Gehl 803 parts manual. s/n AC02528 and up

INTRODUCTION When ordering service parts, specify the correct part number, full description, quantity required, the unit model number and serial number. For your safety and continued proper operation, use only genuine GEHL service parts. The model and serial number for this unit are on a tag located on a panel on the front of the cabin. ''Right'' and ''left'' are determined from a position sitting on the seat and facing forward. GEHL Company reserves the right to make changes or improvements in the design or construction of any part of the unit without incurring the obligation to install such changes on any previously delivered units. Refer to the abbreviations table located on this page for the various fastener descriptions. Standard attaching hardware torque values are also provided on the inside back cover. Metric torque values shown in the illustrations are in Newton- meters and can be converted to foot-pounds by multiplying by 0.738. Specific Reference Numbers, indicating a complete assembly, are circled in some illustrations. A small bag, pictured in some illustrations, indicates a seal kit (seals, o-rings, etc.). In the exploded view parts list, additional information may follow the Reference Number. Serial number breaks are indicated as follows: • (SN 999 and before) - indicates serial numbers up to and including 999. • (SN 1000 - 2000) - indicates serial numbers between 1000 and 2000. • (SN 999 and up) - indicates serial numbers including 999 and after. Serial number exceptions and inclusions are indicated as follows: • (SN 999 and before except 997) - indicates serial numbers up to and including 999, EXCEPT 997. • (SN 1000 - 2000 except 1996 including 997) - indicates serial numbers between 1000 and 2000, INCLUDING 997 EXCEPT 1996. • (SN 2001 and up including 1996) - indicates serial numbers including 2001 and after, INCLUDING 1996. Unless otherwise specified, all cap screws, nuts, and bolts are Grade 8.8, cadmium or zinc plated. NOTE: The following abbreviations may be used herein: ASSD...................... Assembled ASSY...................... Assembly AR .......................... As Required CB........................... Carriage Bolt CP ........................... Cotter Pin CS ........................... Cap Screw (Hexagon Head) CYL ........................ Cylinder DIA......................... Diameter FHCS ...................... Flat Head Cap Screw GR .......................... Grade HB .......................... Hex Bolt HLN........................ Hex Lock Nut HN .......................... Hex Nut HP ........................... High Pressure HYD ....................... Hydraulic INS ......................... Insert LN........................... Lock Nut LT ........................... Left LW .......................... Lock Washer M ............................ Meter or Meters MM/mm ................. Millimeter NPT......................... National Pipe Thread RH .......................... Right Hand RT ........................... Right SHCS ...................... Socket Head Cap Screw SLTD ...................... Slotted SN........................... Serial Number or Slotted Nut SQ........................... Square W/ ........................... With W/O ........................ Without

