Form No.

908147
English

GE 802
Crawler
Excavator

OPERATORS MANUAL
 GEHL Warranty

GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl equipment to the Original Retail Purchaser to
be free from defects in material and workmanship for a period of twelve (12) months from the Warranty Start Date.

GEHL WARRANTY SERVICE INCLUDES:

Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealers business loca-
tion.

GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED (INCLUD-

ING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE),
EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT.

GEHL WARRANTY SERVICE DOES NOT INCLUDE:

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

2. Used equipment.

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

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

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

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

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

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

1 GENERAL INFORMATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Machine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Undercarriage and Slewing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Bucket (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
2 SAFETY INFORMATION
General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Safety Symbols and Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Safety Decal and Sticker Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Safety Decals and Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
3 OPERATION
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Machine Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Outer Cab Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Inner Cab Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Console Controls Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Excavating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Console Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Operators Seat Adjustment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Cab Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Checklist Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Starting/Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Moving The Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Mandatory Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Earthmoving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Operating on Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Operating in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Excavator Boom Slewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Grading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Loading Machine for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

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 TABLE OF CONTENTS (continued)
Chapter Description Page

4 MAINTENANCE
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Care and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Changing Engine Oil & Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Purging Air from Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Using a Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Track System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Adjusting Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Changing Final Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
5 TROUBLESHOOTING
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Seals & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Travelling Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Bucket, Boom and Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

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

 GENERAL INFORMATION
INTRODUCTION
The information in this Operators Manual was written to Our Dealer network stands by to provide you with any assis-
give the owner/operator assistance in preparing, adjusting, tance you may require, including genuine GEHL service
maintaining and servicing the Crawler Excavator. More parts. All service parts should be obtained from your GEHL
importantly, this manual provides an operating plan for safe Dealer. Give complete information about the part and
and proper use of the machine. Major points of safe opera- include the model and serial number of your machine.
tion are detailed in Section 2Safety Information. Record the serial number in the space provided on this page,
as a handy reference.
The GEHL Company asks that you read and understand the
contents of this manual COMPLETELY and become familiar Purchased From:
with your new machine BEFORE attempting to operate it.
Consult your GEHL Dealer to obtain extra manuals, or manu- Date of Purchase:
als in other languages.
Model No.:
Throughout this manual, information is provided which is set
Serial No.:
in italic type and introduced by the word NOTE or IMPOR-
TANT. Be sure to read carefully and comply with the mes- SERIAL NUMBER LOCATION
sage. Following this information will improve your operat-
ing and maintenance efficiency, help you to avoid breakdown The serial plate is located on the inside cab wall next to the
and damage, and extend the machines life. throttle lever (Figure 1-1).

Do not use this machine for any application or purpose other

than those described in this manual. If the machine is to be
used with special attachments or equipment other than those
Serial Plate
approved by Gehl, consult your GEHL Dealer. Any person
making unauthorized modifications is responsible for the
consequences.

The use of this equipment is subject to certain hazards that

cannot be eliminated by mechanical means, but only by exer-
cising intelligence, care and common sense. Such hazards
include, but are not limited to, hillside operation, overload-
ing, instability of the load, poor maintenance and using the
equipment for a purpose for which it is not intended or
designed.

It is essential to have competent and careful operators, who Figure 1-1. Serial Number Location
are not physically or mentally impaired, and who are thor-
oughly trained in the safe operation of the equipment and the
handling of loads. It is recommended that the operator be
capable of obtaining a valid motor vehicle operators license.

GEHL Company reserves the right to make changes and

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

NOTE: All references to Left-hand or Right-hand are determined from sitting in the operators seat and facing forward.

IMPORTANT! Keep these instructions with the machine for future reference.
If the machine changes ownership, be sure this manual accompanies the equipment.

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

 MACHINE IDENTIFICATION

Arm Cylinder

Boom

Arm
Left-hand & Right-hand
Travel Levers

Bucket Cylinder Cab

Operators
Seat

Bucket

Engine Hood

Boom
Cylinder

Control Lever
Console

Dozer
Blade Superstructure Track Frame

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

 SPECIFICATIONS
GE 802

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

HYDRAULIC SYSTEM
Pumps Double Axial Piston Pump & One Gear Pump
Flow Rate 21 gpm (80 L/min)
21 gpm (80 L/min)
13 gpm (50 L/min)
Working Pressure 4359 psi (300 bar)
Swing System Pressure 3632 psi (250 bar)
Oil Cooler Standard
Hydraulic Tank 32 gal. (122 L)

UNDER CARRIAGE & SLEWING SYSTEM

Travel Speed-Dual 4 mph (6.4 km/h))
6 mph (9.6 km/h)
Ground Clearance 15 in. (335 mm)
Slew Speed 9.5 rpm
Gradability 30 (= 58%)
Rubber Track Width 17.7 in. (450 mm)
Number of Track Rollers 5 each side
Average Ground Pressure 4.27 psi (29.4 kPa)

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

BUCKET (STANDARD)
Width 129.5 in. (750 mm)
Capacity 9 cu. ft. (0.26m3)

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

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

 SPECIFICATIONS (continued)
GE 802

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

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

Model GE802

15"
284" (3800 mm)
(7220 mm)

59"
204" (1500 mm) 214"
(5180 mm) (5440 mm)

101"
(2570 mm) 72.8"
(2150 mm)
21.3" 17.7"
(540 mm) (450 mm)

173" 17.7"
(4400 mm) (450 mm)

50
109"
(2780 mm)
72.8"
(2150 mm)

80

285" 62.6"
(7240 mm) (1590 mm)

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

 CHECKLISTS
I acknowledge that pre-delivery procedures were performed
Pre-Delivery Checklist
on this unit as outlined on this page.
The following checklist is an important reminder of valuable
information and inspections which MUST be made before
delivering the machine to the customer. Check off each item Dealership Name
after prescribed action is taken.

CHECK THAT:
Dealer Representative Name
Unit has NOT been damaged in shipment. Check for
such things as dents and loose or missing parts; correct
or replace components as required.
Date Checklist Filled Out
Battery is securely mounted and NOT cracked. Make
sure cable connections are tight.
Cylinders, hoses and fittings are not damaged, leaking or
loosely connected. Model & Serial Number
Filters are not damaged, leaking or loosely secured.
Machine is properly lubricated and no grease fittings are Delivery Checklist
missing or damaged.
Hydraulic system reservoir, engine crankcase and drive The following checklist is an important reminder of valuable
chaincases are filled to their proper levels. information that MUST be passed on to the customer at the
All adjustments are made to comply with settings given time of delivery. Check off each item as you explain it to the
in Section 4Maintenance of this manual. customer.
All guards, shields and decals are in place and secured.
EXPLAIN:
Model and serial numbers for this unit are recorded in
the space provided on this page and on page 1-1. The Safety Information and Operation chapters of this
IMPORTANT: Start the engine and test run the unit manual, regarding the safe operation of this machine.
while checking that all controls operate properly. The Maintenance and Troubleshooting chapters for
information regarding the proper maintenance of this
CHECK THAT: machine. Explain that regular lubrication and mainte-
nance is required for continued safe operation and long
Drive controls and boom/arm/bucket/swing/pivot machine life.
controls operate properly and are not damaged or Give the Operators Manual to the customer and instruct
binding. the customer to read and completely understand the con-
Drive controls are properly adjusted for a correct neutral tents before operating the unit.
position. Explain that the customer MUST consult the engine
The parking and travelling gear brake, along with the manual (provided) for related specifications, operating
blocking devices, are automatically activated with unit adjustments and maintenance instructions.
stationary (no pilot control pressure). Completely fill out the Owners Registration, including
All hydraulic functions are NOT operational with the customers signature and return it to the Gehl Company.
left-hand control console in the pivoted rearward
position.

