine warms up move the throttle lever to the idle position After Starting During Operation Check the following after startup and during operation Stop the...

Page 76: ... period damage to operating sys tems may occur Perform the following when operating a new machine Perform all steps in Pre Operation Checklist on page 3 28 Start engine and let it idle for 10 15 minutes so all components and systems can warm up Operate machine at about 80 of maximum loads and speed At the end of the first 100 operational hours drain and replace the engine oil and engine oil filter...

Page 77: ...machine starts to slide or becomes unstable lower the bucket to regain control If the engine stalls lower the bucket make sure that all controls are in the neutral position and restart the engine See Operating on Slopes on page 3 33 for more information about operating the machine on slopes Figure 3 39 Travel Down Slopes 4 To travel straight push both travel control levers or pedals forward or rea...

Page 78: ...reakout force when the bucket is in the ground IMPORTANT Hydraulic swivel unit brake function is not optimal if the hydraulic system has not reached operating temperature DANGER DO NOT elevate the front end of the tracks by use of downward pressure on the dozer blade This will cause the machine to become unstable DO NOT excavate underneath the machine Always be sure that there is adequate support ...

Page 79: ...et be sure that all controls are in the neutral position and restart the engine When traveling down a slope put the machine in the position shown in Figure 3 42 control the speed with the travel levers and the throttle controls and reduce engine RPM Figure 3 42 Travel Down Slope To achieve the best stability while excavating lower the dozer blade to the ground Operate as slowly as possible and avo...

Page 80: ...ater Do not operate or immerse the machine in water higher than the top of the upper track rollers Thoroughly grease the machine if it has been operated in deep water Swiveling the Boom The excavator boom can be swiveled from the front position 61º to the right and 65º to the left on the 503Z and 51º to the right and 75º to the left on the 603 This allows excavation of trenches along walls fences ...

Page 81: ...Raise the dozer blade slightly if excessive resis tance occurs 5 When the blade is in position use the travel con trols to move the machine as in normal travel Figure 3 44 Dozer Blade Control WARNING Be sure there is proper clearance for the front end attachments when bulldozing Be sure that the front end attachments do not contact any overhead power lines or obstructions during bulldozing DO NOT ...

Page 82: ... the ground to aid machine stability Whenever possi ble it is best to position the dozer blade on the same side as the excavation Do not support the weight of the machine on one side of the dozer blade Figure 3 46 Machine Operation Exclusions IMPORTANT Never use the excavator bucket to perform actions other than digging grading loading and excavating Damage to the excavator could result Do not use...

Page 83: ...he dipper arm toward the excavator b Extend the dipper arm cylinder so the bucket is tilted upward 6 Figure 3 48 c Raise the boom Figure 3 48 Proper Digging Technique Trench Excavating Trench excavating is most efficient when the machine tracks are parallel to the line of the trench Figure 3 49 For larger trenches excavate each side first and then the center Figure 3 49 Efficient Trench Excavating...

Page 84: ...er loading in a confined area with a limited range of motion position the truck so maximum visibility is ensured for the excavator operator When work conditions permit position the truck so the excavator can load material at the rear of the truck instead of the sides 1 Figure 3 52 The most effective way to load into the rear of the truck is when the truck and excavator form a 45 angle 2 Figure 3 5...

Page 85: ...vator weights Figure 3 54 Machine Lifting Points WARNING When towing the machine make sure no one is close to the towing apparatus or in between the vehicles The machine may only be towed using suitable tow ing equipment in connection with suit able towing apparatus such as a towing coupling hooks and eyes Do not use a towing apparatus that is kinked twisted or otherwise damaged Do not apply high ...

Page 86: ... dozer blade and the bucket onto the load ing surface and turn of the engine See Figure 3 55 8 Perform the Mandatory Safety Shutdown Proce dure on page 2 2 9 Lock the cab Do not allow anyone to stay in the machine 10 Place chocks under the machine tracks and secure the machine to prevent slipping overturning and moving on the transport machine 11 Use the tie down points 1 identified by decals for ...

