Gehl 803 Compact Excavator Service Manual 918169 – PDF DOWNLOAD

Gehl 803 Compact Excavator Service Manual 918169 – PDF DOWNLOAD

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Gehl 803 Compact Excavator Service Manual 918169 – PDF DOWNLOAD

Language : English
Pages : 184
Downloadable : Yes
File Type : PDF
Size: 20.7 MB

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Gehl 803 Compact Excavator Service Manual 918169 – PDF DOWNLOAD

1Operation:
1.1Important information about this service manual:

• This service manual contains important information about safely servicing the machine,
  correctly and economically. It serves as a reference for experienced users, helps to avoid
  potentially hazardous situations, and reduces repair costs and downtimes. Additionally,
  the reliability and the service life of the machine will be increased by following the instructions
  in this manual.
• Proper and careful work is the best protection against accidents.
  Operational safety and readiness of the machine depends not only upon operator skill, but
  also upon proper maintenance and service.
  Always use Gehl original equipment service parts when performing maintenance and
  repair work. This ensures operational safety and readiness of the machine, and maintains
  its value.

TABLE OF CONTENTS:

Gehl 803 Compact Excavator Service Manual 918169 – PDF DOWNLOAD

1 Operation…………………………………………………………… 7
1.1 Important information about this service manual……………………….. 7
1.2 Abbreviations/symbols………………………………………………. 7
1.3 Identification of warnings and hazards……………………………….. 8
1.4 Designated use and exemption from liability…………………………… 8
1.5 Serial plates and component numbers………………………………….. 9
Serial number location…………………………………………………. 9
Engine number…………………………………………………………. 9
Hydraulic pump identification number…………………………………….. 10
Main valve block identification number…………………………………… 10
Travel drive identification number………………………………………. 10
Swivel unit identification number……………………………………….. 10
1.6 Machine: overview………………………………………………….. 11
1.7 Cab overview………………………………………………………. 12
1.8 Cab legend………………………………………………………… 13
1.9 Instrument panel overview…………………………………………… 14
1.10 Instrument panel legend……………………………………………. 15
1.11 Engine compartment: overview……………………………………….. 16
1.12 Chassis: overview…………………………………………………. 17
1.13 Tilting the cab…………………………………………………… 18
Tilting the cab up…………………………………………………….. 19
Tilting the cab down…………………………………………………… 19
1.14 SAE operating controls (standard)…………………………………… 20
1.15 ISO operating controls (selectable)…………………………………. 21
1.16 Boom slew/auxiliary hydraulics pedal………………………………… 22
1.17 Dozer blade………………………………………………………. 22
1.18 Throttle lever……………………………………………………. 23
1.19 Operator’s seat adjustments………………………………………… 24
1.20 Ventilation………………………………………………………. 26
Windshield……………………………………………………………. 26
1.21 Cab door latch release…………………………………………….. 27
1.22 Interior light……………………………………………………. 27
1.23 Tool kit and cab jack handle……………………………………….. 27
1.24 Cab heat control………………………………………………….. 28
1.25 Recirculated air mode……………………………………………… 28
1.26 Hydraulics/swiveling and boom rotation pedal adjustment……………….. 29
1.27 Battery master switch……………………………………………… 29
2 Specifications………………………………………………………. 31
2.1 Chassis…………………………………………………………… 31
2.2 Engine……………………………………………………………. 31
2.3 Hydraulic system…………………………………………………… 33
2.4 Undercarriage/swivel unit…………………………………………… 34
2.5 Dozer blade……………………………………………………….. 34
2.6 Electrical system………………………………………………….. 35
2.7 Sound levels………………………………………………………. 37
2.8 Coolant compound table……………………………………………… 37
2.9 Specific tightening torques…………………………………………. 37
2.10 General tightening torques…………………………………………. 38
2.11 Dimensions……………………………………………………….. 41
2.12 Lift capacities…………………………………………………… 42
2.13 Lift capacity table (with extended dipper arm and counterweight)……….. 44
2.14 Geometry…………………………………………………………. 45
3 Maintenance…………………………………………………………. 47
3.1 General information care and servicing……………………………….. 47
Care and servicing…………………………………………………….. 47
Maintenance safety…………………………………………………….. 48
3.2 Fluids and lubricants………………………………………………. 49
3.3 Maintenance decal symbols…………………………………………… 51
3.4 Maintenance decal………………………………………………….. 52
3.5 Maintenance schedule……………………………………………….. 53
3.6 General maintenance………………………………………………… 56
3.7 Lubrication……………………………………………………….. 58
3.8 Fuel system……………………………………………………….. 59
Specific safety instructions……………………………………………. 59
Filling the fuel tank………………………………………………….. 59