Customers Signature

Date Delivered

Retain for Customers Records

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

 CHECKLISTS
I acknowledge that pre-delivery procedures were performed
Pre-Delivery Checklist
on this unit as outlined on this page.
The following checklist is an important reminder of valuable
information and inspections which MUST be made before
delivering the machine to the customer. Check off each item Dealership Name
after prescribed action is taken.

CHECK THAT:
Dealer Representative Name
Unit has NOT been damaged in shipment. Check for
such things as dents and loose or missing parts; correct
or replace components as required.
Date Checklist Filled Out
Battery is securely mounted and NOT cracked. Make
sure cable connections are tight.
Cylinders, hoses and fittings are not damaged, leaking or
loosely connected. Model & Serial Number
Filters are not damaged, leaking or loosely secured.
Machine is properly lubricated and no grease fittings are Delivery Checklist
missing or damaged.
Hydraulic system reservoir, engine crankcase and drive The following checklist is an important reminder of valuable
Cut along dotted line and retain for Dealers records.

chaincases are filled to their proper levels. information that MUST be passed on to the customer at the
All adjustments are made to comply with settings given time of delivery. Check off each item as you explain it to the
in Section 4Maintenance of this manual. customer.
All guards, shields and decals are in place and secured.
EXPLAIN:
Model and serial numbers for this unit are recorded in
the space provided on this page and on page 1-1. The Safety Information and Operation chapters of this
IMPORTANT: Start the engine and test run the unit manual, regarding the safe operation of this machine.
while checking that all controls operate properly. The Maintenance and Troubleshooting chapters for
information regarding the proper maintenance of this
CHECK THAT: machine. Explain that regular lubrication and mainte-
nance is required for continued safe operation and long
Drive controls and boom/arm/bucket/swing/pivot machine life.
controls operate properly and are not damaged or Give the Operators Manual to the customer and instruct
binding. the customer to read and completely understand the con-
Drive controls are properly adjusted for a correct neutral tents before operating the unit.
position. Explain that the customer MUST consult the engine
The parking and travelling gear brake, along with the manual (provided) for related specifications, operating
blocking devices, are automatically activated with unit adjustments and maintenance instructions.
stationary (no pilot control pressure). Completely fill out the Owners Registration, including
All hydraulic functions are NOT operational with the customers signature and return it to the Gehl Company.
left-hand control console in the pivoted rearward
position.

Customers Signature

Date Delivered

Retain for Dealers Records

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

 This Page Intentionally Blank

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 SAFETY INFORMATION
GENERAL SAFETY INFORMATION
Safety Symbols & Terminology Safety Reminders

The GEHL Company, in cooperation with the Some illustrations in this manual may show doors,
Society of Automotive Engineers, has adopted guards and shields open or removed for illustrative pur-
this Safety Alert Symbol to pinpoint precautions poses only. BE SURE all doors, guards and shields are
which, if NOT properly followed, can create a safety haz- in their proper operating positions BEFORE starting the
ard. This symbol means ATTENTION! BECOME engine to operate the machine.
ALERT! YOUR SAFETY IS INVOLVED! It stresses an
attitude of Heads Up For Safety and can be found To ensure safe operation, replace damaged or worn-out
throughout this Operators Manual and on the machine. parts with genuine Gehl service parts.

Before you operate this equipment, read and study the Gehl units are designed and intended to be used ONLY
following safety information. In addition, be sure that with Gehl Company attachments or approved referral
every individual who operates or works with this equip- attachments. The Gehl Company cannot be responsible
ment, whether family member or employee, is familiar for operator safety if the unit is used with non-approved
with these safety precautions. attachments.

The Gehl Company always considers the operators safety The terrain, engine speed, load carried, and abrupt con-
when designing its machinery, and guards exposed moving trol movements can affect machine stability. If misused,
parts for the operators protection. However, some areas can- any of the above factors can cause the machine to tip,
not be guarded or shielded in order to assure proper opera- throwing the operator forward or out of the unit,
tion. causing death of serious injury. Therefore, ALWAYS
wear the seatbelt when operating the equipment.
The following safety words and symbols are used throughout Operate the controls smoothly and gradually at an appro-
the manual and on the machine to warn of dangerous situa- priate engine speed which matches the operating condi-
tions. tions.

For additional stability when operating on inclines or

DANGER ramps, ALWAYS travel with the bucket and blade

towards the top of the incline.
DANGER indicates an imminently hazardous * DO NOT raise or lower a loaded bucket suddenly.
situation which, if not avoided, will result in Abrupt movements under load can cause serious instabil-
death or serious injury. ity.

WARNING NEVER attempt to bypass the keyswitch to start the

engine. Use only the jump-starting procedure detailed in
WARNING indicates a potentially hazardous sit- the Maintenance section of this manual.
uation which, if not avoided, could result in NEVER use your hands to search for hydraulic fluid
death or serious injury. leaks; use a piece of paper or cardboard. Escaping fluid
under pressure can be invisible and can penetrate the
CAUTION skin and cause serious injury. If any fluid is injected
into your skin, see a doctor at once. Injected fluid MUST
CAUTION indicates a potentially hazardous sit- be surgically removed by a doctor or gangrene may
uation which, if not avoided, may result in result.
minor or moderate injury. May also alert
Do not operate too close to an excavation or ditch. BE
against unsafe practices.
SURE that the surrounding ground has adequate strength
to support the weight of the machine and the load.

DO NOT smoke or have any spark producing equipment

in the area while filling the fuel tank or while working
on the fuel or hydraulic systems.

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

 Never drive across the incline on sloping ground.
Safety Reminders (continued) Extreme caution is required when working across an
incline or changing direction.
When driving on or across roads, the machine must be
equipped according to the road/traffic laws, and these Never use the weight of the machine to obtain more
laws must be observed. force when excavating. There is a risk overturning.
Adapt working speed to local visibility. Before starting up the machine or setting it in motion,
warn any personnel in the area.
The driving speed must be adapted to the road and
ground conditions. Attach a clearly visible, legible OUT OF SERVICE sign
when repair and adjustments are being performed on the
Particular attention is required when working on slopes.
machine.
Angle of inclination of machine for all directions of trav-
el: for brief operation (2-3 minutes)maximum of 30; Unless necessary for servicing the engine, the engine
for continuous operationmaximum of 25. hood must not be opened while the engine is running.
Unauthorized personnel must not start-up the machine. Be familiar with the machine safety devices.
No one but the operator must be on the machine when in The machine is not to be used to lift equipment or trans-
use. PASSENGERS PROHIBITED! port personnel.
Use the towing bracket provided for towing the machine. The excavator arm is not a ramming tool. Never attempt
to use the working equipment to drive piles or similar
The operating area, steps, and grips must be free of oil,
items into the ground, or to flatten the ground.
dirt, ice and unsecured objects.
Never excavate while the machine is travelling. Never
The proper working condition of the lighting system
move the machine to dig. Never slew with lowered
must be checked before and while working in darkness.
working equipment and never move the machine when
Always keep the windshield and windows clean. Poor the working equipment is resting on the ground.
visibility can cause accidents.
Fire Prevention
Operate the machine from the operators seat only. Wear
seatbelt which is provided. The machine has several components that operate at high
temperature under normal operating conditions, primarily the
Control the machine cautiously and gradually until you engine and exhaust systems. Also, the electrical system, if
are fully familiar with all the controls and handling. not properly maintained or is damaged, can arc or produce
sparks. These conditions make it extremely important to
Pay attention to all movements of machines and avoid conditions where explosive dust or gasses can be ignit-
machines in the working area. ed by arcs, sparks or heat.
Personnel must not be in the working area. Never oper- The machine must be cleaned on a regular basis to avoid the
ate equipment above people. buildup of flammable debris such as leaves, straw, etc.
Accumulated debris, particularly in the engine compartment,
Always wear appropriate protective clothing: hard hat,
poses a fire hazard.
work gloves, strong work shoes, reflective clothing.
The spark arrestor muffler is designed to control the emission
Make sure you have sufficient knowledge of the working
of hot particles from the engine and exhaust system, but the
area; location of utility lines (water, gas, electric, etc.)
muffler system still gets hot during operation. For this rea-
and load bearing capacity of the ground.
son, it is extremely important not to operate the machine in
Before working in the area of utility lines, contact the an area where explosive dust or gasses can contact the hot
proper authority to determine the measures required for exhaust.
safety.
Do not use the machine where explosive gasses or dust
Never dig underneath the machine. Support walls prop- can be ignited by arcs, sparks, hot components or
erly when excavating or working in, or close to, trench- exhaust gasses.
es.
The operator cab, engine compartment and engine cool-
Never drive long distances with the working equipment ing system must be inspected every day and cleaned if
fully raised. Lowering the working equipment produces necessary to remove any flammable debris.
improved visibility and improved weight distribution.

