GE1202. Compact Excavator

Transcription

1 GE1202 Form No Compact Excavator PARTS MANUAL

2 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. From this position, the cab is on the left and the hydraulic valve compartment is on the right. 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 In the exploded view parts list, Reference Numbers may have additional information following the Reference Number. Unless otherwise specified, all Cap Screws or Bolts are Grade 5, cadmium or zinc plated; Hexagon Nuts for Grade 5 Screws or Bolts are Grade B; Hexagon Nuts for other Screws or Bolts are Grade A. NOTE: The following abbreviations may be used herein: CP Cotter Pin CS Cap Screw (Hexagon Head) FHCS Flat Head Cap Screw HN Hex Nut LN Lock Nut LT Left Hand M Metric MM/mm Millimeter RT Right

3 TABLE OF CONTENTS Introduction Inside Front Cover Decal Locations Undercarriage, Steel Tracks Bottom Roller Top Roller Steel Track Track Tensioner Undercarriage, Rubber Track Roller Track Tensioner, Rubber Track Dozer Blade Upper Carriage Chassis Cover Lubrication Rear Wall Side Cover Counterweight Hood Valve Body Cover Tank Cover Boom Arm Dipper Arm Connecting Link Cabin Frame Cabin Frame Cabin Frame Main Harness Windshield Cabin Windows Sliding Side Window Cabin Door Cabin Mats Heater Seat Heater Box Engine Fan, Water Pump & Thermostat Gasket Set & Cylinder Hone Engine Alternator & Starter Oil Filter & Pan Fuel Tank Fuel Injection System Fuel Pump Hand Throttle Motor Mounts Radiator Air Cleaner Exhaust Hydraulic Pump Drive Hydraulic Oil Tank Hydraulic Pump Track Drive Swivel Joint Swivel Joint Breakdown Swivel Drive Main Control Valve Double Control Valve Pilot Supply Unit Stop Valve Selection Valve Valve Distribution Block Hand Controls Travel Valve Dozer Valve Auxiliary Hydraulics Valve Boom Cylinder Dipper Cylinder Bucket Cylinder Dozer Cylinder Boom Offset Cylinder Hoses, Oil Cooler Hoses, Hydraulic Pump Hoses, Track Drive Hoses, Hydraulic Pump Hoses, Control Return Valves Hoses, Boom Offset Cylinder Hoses, Dozer Blade Cylinder Hoses, Auxiliary Hydraulics Hoses, Hand Controls Hoses, Check Valves Hoses, Boom Hoses, Boom Cylinders Hoses, Dipper Arm Hoses, Stall Warning Device Electrical, Battery & Mount Electrical, Engine Harness Electrical, Chassis Harness Electrical, Left Armrest Electrical Right Armrest Electrical, Relay Plate Electrical, Lights Electrical, Boom Work Light Tool Kit Alphabetical Index Numerical Index Torque Chart Inside Rear Cover Printed in U.S.A /AP0601

4 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 shown decal (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 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 your unit. PAINT NOTICE Use this list to order paint for refinishing: One Gal. Construction Yellow One Qt. Charcoal Grey One Gal. Charcoal Grey (12 oz. Spray Cans) Yellow (12 oz. Spray Cans) Grey The decal kit for the GE1202 Compact Excavator is listed below: Ref. Part No. No. Description & Quantity Decal Kit - GE Diesel Fuel Hydraulic Oil Lubrication WARNING Hydraulic Reservoir Arrow (2 places) Lift Point (4 places) Tiedown Point (4 places) WARNING Keep Away (2 places) WARNING Read Manual WARNING Engine Fan Dozer Blade Travel Left Travel Right Right Joystick Control Left Joystick Control Left Graphic Right Graphic Hydraulics Compartment Latch (2 places) WARNING Mandatory Shutdown Manual Throttle WARNING Avoid Injury WARNING Avoid Injury WARNING Entanglement Hazard WARNING Hot Surface Valve Position Joystick Throttle Engine Compartment Latch WARNING Avoid Injury IMPORTANT Do Not Pressure Wash Color Bar (2 places) GEHL GEHL (2 places) GEHL GEHL (2 places) GE1202 (2 places) /AP Printed in U.S.A.