Printed in U.S.A 1 918076/CP0508 TABLE OF CONTENTS Introduction ..................... Inside Front Cover Table of Contents .........................................1 Decal Locations ...........................................4 Diesel Engine - Tier III ................................8 Diesel Engine - Tier II .................................9 Engine Mounts - Tier III ............................10 Engine Mounts - Tier II .............................11 Cylinder Head, Valve Cover ......................12 Cylinder Block ...........................................13 Seal - Crankshaft - Tier III .........................14 Seal - Crankshaft - Tier II ..........................15 Oil Pan - Tier III ........................................16 Oil Pan - Tier II ..........................................17 Camshaft - Tier III .....................................18 Camshaft - Tier II ......................................19 Crankshaft, Piston - Tier III .......................20 Crankshaft, Piston - Tier II ........................21 Lubrication - Tier III ..................................22 Lubrication - Tier II ...................................23 Cooling System - Tier III ...........................24 Cooling System - Tier II ............................25 Fuel Injection System - Tier III .................26 Fuel Injection System - Tier II ...................27 Engine Air Filter - Tier III .........................28 Engine Air Filter - Tier II ..........................29 Intake Manifold - Tier III...........................30 Intake Manifold - Tier II ............................31 Exhaust Components - Tier III ..................32 Exhaust Components - Tier II ....................33 Diesel Tank ................................................34 Hydraulic Pump Drive ...............................35 Fuel Supply - Tier III .................................36 Fuel Supply - Tier II ..................................37 Auto Idle/Throttle - Tier III .......................38 Throttle Lever - Tier II...............................39 Radiator - Tier III .......................................40 Radiator - Tier II ........................................41 Turntable Drive Unit Installation ...............44 Turntable Drive Unit ..................................46 Oil Cooler ..................................................47 Pilot Control Drive Unit ............................48 Drive Motor Installation ............................50 Drive Motor (Mag 50) ...............................52 Drive Motor (Mag 44) ...............................53 Hydraulic Oil Tank ....................................55 Hydraulic Pump ......................................... 58 Hydraulic Pump Components .................... 59 Control Valve Fittings ............................... 60 Control Valve Assembly............................ 62 Pilot Oil Supply Unit ................................. 63 Cut-Off Valve ............................................ 64 Swivel Joint................................................67 Joysticks ..................................................... 68 Pilot Valve, Travel ..................................... 70 Auxiliary Hydraulics - Pilot Valve ............ 72 Control Valve Fittings ............................... 72 Dozer Blade Valve ..................................... 73 Proportional Valve (Option) ...................... 74 Selection Valve .......................................... 75 ISO/SAE Valve .......................................... 76 Manifold Block .......................................... 77 Valve Block ...............................................78 Manifold..................................................... 80 Hydraulic Pump Installation ...................... 82 Boom Installation....................................... 83 Boom Cylinder ........................................... 84 Dipper Arm Installation ............................. 86 Dipper Arm Cylinder ................................. 87 Bucket Installation - Short Dipper Arm..... 88 Bucket Installation - Long Dipper Arm (Option) .................................................. 89 Bucket Cylinder ......................................... 90 Boom Offset Cylinder Installation ............. 92 Boom Offset Cylinder ................................ 93 Dozer Blade Installation ............................ 94 Dozer Blade Cylinder ................................ 95 Auxiliary Hydraulics Installation............... 96 Proportional Control (Option) ................... 98 ISO/SAE Valve Installation ....................... 99 Hydraulic Tank Hoses ............................. 100 Pilot Pressure Hoses................................. 102 Battery...................................................... 103 Dashboard ................................................ 104 Radio (Option) ......................................... 106 Horn ......................................................... 107 Relay Box ................................................ 108 Cab Work Lights - Front (Option) ........... 110 Cab Work Light - Rear (Option).............. 112 Boom Work Light .................................... 113 Wire Harness - Engine ............................. 114

918076/CP0508 2 Printed in U.S.A TABLE OF CONTENTS Wire Harness - Chassis, Engine ...............115 Wire Harness - Chassis ............................117 Wire Harness - Oil Control ......................118 Wire Harness - Armrest ...........................119 Wire Harness - Switch .............................120 Wire Harness - Work Light - Front..........122 Wire Harness - Cab ..................................123 Wire Harness - Auto-Idle (Option) ..........124 Wire Harness - Proportional Control (Option) ................................................126 Dozer Blade .............................................127 Undercarriage, Rubber Track...................128 Rubber Track ...........................................129 Undercarriage, Steel Track (Option)........130 Steel Track (Option) ................................131 Track Tensioner, Rubber Track ...............132 Track Tensioner, Steel Track (Option) ....134 Track Roller (Rubber Track) ...................136 Bottom Roller ..........................................137 Top Roller ................................................138 Top Roller ................................................139 Chassis .....................................................140 Lubrication ...............................................141 Counterweight ..........................................142 Counterweight (Option) ...........................144 Engine Hood - Tier III .............................145 Engine Hood - Tier II...............................146 Tank Cover ..............................................148 Partition Wall ...........................................149 Isolation Mats ..........................................152 Undercarriage Cover ................................155 Chassis Cover ..........................................156 Mirrors .....................................................158 Boom........................................................159 Dipper Arm - Short ..................................160 Dipper Arm - Long (Option) ...................162 Cab Mounting ..........................................164 Cab Frame 1 .............................................165 Cab Frame 2 .............................................168 Cab Door ..................................................171 Windshield ...............................................172 Cabin Windows........................................175 Cab Trim ..................................................176 Operator’s Seat ........................................178 Heater .......................................................180 Air Conditioning (Option) .......................182 Air Conditioning Compressor (Option) ...183 Air Conditioning Installation (Option) ....185 Rotating Beacon (Option) ........................188 Tools ........................................................189 Alphabetical Index ...................................191 Numerical Index ......................................193

