Gehl Z25 250Z Compact Excavator Service Manual 50940346 – PDF DOWNLOAD

Gehl Z25 250Z Compact Excavator Service Manual 50940346 – PDF DOWNLOAD

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Gehl Z25 250Z Compact Excavator Service Manual 50940346 – PDF DOWNLOAD

Language : English
Pages : 576
Downloadable : Yes
File Type : PDF
Size: 32.4 MB

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Gehl Z25 250Z Compact Excavator Service Manual 50940346 – PDF DOWNLOAD

1. General Cautions for Maintenance Work
1-1 Correct Work
Correct work means the quickest possible completion of according to the correct procedures and the specified standards.
It is important when conducting certain operations always to bear in mind the equipment, tools, gauges, materials, oil
and grease, etc. that you must have ready, as well as items to be checked, adjusted, or disassembled, and cautions
to watch out for.
1-2 Safety Precautions
(1) Never attempt servicing while engine is running or immediately after stopping operation.
(2) Wear work cloths, safety shoes and helmet.
(3) Check the equipment and tools before use. Especially, be sure to check the crane, lifting equipment and tools.
(4) When working together with other persons, allocate everyone’s share of job, arrange the signals and act in concert
with the other persons.
(5) The operation of the crane and slinging work must be performed by qualified persons.
(6) Do not enter or pass under the raised load.
(7) Lift and support the massive parts by crane before removing the installation bolts.
(8) Disconnect cables from battery before repairing the electric system.
(9) Remove the battery when welding the machine.
1-3 Preparations
(1) Check the service record of the machine. (That is, check how many months or hours the machine has been
used since the preceding overhaul, what was the trouble then and what parts were replaced.)
(2) Have all servicing tools ready, i.e., tools, measuring devices (which have received periodic maintenance), containers,
oil & grease, etc.
(3) Have the service literature (operation manual, parts catalog, etc.) ready.

TABLE OF CONTENTS:

