rs5-34 operator manual - midtn equipment & services

Form No.

913227

OPERATOR’S MANUAL

RS5-34

TelescopicHandlerBeginning with Serial Number 12101

®

Indicator and Operation Symbols

Read Operator’sManual

Turn SignalsParking Brake Safety Alert

Fuel

Lights

Volume Half FullVolume Full

Engine OilPressure

Hazard Flasher

Battery

Work Lights

Clutch Disengaged

TransmissionTemperature

Fan

Frame Level Left

Crab Steer

Lower Load

2-Wheel Steer

Raise Load

4-Wheel Steer

Engine CoolantTemperature

Hourmeter

Retract Load

Volume Empty

Starting AidInjection

Tilt Rearward

Wiper/Washer

Extend LoadTilt Forward

Hydraulic OilEngine Start Horn

Frame Level Right

Clutch Engaged

Ignition Off Ignition ON

Outriggers Down(right side shown)

Outriggers Up(right side shown)

Brake Failure

Diesel Fuel Engine FaultShutdown Override

PRINTED IN U.S.A. 1 913227/AP0505

Table of ContentsChapter Description Page

International Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Check Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Indicators and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236 Operation and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438 Service and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .469 Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6110 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76Standard Hardware Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Back Cover

IDENTIFICATION INFORMATION

Write your Gehl Telescopic Handler Serial Number below.Refer to the model and serial number when inquiring about parts or service from your Gehl dealer.

The model and serial numbers for this machine are on a decal located inside the operator’s station.

MODEL NO. RS5-34

SERIAL NO.

913227/AP0505 2 PRINTED IN U.S.A.

The information in this Operator’s Manual was written to give the owner/operator assistance in preparing, adjust-ing, maintaining and servicing of the Telescopic Handler. More importantly, this manual provides an operating planfor safe and proper use of the machine. Major points of safe operation are detailed in the SAFETY chapter of thismanual.

The Gehl Company asks that you read and understand the contents of this manualCOMPLETELY and become familiar with your new machine, BEFORE operating it.

This Telescopic Handler is primarily intended for use as a material handler. However, it may be equipped with anoptional system: the Personnel Work Platform (PWP) System, which is intended for use when lifting personnel.When there is no other practical option available, this machine, when equipped with the PWP System, is approvedfor use to lift personnel, but only with an approved work platform, with the PWP System activated, and in full com-pliance with the “Mandatory Work Platform Safety Rules” (see SAFETY chapter).

The use of this Telescopic Handler is subject to certain hazards that cannot be eliminated by mechanical means,but only by the exercise of intelligence, care and common sense. It is therefore essential to have competent andcareful operators, who are not physically or mentally impaired, and who are thoroughly trained in the safe opera-tion of the equipment and the handling of the loads.

Throughout this manual information is provided that is set in italic type and introduced by the word IMPORTANTor NOTE. Be sure to read carefully and comply with the message or directive given. Following this informationwill improve operating or maintenance efficiency, help to avoid breakdowns or damage, and extend the machine’slife. A chart of standard hardware torques is located in the back of this manual.

A storage pocket in the back of the seat is provided for storing the Operator’s Manual. After using the manual,please return it to the pocket and keep it with the unit at all times! If this machine is resold, Gehl Company rec-ommends that this manual be given to the new owner.

If this machine was purchased “used,” or if the owner’s addrress has changed, please provide your Gehl dealer orGehl Company Service Department with the owner’s name and current address, along with the machine model andserial number. This will allow the registered owner information to be updated, so that the owner can be notifieddirectly in case of and important product issue, such as a safety update program.

“Right” and “left” are determined from a position sitting on the seat and facing forward.

Our wide dealership network stands ready to provide any assistance required, including providing genuine Gehlservice parts. All parts should be obtained from or ordered through your Gehl dealer. Give complete informationabout the part, and include the model and serial number of the machine. Record the serial number in the space pro-vided on the previous page, as a handy record for quick reference.

Gehl Company reserves the right to make changes or improvements in the design or construction of any part with-out incurring the obligation to install such changes on any unit previously delivered.

Chapter 1INTRODUCTION

The Gehl Company, in cooperation with the Society of AutomotiveEngineers, has adopted this

Safety Alert Symbolto pinpoint characteristics which, if NOT properly followed, can create asafety hazard. When you see this symbol in this manual or on the machineitself, you are reminded to BE ALERT! Your personal safety is involved!


