{"product_id":"gehl-ge-503z-ge-603-mini-excavator-repair-service-manual","title":"Gehl GE 503Z, GE 603 Mini Excavator Repair Service Manual","description":"Format : PDF\u003cbr\u003eSUPPLIED AS DOWNLOADABLE LINK\u003cbr\u003e\u003cbr\u003eLanguage: English\u003cbr\u003eFormat: PDF\u003cbr\u003eApplicable for the\u003cbr\u003eGehl Excavator\u003cbr\u003eModel GE 503Z, GE 603 Mini Excavator\u003cbr\u003eGehl GE 503Z, GE 603 Mini Excavator Repair Service Manual – 206 Pages\u003cbr\u003eGehl GE 503Z, GE 603 Mini Excavator Operators Manual – 132 Pages\u003cbr\u003eGehl GE 503Z, GE 603 Mini Excavator Parts Manual – 260 Pages\u003cbr\u003e\u003cbr\u003eDescription\u003cbr\u003eGehl GE 503Z, GE 603 Mini Excavator Repair Service Manual\u003cbr\u003eLanguage: English\u003cbr\u003eFormat: PDF\u003cbr\u003eApplicable for the\u003cbr\u003eGehl Excavator\u003cbr\u003eModel GE 503Z, GE 603 Mini Excavator\u003cbr\u003eGehl GE 503Z, GE 603 Mini Excavator Repair Service Manual – 206 Pages\u003cbr\u003eGehl GE 503Z, GE 603 Mini Excavator Operators Manual – 132 Pages\u003cbr\u003eGehl GE 503Z, GE 603 Mini Excavator Parts Manual – 260 Pages\u003cbr\u003eTable of Content of the Gehl GE 503Z, GE 603 Mini Excavator Manual:\u003cbr\u003eOperation …………………………………………………………………………………………………………… 5\u003cbr\u003eGeneral information ……………………………………………………………………………………….. 5\u003cbr\u003eSerial number location ……………………………………………………………………………………. 6\u003cbr\u003eIdentification of warnings and hazards ……………………………………………………………… 8\u003cbr\u003eType decals and component numbers ………………………………………………………………. 9\u003cbr\u003eMachine: overview ……………………………………………………………………………………….. 10\u003cbr\u003eCab: overview ……………………………………………………………………………………………… 12\u003cbr\u003eCab: legend ………………………………………………………………………………………………… 13\u003cbr\u003eInstrument panel, switches and indicators: overview (SN AC02893 and up) ………… 14\u003cbr\u003eInstrument panel, switches and indicators: legend (SN AC02893 and up) ……………. 15\u003cbr\u003eInstrument panel, switches and indicators: overview (SN AC02877 and before) …… 16\u003cbr\u003eInstrument panel, switches and indicators: legend (SN AC02877 and before) ……… 17\u003cbr\u003eEngine compartment: overview (SN AH00579 and up) ……………………………………… 18\u003cbr\u003eEngine compartment: overview (SN AH00578 and before) ………………………………… 19\u003cbr\u003eChassis: overview ………………………………………………………………………………………… 20\u003cbr\u003ePedal for auxiliary hydraulics\/swivelling and rotating the boom …………………………… 20\u003cbr\u003eTilting the cab ……………………………………………………………………………………………… 21\u003cbr\u003eHeating ………………………………………………………………………………………………………. 22\u003cbr\u003eSpecifications ……………………………………………………………………………………………………. 23\u003cbr\u003eHydraulic system …………………………………………………………………………………………. 25\u003cbr\u003eUndercarriage and swivel unit ……………………………………………………………………….. 26\u003cbr\u003eDozer blade ………………………………………………………………………………………………… 26\u003cbr\u003eElectrical system ………………………………………………………………………………………….. 27\u003cbr\u003eSound levels ………………………………………………………………………………………………. 28\u003cbr\u003eCoolant compound table ……………………………………………………………………………….. 28\u003cbr\u003eModel-specific tightening torques …………………………………………………………………… 29\u003cbr\u003eGeneral tightening torques ……………………………………………………………………………. 29\u003cbr\u003e503Z dimensions …………………………………………………………………………………………. 32\u003cbr\u003eLift capacity table with short dipper arm ………………………………………………………….. 33\u003cbr\u003eLift capacity table with long dipper arm ……………………………………………………………. 34\u003cbr\u003eLift capacity table with short dipper arm and counterweight ……………………………….. 35\u003cbr\u003eLift capacity table with long dipper arm and counterweight ………………………………… 36\u003cbr\u003eBucket geometry ………………………………………………………………………………………….. 37\u003cbr\u003eMaintenance …………………………………………………………………………………………………….. 39\u003cbr\u003eFluids and lubricants ……………………………………………………………………………………. 39\u003cbr\u003eMaintenance decal ……………………………………………………………………………………….. 41\u003cbr\u003eMaintenance schedule (overview) ………………………………………………………………….. 43\u003cbr\u003eIntroduction …………………………………………………………………………………………………. 47\u003cbr\u003eFuel system ………………………………………………………………………………………………… 48\u003cbr\u003eEngine lubrication system ……………………………………………………………………………… 52\u003cbr\u003eCooling system ……………………………………………………………………………………………. 