Gehl Z25 250Z Compact Excavator Service Manual 50940346 – PDF DOWNLOAD

CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work 1-1-1
1-2 Safety Precautions 1-2-1
1-3 Preparations 1-3-1
1-4 Cautions for Disassembly and Reassembly 1-4-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment 1-5-2
1-6 Cautions for Removal and Installation of Hydraulic Piping 1-6-2
1-7 Cautions for Handling Seals 1-7-3
1-8 Correct Installation of Hydraulic Hose 1-8-3
1-9 Specifications of Hydraulic Hose 1-9-6
1-10 Air Release of Hydraulic Equipment 1-10-8
CHAPTER 2
TECHNICAL DATA
2-1 Specifications 2-1-1
2-2 Outline Drawing and Working Area 2-2-1
2-3 Weight List of Main Parts 2-3-1
2-4 Lifting Capacity List 2-4-1
2-5 Specifications for Attachment 2-5-1
2-6 Periodic Inspection and Servicing 2-6-1
2-7 Fuel, Lube Oil and Grease Recommended 2-7-1
2-8 Hydraulic Circuit Schematic 2-8-1
2-9 Wiring Diagram 2-9-1
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance 3-1-1
3-2 Engine 3-2-1
3-3 Undercarriage 3-3-1
3-3-1 Rubber Track Specifications 3-3-1
3-3-2 Common Specifications of Rubber Crawlers 3-3-2
3-4 Controls 3-4-1
3-5 Hydraulic Equipment 3-5-1
3-5-1 Hydraulic Cylinders 3-5-1
3-6 Implement 3-6-1
3-6-1 Front Attachments 3-6-1
3-6-2 Blade Moving Device 3-6-2
3-6-3 Bucket Teeth 3-6-2
3-7 List of Tightening Torque 3-7-1
3-7-1 Machine 3-7-1
3-7-2 Engine 3-7-6
3-8 Pressure Adjustment 3-8-1
3-8-1 Relief Valves 3-8-1
3-8-2 Swing Brake Valve 3-8-4
3-8-3 Cut-Off Valve 3-8-5
CHAPTER 4
ENGINE
4-1 Safety 4-1-1
4-1-1 Safety Statements 4-1-1
4-1-2 Safety Precautions 4-1-2
4-2 Engine 4-2-1
4-2-1 Before You Begin Servicing 4-2-1
4-2-2 Introduction 4-2-2
4-2-3 Special Service Tools 4-2-3
4-2-4 Measuring Instruments 4-2-5
4-2-5 Cylinder Head 4-2-7
4-2-6 Disassembly of rocker arm assembly 4-2-10
4-2-7 Measuring and Adjusting Valve Clearance 4-2-20
4-2-8 Crankshaft and Camshaft Components 4-2-22
4-3 Fuel System 4-3-1
4-3-1 Before You Begin Servicing 4-3-1
4-3-2 Introduction 4-3-2
4-3-3 Fuel System Specifications and Tools 4-3-6
4-3-4 Fuel System Diagram 4-3-8
4-3-5 Fuel System Components 4-3-9
4-4 Cooling System 4-4-1
4-4-1 Before You Begin Servicing 4-4-1
4-4-2 Introduction 4-4-2
4-4-3 Cooling System Diagram 4-4-2
4-4-4 Engine Coolant Pump Components 4-4-3
4-4-5 Engine Coolant System Check 4-4-4
4-4-6 Engine Coolant Pump 4-4-4
4-5 Lubrication System 4-5-1
4-5-1 Before You Begin Servicing 4-5-1
4-5-2 Introduction 4-5-2
4-5-3 Oil Pump Service Information 4-5-2
4-5-4 Lubrication System Diagram 4-5-3
4-5-5 Checking Engine Oil Pressure 4-5-4
4-5-6 Trochoid Oil Pump 4-5-4
4-6 Starter Motor 4-6-1
4-6-1 Before You Begin Servicing 4-6-1
4-6-2 Introduction 4-6-2
4-6-3 Starter Motor Specifications 4-6-2
4-6-4 Starter Motor Troubleshooting 4-6-3
4-6-5 Starter Motor Components 4-6-4
4-6-6 Starter Motor 4-6-5
4-7 Alternator 4-7-1
4-7-1 Before You Begin Servicing 4-7-1
4-7-2 Introduction 4-7-2
4-7-3 Alternator Specifications 4-7-2
4-7-4 Alternator Troubleshooting 4-7-3
4-7-5 Alternator Components 4-7-4
4-7-6 Alternator Wiring Diagram 4-7-5
4-7-7 Alternator Standard Output 4-7-6
4-7-8 Alternator 4-7-7
4-8 Electric Wiring 4-8-1
4-8-1 Electric Wiring Precautions 4-8-1
4-9 Failure Diagnosis 4-9-1
4-9-1 Special Service Tools 4-9-1
4-9-2 Troubleshooting By Measuring Compression Pressure 4-9-2
4-10 Troubleshooting 4-10-1
4-10-1 Quick Reference Table for Troubleshooting 4-10-1
CHAPTER 5
ELECTRIC SYSTEM
5-1 Electric Equipment of Machine 5-1-1
5-1-1 Parts Layout of Electrical Equipment 5-1-1
5-1-2 LCD Monitor and Alarm Systems 5-1-7
