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Gehl Z35 User Manual

Gehl Z35
232 pages
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Compact Excavator
Z27
Z35
Form No.
50940101
Revision A
Jun. 2012
Operator’s Manual
© 2012 Manitou America • All Rights Reserved. • Printed in USA
®

Table of Contents

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Gehl Z35 Specifications

General IconGeneral
BrandGehl
ModelZ35
CategoryCompact Excavator
LanguageEnglish

Summary

GEHL COMPANY WARRANTY

Warranty Service Inclusions

Details what the Gehl warranty covers, including parts and labor.

Warranty Exclusions

Lists items and conditions not covered by the Gehl warranty.

1. Introduction

Manual Usage and Safety Awareness

Emphasizes reading the manual for safe and efficient operation to prevent accidents.

2. Safety Information

Understanding Hazard Signal Words

Explains signal words like DANGER, WARNING, CAUTION, and IMPORTANT for hazard communication.

3. Product Overview

Intended Uses and Break-in Period

Outlines the machine's intended tasks and essential steps for proper break-in.

EPA Emission Standards Compliance

Details conditions for the engine to meet EPA emission standards.

4. Operation License

Confirming Licensing Requirements

Advises confirming licensing requirements and complying with all applicable laws.

5. Ordering Replacement Parts and Service Call

Location of Identification Plates

Identifies the location of machine, engine, and EPA emission control plates for reference.

Information Needed for Parts and Service

Specifies model, serial numbers, and hour meter reading required when ordering parts or service.

7. Basic Precautions

General Safety Rules and Gear

Covers workplace safety, safety devices, proper clothing, and avoiding alcohol while operating.

Prevent Hazards from Modifications and Unattended Machines

Advises against unauthorized modifications and how to secure the machine when leaving the operator's seat.

Handle Fuel, Fluids, and Hazardous Materials Safely

Provides precautions for handling fuel, hot fluids, and asbestos dust to prevent fires and injury.

Prevent Mechanical and General Hazards

Covers crush injury prevention, safety kits, attachment installation, and cabin glass safety.

8. Operating Precautions

Pre-Operation Checks and Engine Start

Details checks before starting, workplace safety, fire prevention, and operator seat inspection.

Engine Start, Working, and Parking Procedures

Outlines procedures for starting the engine, working safely, and ensuring no persons are nearby when moving.

Safe Travel and Slope Operation

Provides guidance on traveling safely, including implement height and operating on slopes.

Avoid Hazardous Work and Power Lines

Warns against undermining cliffs, undercutting, and working near overhead electric power lines.

Working Safely in Various Conditions

Offers precautions for bumping implements, visibility, snow, unstable ground, and quick coupler usage.

Slope Operation and Machine Parking

Details safe practices for working on slopes and properly parking the machine.

Transportation Safety Procedures

Covers safe loading, unloading, securing, and transporting the machine in compliance with laws.

Battery Handling and Booster Cable Use

Provides critical safety information for handling batteries and using booster cables.

Safe Towing Procedures

Explains proper methods and precautions for towing the machine safely using wire ropes.

9. Precautions for Servicing

Pre-Service Checks and Tool Usage

Emphasizes using the "SERVICING IN PROGRESS" tag and appropriate tools before starting service.

Essential Parts Replacement and Engine Shutdown

Highlights periodically replacing safety-critical parts and stopping the engine before inspection.

Servicing Safety and Machine Cleanliness

Covers keeping unauthorized persons away, securing removed attachments, working under the machine, and maintaining cleanliness.

Fueling, Cooling, and Battery Handling Safety

Details precautions for fueling, checking cooling water, using explosion-proof lighting, and handling batteries.

High-Pressure Systems and Temperature Safety

Warns about high-pressure hoses, hot oil, and servicing systems under high temperature and pressure.

Grease Hazards, Fan Belt, and Waste Disposal

Addresses hazards from high-pressure grease, rotating fan belts, and proper disposal of processing wastes.

10. Safety Messages (Warning Labels)

Location and Importance of Warning Labels

Explains the presence of warning labels on the machine and the need for their periodic confirmation and replacement.