55\u003cbr\u003eAir filter ……………………………………………………………………………………………………….. 58\u003cbr\u003eV-belt …………………………………………………………………………………………………………. 60\u003cbr\u003ePressure check ……………………………………………………………………………………………. 64\u003cbr\u003eTest report ………………………………………………………………………………………………….. 71\u003cbr\u003eHydraulic system …………………………………………………………………………………………. 75\u003cbr\u003eTravel drive …………………………………………………………………………………………………. 80\u003cbr\u003eTracks ………………………………………………………………………………………………………… 81\u003cbr\u003eLubrication work …………………………………………………………………………………………… 83\u003cbr\u003eElectrical system ………………………………………………………………………………………….. 86\u003cbr\u003eCab ……………………………………………………………………………………………………………. 90\u003cbr\u003eGeneral maintenance work ……………………………………………………………………………. 91\u003cbr\u003eLong-term storage ……………………………………………………………………………………….. 93\u003cbr\u003eEngine (SN AH00579 and up) ………………………………………………………………………………95\u003cbr\u003eEngine marked 4TNV88-BPNS (SN AH00579 and up): overview ………………………..95\u003cbr\u003eFuel system ………………………………………………………………………………………………….97\u003cbr\u003ePreparing for cylinder head removal ………………………………………………………………..98\u003cbr\u003eChecking and adjusting valve tip clearance ………………………………………………………98\u003cbr\u003eRemoving\/Tightening order for cylinder head bolts ……………………………………………99\u003cbr\u003eChecking the injection nozzles ………………………………………………………………………100\u003cbr\u003eChecking the nozzle jet ………………………………………………………………………………..100\u003cbr\u003eInjection timing ……………………………………………………………………………………………101\u003cbr\u003eAdjusting engine speeds ………………………………………………………………………………104\u003cbr\u003eCompression ………………………………………………………………………………………………105\u003cbr\u003eChecking the coolant thermostat …………………………………………………………………..105\u003cbr\u003eChecking the thermal switch …………………………………………………………………………106\u003cbr\u003eOil pressure switch ………………………………………………………………………………………106\u003cbr\u003eChecking the coolant circuit ………………………………………………………………………….106\u003cbr\u003eEngine (SN AD07125 and before) ………………………………………………………………………107\u003cbr\u003eEngine marked 4TNV88-PNS (SN AD07125 and before): overview …………………..107\u003cbr\u003eFuel system ………………………………………………………………………………………………..109\u003cbr\u003eChecking and adjusting valve tip clearance …………………………………………………….110\u003cbr\u003eRemoving\/Tightening order for cylinder head bolts ………………………………………….110\u003cbr\u003eChecking the injection nozzles ………………………………………………………………………111\u003cbr\u003eChecking the nozzle jet ………………………………………………………………………………..112\u003cbr\u003eInjection timing ……………………………………………………………………………………………112\u003cbr\u003eAdjusting engine speeds ………………………………………………………………………………116\u003cbr\u003eCompression ………………………………………………………………………………………………116\u003cbr\u003eChecking the coolant thermostat …………………………………………………………………..116\u003cbr\u003eChecking the thermal switch …………………………………………………………………………117\u003cbr\u003eOil pressure switch ………………………………………………………………………………………117\u003cbr\u003eChecking the coolant circuit ………………………………………………………………………….118\u003cbr\u003eEngine Troubleshooting ……………………………………………………………………………………119\u003cbr\u003eHydraulic system ………………………………………………………………………………………………121\u003cbr\u003eHydraulic pump: PVD-2B-41BP-16G5-4713F (SN AH00579 and up)\u003cbr\u003ePVD-2B-44BP-16G5-4713F (AD07125 and before) ……………………………………121\u003cbr\u003eMain valve block …………………………………………………………………………………………125\u003cbr\u003eDrive counterbalancing system ……………………………………………………………………..130\u003cbr\u003eRegeneration – dipper arm section ………………………………………………………………..132\u003cbr\u003eBucket pre-tension ………………………………………………………………………………………132\u003cbr\u003eFlow rate adjustment for auxiliary hydraulics …………………………………………………..133\u003cbr\u003ePilot valves …………………………………………………………………………………………………134\u003cbr\u003eValves ……………………………………………………………………………………………………….140\u003cbr\u003eTravel drive ………………………………………………………………………………………………..143\u003cbr\u003eSwivel unit ………………………………………………………………………………………………….146\u003cbr\u003eSwivel joint …………………………………………………………………………………………………150\u003cbr\u003eBreather filter ……………………………………………………………………………………………..151\u003cbr\u003eTroubleshooting the hydraulic system ……………………………………………………………152\u003cbr\u003eHydraulics diagram (legend) …………………………………………………………………………153\u003cbr\u003eHydraulics diagram 503Z ……………………………………………………………………………..155\u003cbr\u003eOptions diagram ………………………………………………………………………………………….156\u003cbr\u003eMain valve block diagram 503Z …………………………………………………………………….157\u003cbr\u003eElectrical system ……………………………………………………………………………………………… 159\u003cbr\u003eOhm's Law (defines current, voltage and resistance relationship) …………………….. 