Gehl GE 802 Operator'S Manual Download Page 4

Page: 4 / 52

PRINTED IN U.S.A.

8147

/0999

TABLE OF CONTENTS (continued)

Chapter

Description

Page

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

TROUBLESHOOTING

Summary of Contents for GE 802

Page 1: ...GE 802 Crawler Excavator OPERATOR S MANUAL Form No 908147 English...

Page 2: ...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 tra...

Page 3: ...tion 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...

Page 4: ...vice 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...

Page 5: ...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...

Page 6: ...908147 0999 MACHINE IDENTIFICATION Arm Cylinder Arm Bucket Cylinder Bucket Boom Cylinder Control Lever Console Dozer Blade Superstructure Track Frame Engine Hood Operator s Seat Cab Left hand Right ha...

Page 7: ...0 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...

Page 8: ...50 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...

Page 9: ...1 5 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...

Page 10: ...e 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...

Page 11: ...e 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...

Page 12: ...PRINTED IN U S A 1 8 908147 0999 This Page Intentionally Blank...

Page 13: ...cally 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 t...

Page 14: ...rive 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 Ther...

Page 15: ...7 8 9 10 11 12 14 13 17 5 3 4 6 15 16 18 14 22 20 21 29 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 Hydraul...

Page 16: ...ING 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 INJUR...

Page 17: ...OOM 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 Manua...

Page 18: ...ATORY 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 21 WARNING AVOID INJURY OR D...

Page 19: ...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 th...

Page 20: ...nd 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...

Page 21: ...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 1 2 3 4 5 6 7 8 9 10 11 1 Fast Speed Tilt Switch an...

Page 22: ...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...

Page 23: ...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 fu...

Page 24: ...e 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...

Page 25: ...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...

Page 26: ...ic 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 ope...

Page 27: ...ast 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 forw...

Page 28: ...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 prev...

Page 29: ...3 15 PRINTED IN U S A 3 11 908147 0999 WARNING Always ensure adequate stability when work ing with the machine Particularly when work ing with equipment slewed to the side Changing the working equipm...

Page 30: ...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...

Page 31: ...unction 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 lo...

Page 32: ...esult The operating pressure settings of the hydraulic system should only be set by trained qualified personnel If malfunctions are caused by unau thorized alteration of operating pressure set tings a...

Page 33: ...y 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 be...

Page 34: ...25 250 500 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...

Page 35: ...ours 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 C...

Page 36: ...rs Hours Hours Check hydraulic system Check bolts Check lights Check windshield wiper system Check for leaks General Lubrication Points MAINTENANCE SCHEDULE continued LUBRICATION W W W W Superstructur...

Page 37: ...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 1...

Page 38: ...ine 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 loca...

Page 39: ...on the seal of the new filter ele ment 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 fu...

Page 40: ...om 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...

Page 41: ...perated with battery cables dis connected Battery cables are connected when using a fast charger or when welding on the machine Remove both cables from the bat tery Extra battery cables booster cables...

Page 42: ...ed 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 hy...

Page 43: ...ely 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...

Page 44: ...RTANT 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 surfac...

Page 45: ...PRINTED IN U S A 4 15 908147 0999 MAINTENANCE LOG DATE HOURS SERVICE PROCEDURE...

Page 46: ...PRINTED IN U S A 4 16 908147 0999 MAINTENANCE LOG DATE HOURS SERVICE PROCEDURE...

Page 47: ...ION WARNING Instructions are necessary before operating and servicing the machine Read and under stand this entire manual Follow warnings and instructions for operation and maintenance Check for corre...

Page 48: ...ing 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 f...

Page 49: ...cient 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 Seconda...

Page 50: ...PRINTED IN U S A 5 4 908147 0999 NOTES...

Page 51: ......

Page 52: ...5 0179 U S A California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 908147...

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