Page 87: ...rtional auxiliary hydraulic joystick control enables the following new functions Selectable two speed variable auxiliary hydraulic mode at startup precision or power Auxiliary hydraulic control moved to the right joystick thumb control Auxiliary hammer operation is enabled for the right joystick trigger button control Note With proportional auxiliary hydraulic joystick control the auxiliary hydrau...

Page 88: ...ode slide and hold the thumb switch C Figure 3 57 on the right joystick to the left and start the excavator Figure 3 57 Right Joystick 4 Continue holding thumb switch C until the pro portional control indicator D Figure 3 58 flashes It will flash once when starting in precision mode twice when starting in power mode Figure 3 58 Proportional Control Indicator Note After the excavator is started it ...

Page 89: ...b switch C to the left to move the auxiliary hydraulics in the oppo site direction Auxiliary Hydraulic Hammer Operation Note Use the power mode refer to Two Speed Vari able Auxiliary Hydraulic Mode Selection when oper ating a hydraulic hammer attachment Maximum performance of hammer attachments is only possible using the power mode To operate an auxiliary hydraulic hammer attachment press and hold...

Page 90: ...Printed in U S A 3 44 918070 FP0811 NOTES ...

Page 91: ...pped within these components causing premature failure The operating pressure settings of the hydraulic system should only be adjusted by trained qualified personnel If malfunctions are caused by unauthorized alteration of operating pressure settings all warranty responsibil ities of the manufacturer are invalidated WARNING Instructions are necessary before operating or servicing the machine Read ...

Page 92: ...just machine with the engine running unless the service procedure requires it Avoid contact with leaking hydraulic fluid and diesel fuel under pressure which can penetrate the skin and eyes NEVER use your hands to search for hydraulic fluid leaks use a piece of paper or cardboard Escaping fluid under pres sure can be invisible and can penetrate skin and cause serious injury If any fluid is injecte...

Page 93: ... valve clearance adjust if necessary Engine Check engine oil level Engine Change engine oil Engine Replace oil filter Engine Check V belt tension Travel drive Change final drive oil Travel drive Check final drive oil level Undercarriage Check track tension Hydraulic system Check hydraulic oil level Hydraulic system Change hydraulic oil Hydraulic system Replace hydraulic oil filter replace hydrauli...

Page 94: ...Printed in U S A 4 4 918070 FP0811 Maintenance Label ...

Page 95: ...spect water separator pre filter drain 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 Clean battery x x Replace cab air filter for heating and air conditioning x x Empty diesel fuel tanka x x Clean water separator x x Inspect alternator starter and electrical connection...

Page 96: ...dicator lights for correct func tiona x x x Inspect cab canopy tilt lock support componentsa x x x Inspect insulating mats in the engine compartmenta x x x Check bearing play on tread rollers track carrier rollers and front idlers x x Check air filter restriction indicator x x a Check after first 50 hrs every 500 hrs thereafter Service Activity Daily Every 50 Hours Every 250 Hours Every 500 Hours ...

Page 97: ... oila a Replace 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 audible warn ing systema x x Heating functiona x x a Operate weekly Service Activity Daily Every 50 Hours Every 250 Hours Every 500 Hours Every 1000 Hours Customer Dealer Inspect hydraulic lines...

Page 98: ...ication 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 Attachments x x Chassis front of undercarriage x x D Daily W Weekly D D D D D D D D D D W W W W W W W ...

Page 99: ...BP Energrease Moly EP2 Ranges of Applications From 13 F to 104 F 25 C to 40 C outside temperature Engine Checking Engine Oil Level To check the engine oil the machine must be on a level surface with the engine turned off Check the oil level before starting the engine or at least five minutes after shutting off the engine 1 Open the engine cover 2 Check the engine oil level using the dipstick 1 loc...

