PDF Service Manual Gehl 383Z Compact Excavator - 2 MB
This is the complete factory service manual for the Gehl 383Z compact excavator.
It contains detailed repair and maintenance procedures for all major systems, including hydraulics, engine, and electrical components.
With clear instructions and diagrams, this manual is the definitive guide for technicians to perform accurate and efficient service.
Keep your 383Z in top condition with this essential resource.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
Ā®
Form No.
918197
English
383z
Revision A
08/06
Compact Excavator
Service Manual
Ā©2006 Gehl Company ā¢ All Rights Reserved ā¢ Printed in USA ā¢ Part #918197
--- Page 3 ---
Operation
1.3 Designated uses and exemption from liability
ā¢ The machine is intended for:
- Excavating earth, gravel, coarse gravel, ballast or rubble.
- Working with the attachments mentioned.
ā¢ Every other use and attachment is not designated for this machine. Gehl will not be
liable for damage resulting from any other use or attachment. The user alone will bear
the risk.
ā¢ Follow the instructions in the Operatorās Manual, and also accident prevention regula-
tions, safety and occupational regulations, and machine and traffic regulations. Gehl is
not liable for damage resulting from the failure to follow these regulations.
ā¢ You can damage the machine by modifying it with parts, equipment, attachments and
optional equipment not authorized by Gehl. Gehl is not liable for damage resulting from
unauthorized modifications.
ā¢ Gehl is not liable for personal injury and/or damage to property caused by failure to
properly:
- operate,
- transport,
- service and maintain,
- and repair the machine.
as instructed in this manual and the Operatorās Manual.
ā¢ Read and understand the Operatorās Manual before starting, servicing, or repairing the
machine. Follow the safety instructions.
ā¢ The machine may not be used for transportation on public roads.
ā¢ In applications with lifting gear, only use the machine according to its designated use.
1.4 Abbreviations/symbols
Abbreviations/symbols
ā¢ This symbol stands for a list
- Subdivision within lists or an activity. Follow the steps in the sequence presented.
ā This symbol requires you to carry out the activity described.
ā„ Description of the effects or results of an activity.
n. s. = not shown
āOptionā = optional equipment (indicated whenever controls or other components of the
machine are installed as an option)
A combination of digits, or a combination of digits and letters, e.g. 40/18 or 40/A, is used
for identifying figure elements. For example:
ā¢ Figure no. 40/ element no. 18, or position A in figure no. 40.
ā¢ Figures carry no numbers if they are placed to the left of the text.
Printed in U.S.A. 1-3 918197/AP0806
--- Page 4 ---
Operation
1.14 Tilting the cab
WARNING!
Careful when tilting the cab ā
Risk of accidents.
B A ā Always tighten cab lock-down nuts before driving or using the machine.
ā Always close the cab door before tilting the cab.
ā Stay clear from underneath the cab as it is tilted.
ā Always secure the tilt rod in the support position the when cab is tilted.
Tilting the cab up:
Tilt the cab up as follows:
C
ā Follow the āMandatory Safety Shutdown Procedureā in the Operatorās Manual.
ā Raise the floor mat (B) on the right, front of the cab and remove cab lock-down nut (A).
Remove cab lock-down nut (C) at the right rear of the cab.
ā Securely close the cab door.
ā Locate the jack handle tubes (D) from the tool kit in the engine compartment and insert
E into the jack (E) and jack to the limit. The cab will be raised as far as the jack will travel.
L
ā Pull on handle (F) until the cab is completely tilted and supported by safety cable (G).
ā Remove the tilt rod (H) from the storage bracket (J) and slide the tilt rod into the guide
bracket (K) and secure with the split pin.
D Tilting the cab down:
Tilt the cab down as follows:
ā Remove the tilt rod (H) from the guide bracket (K) by removing the split pin and slide
the tilt rod out of the guide bracket and secure with the split pin back in the storage
bracket (J).
ā Use handle (F) to slowly lower the cab back onto the jack.
ā Remove jack handle tubes (D) from the jack and insert the opposite end of the jack
handle tubes onto the release pin (L). Slowly turn the release pin counter-clockwise
G
until the cab is lowered.
ā Turn the release pin (L) clockwise.
F ā Reinstall the cab lock-down nuts (C) and (A).
ā Place the jack handle tubes (D) back in the tool kit.
CAUTION!
H
Check the tilt rod (H), split pin (K) and safety cable (G) at regular intervals for
K cracks and cuts.