5 t Printed in U.S.A /AP0701

6 The decal listing has been repeated for your convenience. The decal kit for the GE1202 Compact Excavator is listed below: Ref. Part No. No. Description & Quantity Decal Kit - GE Diesel Fuel Hydraulic Oil Lubrication WARNING Hydraulic Reservoir Arrow (2 places) Lift Point (4 places) Tiedown Point (4 places) WARNING Keep Away (2 places) WARNING Read Manual WARNING Engine Fan Dozer Blade Travel Left Travel Right Right Joystick Control Left Joystick Control Left Graphic Right Graphic Hydraulics Compartment Latch (2 places) WARNING Mandatory Shutdown Manual Throttle WARNING Avoid Injury WARNING Avoid Injury WARNING Entanglement Hazard WARNING Hot Surface Valve Position Joystick Throttle Engine Compartment Latch WARNING Avoid Injury IMPORTANT Do Not Pressure Wash Color Bar (2 places) GEHL GEHL (2 places) GEHL GEHL (2 places) GE1202 (2 places) /AP Printed in U.S.A.

7 Both Sides 6 6 Both Sides Both Sides 7 7 Printed in U.S.A /AP0701

8 The decal listing has been repeated for your convenience. The decal kit for the GE1202 Compact Excavator is listed below: Ref. Part No. No. Description & Quantity Decal Kit - GE Diesel Fuel Hydraulic Oil Lubrication WARNING Hydraulic Reservoir Arrow (2 places) Lift Point (4 places) Tiedown Point (4 places) WARNING Keep Away (2 places) WARNING Read Manual WARNING Engine Fan Dozer Blade Travel Left Travel Right Right Joystick Control Left Joystick Control Left Graphic Right Graphic Hydraulics Compartment Latch (2 places) WARNING Mandatory Shutdown Manual Throttle WARNING Avoid Injury WARNING Avoid Injury WARNING Entanglement Hazard WARNING Hot Surface Valve Position Joystick Throttle Engine Compartment Latch WARNING Avoid Injury IMPORTANT Do Not Pressure Wash Color Bar (2 places) GEHL GEHL (2 places) GEHL GEHL (2 places) GE1202 (2 places) /AP Printed in U.S.A.

9 Both Sides Printed in U.S.A /AP0701

10 GE1202 UNDERCARRIAGE, STEEL TRACKS UNDERCARRIAGE TURNTABLE STEEL CHAIN TRACK DRIVE UNIT SPROCKET SHCS HS M X WASHER/NORD LOCK NL 16 STUCK TRACK TENSIONING COMPLETE NON RETURN VALVE SCREW SEAL ROLLER COMPLETE SCREW TENSION CYLINDER ROLLER COMPLETE CS M X 20 C WASHER/ROUND COVER SHCS HS M X RING/SNAP S WASHER/GR A COVER WASHER/NORD LOCK NL WASHER/GR A SPRING SET TENSION WHEEL + SLIDE PART COVER LEFT COVER RIGHT SHCS HS M8 1.2 X RING/SNAP S PLUG LUBRICATION NIPPLE PROTECTION CAP SECTION CS M X 30 C WASHER/NORD LOCK NL SCREW SEALS TRACK TENSION CYL BRACKET CHAIN GUARD LEFT CHAIN GUARD RIGHT WASHER/ROUND HI TENS SCREW /AP Printed in U.S.A.