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

 Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or Mandatory Safety Shutdown Procedure
replace any damaged parts.
Before leaving the machine:
Check fuel and hydraulic tubes, hoses and fittings for
1. Lower the working equipment to the ground and support
damage and leakage. Tighten or replace any parts that
it securely.
show leakage. Always clean fluid spills.
2. Reduce throttle and turn off the engine.
Always the clean the machine before performing any
welding. Cover rubber hoses, battery and all other flam- 3. Lock out controls by raising left control console.
mable parts. Keep a fire extinguisher near the machine
when welding. 4. Remove the ignition key and take it with you.

Stop the engine and let it cool before adding fuel.

SAFETY DECAL & STICKER LOCATIONS

1. WARNING: Danger zone. Keep away! (both sides 1
of the boom)
2. Direction arrow (left and right on track frames) 18
3. Hydraulic Oil
25, 26 14
4. WARNINGHydraulic reservoir under pressure
5. Diesel 22
6. WARNING: Do not open when engine is running 20, 21
7. Lower boom, raise boom, close bucket, open
bucket (on windshield)
8. Lower dozer blade, raise dozer blade (on wind-
shield)
9. Travel right, forward/reverse (on windshield) 18,19
10. Travel left, forward/reverse (on windshield)
11. Bucket arm out, bucket arm in, superstructure left,
superstructure right (on windshield) 2
12. Environmental symbol (blue angel) (on windshield)
13. Nameplate 7 8 9 10
11
14. Warning. TO AVOID INJURY: Read the Operators 12
Manual before using the machine. Be sure all
users are instructed on safe use and mainte-
23
nance. Service the machine per the manual.
Contact dealer (or manufacturer) for information
and service parts.
15. LWA 96
16. LPA 78
14
17. CE symbol
18. Lifting point for lifting the excavator (left and right
on boom and dozer blade)
19. Tie down point (left and right on dozer blade and 13,17
chassis
4
5 3 29 6

18

15,16

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

 SAFETY DECAL & STICKER LOCATIONS
20. WARNING: TO AVOID INJURY: 1
Load and transport unit properly. Inspect job-site
for hazards. 18
Operate only from operators seat. Fasten seat-
25, 26 14
belt.
Keep people out of DANGER ZONE. 22
Operate within stability limit of machine. DO NOT 20, 21
OVERLOAD. Use only approved attachments.
21. WARNING: Mandatory Safety Shutdown
Procedure:
1. Lower all equipment to ground.
2. Reduce throttle; shut off engine. 18,19
3. Lock out controls before exiting.
4. Remove key and take it with you.
22. WARNING: TO AVOID INJURY: Always hold handle 2
when closing front window. When opening win-
dow, be sure to lock both sides. 7 8 9 10
11
23. WARNING: TO AVOID INJURY OR DEATH: Do not 12
loosen lubricator more than 2 turns. Do not
loosen parts other than lubricator. Grease is
23
under high pressure.
24. Lubrication hours
25. Engine cover release latch
26. Hydraulic valve cover release latch
27. Throttle speed
14
28. Hydraulic breaker
29. Keep hands away from fan blade

13,17

4
5 3 29 6

18

15,16

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

 SAFETY DECALS

WARNING

DANGER ZONE

Keep away!
HYDRAULIC OIL
1 2 3

WARNING D WARNING
HYDRAULIC RESERVOIR DO NOT OPEN WHILE
UNDER PRESSURE DIESEL ENGINE IS RUNNING

4 5 6

TRAVEL RIGHT TRAVEL LEFT

BOOM DOWN

FORWARD FORWARD

DOZER BLADE DOWN

BUCKET BUCKET
CLOSED OPEN

DOZER BLADE UP REVERSE REVERSE

BOOM UP

7 8 9 10

ARM OUT WARNING

BOOM LEFT BOOM RIGHT

TO AVOID INJURY:
SWING SWING
LEFT RIGHT Read the Operator's Manual before
using this machine.

Be sure all users are instructed on

safe use and maintenance.

ARM IN Service machine per the Manual.

Contact dealer (or manuafacturer) for

information and service parts.

11 14

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

 SAFETY DECALS (continued)

1. 2.
WARNING
TO AVOID INJURY:
1. Load and transport unit properly.
Inspect job-site for hazards.
3. 4. 2. Operate only from operator's seat.
Fasten seatbelt.
3. Keep people out of DANGER ZONE.

4. Operate within stability limit of

machine. DO NOT OVERLOAD.
Use only approved attachments.

18 19 20

1. 2.
WARNING
STOP
MANDATORY SAFETY WARNING
SHUTDOWN PROCEDURE:
TO AVOID INJURY:
3. 4. 1. Lower all equipment to ground.

2. Reduce throttle; shut off engine.

ALWAYS hold handle
when closing front
3. Lock out controls before exiting. window.
When opening window be
4. Remove key and take it with you.
sure to lock both sides

21 22

WARNING
AVOID INJURY OR DEATH
Do not loosen lubricator more
10
than 2 turns
Do not loosen parts other than lubricator.
Grease is under high presure. 50
23 24

25 26

A+B A+T

HYDRAULIC BREAKER

27 28 29

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

 OPERATION
GENERAL INFORMATION
WARNING Guards & Shields

Be sure you are familiar with all safety devices Whenever possible, guards and shields are used to protect
and controls before operating the machine. potentially hazardous areas on the machine. In many places,
Know how to stop before starting. This GEHL decals are also provided to warn of potential hazards and/or
to display special operating procedures (see Safety Decals
Company machine is designed for use only
Locations in Section 2).
with GEHL Company approved accessories or
referral attachments. The GEHL Company The operators seat left-hand console must be raised in order
cannot be responsible for operator safety if the to exit the cab. In the raised position, the left-hand console
unit is used with non-approved attachments. locks out all hydraulic functions of the machine (Figure 3-1).

WARNING Armrest Lever

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

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

Figure 3-1. Left-Hand Console Raised

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

 OPERATOR CONTROLS
Outer Cab Layout

1 7 9 13
1. Fuel Filler 2
2. Hydraulic Reservoir
3. Hydraulic Valves 3
4. Diesel Pump (Option)
5. Hydraulic Oil Filler
6. Hydraulic Oil Filter + - 10
7. Hydraulic Oil Sight Gauge 5
8. Battery
9. Hydraulic Reservoir Drain 6
10. Fuel Tank Drain
11. Fuel Tank
12. Engine Hood 4
13. Fire Extinguisher in Tool Box
8