ā Replace defective parts immediately.
J
Fig. 10: Cab tilting
Printed in U.S.A. 1-13 918197/AP0806
--- Page 5 ---
Specifications
Tightening torques for high-resistance screw connections
With coarse-pitch thread, torques in lb.-ft. (Nm)
Screws according to DIN 912, DIN Screws according to
931, DIN 933, etc. DIN 7984
Thread
Grade 7 Grade 8 Grade 10 Grade 7
Grade 8 (10.9)
(8.8) (10.9) (12.9) (8.8)
M5 4.0 (5.5) 6 (8) 7 (10) 4 (5) 5 (7)
M6 7 (10) 10 (14) 13 (17) 6.3 (8.5) 9 (12)
M8 18 (25) 26 (35) 31 (42) 15 (20) 22 (30)
M10 33 (45) 48 (65) 59 (80) 30 (40) 44 (59)
M12 64 (87) 81 (110) 108 (147) 51 (69) 74 (100)
M14 100 (135) 133 (180) 170 (230) 81 (110) 118 (160)
M16 155 (210) 203 (275) 258 (350) 125 (170) 184 (250)
M18 207 (280) 302 (410) 354 (480) 181 (245) 254 (345)
M20 302 (410) 420 (570) 509 (690) 251 (340) 361 (490)
M22 406 (550) 575 (780) 686 (930) 339 (460) 487 (660)
M24 524 (710) 738 (1000) 878 (1190) 435 (590) 620 (840)
M27 767 (1040) 1092 (1480) 1305 (1770) 642 (870) 922 (1250)
M30 1047 (1420) 1482 (2010) 1770 (2400) 885 (1200) 1254 (1700)
DIN 912 ā hexagon socket head cap screw; DIN 931/DIN 933 ā hexagon head screw with/without shaft;
DIN 7984 ā hexagon socket head cap screw with short head
All values subject to a friction coefficient of Āµ = 0.12 and are to be used as approximate figures.
With fine-pitch thread, torques in lb.-ft. (Nm)
Screws according to DIN 912, DIN Screws according to
931, DIN 933, etc. DIN 7984
Thread
Grade 7 Grade 8 Grade 10 Grade 7
Grade 8 (10.9)
(8.8) (10.9) (12.9) (8.8)
M8X1.0 18 (25) 27 (37) 32 (43) 16 (22) 24 (32)
M10X1.0 37 (50) 55 (75) 65 (88) 32 (43) 48 (65)
M10X1.25 36 (49) 52 (71) 61 (83) 31 (42) 46 (62)
M12X1.25 64 (87) 96 (130) 111 (150) 55 (75) 81 (110)
M12X1.5 61 (83) 92 (125) 107 (145) 53 (72) 77 (105)
M14X1.5 100 (135) 148 (200) 173 (235) 89 (120) 129 (175)
M16X1.5 155 (210) 229 (310) 266 (360) 133 (180) 195 (265)
M18X1.5 232 (315) 332 (450) 391 (530) 199 (270) 284 (385)
M20X1.5 325 (440) 465 (630) 538 (730) 277 (375) 391 (530)
M22X1.5 435 (590) 620 (840) 723 (980) 369 (500) 524 (710)
M24X2.0 546 (740) 789 (1070) 922 (1250) 465 (630) 664 (900)
M27X2.0 811 (1100) 1143 (1550) 1328 (1800) 679 (920) 959 (1300)
M30X2.0 1106 (1500) 1586 (2150) 1844 (2500) 959 (1300) 1364 (1850)
DIN 912 ā hexagon socket head cap screw; DIN 931/DIN 933 ā hexagon head screw with/without shaft;
DIN 7984 ā hexagon socket head cap screw with short head
All values subject to a friction coefficient of Āµ = 0.12 and are to be used as approximate figures.
Printed in U.S.A. 2-9 918197/AP0806
--- Page 6 ---
3.2 Maintenance label
Explanation of symbols on the maintenance label
Symbol Assembly Explanation
General Visual check
General Grease instructions
Fuel system Drain condensation water
Fuel system Replace the fuel filter, clean the fuel prefilter
Radiator Check the coolant level
Radiator Drain and fill in new coolant
Engine Check valve tip clearance. Adjust if necessary
Engine Check the engine oil level
Engine Change the engine oil
Engine Replace the oil filter
Engine Check V-belt tension
Travel drive Change oil
Travel drive Check oil
Undercarriage Check chain tension
Hydraulic system Check oil level
Hydraulic system Change the hydraulic oil
Hydraulic system Replace the hydraulic oil filter, replace the breather filter
Printed in U.S.A. 3-3 918197/AP0806
--- Page 7 ---
Maintenance
Emptying the fuel tank
1 DANGER!
Do not allow draining fuel to contact hot engine parts or the exhaust system to
avoid an increased
Risk of burns.