11 GE BOTTOM ROLLER ROLLER SHAFT SHAFT BUSHING O RING SEAL BRACKET BRACKET O RING COTTER PIN SEAL KIT Printed in U.S.A /AP0701

12 GE1202 TOP ROLLER ROLLER ROLLER SHAFT PLUG O RING SEAL SEAL COVER COVER WASHER SEAL KIT /AP Printed in U.S.A.

13 GE STEEL TRACK LINK RIGHT LINK LEFT PIN BUSHING BUSHING SEAL WASHER PIN SCREW NUT BOTTOM COVER Printed in U.S.A /AP0701

14 GE1202 TRACK TENSIONER TENSION WHEEL SHAFT BUSHING SEAL COTTER PIN BRACKET SEAL O RING PLUG SEAL FORK SCREW PLUG WASHER SCREW PLATE SPRING BRACKET COTTER PIN NUT SEAL KIT /AP Printed in U.S.A.

15 GE UNDERCARRIAGE, RUBBER TRACK UNDERCARRIAGE TURNTABLE RUBBER CHAIN TRACK DRIVE UNIT SPROCKET SHCS HS M X WASHER/NORD LOCK NL 16 STUCK TRACK TENSIONING COMPLETE NON RETURN VALVE SCREW SEAL ROLLER COMPLETE SCREW TENSION CYLINDER ROLLER COMPLETE CS M X 20 C WASHER/ROUND COVER SHCS HS M X RING/SNAP S WASHER/GR A COVER WASHER/NORD LOCK NL WASHER/GR A SPRING SET TENSION WHEEL + SLIDE PART COVER LEFT COVER RIGHT SHCS HS M8 1.2 X RING/SNAP S PLUG LUBRICATION NIPPLE PROTECTION CAP SECTION CS M X 30 C WASHER/NORD LOCK NL SCREW SEALS TRACK TENSION CYL Printed in U.S.A /AP0701

16 GE1202 ROLLER ROLLER COMPLETE ROLLER (INCL. BUSHING, #5) ROLLER LOCK SCREW BUSHING AXLE COTTER PIN SEAL WASHER O RING O RING BRACKET /AP Printed in U.S.A.

17 GE TRACK TENSIONER, RUBBER TRACK TENSION WHEEL SHAFT BUSHING SEAL COTTER PIN BRACKET SEAL O RING PLUG SEAL FORK SCREW PLUG WASHER SCREW PLATE SPRING BRACKET COTTER PIN NUT SEAL KIT Printed in U.S.A /AP0701

18 GE1202 DOZER BLADE DOZER BLADE PIN DM=70X BUSHING 85/70X PIN SEAL SCREW HLN INS M LUBRICATION NIPPLE PROTECTION CAP DOZER BLADE CYLINDER COMPLETE /AP Printed in U.S.A.

19 GE UPPER CARRIAGE CHASSIS SWING BRACKET BUSHING 120/105x PIN DM=105X WASHER BOOM OFFSET CYLINDER PIN DM=75X PIN COVER CS M X 30 C RING/SNAP S WASHER/GR A 13 ZO PIN LUBRICATION NIPPLE PROTECTION CAP REFLECTOR RIVET/BLIND A4 X 12 DIN TURNTABLE SCREW WASHER ROTARY ACTUATOR COMPLETE SCREW WASHER BRACKET SHCS HS M X ISOLATION MAT GLUE ISOLATION MAT ISOLATION MAT Printed in U.S.A /AP0701

20 GE1202 CHASSIS COVERS COVER COVER COVER COVER COVER CS M8 1.2 X 20 C RING/SNAP S WASHER/GR A COVER NUT/CAGE M /AP Printed in U.S.A.

21 GE LUBRICATION LUBRICATION NIPPLE BLOCK SHCS HS M6 1 X RING/SNAP S SCREW LUBRICATION NIPPLE PROTECTION CAP SCREW JOINT HP HOSE GRUB SCREW Printed in U.S.A /AP0701

22 GE1202 REAR WALL REAR WALL PLATE SCREW FCHC HS M5 0.8 X NUT/CAGE M BRACKET QUICKLOCK/HEXAGON WASHER/QUICK LOCK QUICKLOCK/LOWER RIVET/BLIND A3 X 12 DIN SHCS HS M5 0.8 X CS M X 25 C RING/SNAP S WASHER/GRA CS M X 30 C RING/SNAP S WASHER/GR A CS M X 20 C AIR DUCT COVER HB M12 1.7X 60 C ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT ISOLATION MAT CS M8 1.2 X 16 C RING/SNAP S WASHER/GR A NUT/CAGE M COVER TOOL BOX BRACKET NUT CS M8 1.2 X 20 C CS M8 1.2 X 25 C /AP Printed in U.S.A.