12
11

Inner Cab Layout

1. Auxiliary Hydraulics Pedal 1 2 3 4 5 6 7

2. Left-Hand Travel Lever w/Foot Pedal
3. Seat Suspension Adjustment Lever
4. Right-Hand Travel Lever w/Foot Pedal
5. Seat Adjustment Lever
6. Footrest
7. Dozer Blade Control Lever w/Foot Pedal
8. Ventilation Controls
8
9. Cab Light
10. Windshield Washer Reservoir 8
11. Throttle Lever 9
12. Hydraulic Valve Cover Latch Lever 26
13. Engine Cover Latch Lever + -
10
14. Right-Hand Control Lever for Boom, Bucket 25
Cylinder and Horn 11
24
15. Ashtray
16. Console Controls (see next page) 14
13 12, 13
17. Radio
18. Stereo Speaker 15
19. Ignition Key Switch 12
20. Armrest 16
21. Storage Shelf 23
22. Fuse Panel (see next page)
23. Heater 20
24. Left-Hand Control Lever for Rotating/Slewing
Bucket Arm; Control Button for Boom Swing when 18
used with Auxiliary Hydraulics Pedal (#1) 18
17
25. Armrest Lever (for folding back the armrest which
disables the hydraulic controls)
22 21 20 19
26. Seat and Console Adjustment Lever

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

 Console Controls Layout

1. Fuel Level Gauge

2. Coolant Temperature Indicator
3 - +
4
3. Battery Voltage Indicator
4. Engine Oil Pressure Indicator
5. Glow Plug Indicator 2 5
6. Engine Air Filter Indicator
7. Hydraulic Oil Level Indicator 6 7
8. Low Fuel Indicator
9. Work Lights ON Indicator 9 8
10. Hour Meter
11. Heater Control
12. 2-Speed Travel Switch 1
13. Light SwitchCab Front Work Light 00000000
HOURS

14. Ignition Key Switch

10
15. Light SwitchBoom Work Light
16. Light SwitchRear Work Light (optional)

11
17

16
12

15
13

14

Fuse Panel

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

2. Windshield Wiper and Washer (7.5 Amp)

1 5
3. Turn Engine Off (Stop Solenoid) (3.0 Amp)
4. Switch Lighting, Instrument Panel and Lighting (7.5 Amp)

9
5. Front Work Lights (15 Amp)
6. Heating, Horn (15 Amp)

2 6
7. Safety (turning) Light, Free (10 Amp)
8. Cabin Lighting, Socket, Radio (Optional) (10 Amp)

10
9. Alternator, Starter (10 Amp)
10. Fuel Pump, Free (15 Amp)

3 7
11. Changeover Valve, Safety Solenoid Valve (10 Amp)

11
4 8

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

 OPERATOR CONTROLS (continued)
Left-Hand Lever w/Foot Pedal
WARNING Right-Hand Lever w/Foot Pedal
Levers and controls should return to neutral
Dozer Lever
position when released. Be sure the levers and w/Foot Pedal
controls are in the neutral (middle) position
before starting the engine. Operate lever con-
trols gradually and smoothly. Excessive speed
and quick handle movements without regard
for conditions and circumstances is hazardous
and could cause an accident.

Travel Controls

NOTE: Moving the handles equally in the same direc-

tion will result in travelling straight forward or straight Figure 3-2. Travel Controls; Dozer Control
backward.
Boom Swing
FORWARD TRAVEL Control (used with
Push both levers (Figure 3-2) straight forward, slowly the Auxiliary Hydraulic Pedal)
same distance. Left-Hand Control

REVERSE TRAVEL
Pull both levers straight backward, slowly the same distance.

TURNING DURING TRAVEL

Horn
Move one lever farther than the other one. To turn left while
Right-Hand
moving forward, move the right lever farther forward; to turn
Control
right while moving forward, move the left lever farther for-
ward.
Figure 3-3. Boom & Bucket Controls
PIVOTING
Move the levers in opposite directions to pivot the machine Right-Hand Control
on its axis. To pivot left, move the right lever farther forward
while pulling the left lever to the rear; to pivot right, move
7
the left lever forward while pulling the right lever to the rear. 5

Excavating Controls 6
8 7
8

The boom and bucket are controlled by the right- and left- 6
hand levers on the seat consoles (Figure 3-3).

The superstructure or house is slewed (swung) by moving

the left-hand lever left or right (Figure 3-4). Left-Hand Control

3
The boom can be slewed (swung) without moving the cab by 1
1
pressing the auxiliary hydraulics pedal left or right (Figure 3-
5) while pressing the boom swing switch on the left-hand 2
4
control lever. 3 4

The boom and bucket are moved using the right-hand control
2
lever. The button located on the right-hand lever sounds the
horn (Figure 3-3).

The dozer is controlled by the dozer lever (Figure 3-2). Figure 3-4. Boom and Bucket Controls

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

LEFT-HAND CONTROL LEVER (FIGURE 3-3)
1. Move the left-hand lever forward to move bucket arm
away from the machine.

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

towards the machine.

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

ture to the left.

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

ture to the right.

RIGHT-HAND CONTROL LEVER (FIGURE 3-4)

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

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

7. Move the right-hand lever to the left to close the bucket

(bucket moves up and toward the boom). Must use with Boom Swing Switch on Left-Hand Control

8. Move the right-hand lever to the right to open the bucket Figure 3-5. Auxiliary Hydraulics Pedal
(bucket moves down and away from the boom).
3
AUXILIARY HYDRAULICS PEDAL (FIGURE 3-5) 4
- +

Lift the protective shield, then depress the pedal left or right 2 5
while depressing the switch located on top of the left-hand
control lever to slew only the bucket (superstructure will 6 7
remain stationary). 9 8

DOZER BLADE
1
The dozer blade is raised and lowered by the dozer lever 00000000
HOURS

w/foot pedal (Figure 3-2). Push the lever forward to lower

10
the blade; pull the lever to the rear to raise the dozer blade.

Console Controls (Figure 3-6) 11

17
1. FUEL LEVEL GAUGE
The fuel gauge shows the level of fuel in the tank. 16
12
2. COOLANT TEMPERATURE INDICATOR
Indicator light comes on when coolant temperature is too 15
high. 13

3. BATTERY VOLTAGE INDICATOR 14

Indicator light comes on when battery voltage is too low.

4. ENGINE OIL PRESSURE INDICATOR

During normal operation, this indicator light should remain Figure 3-6. Console Controls
off. The indicator will light if the engine oil pressure drops
too low. If this occurs, shut off the engine IMMEDIATELY 7. HYDRAULIC OIL LEVEL INDICATOR
and determine the cause of the pressure drop. Indicator light comes on when hydraulic oil level is too low.
Shut off engine and add oil.
5. GLOW PLUG INDICATOR
Indicator light comes on when the ignition key is turned on. 8. LOW FUEL INDICATOR
Indicator will go out when glow plugs have heated sufficient- Indicator light comes on when fuel level is too low.
ly to start the engine.
9. WORK LIGHTS INDICATOR
6. ENGINE AIR FILTER INDICATOR Indicator light comes on when work lights are turned on.
Indicator light comes on when engine air filter is too dirty.

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

 OPERATOR CONTROLS (continued)
Console Controls (continued) (Figure 3-6)
Armrest Lever
10. HOUR METER
Indicates total operating hours of the machine. Use the hour
meter to log maintenance time in the log located in Left-Hand Console
Section 4Maintenance. In Raised Position

11. HEATER CONTROL SWITCH

Turns on the cab heater and controls the fan speed.

12. 2-SPEED TRAVEL CONTROL SWITCH

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

13. CAB FRONT WORKING LIGHT SWITCH

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

14. IGNITION KEYSWITCH

With the key in the OFF (vertical) position, power from the
battery is disconnected to the controls and console. This is Figure 3-7. Operators Seat with Left-Hand
the only position that the key can be inserted or removed Console Raised
from the switch.
Seat Adjustment Lever
With the key turned one position clockwise (RUN) from the
vertical position, power from the battery is supplied to all
controls and electrical circuits.