Page 100: ...ine cause 12 Stop the engine and check for leaks at the oil filter and oil drain plug 13 Check the oil level again and add oil if necessary Air Cleaner Service 1 Perform the Mandatory Safety Shutdown Proce dure on page 2 2 2 The air cleaner is located under the engine cover Press the engine cover release button and raise the engine cover 3 Release the bow clips 1 to remove the air cleaner cover an...

Page 101: ...ge Fuel Filler Cap IMPORTANT Do not knock the element against a solid object to remove dust The element may become distorted and damaged IMPORTANT Do not operate engine without the air cleaner components installed or damage to the engine could occur WARNING Stop the engine and allow it to cool before filling the fuel tank NO SMOKING Failure to obey warnings can cause an explosion or fire 2 3 MPH K...

Page 102: ...r operate the machine until the fuel tank is completely empty The fuel system has to be bled of air whenever the fuel tank is run empty Always fill the fuel tank after use IMPORTANT When using the machine in cold weather it is important to use the proper fuel blend to prevent fuel gelling See the engine oper ator s manual for fuel blend information related to temperature Fuel gelling can per manen...

Page 103: ...ve 2 on the water sepa rator to the ON position Purging Air from the Fuel System Starting from the fuel tank the fuel system runs through the water separator fuel filter fuel injection pump and high pressure piping to the fuel injection nozzles If the fuel tank is run dry or if the fuel filter water separator or fuel lines are replaced trapped air must be removed or bled from the fuel system Bleed...

Page 104: ...rical System Fuses The fuse panel is located on the right consoles See 1 Figure 4 10 To replace a fuse remove the panel cover and pull the old fuse from the socket Install a new fuse of the same rating and re install the fuse panel cover Refer to page 1 6 for fuse identification Figure 4 10 Fuse Panel 1 2 1 2 WARNING Inspect and check the machine s electrical equipment at regular intervals Defects...

Page 105: ... in a wellventilated area Do not jump start a frozen battery or it may explode A discharged battery can freeze at 14 F 10 C To prevent short circuits keep metal parts on your clothing and metal watchbands away from the positive terminal of the battery WARNING Never lay a metal object on top of a battery because a short circuit can result Battery acid is harmful to skin and fabrics If acid spills f...

Page 106: ...ection switch is turned to the ON position 2 Turn ignition key to the OFF position 3 Open the engine cover 4 Slide the boot 7 Figure 4 12 down cable 6 to expose terminal 3 on the battery disconnect switch Note Cable 6 connected to terminal 3 on the battery disconnect switch is also connected to the positive terminal on the starter IMPORTANT When jump starting from another machine be sure the secon...

Page 107: ...on a level surface 2 Fully extend the bucket and boom retract arm and position as shown in Figure 4 13 3 Lower the bucket and dozer blade to the ground Engage the parking brake 4 Shut off the engine Remove the ignition key and take it with you Lock out the controls by raising left control console IMPORTANT DO NOT allow the cable ends to touch when removing them from the batteries Arcs and direct s...

Page 108: ...re 4 14 Hydraulic Oil Level Indicator Tube 6 If the hydraulic oil level is low a Remove the three screws with lockwashers securing the fuel tank hydraulic reservoir cover Remove the tank hydraulic reservoir cover Place the cover away from the work area to protect it from damage b Assemble the tools included in the tool kit as shown in Figure 4 15 The short hex shaft tool 6 is designed to fit the h...

Page 109: ...r bucket and dozer blade to the ground Turn off the machine 3 Perform steps 6 a through c in Checking Hydrau lic Oil Level on page 4 17 4 Remove filter insert 5 Figure 4 16 5 Open the reservoir drain plug and drain oil into a suitable container Re install drain plug and tighten securely 6 Reinstall filter insert 5 7 Fill reservoir with hydraulic oil until oil level is between marks on sight gauge ...

Page 110: ...nnect hose A Figure 4 17 connected to the pilot control filter restrictor fitting B on the side of a joystick control valve 8 Disconnect the pilot control filter restrictor fitting B from the valve Figure 4 17 Pilot Control Filter Restrictor 9 Check the filter restrictor fitting filter screen C for contamination dirt and clean if necessary Replace the filter restrictor if it is damaged 10 Replace ...