23 GE SIDE COVER SIDEFLAP BRACKET HINGE BRACKET CS M8 1.2 X 30 C RING/SNAP S WASHER/GR A 8.4 ZO COUNTERWEIGHT COLLAR WASHER/GR A 8.4 ZO NUT/CAGE M RUBBER PROFILE CS M5 0.8 X 20 C HANDLE SCREW FCHC HS M X HN M BRACKET CS M8 1.2 X 16 C BRACKET CS M8 1.2 X 20 C CS M6 1.0 X 16 C RING/SNAP S WASHER/GR A BRACKET CABLE UPPER WINDSCREEN FRAME HLN INS M HAND LEVER WASHER/GR A RING/SNAP S WASHER/GR A HN M RUBBER BELLOWS ANGLE Printed in U.S.A /AP0701

24 GE1202 COUNTERWEIGHT COUNTERWEIGHT WASHER/ROUND CS M X 70 C BRACKET BRACKET CS M6 1.0 X 16 C RING/SNAP S LW SPRING CS M X 25 C RING/SNAP S WASHER/GR A CABLE UPPER WINDSCREEN FRAME HN M HAND LEVER COVER FRAME REFLECTOR RIVET/BLIND A4 X HB M8 1.2 X 40 C WASHER/GR A BELLOWS WINDSCREEN WASHING CLAMP SHCS HS M5 0.8 X WASHER/GR A ANGLE /AP Printed in U.S.A.

25 GE HOOD BONNET ISOLATION MAT BRACKET HINGE BRACKET CS M8 1.2 X 30 C RING/SNAP S WASHER/GR A PNEUMATIC SPRING HN M HANDLE SCREW FCHC HS M X HN M BRACKET WASHER/GR A CS M8 1.2 X 16 C RUBBER SEAL Printed in U.S.A /AP0701

26 GE1202 VALVE BODY COVER VALVE COVER PNEUMATIC SPRING HINGE HINGE HN M BRACKET CS M8 1.2 X 30 C RING/SNAP S WASHER/GR A BRACKET BRACKET BRACKET CS M X 20 C RING/SNAP S WASHER/GRA BRACKET CS M6 1.0 X 16 C RING/SNAP S WASHER/GR A CABLE UPPER WINDSCREEN FRAME HLN INS M WASHER/GR A HAND LEVER RUBBER CS M X 30 C WASHER/GR A SCREW HLN INS M HANDLE SCREW FCHC HS M X SCREW BRACKET CS M8 1.2 X 16 C RING/SNAP S WASHER/GR A RING/SNAP S WASHER/GR A BRACKET BELLOWS ANGLE /AP Printed in U.S.A.

27 GE TANK COVER HOSE COVER SEAL TANK COVER COVER COVER VALVE BRACKET CS M X 30 C RING/SNAP S WASHER/GR A NUT/CAGE M CS M8 1.2 X 20 C RING/SNAP S WASHER/GR A CS M X 50 C CS M X 25 C NUT/CAGE M CS M8 1.2 X 35 C WASHER/GR A THREADED PIECE BRACKET Printed in U.S.A /AP0701

28 GE1202 BOOM ARM BOOM PIN DM=75X BUSHING 90/75X WASHER SEAL SCREW NUT PIN DM=70X PIN DM=70X BRACKET SCREW HLN INS M LUBRICATION NIPPLE WASHER BOOM CYLINDER COMPLETE /AP Printed in U.S.A.