With the key turned fully clockwise (START) and held in

position, the electric starter energizes and starts the engine
when the glow plug indicator goes out. Release the key after
the engine starts.
Seat/Console
NOTE: The key must always be returned to the OFF Adjustment Lever

position between attempts to start the engine in order to

activate the glow plug system.
Seat Suspension
15. BOOM WORKING LIGHT SWITCH Adjustment Lever
Turns the boom working light on and off.
Figure 3-8. Operators Seat Adjustment Controls
16. REAR WORKING LIGHT SWITCH (Optional)
Turns the optional rear working light on and off. SEAT SUSPENSION ADJUSTMENT LEVER
Turn the lever (Figure 3-8) to adjust the seat suspension for
17. WINDSHIELD WIPER SWITCH the operators weight. An indicator on the front of the seat
Pushing the switch to the first position turns the windshield base shows the weight adjustment.
wiper on. Pushing and holding the switch in the second posi-
tion activates the washer fluid pump. SEAT/CONSOLE ADJUSTMENT LEVER
The seat/console lever (Figure 3-8) allows the operator to
Operators Seat Adjustment Controls move the seat and console forward or rearward as a unit.

NOTE: The operators seat left-hand console must be SEAT ADJUSTMENT LEVER
raised in order to exit the cab. In the raised position, The seat adjustment lever (Figure 3-8) allows the operator to
the left-hand console locks out all hydraulic functions of move the seat only (without console) forward or rearward.
the machine (Figure 3-7).

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

 Ventilation

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

To close the windshield, turn the latches then lower the wind- Latch
shield until the latches lock in position.
Handle

WARNING
When opening windshield, be sure to lock both
latches. When closing windshield, keep hands
on handle and away from path of window. Figure 3-9. Windshield

SIDE WINDOW
The side window can be opened for ventilation. Squeeze the
latch (Figure 3-10) located on the window, then slide window
to desired position and release latch.
Latch
VENTS
Vents
There are two side vents located underneath the side window
(Figure 3-10. Open the slats for better ventilation.

Cab Latches

CAB DOOR LATCH

When fully opened, the cab door will lock in position to the
side of the cab. To release the latch, pull the black knob
located on the right side of the door jamb.
Figure 3-10. Side Window
ENGINE AND HYDRAULIC VALVE COVER LATCHES
The engine cover and hydraulic valve cover latches are locat-
ed next to the operators seat, on the right-hand side.

To unlock a cover, pull the respective latch handle. The

cover can then be opened.

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

 MACHINE OPERATION
Starting/Stopping the Engine
WARNING SAFETY DEVICES
Instructions are necessary before operating or
When the machine is stationary (no pilot control pressure),
servicing the machine. Read this entire manu-
the parking and travelling gear brake are automatically acti-
al and all decals on the machine. Follow all vated.
warnings and instructions. Failure to follow all
instructions can cause injury or death. All hydraulic functions are inoperable with the operators
seat left-hand console in the raised position.
Checklist Before Operation The brakes are not released and hydraulic functions activated
until a travel lever or control lever is operated.
Check the following items before each day of operation:

Seat belt and mounting hardware. NORMAL STARTING/STOPPING PROCEDURE

1. Adjust the operators seat to desired settings.
Decals. Replace as required.
2. Be sure all levers and controls are in neutral positions.
Air cleaner and intake hoses.
3. Insert ignition key into switch and turn clockwise to the
Engine coolant level and system for leaks. first position. Indicators for oil pressure and battery
voltage will light.
Clean engine area of any flammable materials.
4. Turn the key fully clockwise and hold in position until
Check engine oil level and fill if required. glow plug indicator goes out (approximately 10 seconds
when engine is cold).
Check hydraulic system for leaks and check hydraulic
fluid level. 5. When engine starts, release the key.

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

WARNING to warm the hydraulic fluid.

See the list of recommended lubricants in 7. Turn the key fully counterclockwise to turn the engine
Section 4Maintenance for proper grade of off.
engine oil and hydraulic oil. Only use oils of
IMPORTANT: Do not engage the starter motor for
specified on the list or serious injury or death
longer than 10 seconds at each starting attempt. If
could occur. the engine does not start, wait 30 seconds, turn the
Check all pivot points for proper operation. key fully off, then attempt to start the engine again.

Check track tension.

Check for broken and loose parts, and repair.

WARNING
When an engine is running in an enclosed
Check fuel tank. area, fresh air must be added to avoid concen-
tration of exhaust fumes. If the machine is sta-
IMPORTANT: Never operate machine until fuel tank tionary, vent the exhaust outside. Exhaust
is completely empty. If this occurs, the fuel system fumes contain odorless, invisible gases which
will have to be bled of air. Always fill tank after use.
can kill without warning.

Engines have hot parts and hot exhaust gas.

WARNING Keep flammable materials away from engine.
Do not use ether with glow plugs (preheat) sys-
tems. Explosion can result which can cause Do not use machine in atmosphere containing
injury or damage. explosive gas.

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

 Starting/Stopping the Engine (continued) Throttle Lever

IMPORTANT: Indicator lamps must go out when

engine starts. If they do not, turn off the engine
IMMEDIATELY until cause has been determined and
fixed.
COLD WEATHER STARTING PROCEDURE
1. Install an engine heater.

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

ambient temperature.

3. Be sure battery is fully charged. Figure 3-11. Throttle Lever

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

Left-Hand Lever w/Foot Pedal
5. Follow all steps under Normal Starting Procedure on Right-Hand Lever w/Foot Pedal Travel Speed
previous page. Switch

6. As the engine warms up and engine speed increases,

move the throttle lever to the idling position.

NEW MACHINE BREAK-IN PROCEDURE

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

Perform the following when operating a new machine:

After starting, let the engine idle for 5 minutes so all the
components can warm-up.
Figure 3-12. Travel Levers & Speed Switch
Avoid operation with heavy loads or at high speeds.
3. To turn left, pull the left-hand travel lever back and push
Avoid sudden starting and stopping or abrupt motions. the right-hand lever forward.
Moving the Excavator To turn right, pull the right-hand lever back and push the
left-hand lever forward.
1. Set the travel speed using the travel speed switch on the
console: 4. To stop travelling, return levers to neutral (middle) posi-
Slow Speed Maximum = 4 mph (6.4 km/h) tion.
Fast Speed Maximum = 6 mph (9.6 km/h)
NOTE: When released, levers and controls return to the
NOTE: If the travel speed switch on the console neutral position automatically.
(Figure 3-12) is in the fast speed position, machine will
not turn right or left. It will only go straight forward or
rearward. Mandatory Safety Shutdown Procedure

2. Push or pull the travel levers w/foot pedals to move the Before leaving the machine:
machine (Figure 3-12). 1. Lower the working equipment to the ground and support
Push both levers forward to move forward. it securely.

Pull both levers rearward to travel in reverse. 2. Reduce throttle and turn off the engine.

NOTE: If the superstructure has been rotated 180 3. Lock out controls by raising left control console.
(dozer blade at the rear), travel levers will work in the 4. Remove the ignition key and take it with you.
opposite manner. Pushing levers forward will cause the
machine to travel in reverse and pulling levers to the
rear will move the machine forward.

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

 EARTHMOVING
Operating on Slopes

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

Keep attachments as low as possible when

travelling on slopes or rough terrain.

Operating on a slope is inherently dangerous. It is recom-

mended to level the work area as shown in Figure 3-13. If
this is not possible, use the following guidelines.

When going down a slope, control the speed with the

Figure 3-13. Levelling the Work Site on a Slope
travelling levers and the the throttle lever.

When going down grades that exceed 15, put the

machine in the position shown in Figure 3-14. Run the
engine slowly.

Operate as slowly as possible and avoid sudden changes

in direction.

Avoid travelling over objects such as rocks, trees,

stumps, etc. 12" m
imu
Max mm)
Stop the machine travel before moving the bucket or (305
dozer controls.

Slow down the work cycle. Take your time.