Fuel filter…………………………………………………………… 60
Fuel shut-off valve, fuel prefilter and water separator……………………. 60
Purging air from the fuel system………………………………………… 61
3.9 Engine lubrication system…………………………………………… 62
3.10 Changing engine oil and filter……………………………………… 62
3.11 Coolant system……………………………………………………. 64
Checking coolant level…………………………………………………. 64
3.12 Air cleaner service……………………………………………….. 65
Dust valve functional check…………………………………………….. 66
3.13 Checking and adjusting V-belt tension……………………………….. 67
Checking and adjusting air conditioning V-belt tension…………………….. 68
3.14 Pressure check……………………………………………………. 69
3.15 Test report………………………………………………………. 74
3.16 Hydraulic system………………………………………………….. 77
Checking hydraulic oil level……………………………………………. 77
Checking hydraulic pressure lines……………………………………….. 81
3.17 Track system……………………………………………………… 82
Changing final drive oil……………………………………………….. 82
3.18 Electrical system…………………………………………………. 85
Battery………………………………………………………………. 86
Using a booster battery (jump-starting)………………………………….. 86
3.19 Cab heater filter…………………………………………………. 88
4 Engine……………………………………………………………… 89
4.1 4TNV98 engine: overview…………………………………………….. 89
4.2 Fuel system……………………………………………………….. 91
4.3 Removing the cylinder head cover…………………………………….. 92
4.4 Checking and adjusting valve tip clearance……………………………. 92
4.5 Cylinder head bolt tightening order………………………………….. 94
4.6 Checking the injection nozzles………………………………………. 94
4.7 Checking the nozzle jet…………………………………………….. 95
4.8 Injection timing…………………………………………………… 96
4.9 Adjusting engine RPM……………………………………………….. 97
4.10 Checking compression………………………………………………. 97
4.11 Checking the coolant thermostat…………………………………….. 98
4.12 Checking the thermal switch………………………………………… 98
4.13 Oil pressure switch……………………………………………….. 99
4.14 Checking the coolant circuit……………………………………….. 99
4.15 Engine troubleshooting……………………………………………..100
5 Hydraulic system……………………………………………………..103
5.1 Hydraulic pump……………………………………………………..103
5.2 Main valve block……………………………………………………108
5.3 Drive counterbalancing system………………………………………..116
5.4 Boom summation – raise………………………………………………118
5.5 Check valve (load retaining valve)……………………………………119
5.6 Dipper arm cylinder summation………………………………………..119
5.7 Dipper arm check valve (load retaining valve)………………………….120
5.8 Secondary pressure limiting valves for the auxiliary hydraulics (option)….121
5.9 Pilot valves……………………………………………………….122
5.10 Valves……………………………………………………………127
5.11 Travel drive up to serial no. AC 02793……………………………….134
5.12 Travel drive Auto 2-speed (starting serial no. AC 02957)……………….136
5.13 Swivel unit……………………………………………………….139
5.14 Swivel joint………………………………………………………144
5.15 Breather filter……………………………………………………145
5.16 Troubleshooting the hydraulic system…………………………………146
5.17 Hydraulic diagram (legend)…………………………………………. 0
5.18 Hydraulic diagram…………………………………………………. 0
5.19 Main valve block diagram…………………………………………… 0
6 Electrical system…………………………………………………….151
6.1 Ohm’s law (current, voltage, resistance); power………………………..151
6.2 Measuring equipment, measuring methods………………………………..151
6.3 Cable color coding………………………………………………….152
6.4 Relays…………………………………………………………….153
6.5 Electrical units……………………………………………………153
6.6 Fuse box in instrument panel…………………………………………153
6.7 Main fuse box with relays……………………………………………154
6.8 Relays…………………………………………………………….154
6.9 Lubrication strip accessory power socket………………………………155
6.10 Joystick tip switches………………………………………………155
6.11 Instrument panel overview…………………………………………..156
6.12 Switches: overview…………………………………………………157
6.13 Alternator………………………………………………………..158
6.14 Starter…………………………………………………………..158
6.15 Wiring diagram legend……………………………………………… 0
6.16 Wiring diagram……………………………………………………. 0
6.17 Wiring harness legend: engine-chassis……………………………….. 0
6.18 Wiring harness: engine-chassis……………………………………… 0
6.19 Wiring harness legend: switches…………………………………….. 0
6.20 Wiring harness: switches…………………………………………… 0
6.21 Wiring harness: cab roof…………………………………………… 0
6.22 Wiring harness: armrest……………………………………………. 0
6.23 Wiring harness: boom working light………………………………….. 0
7 Options……………………………………………………………..169
7.1 Air conditioning……………………………………………………169
7.2 Counterweight………………………………………………………177
7.3 Extended dipper arm…………………………………………………177
7.4 Control circuit hydraulic coupling connections…………………………178
7.5 3rd control circuit connections………………………………………178
7.6 Auxiliary hydraulics connections……………………………………..179
Torque specifications…………………………………………………..181