11. Identification of Important Parts

Machine Component Overview

Provides diagrams identifying key external parts of the excavator.

Controls and Switches Identification

Identifies various controls, levers, pedals, and switches on the machine's operator console.

12. Description of Control Devices

Machine Displays and Indicators

Describes the function and operation of the monitor panel, including various indicators and gauges.

Switches and Electrical Controls

Details the operation of the starter switch, light switch, horn switch, and wiper controls.

Operator Interface Controls

Explains the function of control levers, pedals, lock levers, and travel controls for machine operation.

Engine Hood and Access Covers

Describes how to open and close the engine hood and rear cover for access and maintenance.

Storage and Cabin Features

Details the storage space for the manual and cabin features like the rear engine hood cover.

Windshield Operation and Safety

Explains how to open, close, and secure the machine's windshields for operator safety.

Operator Seat Adjustments and Features

Covers adjusting the operator's seat for comfort, position, and weight.

Cabin Amenities and Lighting

Describes cabin features like the ash tray and headlight operation.

Cabin Air Outlets and Windows

Details the adjustment of air outlets and operation of cabin windows.

Cabin Door and Washer Fluid

Explains cabin side door operation, locking, and replenishing windshield washer fluid.

Fuse Box and Replacement

Details the location and replacement procedure for machine fuses to protect electrical systems.

Power Outlet Usage and Care

Describes the use of the DC power outlet and precautions for its maintenance.

13. Operating Instructions

Pre-Operation Checks and Engine Start

Covers visual checks, fluid levels, and starting procedures for safe machine operation.

Machine Travel Operations

Details forward and reverse travel procedures, including blade position and safety checks.

Steering and Machine Turning

Explains how to steer the machine using travel levers and the importance of blade position.

Machine Stopping and Parking Procedures

Provides instructions on safely stopping the machine and parking it properly.

Upperstructure Swing Operation

Details how to swing the upperstructure, emphasizing safety checks for surrounding areas.

Implement Operation and Pattern Selection

Describes how to operate various implements using control levers and the function of pattern change levers.

Precautions for Implement Operation

Warns against misuse of implement forces, operating cylinders to stroke end, and using dropping force.

Safe Working Practices and Water Depth

Covers precautions for traveling over obstacles, working in water, and allowable water depth limits.

Slope Operation Guidelines

Provides detailed instructions and warnings for safely operating the machine on slopes.

Escaping from Mud and Stuck Situations

Offers methods for freeing the machine if it becomes stuck in mud.

Bucket Operations for Digging, Ditching, and Loading

Explains techniques for efficient digging, ditching, and loading using the bucket.

Quick Coupler Features and Switch Operation

Describes the features of the quick coupler and the operation of its control switches.

Attachment Types and Bucket Size Limits

Lists compatible attachment types and allowable bucket sizes for the quick coupler.

Dismounting Machine Attachments Safely

Details the procedure for safely removing attachments from the machine.

Mounting Machine Attachments Securely

Explains the process for safely attaching implements, ensuring proper securing and lock pin installation.

Quick Coupler Maintenance and Pin Installation

Covers maintenance for the quick coupler and proper installation of the lock pin.

Machine Parking and Shutdown Procedures

Provides steps for safely parking the machine and performing post-operation inspections.

Engine Stopping Procedures

Details the correct method for stopping the engine to prevent premature wear.

Post-Operation Checks and Machine Locking

Lists essential checks after stopping the engine and procedures for locking the machine.

Rubber Track Usage and Warranty

Compares rubber and steel tracks, explains rubber track warranty, and provides usage precautions.

Rubber Track Prohibitions and Care

Lists specific prohibitions and precautions for using and storing rubber tracks to prevent damage.

Rubber Track Handling and Environmental Precautions

Offers additional precautions for rubber track operation, including environmental factors and cleaning.

Hydraulic PTO System Operation

Describes the hydraulic PTO system, including stop valves, selector valves, and lever switches.