Page 111: ...t 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 could result in gangrene or other seri ous damage to tissue Always relieve hydraulic system pres sure before performing any mainte nance on the machine Do not tighten leaking connections when the hydr...

Page 112: ...ter nator 3 in the direction of the arrow until reaching the correct V belt tension b Tighten adjustment bolt 2 and re check V belt tension Close the engine cover when fin ished Figure 4 19 Checking Adjusting V belt Tension Checking and Adjusting Air Conditioning V Belt Tension 1 Position the machine on a level surface 2 Lower the bucket and dozer blade to the ground Move the joysticks in all dire...

Page 113: ...should be at 90º See Figure 4 21 Changing Final Drive Oil 1 Position the machine on a level surface with final drive plugs positioned as shown in Drain Posi tion Figure 4 22 Turn off the engine 2 Open both plugs and drain oil into a suitable con tainer Re install plugs 3 Start the engine and move the machine slightly until plugs are positioned as shown in Fill Posi tion Figure 4 22 4 Shut off the ...

Page 114: ...rack tension roller 3 Figure 4 23 Rubber Track Tensioning Position ing 2 Use the bucket and dozer blade to lift the unit up until tracks are just clear of the ground as shown in Figure 4 24 3 Shut off the engine Remove the ignition key and take it with you Lock out the controls by raising left control console 4 Measure the clearance at the raised track roller from the drive gear Deflection should ...

Page 115: ...re for the other track Figure 4 24 Track Adjustment IMPORTANT Do not over tension the track If track is too tight loosen the grease fitting to relieve pressure WARNING Do not loosen grease fitting more than two turns or grease fitting could be ejected under pressure and cause injury Keep your face and body away from the fitting when loosening 3 4 1 20 25 mm ...

Page 116: ... page 4 9 3 Change the engine oil and filter according to Changing Engine Oil and Filter on page 4 10 4 Add a fuel stabilizer to the fuel system according to the fuel supplier s recommendations 5 Remove and fully charge the battery Store the bat tery in a cool dry location 6 If the machine will not be operated for a month or longer apply grease to all exposed hydraulic cylin der rod areas or retra...

Page 117: ...4 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 the machine and let the engine idle for at least five minutes 7 Shut off the engine and walk around machine Make a visual inspection looking for evidence of leaks Review and re familiarize yourself...

Page 118: ...Printed in U S A 4 28 918070 FP0811 NOTES ...

Page 119: ...enter Starter not working pinion fails to engage Repair starter pinion contact authorized service center Rough running engine Incorrect fuel grade Replace fuel with proper grade see Fluid Capaci ties Lubricants on page 1 4 Incorrect engine valve clearance Adjust valve clearance contact authorized service center Fuel line leakage Replace fuel line contact authorized service cen ter Malfunctioning f...

Page 120: ...gh 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 1 4 Engine smoke Blue Oil level too high Adjust oil level see Changing Engine Oil and Fil ter on page 4 10 Machine inclination too high 15 maximum inclination up and across slopes 25 maximum inclination down sl...

Page 121: ...ension on page 4 22 contact autho rized service center Air filter contaminated Service air filter see Air Cleaner Service on page 4 10 Coolant system malfunction Service cooling system contact authorized service center Battery voltage light comes on during operation Alternator not charging properly malfunction ing alternator Adjust v belt tension see Checking and Adjusting V Belt Tension on page 4...

Page 122: ...Low hydraulic fluid level Add hydraulic fluid see Checking Hydraulic Oil Level on page 4 17 Low engine power See Engine troubleshooting on page 5 1 contact authorized service center Engine to pump coupling or hydraulic pump damaged Contact authorized service center Pressure limiting valves set too low Contact authorized service center Hydraulic cylinder damaged Contact authorized service center Co...