ā Do not bleed the fuel system if the engine is hot.
Fig. 4: Fuel drain plug
Due to the formation of condensation in the fuel tank, empty the fuel tank every 500 hours
as follows:
ā Place a container with sufficient capacity underneath the drain plug 1/Fig. 3 in
the chassis.
ā Open the drain plug to drain the fuel.
ā Check the fuel tank for contamination and clean if necessary.
ā Replace the filter according to the maintenance specifications.
ā Screw the drain plug back in correctly.
ā Fill the fuel tank.
ā Bleed the fuel system according to "Bleeding the fuel system" on page 3-12.
Fuel shut-off valve and water separator
If water is seen in the water separator bowl, or the indicator ring rises to position C, the
On separator needs to be drained.
ā Twist the fuel shut-off valve B to the Off position as shown.
Off ā Unscrew plug A.
ā„ Wait until the indicator ring returns to the bottom of the water separator.
ā Tighten plug A.
B
ā Twist the fuel shut-off valve B to the On position.
C Environment!
Collect the water as it drains into a suitable container and dispose of it accord-
ing to evironmental laws.
A
Fig. 5: Fuel shut-off valve and water separator
Printed in U.S.A. 3-13 918197/AP0806
--- Page 8 ---
Maintenance
Weekly functional check of the dust valve
ā Proceed as follows:
ā¢ Turn off the engine.
ā¢ Fold up the control lever base.
ā¢ Remove the key and keep it with you.
ā¢ Let the engine cool down.
ā¢ Open the engine cover.
ā¢ Squeeze the discharge slot of dust valve B.
B ā¢ Remove hardened dust by compressing the upper area of the valve.
ā Clean the discharge slot if necessary.
Fig. 22: Air filter ā dust valve
Printed in U.S.A. 3-23 918197/AP0806
--- Page 9 ---
Maintenance
Printed in U.S.A.
Maintenance
3.12 Test report
Pilot control
Pressure limiting Measuring
Function Movement Symbol
valve port
Specified values Measured ā
Pressure
limiting valve Measuring 507Ā±44 psi
Joystick ANY port Rated value
PRV 4 (35Ā±3 bar)
MP 4 (pump)
(control oil unit)
Pump 1
Pressure limiting Measuring
Function Movement Symbol
valve port
Specified values Measured ā
Rated value 3481Ā±44 psi (240Ā±3 bar)
UP
Primary pressure limiting valve PPLV 1
Drop 348 psi (24 bar)
Boom
3-33
Rated value 3481Ā±44 psi (240Ā±3 bar)
DOWN
Drop 348 psi (24 bar)
Measuring port MP 1
(main valve block)
Rated value 3481Ā±44 psi (240Ā±3 bar)
EXTEND
Drop 348 psi (24 bar)
(pump)
Bucket
Rated value 3481Ā±44 psi (240Ā±3 bar)
RETRACT
Drop 348 psi (24 bar)
Rated value 3481Ā±44 psi (240Ā±3 bar)
FORWARD
Drop 348 psi (24 bar)
Left-hand side drive
Rated value 3481Ā±44 psi (240Ā±3 bar)
REVERSE
Drop 348 psi (24 bar)
Maintenance
918197/AP0806
--- Page 11 ---
Maintenance
3.14 Tracks
ā¢ Track wear may vary according to work and ground conditions.
ā We recommend checking track wear and tension daily.
ā Park the machine on firm and level ground when performing track maintenance.
Checking track tension
DANGER!
Working under the machine with the tracks off the ground and only supported
by the attachment is extremely dangerous.
Risk of injury.
ā Firmly support the machine with chocks or appropriate brackets.
Check track tension as follows:
ā¢ The rubber track has a mark B as shown in Fig. 46.
ā Place the excavator so that mark B of the rubber track is between the drive pinion C
and the track tension roller D.
B
NOTE:
D C There is no mark on the steel tracks (option). Positioning the steel tracks
is not necessary.
ā¢ No specific position is required for steel tracks (option).