Printed in U.S.A 3 918076/CP0508 NOTES

918076/CP0508 4 Printed in U.S.A DECAL LOCATIONS GENERAL INFORMATION Decal location information is provided to assist in the proper selection and application of new decals, in the event the original decals become damaged or the machine is repainted. Refer to the listing for the illustration reference number, part number, description and quantity of each decal provided in the kit. Refer to the appropriate illustrations for replacement locations. To ensure proper selection of the correct replacement decals, compare all of the various closeup location drawings to your machine before starting to refinish the unit. Then circle each decal shown (applicable to your machine) while checking off its part number in the listing. After you have verified all the decals needed for replacement, place any extra unnecessary decals aside for disposal. NOTE: Refer to the SAFETY chapter of the Operator's Manual for the specific information provided on all of the various safety decals furnished in the decal kit(s). NEW DECAL APPLICATION If there is a decal on a part that is to be replaced, be sure that the decal is applied to the replacement part. Surfaces MUST be free from dirt, dust, grease and other foreign material before applying the new decal. To apply, remove the smaller portion of the decal backing paper and apply this part of the exposed adhesive backing to the clean surface while maintaining proper position and alignment. Peel the other portion of the backing paper off slowly while applying hand pressure to smooth out the decal surface. CAUTION ALWAYS follow safety precautions on decals. Replace the decals if they are damaged, or if the unit is repainted. If repainting, BE SURE all applicable decals are affixed to the machine. The decal kit for the 803 Compact Excavator is listed below: PAINT NOTICE Use this list to order paint for refinishing: 167788 4 qts. Construction Yellow (GEHL) 167780 4 qts. Light Gray (GEHL) 167774 4 qts. Dark Gray (GEHL) 167789 6 (12.8 oz. Spray Cans) Yellow (GEHL) 167775 6 (12.8 oz. Spray Cans) Dark Gray (GEHL) 167781 6 (12.8 oz. Spray Cans) Light Gray (GEHL) Ref. No. Part No. Decal/Part Description Qty. 176918 Decal Kit - 803 1 1 161965 Decal/Diesel Fuel 1 2 161966 Decal/Hydraulic Oil 1 3 161970 Decal/Arrow 2 4 161981 Decal/Lift Point 4 5 161982 Decal/Tiedown Point 4 6 161985 Decal/Warning Keep Away 2 7 161986 Decal/Warning Read Manual 1 8 161987 Decal/Warning Rotating Fan 2 9 162450 Decal/Travel Left 1 10 162451 Decal/Travel Right 1 11 163973 Decal/Warning Mandatory Shutdown 1 12 163974 Decal/Throttle Speed 1 13 163975 Decal/Warning Avoid Injury 2 14 163976 Decal/Warning Avoid Injury 1 15 163977 Decal/Warning Entanglement Hazard 1 16 163978 Decal/Warning Hot Surface 1 17 164854 Decal/Warning Avoid Injury 1 19 173907 Decal/803 2 20 177442 Decal SAE/ISO Control 1 21 177871 Decal/Dozer Blade Up/Down 1 22 177441 Decal/Warning Avoid Injury 1 23 177443 Decal/Controls SAE/ISO Lt 1 24 177444 Decal/Controls SAE/ISO Rt 1 25 205842 Lube Chart 1 26 184043 Decal/Gehl 3.75 x 15.92 (white) 1 27 183935 Decal/Gehl 5.50 x 23.34 1 28 184069 Decal/Gehl 6.75 x 28.65 2 29 205088 Decal/Lift Capacity 1