Page 123: ...s Table on the follow ing pages Note As shown in Figure 5 2 a two second ignition on flash followed by a three second separator pause before the error codes are displayed Error codes are then repeated separated by additional three second separator pauses Example 1 Indicates a throttle problem possibly a wiring error or a defective throttle lever sensor Example 2 Indicates an exhaust gas recirculat...

Page 124: ...oolant Add coolant Defective engine cooling system Check replace defective component s Defective coolant temperature sensor Replace sensor 2 4 5 V sensor Wiring harness error Check replace defective component s Internal ECU error Contact dealer 2 3 Battery voltage Worn battery Replace battery Oxidized battery terminals Clean battery terminals Defective alternator Replace alternator Wiring harness ...

Page 125: ...exhaust gas recirculation valve Contact dealer Internal ECU error Contact dealer 2 1 Oil pressure Loose connector Tighten connector Wiring harness error Check replace defective component s Defective oil pressure switch Replace oil pressure switch Internal ECU error Contact dealer 3 3 Coolant temperature Overheated engine Allow to cool down Coolant level too low Add coolant Defective engine cooling...

Page 126: ...nection Battery voltage too low Charge battery Loose connector Tighten connector Wiring harness error Check replace defective component s Internal ECU error Contact dealer 4 2 Antitheft protection Battery voltage too low Charge the battery Loose connector Tighten connector Wiring harness error Check replace defective component s Internal ECU error Contact dealer Flashing Code Error Sender Associat...

Page 127: ...ions 2 10 To Avoid Injury or Death 2 18 Warning Avoid Injury or Death 2 17 Dozer Blade 1 6 3 18 Drive Oil Changing Final 4 23 E Electrical System 1 6 4 14 Engine 1 5 4 9 Checking Engine Oil Level 4 9 Cold Weather Starting Procedure 3 29 Mandatory Safety Shutdown Procedure 3 30 Shut Down 3 30 Start 3 28 Start Procedure 3 29 Stop 3 28 Engine Oil 4 9 Changing 4 10 Filter 4 10 Excavation 3 37 Trench 3...

Page 128: ...3 1 In Cold Weather 3 34 In Water 3 34 On Slopes 3 33 Precautions 3 32 Operational Safety 2 2 Operator s Seat Adjustments 3 19 Ownership Change 1 2 R Ranges of Applications 4 9 Recommended Lubricants 4 9 Relays 1 7 S SAE ISO Operating Controls ISO Operating Controls 3 17 SAE Operating Controls 3 17 Selector Valve 3 16 Safety 2 1 Decals 2 10 Serial Number Location 1 1 Engine Serial Number Location ...

Page 129: ...h Excavating 3 37 Troubleshooting 5 1 Bucket Boom and Dozer Blade 5 4 Engine 5 1 Indicator Lamps 5 3 Seals and Hoses 5 3 Traveling Gear 5 4 U Undercarriage 1 6 V V belt Tension Adjusting 4 22 Checking 4 22 V belt Tension Air Conditioning Adjusting 4 22 Checking 4 22 W Water Separator 4 13 ...

Page 130: ... 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 47 80 mm Hydraulic fittings with various seals heavy application All torque values are in lb ft Nm unless marked otherwise Thread Straight pipe fitting with thread and screwed plug GE Non return valve w...

Page 131: ...642 870 922 1250 M30 1047 1420 1482 2010 1770 2400 885 1200 1254 1700 Bolts and capscrews with fine pitch thread All torque values are in lb ft Nm unless marked otherwise Thread Threads according to DIN 912 DIN 931 DIN 933 etc Threads according to DIN 7984 8 8 10 9 12 9 8 8 10 9 M8X1 0 18 25 27 37 32 43 16 22 24 32 M10X1 0 37 50 55 75 65 88 32 43 48 65 M10X1 25 36 49 52 71 61 83 31 42 46 62 M12X1 ...

Page 132: ...ons on proper operation adjustment or mainte nance of this machine contact your dealer or the GEHL Company service department before starting or continuing operation California Proposition 65 Warnings Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer and birth defects and other reproductive harm Battery post terminals and related accessories co...

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