Identification

Telescopic Boom

Operator’s Station

Quick-attachSystem

Tilt Cylinder

Slave Cylinder

Dash Indicatorsand Controls

Seat

Fuel Tank

Access Cover withRear Lights andBackup Alarm

Rear BoomAccess Cover

Lift Cylinder

Frame LevelingCylinderHydraulic Tank

Extend Cylinder

Air Cleaner

Exhaust Pipe

AuxilluaryHydraulics

(not shown)

Boom AngleIndicator

Side ViewMirror


Chapter 2SPECIFICATIONS

Lifting PerformanceMaximum lift capacity:

6000 lbs. (2721 kg)

Maximum lift height:34’-3” (10.44 m)

Capacity at maximum lift height:4000 lbs. (1820 kg)

Max. forward reach to load center:23’-3” (7.09 m)

Capacity at maximum forward reach:900 lbs. (408 kg)

Maximum below grade reach:24” (610 mm)

Frame leveling:10o left/10o right

General DimensionsBased on standard machine equippedwith listed tires, 48” masonry carriageand 48” pallet forks.

Recommended tire type:15.00 x 19.5 12-ply405/70 R 20 x M27 Traction Type

Overall length, less forks:16’-0” (4.88 m)

Overall width:7’-10” (2.39 m)

Overall height:7’-9” (2.36 m)

Ground clearance: 14” (356 mm)Wheel base: 9’-2” (2.8 m)Outside turn radius: 12’-6” (3.81 m)

Machine weight:15,100 lbs. (6855 kg)

InstrumentationGauges: Fuel level, hourmeter

and coolant temperatureMonitoring lights:

Engine oil pressure, alternator,transmission oil temperature,brake failure

Visual indicators:Boom angle, frame angle

Steering SystemSteer Valve: Fixed displacement rotaryDisplacement/Rev: 17.9 cu. in. (293 cc)System pressure: 2000 psi (138 bar)Steer cylinders: 1 per axleSteer mode valve:

3-position, 4-way solenoid withdash-mounted switch actuation

Steer modes: 2-wheel, 4-wheel, crab

Braking SystemService brakes: Oil-immersed inboard

hydraulic wet-disc type; separate front and rear systems;Manual foot pedal actuation

Parking brake: Spring-applied, hydraulic-release disc-type in front axle

Actuation is electric switch with enginerunning, automatic with engine off.

Electrical SystemType: 12-volt, negative groundBattery: 950 cold cranking ampsCircuit protection: Fuse panelBackup alarm: 107 dB(A)Horn: 111 dB(A)Standard on all models:

Brake lights, rear backup light, neutral start switch

Alternator: 65-amp

Service CapacitiesCooling System: 4.3 gallons (16.3 L)

50/50 mixtureAnti-freeze protection: -34oF (-31oC)Pressure cap: 10 psi (69 kPa)

Fuel tank: 29 gals. (110 L)Hydraulic tank and

system: 35 gals. (133 L)Transmission and cooler: 24 qts. (22.7 L)Axles:

Differentials: 9.6 qts. (9 L) ea.Hubs: 0.6 qts. (0.5 L) ea.

TransmissionType: Clark Powershift T12000

Speeds: 3 fwd / 3 revTorque converter:

Single stage, dual phase

Travel Speeds:1st gear: 3.6 mph (5.8 km/h)2nd gear: 7.9 mph (12.7 km/h)3rd gear: 20.2 mph (32.5 km/h)

Axles (front and rear)Type: Hurth

Drive/steer, open differential, doublereduction planetary, full-time four-wheel drive

Overall ratio: 15.4:1

Engine OptionsCommon to all options:

In-line 4-cycle, 4-cylinder, direct-injection diesel fuel system, in-linefuel filter w/water trap, positivepressure lubrication, liquidpressurized cooling system,18” (457 mm) blower fan,dry single-element air cleaner,spin-on oil filter.

Turbocharged aspiration:John Deere 4045T276 cu. in. (4523 cc) displacement99 hp (74 kW) @ 2500 rpmOil capacity: 14 qts. (13.3 L)

Turbocharged aspiration:John Deere 4045T276 cu. in. (4523 cc) displacement115 hp (86 kW) @ 2500 rpmOil capacity: 14 qts. (13.3 L)

Hydraulic SystemType: Open-centerPump: Single-section gear type

Displacement / revolution:2.7 cu. in. (44.3 cc)

Flow @ 2500 RPM:29 gpm (110 L/min)

Main relief pressure:3000 psi (207 bar)

Steer relief pressure:2000 psi (138 bar)

Hydraulic filter:In-tank return type, 10 micronmedia, replaceable element.Rated flow: 100 gpm (379 L/min)Rated pressure: 100 psi (690 kPa)By-pass pressure (full flow):25 psi (172 kPa)

Hydraulic strainer:In-tank suction, 149 micron media,replaceable element.Rated flow: 50 gpm (189 L/min)By-pass pressure: 3 psi (21 kPa)


Chapter 3CHECKLISTS

PRE-DELIVERYThe following Checklist is an important reminder of inspec-tions that MUST be made before delivering the TelescopicHandler to the customer. Check off each item after pre-scribed action is taken.