5-2 Circuit Description of Engine Start and Stop 5-2-1
5-2-1 Engine Start and Stop 5-2-1
5-2-2 Battery charge 5-2-3
5-3 Automatic Deceleration System 5-3-1
5-3-1 Main Components and Wiring Diagram 5-3-1
5-3-2 Function and Control 5-3-3
5-4 Error Code List 5-4-1
CHAPTER 6
HYDRAULIC SYSTEM
6-1 Outline 6-1-1
6-1-1 Control Valve Operation 6-1-3
6-1-2 Additional Operation of Control Valve 6-1-4
6-2 Circuit Operation 6-2-1
6-2-1 Boom 6-2-1
6-2-2 Arm 6-2-2
6-2-3 Bucket 6-2-3
6-2-4 Swing 6-2-4
6-2-5 Boom Swing 6-2-5
6-2-6 Blade 6-2-6
6-2-7 Travel 6-2-7
6-2-8 Non-Deviation Travel (with Boom, Arm, Bucket or Boom Swing Operation) 6-2-8
6-2-9 Simultaneous Operation of Boom Up and Arm Retract 6-2-9
6-2-10 Simultaneous Operation of Boom Up and Bucket 6-2-10
6-2-11 Simultaneous Operation of Boom Up and Swing 6-2-11
6-2-12 Simultaneous Operation of Arm and Bucket 6-2-12
6-2-13 Hydraulic P T O 6-2-13
6-2-14 Quick Coupler (Quick coupler spec ) 6-2-14
6-2-15 Travel Alarm 6-2-15
6-2-16 Auto Deceleration (Optional) 6-2-16
6-3 Hydraulic Pump 6-3-1
6-4 Control Valve 6-4-1
6-5 Pilot Valve 6-5-1
6-6 Swing Motor 6-6-1
6-7 Travel Motor 6-7-1
6-8 Proportional solenoid valve 6-8-1
6-9 Pilot Check Valve (For Quick Coupler Circuit) 6-9-1
6-10 2-way valve 6-10-1
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Engine and Electric Equipment 7-1-1
7-1-1 Removal and Reinstallation of Engine 7-1-1
7-1-2 Removal and Reinstallation of Starter Motor 7-1-13
7-1-3 Removal and Reinstallation of Radiator and Oil Cooler 7-1-15
7-1-4 Removal and Reinstallation of Fan Belt 7-1-20
7-2 Undercarriage 7-2-1
7-2-1 Outline 7-2-1
7-2-2 Points of Reassembly (Rubber Track) 7-2-2
7-2-3 Removal and Reinstallation of Track 7-2-3
7-2-4 Removal and Reinstallation of Travel Motor 7-2-4
7-2-5 Disassembly and Reassembly of Idler 7-2-6
7-2-6 Disassembly and Reassembly of Track Roller 7-2-9
7-2-7 Disassembly and Reassembly of Carrier Roller 7-2-12
7-2-8 Installation of Floating Seal 7-2-14
7-2-9 Drawings of Jig 7-2-15
7-3 Controls 7-3-1
7-3-1 Mechanical Control Linkage 7-3-1
7-3-2 Adjustment of Travel Levers 7-3-3
7-3-3 Adjustment of Blade Lever 7-3-4
7-3-4 Adjustment of Lock Lever 7-3-5
7-4 Swing Bearing 7-4-1
7-5 Hydraulic Equipment 7-5-1
7-5-1 Removal and Reinstallation of Hydraulic Pump 7-5-1
7-5-2 Removal and Reinstallation of Control Valve 7-5-3
7-5-3 Removal and Reinstallation of Pilot Valves (L and R) 7-5-7
7-5-4 Removal and Reinstallation of Swing Motor 7-5-9
7-5-5 Removal and Reinstallation of Swivel Joint 7-5-11
7-5-6 Disassembly and Reassembly of Swivel Joint 7-5-15
7-5-7 Disassembly and Reassembly of Hydraulic Cylinder 7-5-18
7-5-8 Removal and Reinstallation of Hydraulic Oil Tank 7-5-25
7-5-9 Piping Layout 7-5-32
7-6 Work Implements 7-6-1
7-6-1 Removal and Reinstallation of Work Implements 7-6-1
7-6-2 Quick Coupler 7-6-9
7-7 Cabin 7-7-1
7-7-1 Removal and Reinstallation of Cabin 7-7-1
CHAPTER 8
TROUBLESHOOTING
8-1 Non-Breakdowns 8-1-1
8-1-1 Natural Release of Bucket 8-1-1
8-1-2 Discontinuous Arm Movement 8-1-1
8-1-3 Drifting of Upperstructure on Quick Travel Operation 8-1-2
8-1-4 Thermal Shock of Travel Motor 8-1-3
8-1-5 Elongation of Boom Swing Cylinder on 65 degrees Swing 8-1-4
8-1-6 Telescopic Motion of Boom Swing Cylinder with Lock Lever Set to Lock Position 8-1-5
8-1-7 Time Lag on Travel Speed Switching 8-1-6
8-1-8 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change 8-1-7
8-1-9 Operation of Quick Coupler Cylinder (for Quick Coupler Type) 8-1-8
8-2 Quick Reference Table for Troubleshooting 8-2-1
APPENDIX
Wiring Diagram