Fig. 46: Rubber track mark
ā Park the machine on firm and level ground.
ā Raise the excavator with the boom and the dipper arm as shown in Fig. 47.
ā Slowly and carefully actuate the control levers.
ā Turn off the engine.
ā Remove the key and keep it with you.
ā Fold up the control lever base.
Fig. 47: Raising the excavator ā Use appropriate auxiliary means to support the machine.
ā¢ Standard play between the sliding block's shoulder and the contact area of the second
support roller of the drive pinion is 3/4" ā 1" (20 ā 25 mm).
ā Set the tension if it is not in accordance with the rated value.
3/4"-1"
(20-25 mm)
Fig. 48: Measuring distance
Printed in U.S.A. 3-43 918197/AP0806
--- Page 12 ---
Engine
Engine
4 Engine
4.1 3TNV88-PNS engine: overview
Air intake
incl. preheater
Oil filler neck
Fuel injection pump
Fuel filter
Engine oil filter
Oil dipstick
Oil pressure switch
Printed in U.S.A. 4-1 918197/AP0806
--- Page 13 ---
Engine
Thermometer ā Heat the thermostat in a container with water.
ā Using a thermometer, check whether the thermostat opens at 157.1 ā 162.5 Ā°F (69.5 ā
Thermostat 72.5 Ā°C).
4.11 Checking the thermal switch
Thermometer ā Remove the thermal switch.
ā Heat the thermal switch in a container with antifreeze or oil.
ā Using an ohmmeter, measure the resistance of the thermal switch.
ā„ The switch must allow the coolant to pass at a temperature
of 225 ā 235 Ā°F (107 ā 113 Ā°C).
Thermal
Switch
Test probes
Fig. 18: Checking the thermal switch
4.12 Oil pressure switch
ā Remove the cable connection from the oil pressure switch (in the area of
the cut-off solenoid).
Measurement probe ā Start the engine; check for correct idling speed (1050 +/- 50 rpm).
ā Using an ohmmeter, measure the resistance of the oil pressure switch.
ā„ Infinite resistance indicates the oil pressure switch is OK.
ā„ The oil pressure switch is defective if the oil can pass.
Fig. 19: Oil pressure switch
Printed in U.S.A. 4-11 918197/AP0806
--- Page 14 ---
Main valve block diagram
3989 PSI (275 bar)
Bucket
3989 PSI (275 bar)
Boom
Left side drive
Input P1
3481 PSI (240 bar)
3481 PSI (240 bar) Input P2
Right side drive
Dipper
3989 PSI (275 bar)
Auxiliary hydraulics/swivel
3rd control circuit
Dozer blade
3989 PSI (275 bar)
Rotate
Drive counterbalancing system P3
3046 PSI (210 bar)
NOTE: See page 5-36 for a
larger version of this hydraulic
schematic.
Printed in U.S.A. 5-7 918197/AP0806
--- Page 15 ---
5.8 Valves
7/2 directional valve (changeover valve)
The 7/2 directional valve (changeover valve) switches from auxiliary hydraulics (valve
de-energized) to boom swivel and vice versa (valve energized).
The 7/2 directional valve is electrically controlled via a push button on left side joystick.
Hydraulic Circuit
B1 B2
C2
C1
L
A1 A2
*
% %
/ C1 C2
$ $
Ref. No. Port
A1 Main valve block
A2 Main valve block
B1 Swivel
B2 Swivel
C1 Auxiliary hydraulics
C2 Auxiliary hydraulics
L Return oil
Printed in U.S.A. 5-17 918197/AP0806
--- Page 16 ---
Printed in U.S.A.
5-27
Ref. Ref.
Description Description
No. No.
1 Pinion shaft 11 O-ring
2 Spacer washer 12 Ring gear
3 Bearing seal ring 13 Gear reduction
4 Bearing 14 Gear reduction
5 Gear housing 15 Sun gear
6 Sealing ring 16 Motor flange
7 Bearing 17 Hydraulic motor
8 Round nut 18 Screw
9 Complete drive 19 Screw
10 Spacer washer 20 Plug
918197/AP0806
--- Page 17 ---
Electrical system
Electrical system
6 Electrical system
6.1 Ohm's Law (current, voltage, resistance); power
It describes the interrelation between current, voltage and resistance.
Current āIā ā Ampere (A)
Voltage āEā ā Volt (V)
Resistance āRā ā Ohm (Ī©)
Mnemonic: E