159\u003cbr\u003eMeasuring equipment and methods ……………………………………………………………… 159\u003cbr\u003eCable color coding ……………………………………………………………………………………… 160\u003cbr\u003eRelays ………………………………………………………………………………………………………. 161\u003cbr\u003eElectrical units ……………………………………………………………………………………………. 161\u003cbr\u003eFuse box in instrument panel ……………………………………………………………………….. 161\u003cbr\u003eMain fuse box with relays ……………………………………………………………………………. 162\u003cbr\u003eRelays ………………………………………………………………………………………………………. 162\u003cbr\u003eSocket ………………………………………………………………………………………………………. 163\u003cbr\u003eJoystick switch buttons ……………………………………………………………………………….. 163\u003cbr\u003eInstrument panel: overview ………………………………………………………………………….. 164\u003cbr\u003eSwitches overview (SN AC02893 and up) ……………………………………………………… 165\u003cbr\u003eSwitches overview (SN AC02877 and below) ………………………………………………… 165\u003cbr\u003eAlternator ………………………………………………………………………………………………….. 166\u003cbr\u003eStarter ………………………………………………………………………………………………………. 166\u003cbr\u003eWiring harness overview ……………………………………………………………………………… 166\u003cbr\u003eWiring diagram legend (SN AC02890 and up) ……………………………………………….. 167\u003cbr\u003eWiring diagram (SN AC02890 and up) ………………………………………………………….. 168\u003cbr\u003eWiring diagram legend (SN AC02889 and before) ………………………………………….. 169\u003cbr\u003eWiring diagram (SN AC02889 and before) …………………………………………………….. 170\u003cbr\u003eEngine – chassis wiring harness legend ………………………………………………………… 171\u003cbr\u003eEngine – chassis wiring harness …………………………………………………………………… 172\u003cbr\u003eWiring harness switches (SN AC02890 and up) ……………………………………………… 174\u003cbr\u003eWiring harness switches legend (SN AC02889 and before) ……………………………… 175\u003cbr\u003eWiring harness switches (SN AC02889 and before) ……………………………………….. 176\u003cbr\u003eCab roof wiring harness ………………………………………………………………………………. 177\u003cbr\u003eArmrest wiring harness ……………………………………………………………………………….. 178\u003cbr\u003eBoom working light wiring harness ……………………………………………………………….. 179\u003cbr\u003eOptions …………………………………………………………………………………………………………… 181\u003cbr\u003eAir conditioning ………………………………………………………………………………………….. 181\u003cbr\u003eAir-suspension seat ……………………………………………………………………………………. 188\u003cbr\u003eCounterweight ……………………………………………………………………………………………. 188\u003cbr\u003eLong dipper arm …………………………………………………………………………………………. 189\u003cbr\u003eAuxiliary hydraulics connections …………………………………………………………………… 189\u003cbr\u003eProportional controls …………………………………………………………………………………… 191\u003cbr\u003eAuto-idle feature (SN AH00579 and up) ………………………………………………………… 197\u003cbr\u003eThis Service Manual is intended for Gehl GE 503Z, GE 603 Mini Excavator so as to give the owner\/operator assistance in preparing, adjusting, maintaining and servicing the machine. More importantly, this manual provides an operating plan for safe and proper use of the machine. Major points of safe operation are\u003cbr\u003edetailed in Chapter 2 – Safety. Read and understand the contents of this manual completely and become familiar with the machine before\u003cbr\u003eattempting to operate it..\u003cbr\u003eThroughout this manual, information is introduced by the word NOTE or IMPORTANT. Be sure to read the message carefully and comply with the message. Following this information will improve operating and maintenance efficiency, help to avoid breakdown and damage and extend the service life of the machine.","brand":"Uploader","offers":[{"title":"Default Title","offer_id":53601554891083,"sku":null,"price":63.0,"currency_code":"USD","in_stock":true}],"thumbnail_url":"\/\/cdn.shopify.com\/s\/files\/1\/0978\/2519\/4315\/files\/1-5_dc6c1342-93d5-4728-ac03-25031f647397.jpg?v=1760443167","url":"https:\/\/manualbull.com\/products\/gehl-ge-503z-ge-603-mini-excavator-repair-service-manual","provider":"ManualBull","version":"1.0","type":"link"}