This is the Gehl service manual for the 502, 602, and 652 compact excavators, powered by the Yanmar 4TNE88-ENSW and 4TNE98-NSR diesel engines. Its 148 pages carry a high quality scan with clear diagrams and specification tables.Coverage spans technical data and lift capacity charts, maintenance schedules and lubrication, the full hydraulic system (pump, pilot oil supply unit, main valve block, pilot control valves, swivel and drive units), the diesel engine, wiring diagrams, and a torque specification chart.Owners and independent mechanics can use it to set hydraulic pressures, service the engine, trace the electrical system, and rebuild the drive and swivel units. Main relief pressure is 3336 psi on the 502 and 3553 psi on the 602 and 652. The manual is a searchable PDF, available for instant download and easy to print by the page.
What's Inside This Gehl 502, 602, 652 Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Data | 5-20 | Dimensions, Primary Dimensions / Performance, Bucket and Geometry, Lift Capacity Charts, Model Ge 502, Model Ge 602, Lift Capacity Chart, Model 502 Lift Capacity |
| Maintenance | 21-58 | Maintenance Schedule Gehl 502 - 602, Maintenance - General, Lubricants, Lubrication Chart |
| Hydraulic | 59-110 | Hydraulic System, Position of Components, Hydraulic Pump, Pilot Oil Supply Unit, Main Valve Block, Pilot Control Valves, Swivel Unit, Shuttle Valve Block |
| Diesel Engine | 111-116 | Diesel Engine Specifications (Important Diesel Engine Service Items – Model 602), Fuel Line Diagram, Battery (Cooling Water Line) |
| Electrical | 117-144 | Electrical Diagram, Legend Wiring Diagram 502 - 602, Relay Position 502, Plug Timer Relay for Pull Wiring, Starter Relay, Relay 602, Solenoid Stop Plug, Solenoid Stop Relay Plug |
| Torque Specifications | 145-148 | Hydraulic Fittings with Various Seals, With Coarse-Pitch Thread. All Torque Values Are in Lb.-Ft. Unless Marked Otherwise. |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| General Torque Specifications Location | Page 145 | p. 145 |
| Drive motor torque | 132.7 ft-lbs. (180 Nm) | p. 105 |
| Ground clearance | 1'-1" (340 mm) | p. 7 |
| Pilot oil pressure | 508 psi (35 bar) | p. 16 |
| 502 | ||
| Clearance S for Dozer Blade Cylinder (Hose burst protection valve) | 0.047" (1.2 mm) | p. 17 |
| Main pressure limiting valve Pump P1, P2 setting | 3336 psi (230 bar) | p. 16 |
| Hydraulic oil tank capacity | 16.1 gals. (61 L) | p. 16 |
| Main pressure limiting valve Pump P1, P2 | 3336 psi (230 bar) | p. 16 |
| 602, 652 | ||
| Clearance S for Dozer Blade Cylinder (Hose burst protection valve) | 0.059" (1.5 mm) | p. 17 |
| Main pressure limiting valve Pump P1, P2 setting | 3553 psi (245 bar) | p. 16 |
| 602/652 | ||
| Hydraulic oil tank capacity | 21.1 gals. (80 L) | p. 16 |
| Main pressure limiting valve Pump P1, P2 | 3553 psi (245 bar) | p. 16 |
Gehl 502, 602, 652 Common Problems This Manual Covers
Weak, slow, or noisy hydraulics
Hydraulic functions that turn weak, slow, or noisy, sometimes with overheating, usually follow fluid loss, contamination, or worn hoses and seals. The Hydraulic section covers the pump, pilot oil supply, main valve block, and pilot control valves, with the main relief valve set to 3336 psi on the 502 and 3553 psi on the 602 and 652.
Manual Section: Hydraulic p. 59Final drive loses power or stalls one side
A loss of travel power or a track that stops on one side often means final drive motor wear or contamination. The Hydraulic section covers the drive unit and swivel joint, including the drive motor with its rated torque of 132.7 ft-lbs (180 Nm).
Manual Section: Hydraulic p. 59Tracks run too tight or too loose
Incorrect track tension and worn idlers or rollers cause frequent de-tracking and rapid wear. The Maintenance section covers the undercarriage along with the service schedule that keeps track deflection in the correct range.
Manual Section: Maintenance p. 21Boom or bucket develops excessive play
Jerky movement or slop in the boom, arm, and bucket usually points to dry or worn pins and bushings. The Maintenance section covers greasing and the lubrication chart that keep these joints tight.
Manual Section: Maintenance p. 21Hard starting or electrical faults
No-start and intermittent electrical problems trace to the battery, relays, or wiring. The Electrical section gives the wiring diagram, relay positions, starter relay, and solenoid stop circuit for the 502 and 602 to isolate the fault.
Manual Section: Electrical p. 117Engine runs rough or underpowered
Rough running or low power can come from fuel delivery or engine wear. The Diesel Engine section gives the engine specifications, fuel line diagram, and cooling water line details needed to service the Yanmar power unit.
Manual Section: Diesel Engine p. 111Frequently Asked Questions
Which models and engines does this manual cover?
It covers the Gehl 502, 602, and 652 compact excavators, powered by the Yanmar 4TNE88-ENSW and 4TNE98-NSR diesel engines.
Is this the complete service manual?
Yes. Its 148 pages cover technical data, maintenance, the hydraulic system, the diesel engine, the electrical system, and a torque specification chart, with wiring diagrams and lift capacity charts.
What are the hydraulic pressure settings?
The Technical Data section lists the hydraulic settings, including a main pressure limiting valve of 3336 psi (230 bar) on the 502 and 3553 psi (245 bar) on the 602 and 652, with pilot oil pressure at 508 psi (35 bar). p. 5
Where are the torque specifications?
The Torque Specifications section lists tightening values for hydraulic fittings and coarse-pitch thread fasteners, given in lb-ft unless marked otherwise. p. 145
How quickly can I access this Gehl 502, 602, 652 manual after buying?
Your download starts immediately: the full 148-page searchable Service Manual. Open it on any device, whether that's a laptop at the desk or a phone in the field.
Are there any print restrictions on this Gehl 502, 602, 652 manual?
No restrictions at all. Print individual pages, full chapters, or the entire manual. The PDF is completely unlocked.
Are there wiring harness diagrams in this Gehl 502, 602, 652 manual?
Yes, this Gehl 502, 602, 652 Service Manual includes complete electrical wiring diagrams, wire routing, and connector pinouts.
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