Printed in U.S.A 5 918076/CP0508 DECAL LOCATIONS 20 13 3 5 19 4 6 15 16 8 13 4 5 5 19 3 22 1 2 7 12 25 Both Sides (items 4 and 6) Both Sides (except item 20)

918076/CP0508 6 Printed in U.S.A DECAL LOCATIONS 17 21 29 14 23 9 10 11 24 Overhead Decals - positioning may vary NOTE: The following is a duplicate listing of the decals from page 4. It is provided for convenience when selecting decals from the appropriate illustrations. The decal kit for the 803 Compact Excavator is listed below Ref. No. Part No. Decal/Part Description Qty. 176918 Decal Kit - 803 1 1 161965 Decal/Diesel Fuel 1 2 161966 Decal/Hydraulic Oil 1 3 161970 Decal/Arrow 2 4 161981 Decal/Lift Point 4 5 161982 Decal/Tiedown Point 4 6 161985 Decal/Warning Keep Away 2 7 161986 Decal/Warning Read Manual 1 8 161987 Decal/Warning Rotating Fan 2 9 162450 Decal/Travel Left 1 10 162451 Decal/Travel Right 1 11 163973 Decal/Warning Mandatory Shutdown 1 12 163974 Decal/Throttle Speed 1 13 163975 Decal/Warning Avoid Injury 2 14 163976 Decal/Warning Avoid Injury 1 15 163977 Decal/Warning Entanglement Hazard 1 16 163978 Decal/Warning Hot Surface 1 17 164854 Decal/Warning Avoid Injury 1 19 173907 Decal/803 2 20 177442 Decal SAE/ISO Control 1 21 177871 Decal/Dozer Blade Up/Down 1 22 177441 Decal/Warning Avoid Injury 1 23 177443 Decal/Controls SAE/ISO Lt 1 24 177444 Decal/Controls SAE/ISO Rt 1 25 205842 Lube Chart 1 26 184043 Decal/Gehl 3.75 x 15.92 (white) 1 27 183935 Decal/Gehl 5.50 x 23.34 1 28 184069 Decal/Gehl 6.75 x 28.65 2 29 205088 Decal/Lift Capacity 1 Ref. No. Part No. Decal/Part Description Qty.

Printed in U.S.A 7 918076/CP0508 DECAL LOCATIONS 28 28 27 26

918076/CP0508 8 Printed in U.S.A 803 - DIESEL ENGINE - TIER III 1000180364 - (SN AH00611 AND UP) Ref. No. Part No. Description Qty. 1 203322 BASIC ENGINE 1 2 203323 SEAL KIT 1 3 205501 RADIATOR FAN 1 4 164382 STARTER 1 5 177631 ALTERNATOR 1 6 177560 CLAMP BAR/ALTERNATOR ADJUSTING 1 7 656093 CS M8-1.25X16 C8.8 ZY DIN931 2 8 203324 COVER 1 9 203325 COVER 1 10 163634 WASHER 6 11 205502 SPACER 1 12 656149 CS M6-1X16 C8.8 ZY DIN931 3 13 161675 LOCKWASHER S6 3 14 161660 WASHER GR A6.4 ZO DIN 125 3 15 179784 SCREW 4 16 163670 LOCKWASHER 9 17 203326 DISTRIBUTOR 1 18 656105 CS M8-1.25X25 C8.8 ZY DIN931 3 19 7462680011 WASHER 8.4 ST A2C 3 Ref. No. Part No. Description Qty.

Gehl 803 parts manual. s/n AC02528 and up

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