29 GE DIPPER ARM DIPPER ARM PIN DM=75X BUSHING 90/75X WASHER PIN SEAL SCREW NUT PIN DM=70X BUSHING 75/60X WASHER PIN SEAL LUBRICATION NIPPLE WASHER DIPPER ARM CYLINDER COMPLETE PIN DM=60X DIGGING TOOTH SAFETY BOLT PRE ASSEMBLED DIPPER ARM Printed in U.S.A /AP0701

30 GE1202 CONNECTING LINK CONNECTING LINK CONNECTING LINK LEFT CONNECTING LINK RIGHT PIN DM=60X PIN DM=65X PIN COVER BUSHING 80/65X LUBRICATION NIPPLE PROTECTION CAP PIN DM=65X SCREW NUT PIN DM=60X PIN SEAL BUSHING 75/60X WASHER BUCKET CYLINDER COMPLETE SHCS HS M X RING/SNAP S PRE ASSEMBLED CONNECTING LINK /AP Printed in U.S.A.

31 GE CABIN FRAME CABIN FRAME ASHTRAY WATER HOSE PLUG SWIVEL JOINT BRACKET PLATE BRACKET DOOR LOCK WIPER ENGINE COVER FOR WIPER ENGINE BRUSH HOLDER WIPER BLADE CLIPS WATER HOSE WATER HOSE NOZZLE NON RETURN VALVE ILLUMINATION LAMP PLUG MIRROR CS M6 1.0 X 16 C NUT COVER RADIO FRAME FUSE SPEAKERS 40W NUT COVER COVER Printed in U.S.A /AP0701

32 GE1202 CABIN FRAME PROFILE RUBBER PROFILE RUBBER PROFILE LOCK LOCK SCREW BRACKET BRACKET CS M6 1.0 X 30 C NUT RESILIENT PAD RUBBER PLUG SCREW FIXING HLN INS M IGNITER AIR NOZZLE AIR NOZZLE WASHER PLATE 10X BRACKET SCREW COVER PLATE CS M6 1.0 X 12 C STICKER STICKER STICKER /AP Printed in U.S.A.

33 GE CABIN FRAME SHIELD SCREW/PAN HEAD TAP GUTTER GUTTER SCREW BRACKET LEFT CS M8 1.2 X 16 C WASHER/GR A 8.4 ZO DIN BRACKET RIGHT SEAL HLN INS M SUPPORT SUPPORT HB M X 100 C WASHER/GR A13 DIN134 ZO HLN INS M CUSHION BRACKET PLATE 10X NUT HLN INS M SILICON GLUE AKTIVATOR REMOVER EDGE PROTECTION Printed in U.S.A /AP0701

34 GE1202 MAIN HARNESS MAIN HARNESS WIRING CABLE CLIP SLOTTED INSULATING TUBE /AP Printed in U.S.A.

35 GE WINDSHIELD FRONT WINDOW RUBBER PLUG LOWER WINDSCREEN FRAME SCREW SCREW FCHC HS M8 1.2 X WIPER BLADE RUBBER WASHER RUBBER WASHER WASHER/GR A 8.4 ZO DIN NUT/HEX DOMED CAP M PVC WASHERS EDGE PROTECTION SUN VISOR SCREW SILICON GLUE AKTIVATOR REMOVER PVC WASHER RUBBER BUFFER STICKER WINDSCREEN Printed in U.S.A /AP0701

36 GE1202 CABIN WINDOWS FRONT WINDOW FRONT WINDOW PVC WASHER RUBBER WASHER RUBBER WASHER NUT STRAP HN M RUBBER PROFILE LEFT SIDE PANE SIDE PANE RUBBER PROFILE REAR WINDOW SILICON GLUE AKTIVATOR REMOVER HOSE PROFILE FRONT WINDOW /AP Printed in U.S.A.