25 Maximum
Avoid working with the tracks positioned across the
slope. Position the machine with the blade downhill and
lowered. Figure 3-14. Travelling on a Slope Exceeding 15
Avoid swinging or extending the bucket farther than nec-
essary in a downhill direction. When you must swing Do not operate or immerse the machine in water higher
the bucket downhill, keep the boom low and skid the than the tracks.
bucket along the ground.
Properly grease the machine if it has been operated or
When working with the bucket on the uphill side, keep immersed in water for a period of time.
the bucket as close to the ground as possible. Unload far
enough away from the trench or hole to prevent the pos- IMPORTANT: Never operate machine until fuel tank
sibility of a cave-in. is completely empty. If this occurs, the fuel system
will have to be bled of air. Always fill tank after use.
Operating in Water

Mud and water should be removed from the machine

before parking. If possible, park the machine on boards
or concrete to prevent the track or undercarriage from
freezing to the ground and preventing machine move-
ment.

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

 Excavator Boom Slewing

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

The excavator boom can be slewed 45 to the right and 80

to the left from the basic front position. This allows excava-
tion of trenches along walls, fences, etc.

Digging Figure 3-15. Proper Excavating

OPTIMAL STABILITY WHEN DIGGING

Use the dozer blade to support the excavator on the Grading
ground.
The boom must be fully raised and the bucket tilted in
Never dig under the machine. Support the walls proper- (up) when grading.
ly when excavating or working close to trenches.
When grading, the material may be pushed away to the
front or the side.
WARNING Raise the dozer blade slightly if excessive resistance
Always ensure adequate stability when work- occurs.
ing near trenches. Be aware of conditions that
could cause the earth to collapse resulting in
risk of injury or death.

To obtain maximum digging performance, avoid fully

extending the excavator arm. Excavate using long, flat
pulling movements of the arm (Figure 3-15).

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

 TRANSPORTING
Loading Machine for Transport Lifting Machine

Use only transport machines that are in proper working

order and are approved for use on public roads. WARNING
When using ramps to load machine onto the transport Use lifting device with sufficient capacity for
machine: the weight of the machine plus any attach-
- Do not exceed an incline of 18. ments.
- Ramp width must be at least 1 times the
width of the track. Maintain center of gravity and balance when
- Clean dirt, mud, ice and snow from the lifting.
ramps and tracks.
Do not swing boom or cab.
Use metal loading ramps with a slip-resistant surface.
Never lift machine with operator aboard.
NOTE: The ends of the ramps should be beveled to
prevent damage to the rubber tracks (Figure 3-16). Secure the lifting fixture sling to the lifting points on the
machine (Figure 3-17).
Attach ramps securely to the transport machine to pre-
vent them from slipping off during loading. Install spreader bar above the cab to prevent lifting fix-
ture from rubbing on the machine.
Load the machine on solid, even ground.
Do not exceed rated load capacity.
When loading, apply the transport machine parking
brake and chock the wheels.
Spreader
Determine the direction of the track movement (blade
Bar
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 Lifting
(Figure 3-16). Turn off the engine. Point

Lock the cab.

Place chocks under machine tracks and secure machine

Lifting
to prevent slipping, overturning and moving on the trans-
Point
port machine.

Use the points on the excavator indicated by decals for

tie down.
Figure 3-17. Machine Lifting Points

Beveled Ramps

Figure 3-16. Transporting the Machine

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

 MAINTENANCE
GENERAL INFORMATION
Care and Servicing
WARNING Care and servicing have a significant influence on the
Instructions are necessary before operating
readiness for operation and service life of the machine.
and servicing the machine. Read and under-
stand this entire manual. Follow warnings and For additional servicing work regarding the engine, see
instructions for operation and maintenance. the engine manual provided with the machine.
Check for correct function after adjustments or
maintenance. Failure to follow instructions can Use of lubricants which do not correspond to the manu-
facturers recommendations may invalidate warranty
result in injury or death.
claims.

More frequent servicing, other than the recommended

WARNING intervals, may be required under extreme operating con-
ditions.
Be sure you are familiar with all safety devices
and controls before operating or servicing the Always dispose of waste lubricating oils and hydraulic
machine. Know how to stop before starting. fluids according to local regulations or take to a recy-
This Gehl Company machine is designed for cling center for proper disposal. DO NOT pour fluids
use only with Gehl Company approved acces- onto the ground or down a drain.
sories or referral attachments. The Gehl
Company cannot be responsible for operator Maintenance Safety
safety if the unit is used with non-approved
attachments. Never service the machine without reading the
applicable instructions.

Always lower bucket and dozer blade to the

WARNING ground before performing any maintenance.
Read and thoroughly understand all safety
Use correct procedures to lift and support the
decals before operating the machine. DO NOT
machine. Always lift the blade fully before
operate the machine unless all factory installed installing jackstands.
guards and shields are in place.
Cleaning and maintenance are required daily.

CALIFORNIA PROPOSITION Keep engine cover and valve cover closed

65 WARNING except for service. Close and latch covers
before operating the machine.
Diesel engine exhaust and some of its con-
stituents are known to the State of California to Be sure to have area properly ventilated when
cause cancer, birth defects and other reproduc- grinding or welding parts. Wear dust mask.
tive harm.
Vent exhaust to outside when engine must be
run for service. Exhaust system must be tightly
sealed. Exhaust fumes can kill without warning.
WARNING Never modify equipment or add attachments
Hydraulic reservoir is under pressure. Avoid not approved by Gehl Company.
contact with leaking hydraulic fluid or diesel
fuel under pressure. It can penetrate the skin Stop engine and let cool, then clean engine of
or eyes. any flammable materials before checking fluid
levels.

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

 GENERAL INFORMATION (continued)
Maintenance Safety (continued)

Never service or adjust machine with the engine Never fill fuel tank with engine running, while
running unless service procedure calls for the smoking or when near open flame.
engine to be running.
Keep body, jewelry and clothing away from mov-
Avoid contact with leaking hydraulic fluid or ing parts, electrical contacts, hot parts and
diesel fuel under pressure. It can penetrate the exhaust.
skin or eyes. NEVER use your hands to search
for hydraulic fluid leaks; use a piece of paper or Wear eye protection when servicing the
cardboard. Escaping fluid under pressure can machine.
be invisible and can penetrate the skin and
Lead acid batteries produce flammable and
cause serious injury. If any fluid is injected into
explosive gas. Keep arcs, sparks, flames and
your skin, see a doctor at once. Injected fluid
lighted tobacco away from batteries.
MUST be surgically removed by a doctor or
gangrene may result. Batteries contain acid which burns eyes and
skin on contact. Wear protective clothing. If
The operating pressure settings of the hydraulic
acid contacts body, flush well with water. For
system should only be set by trained, qualified
eye contact, flush well with water and get imme-
personnel. If malfunctions are caused by unau-
diate medical attention.
thorized alteration of operating pressure set-
tings, all warranty responsibilities on the part of
the manufacturer are automatically invalidated.

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

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

Engine

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000
Hours Hours Hours Hours
Check air filter
Check engine oil level
Check fuel level
Check for leakage
Perform visual check
Check coolant level
Check engine mounting bolts
Check V-belt condition and tension
Clean radiator fins
Check fuel filter
Check exhaust system
Change engine oil and filter *
Change fuel filter
Check engine speed regulation
Check valve clearance
Check cooling system and hoses
Check electrical connections
Check pre-glow system
Check coolant thermostat
Check alternator & starter
Clean fuel tank
Check water pump
* First change only.

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

 MAINTENANCE SCHEDULE (continued)
Hydraulic System

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000
Hours Hours Hours Hours
Check hydraulic oil level
Check system for leakage
Check hydraulic pump bolts
Clean cooler fins
Change filter *
Change hydraulic oil *
Check filter
Check hydraulic oil
Check primary & secondary
pressure limiting valves
Check breather filter &
filling strainer

* First change only.

Electrical System

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000
Hours Hours Hours Hours
Check indicator lights
Check system function
Check connections

Travelling Gear

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000
Hours Hours Hours Hours
Check track after work shift
Check track tension
Check bearing play of track
rollers, track carrier rollers &
front idlers.