Attachment Operation and Hydraulic Circuit

Details operating attachments like breakers and tilt buckets, and connecting the hydraulic circuit.

Long-Term Hydraulic Tool Storage and Specifications

Provides instructions for storing hydraulic tools and lists system specifications.

Replacing Bucket Without Quick Coupler

Explains the procedure for replacing the bucket manually, including safety precautions.

14. Transportation

Loading, Unloading, and Securing the Machine

Details safe procedures for loading, unloading, and securing the machine for transport.

Machine Suspension and Transport Safety

Covers safe practices for suspending the machine and general transport safety regulations.

15. Care and Service in Cold Weather

Cold Weather Preparation and Post-Work Care

Provides measures for starting the engine and preventing freezing in cold weather, plus post-work care.

16. Long-term Storage

Storage Procedures and Re-use

Outlines steps for preparing the machine for long-term storage and procedures for its subsequent use.

17. Troubleshooting

Identifying Non-Breakdowns and Towing Procedures

Differentiates normal machine behaviors from actual breakdowns and explains towing methods.

Battery and Engine Starting Issues

Addresses issues related to overdischarged batteries and starting the engine using booster cables.

Common Machine and Engine Problems

Lists common engine and electrical problems, their causes, and recommended solutions.

18. Precautions for Servicing

General Servicing Safety Guidelines

Covers essential practices like using genuine parts, clean fluids, machine cleaning, and temperature precautions.

Specific Servicing Safety Precautions

Details safety measures for welding, pressure relief, mating surfaces, undercarriage checks, and electrical equipment cleaning.

19. Basic Servicing Practices

Fluids, Lubricants, and Filters

Specifies types of engine oil, gear oil, hydraulic oil, fuel, coolant, grease, and filter elements.

Electrical and Hydraulic System Care

Covers precautions for maintaining electrical equipment and the hydraulic system to ensure proper function.

20. Consumables

Replacement Schedule for Consumable Parts

Lists consumable parts like filters and bucket teeth with their replacement intervals.

21. Fueling, Oiling and Greasing Based on Temperature Range

Fuel, Oil, and Cooling Water Specifications

Provides guidelines for selecting fuel, oils, and coolant based on ambient temperature ranges.

22. Standard Tightening Torque for Bolts and Nuts

Required Tools and Torque Specifications

Lists necessary tools for servicing and provides a torque table for proper bolt and nut tightening.

23. Replacing Essential Parts Periodically

Periodic Replacement of Safety-Critical Parts

Emphasizes the importance of periodically replacing parts vulnerable to age and wear for safe operation.

24. Maintenance Table

Service Intervals and Breaker Usage Guidelines

Summarizes inspection and servicing items by interval and provides service intervals specific to hydraulic breaker use.

25. Procedures for Maintenance

Initial Service and Pre-Operation Checks

Details initial services required for new machines and pre-operation checks before starting the engine.

Scheduled Maintenance by Service Hours

Outlines maintenance tasks required at intervals of 50, 100, 250, 500, 1000, and 2000 service hours.

26. Specifications and Dimensional Diagrams

Machine Specifications and Performance Data

Details technical specifications, operating mass, working range, and engine data for Z27 and Z35 models.

Model Views and Working Range Dimensions

Provides dimensional drawings and working range measurements for excavators with canopy and cabin options.

27. General Precautions

Attachment Mounting and Dismounting Safety

Outlines safety measures for mounting and dismounting heavy implements, including using cranes and partner communication.

28. Optional Parts and Attachments

Available Bucket Options and Specifications

Lists available bucket options with their width, capacity, and remarks for Z27 and Z35 models.

29. Handling Air Conditioner (for Model Z35 with Cabin)

Air Conditioner Operation and Controls

Explains the operation of the air conditioner, including temperature control, fan switch, and compressor activation.

Air Conditioner Maintenance and Checks

Details daily inspection, cleaning of the condenser, compressor belt checks, and refrigerant quantity verification.

30. Maintenance Log

Service Record Keeping

Provides a template for recording maintenance dates, machine hours, and services performed.

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