37 GE SLIDING SIDE WINDOW SLIDING SIDE PANE LOCK SILICON GLUE AKTIVATOR REMOVER Printed in U.S.A /AP0701

38 GE1202 CABIN DOOR FRAME OF A DOOR LOCK SCREW HLN INS M HANDLE SHIM SHIM KEY LOCK COVER RUBBER PROFILE DOOR WINDOW HLN INS M COVER CS M6 1.0 X 20 C WASHER SCREW HLN INS M WASHER DOOR LOCK RIVET 11MM STICKER STICKER WASHER CABIN DOOR LEFT COMPLETE /AP Printed in U.S.A.

39 GE CABIN MATS COVER COVER COVER COVER SEAT CONSOLE COVER SEAT CONSOLE COVER LEFT ROOF COVER MAT COVER REAR WALL RIVET 11MM RIVET 20MM FOOT MAT FOOT MAT COVER SCREW Printed in U.S.A /AP0701

40 GE1202 HEATER CAB HEATER BRACKET FOR CAB HEATING SCREW CABIN CS M8 1.2 X 16 C RING/SNAP S WASHER/GR A 8.4 ZO NUT/CAGE M CS M6 1.0 X 20 C RING/SNAP S WASHER/GR A 6.4 ZO DIN PROTECTION HOSE STICKER CAB HEATING HOSE CAB HEATING HOSE SCREW JOINT HOSE COVER NUT WASHER ANGLE SCREW JOINT NOZZLE PROTECTION HOSE VALVE BOWDEN CONTROL KNOB CLIP COLLAR RING/SNAP S WASHER/GR A 6.4 ZO DIN NUT/CAGE M CS M6 1.0 X 20 C RUBBER BUSHING BRACKET/MOUNTING /AP Printed in U.S.A.

41 GE SEAT PROFILE RUBBER METAL BUFFER FIXING PLATE COVER SEAT BELT CS M8 1.2 X 20 C RING/SNAP S WASHER LIMIT CONTROL LEVER CONSOLE ARMREST HANDLE CONSOLE RIGHT CONSOLE LEFT COVER PLUG HLN M PNUEMATIC SPRING TUBE PIN NUT/HEX DOMED CAP M QUICK FIX CS M6 1.0 X 12 C RING/SNAP M WASHER/GR A SHCS HS M8 1.2 X PIN PIN PIN WASHER/GR A HLN INS M MICRO SWITCH NUT/CAGE M NUT WASHER WASHER/GR A LW M HN M SHSS M8 X 12 45H CP SCREW/C SUNK HD M5 X Printed in U.S.A /AP0701

42 GE1202 HEATER BOX CASE AIR CONDITIONING PLANT BRACKET BRACKET AIR NOZZLE KNOB M8 X AIR CONDITIONING PLANT CAB HEATING CONSOLE /AP Printed in U.S.A.

43 GE ENGINE FAN, WATER PUMP & THERMOSTAT VENTILATOR SCREW SPACER PULLEY BELT SCREW SCREW WATER PUMP COMPLETE SEAL THERMO SWITCH SEAL SCREW SCREW THERMOSTAT HOUSING PLUG SEAL SEAL THERMOSTAT SEAL COVER PLATE SCREW THERMOSTAT HOUSING COMPLETE PLUG SEAL Printed in U.S.A /AP0701

44 GE1202 GASKET SET & CYLINDER HONE SEAL KIT CYLINDER HEAD SEAL O RING SEAL SEAL THERMAL SHIELD SEAL SEAL VALVE COVER SEAL SEAL SEAL SEAL SEAL SEAL SEAL SEAL SEAL SEAL SEAL SEAL SEAL SEAL SEAL SEAL SEAL O RING O RING O RING O RING O RING O RING O RING BRUSH LIQUID SEAL /AP Printed in U.S.A.

45 GE ENGINE ALTERNATOR & STARTER BRACKET LINK NUT JOINT STOP SOLENOID NUT WASHER SNAP PIN SCREW SCREW GENERATOR SPACER STARTER SCREW ADJUSTER SCREW SPACER SCREW WASHER NUT Printed in U.S.A /AP0701