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

 Travelling Gear Unit

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000
Hours Hours Hours Hours
Check for leakage
Change final drive gear oil *
* First change only.

Slewing Gear Ring

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000
Hours Hours Hours Hours
Change gear ring
Check bearing system

Cab Heating System

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000
Hours Hours Hours Hours
Check fan
Check function
Check heating circuit
for leaks
Check seals

Bucket, Boom & Dozer Blade

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000
Hours Hours Hours Hours
Lubricate all points
Check bucket teeth for wear
Check pin fastening
Check hydraulic line connections
Check piston rods
Check hydraulic cylinder
under load
Check bearing play

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

 MAINTENANCE SCHEDULE (continued)
General

Service Activity Daily Weekly Every Every Every Every Annually

50 125-250 500 1000
Hours Hours Hours Hours
Check hydraulic system
Check bolts
Check lights
Check windshield wiper system
Check for leaks

LUBRICATION
Lubrication Points

Green Capslubricate weekly (points marked with a W)

Blue Capslubricate daily

Superstructure bearing system (W)

W W W

Figure 4-1. Lubrication Points

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

 Recommended Lubricants

ENGINE OIL SLEWING GEAR UNIT

A diesel engine oil conforming to SAE grade 10W 30 or An EP grade gear oil that conforms to API GL 5, such as
15W 40, and API classification CD (or higher, e.g., CH-4), Chevron Delo Gear 80W 90 or BP Transgear 80W 90
such as BP Vanellus MG 15W 40, BP Vanellus C-Extra
10W 30, or Chevron Delo 400 15W 40 EXCAVATOR ARM
A heavy-duty lithium complex grease with 3% molybde-
HYDRAULIC OIL numdisulfide, such as Chevron RPM Heavy Duty Grease No.
A hydraulic oil with anti-wear,anti-foam, and anti-oxidation 2, Mobilgrease Moly 52, or BP Energrease Moly EP2.
additives that conforms to ISO Viscosity Grade 46, such as,
Mobil DTE 15M, Amoco Rykon 46, or BP Energol ALL LUBRICATION POINTS
HLP-HD 46. A heavy-duty lithium complex grease with 3% molybde-
numdisulfide, such as Chevron RPM Heavy Duty Grease No.
SLEWING RING 2, Mobilgrease Moly 52, or BP Energrease Moly EP2.
A heavy-duty lithium complex grease with 3% molybde-
numdisulfide, such as Chevron RPM Heavy Duty Grease No. RANGES OF APPLICATIONS
2, Mobilgrease Moly 52, or BP Energrease Moly EP2. From -13F to +104F (-25C to +40C)
outside temperature
TRAVELLING GEAR UNIT
An EP grade gear oil that conforms to API GL 5, such as NOTE: All listed greases are suitable for
Chevron Delo Gear 80W 90 or BP Transgear 80W 90 -13F to +104F (-25C to +40C).

ENGINE
NOTE: Be sure to read the engine manual supplied with
this machine.

Checking Engine Oil Level

IMPORTANT: See the lubricant list for engine oil

grade. Only use engine oil specified, or of equiva-
lent quality and grade, or damage to the engine
could occur.

The machine must be on a level surface and the engine

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

2. Pull the engine cover latch lever (located next the right
side of the operators seat) and raise the engine cover. Figure 4-2. Engine Oil Dipstick

3. Check the engine oil level using the dipstick located on

rear of the engine (Figure 4-2).

4. Add oil if required.

NOTE: The marks on the dipstick indicate the minimum

and maximum oil levels.

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

 ENGINE (continued)
Changing Engine Oil & Filter

1. Place the machine on a level surface. Run the engine

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

2. Pull the engine cover latch lever (located next the right
side of the operators seat) and raise the engine cover. Oil Fill

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

4. Remove the oil filter using a filter wrench.

Oil Filter
5. Clean the filter housing surface. Put a film of clean oil
on the filter gasket. Install the new filter with gasket and
hand tighten.
Figure 4-3. Engine Oil Fill and Filter
6. Reinstall the drain plug.

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

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

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

Air Cleaner Service Bolt

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

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

the air cleaner cover and gasket. Figure 4-4. Engine Air Filter

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

4. Clean air cleaner element with compressed air 30 psi

(200 kPa) (Figure 4-5).

5. Reinstall air cleaner element, wingnut, gasket, and air

cleaner cover. Tighten cover bolt.
Gasket
6. Close valve cover. Wingnut

IMPORTANT: Do not knock the element against

solid object to remove dust. The element may
Compressed Air
become distorted and damaged.

Do not operate engine without the air cleaner ele-

ment installed or damage to the engine could occur.

Figure 4-5. Servicing Engine Air Filter

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

 FUEL SYSTEM
Filling the Fuel Tank - +

WARNING
Stop and cool the engine before adding fuel.
Low Fuel
NO SMOKING! Failure to obey warnings can
Indicator Light
cause an explosion or fire.
The fuel level in the tank is indicated by the fuel gauge on Fuel Gauge
the console (Figure 4-6). 00000000
HOURS

NOTE: When the fuel level reaches 2.5 gal. (2.3 L) the
low fuel indicator light (Figure 4-6) will come on to alert Figure 4-6. Fuel Gauge and Low Fuel Indicator
the operator.
Injection Pump
To fill the tank, remove the fuel filler cover located on the
Priming Lever
right-side of the machine. Fill using diesel fuel with a cetane
rating of over 45. Re-install fuel cap.

IMPORTANT: Never operate machine until fuel tank

is completely empty. If this occurs, the fuel system Fuel
Filter
will have to be bled of air. Always fill tank after use.
Valve

WARNING Fuel Filter

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

Water Separator
Fuel Filter
Figure 4-7. Fuel Filter
Unscrew the clear plastic housing (Figure 4-9) to change the
filter element and clean dirt from the housing. Clean around A B
the filter housing. Put oil 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.

E
Purging Air from the Fuel System
Fuel Filter Injection
1. Turn the fuel filter valve (Figure 4-7) to the open posi- Pump
tion (vertical).

2. While operating the priming lever on the fuel injector C

pump, loosen the air bleeding screw (A, Figure 4-8) on
the fuel filter. When fuel starts flowing from the bleeder D
valve (A) without any air, tighten the bleeder screw (A).
Water
Separator
3. Repeat step 2 for bleeder screws B, C, D and E
(Figure 4-8).
Figure 4-8. Bleeding Air from Fuel System

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

 COOLANT SYSTEM
Checking Coolant Level
1. Pull the engine cover latch lever (located next the right
side of the operators seat) and raise the engine cover.

2. Check the coolant level in the expansion reservoir

(Figure 4-9).
Full
3. If low, slowly remove cap and fill reservoir to FULL
Low
line.

WARNING
Engine must be cold. Be careful to avoid
burns when removing the cap. Keep face away
from cap. Cover cap with a cloth, turn cap
slowly to release pressure.
Figure 4-9. Checking Coolant Level
Refer to the engine manual for correct coolant
mixture for your engine.

ELECTRICAL SYSTEM
Fuses
The fuse panel is located on the right arm console
(Figure 4-10).

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

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

Battery

Figure 4-10. Fuse Panel

WARNING
Batteries contain acid which burns eyes and
skin on contact. Wear safety goggles and pro-
tective clothing to keep acid off body.

In case of acid contact, wash immediately with

water for several minutes. In case of eye con-
tact, get medical attention immediately.

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

The battery cables must be clean and tight. Remove any acid
or corrosion from the battery and cables using a sodium Battery
bicarbonate and water solution. Cover the battery terminals Figure 4-11. Battery
and cable ends with battery saver grease.
The battery is maintenance-free and requires no other service.

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

 IMPORTANT: Damage to the alternator can
Using a Booster Battery (Jump Starting)
occur if:
Engine is operated with battery cables dis-

WARNING connected.

Keep arcs, sparks, flames and lighted tobacco Battery cables are connected when using a
away from batteries. When jump starting from fast charger or when welding on the
booster battery, make final connection (nega- machine. Remove both cables from the bat-
tive) at engine frame. tery.

DO NOT jump start or charge a frozen battery. Extra battery cables (booster cables) are
Warm battery to 60F (16C) before connecting incorrectly connected.
to a charger. Unplug charger before connect-
Be very careful when jump starting the machine. Booster
ing or disconnecting cables to battery. battery must be 12 volt.
1. Turn ignition key to the off position.
Battery gas can explode and cause serious
injury. 2. Pull the valve cover latch lever (Figure 4-1) and open
the valve cover.
IMPORTANT: When jump starting from another
machine, be sure the second machine is not run- 3. Connect one end of the cable to the positive (+) termi-
ning while using the glow plugs. High voltage nal on the booster battery. Connect the other end of the
spikes from a running machine can burn out the same cable to the positive (+) terminal on the machine
glow plugs. battery.

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

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

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

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

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

 HYDRAULIC SYSTEM

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

Checking Hydraulic Oil Level

1. Position the machine on a level surface.

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

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

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

12).

3. Check the hydraulic oil level indicator. Oil level should

be between black and red marks on sight glass. If
hydraulic oil is required, proceed to step 4.

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

then remove cap. Figure 4-12. Checking Hydraulic Oil Level

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

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

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

8. Check hydraulic functions. Recheck hydraulic oil level.

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

 Changing Hydraulic Oil
1. Position the machine on a level surface. Filter Filter Cover
Gasket
2. Fully extend the bucket and boom. Lower bucket and
dozer blade to the ground (Figure 4-12). Turn off the Cap w/Strainer
machine.

3. Slowly open the cap to relieve pressure (Figure 4-14). Filter

Remove cap and clean strainer of any debris.

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

IMPORTANT: Always dispose of hydraulic fluids

according to local regulations or take to a recycling
center for proper disposal. DO NOT pour fluids
onto the ground or down a drain.

5. Remove bolts and filter cover (Figure 4-13). Remove

and discard old filter. Put clean hydraulic fluid on the
filter gasket and install gasket and new filter into tank.

6. Reinstall filter cover and bolts.

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

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

Figure 4-13. Hydraulic Oil Tank
9. Start engine and let idle for a few minutes.

10. Check hydraulic functions. Recheck hydraulic oil level.

11. Reinstall access panel.

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

 TRACK SYSTEM
Changing Final Drive Oil

1. Position the machine on a level surface with final drive POSITION A

plugs positioned as shown in POSITION A, Figure 4-14. Screw Plugs in position
Turn off the engine. for draining oil

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

Re-install plugs.

3. Turn the engine on and move the machine slightly until

plugs are positioned as shown in POSITION B, Figure
4-14. Turn off the engine. POSITION B
Screw Plugs in position
4. Remove both screw plugs. Pour fresh oil (Gearoil EP 90 for Filling oil
API GL 4) into the top hole until oil starts to run out of
the bottom hole.

5. Re-install both plugs securely.

Figure 4-14 Changing Final Drive Oil
IMPORTANT: Always dispose of oil according to
local regulations or take to a recycling center for
proper disposal. DO NOT pour fluids onto the
Side Plate
ground or down a drain.

Adjusting Track Tension

1. Position the machine on a level surface.

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

3. Remove the side plate from the left track to expose the
adjustment fitting (Figure 4-15). Adjustment
Fitting
4. Using a grease gun, pump grease into the fitting until the
idler wheel is centered as shown in Figure 4-17. Wrench

NOTE: A grease gun is supplied with machine tool kit.

5. Install side plate.

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

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

Idler wheel should
be centered in
this opening

Figure 4-15. Track Adjustment

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

 MAINTENANCE LOG
DATE HOURS SERVICE PROCEDURE

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

 MAINTENANCE LOG
DATE HOURS SERVICE PROCEDURE

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

 TROUBLESHOOTING
GENERAL INFORMATION
WARNING WARNING
Be sure you are familiar with all safety devices Read and thoroughly understand all safety
and controls before operating or servicing the decals before operating the machine. DO NOT
machine. Know how to stop before starting. operate the machine unless all factory installed
This GEHL Company machine is designed for guards and shields are in place.
use only with GEHL Company approved
accessories or referral attachments. The
GEHL Company cannot be responsible for
operator safety if the unit is used with non-
WARNING
Hydraulic reservoir is under pressure. Avoid
approved attachments.
contact with leaking hydraulic fluid or diesel
fuel under pressure. It can penetrate the skin
WARNING or eyes.

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 correct function after adjustments or
maintenance. Failure to follow instructions can
result in injury or death.

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

 ENGINE
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

Engine will not start. No fuel. Add fuel to tank; bleed fuel system.

Battery power insufficient. Charge battery or replace if necessary.

Fuel filter contaminated. Clean fuel filter.

Pre-glow system not working. Replace pre-glow system (contact authorized

repair center.).

Insufficient engine power. Fuel line leakage. Replace fuel line.

Air filter contaminated. Clean air filter.

Engine not at operating temperature. Warm up the engine.

Engine overheated. Check cooling system.

INDICATOR LAMPS
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

Engine oil pressure indicator Engine oil pressure too low. Stop engine immediately. Check oil level and
light comes on during opera- add oil if necessary. If oil level is correct, oil
pump may be inoperative.
tion.
Engine oil level too low. Add oil.

Water temperature display light Coolant level too low. Add coolant.
comes on during operation.
Fan blades rotate too slowly. Adjust V-belt tension.

Air filter contaminated. Clean air filter.

Battery voltage light comes on Alternator not charging properly. Adjust V-belt tension.
during operation.
Fuel light comes on. Low fuel. Add fuel.

SEALS & HOSES

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

Oil or fuel leakage under Loose hose connections. Tighten hose connections.
engine.
Seals or hoses damaged. Change seals or hoses and check engine oil level.
Add engine oil if required.

Oil losses from hydraulic Loose hose fittings. Tighten hose fittings. Check hydraulic oil level.
system. Add hydraulic oil if required.

Seals, hoses or lines damaged. Change seals, hoses and/or lines.

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

 TRAVELLING GEAR
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

Machine will not travel in any Foreign body jammed in track. Remove foreign body.
direction.
Gears not operative. Repair gears (contact authorized repair center).

Machine will not travel straight Foreign body jammed in track. Remove foreign body.
ahead.
Track tension unequal. Adjust track tension.

Travel valves damaged. Repair/replace valves (contact authorized repair

center).

BUCKET, BOOM AND DOZER BLADE

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

Slewing chassis is difficult or Brakes do not release. Contact authorized repair center.
impossible.
Insufficient lubrication. Lubricate slewing ring hose connections.

Slewing motor not operating. Contact authorized repair center.

Equipment does not work or Insufficient hydraulic oil. Fill hydraulic oil reservoir.
works only at a low perform-
Insufficient engine power. Contact authorized repair center.
ance level.
Coupling or pump damaged. Contact authorized repair center.

Pressure limiting valves set too low. Contact authorized repair center.

Hydraulic cylinder damaged. Contact authorized repair center.

Control valves damaged. Contact authorized repair center.

Hydraulic cylinders lower too Seals contaminated or damaged. Contact authorized repair center.
quickly.
Heavy leakage at control spools. Contact authorized repair center.

Secondary cartridges damaged. Contact authorized repair center.

Hydraulic lines overheat. Hydraulic oil filter blocked. Clean or replace filter.

Insufficient hydraulic oil in oil reservoir. Fill hydraulic oil reservoir.

Secondary cartridges set too low. Contact authorized repair center.

Cooling system not in working order. Clean oil cooler.

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

 NOTES

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


Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 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.

908147/0999 1999 Gehl Company PRINTED IN U.S.A.

All Rights Reserved