Check that:NO parts of machine have been damaged in shipment.Check for such things as dents and loose or missing parts;correct or replace components as required.Battery is securely mounted and not cracked. Cable con-nections are tight. Electrolyte at proper level.Cylinders, hoses and fittings are not damaged, leaking orloosely secured.Oil, fuel and air filters are not damaged, leaking or looselysecured.All grease fittings have been properly lubricated and no fit-tings are missing; see LUBRICATION chapter of this man-ual.Wheel nuts are torqued to 450 ft-lbs (610 Nm).Tires are inflated to 55 psi (380 kPa) cold.Hydraulic system reservoir, engine crankcase, enginecoolant, transmission and axles are filled to the properoperating fluid levels.All adjustments have been made to comply with the set-tings given in this manual and in the separate engine man-ual.All guards, shields and decals are in place and securelyattached.Model and Serial Numbers for this unit are recorded inspace provided on this page and page 1.

Check that:All indicators (lamps, switches, etc.) function properly.All hand and foot controls operate properly.The PWP System operates properly (if equipped). Refer toSERVICE AND STORAGE chapter for the procedure tocheck the PWP System.Boom, Quick-attach System with attachment tool andframe level control all function properly.No hydraulic system leaks when under pressure.Listen for abnormal noises or vibrations; if detected, deter-mine their cause and repair as necessary.

I acknowledge that the pre-delivery procedures were per-formed on this unit as outlined above.

Dealership’s Name

Dealer Representative’s Name

Date Checklist Filled Out

Machine Model # Machine Serial # Engine Serial #

DELIVERYCheck that:

The following Checklist is an important reminder of valu-able information that MUST be passed on to the customer atthe time the unit is delivered. Check off each item as youexplain it to the customer.

Review with the customer the contents of the AEM Safety Manual and this manual for the following:

The Index at the back, for quickly locating topics;

The SAFETY, INDICATORS AND CONTROLS, andOPERATION AND ADJUSTMENTS chapters for infor-mation regarding safe use of the machine.

The LUBRICATION, SERVICE AND STORAGE chap-ters for information regarding proper maintenance of themachine. Explain that regular lubrication and maintenanceare required for continued safe operation and long life.

Give this Operator’s Manual and the AEM Safety Manualto the customer and instruct them to be sure to read andcompletely understand their contents BEFORE operatingthe unit.Remind the customer of U.S. OSHA regulation 1910.178(l), which specifies operator training requirements.

Explain that the customer must consult the engine manual(provided) for related specifications, operating adjustmentsand maintenance instructions.Completely fill out the Owner’s Registration, includingcustomer’s signature, and return it to the Company.

Customer’s Signature

Date Delivered

Start the machine and test-run the unit whilechecking that proper operation is exhibited by allcontrols.

(Dealer’s File Copy - Remove at Perforation)


INTENTIONALLY BLANK

(To be removed as Dealer’s file copy)


Chapter 3CHECKLISTS

PRE-DELIVERYThe following Checklist is an important reminder of inspec-tions that MUST be made before delivering the TelescopicHandler to the customer. Check off each item after pre-scribed action is taken.

Check that:NO parts of machine have been damaged in shipment.Check for such things as dents and loose or missing parts;correct or replace components as required.Battery is securely mounted and not cracked. Cable con-nections are tight. Electrolyte at proper level.Cylinders, hoses and fittings are not damaged, leaking orloosely secured.Oil, fuel and air filters are not damaged, leaking or looselysecured.All grease fittings have been properly lubricated and no fit-tings are missing; see LUBRICATION chapter of this man-ual.Wheel nuts are torqued to 450 ft-lbs (610 Nm).Tires are inflated to 55 psi (380 kPa) cold.Hydraulic system reservoir, engine crankcase, enginecoolant, transmission and axles are filled to the properoperating fluid levels.All adjustments have been made to comply with the set-tings given in this manual and in the separate engine man-ual.All guards, shields and decals are in place and securelyattached.Model and Serial Numbers for this unit are recorded inspace provided on this page and page 1.

Check that:All indicators (lamps, switches, etc.) function properly.All hand and foot controls operate properly.The PWP System operates properly (if equipped). Refer toSERVICE AND STORAGE chapter for the procedure tocheck the PWP System.Boom, Quick-attach System with attachment tool andframe level control all function properly.No hydraulic system leaks when under pressure.Listen for abnormal noises or vibrations; if detected, deter-mine their cause and repair as necessary.

I acknowledge that the pre-delivery procedures were per-formed on this unit as outlined above.

Dealership’s Name

Dealer Representative’s Name

Date Checklist Filled Out

Machine Model # Machine Serial # Engine Serial #

DELIVERYCheck that:

The following Checklist is an important reminder of valu-able information that MUST be passed on to the customer atthe time the unit is delivered. Check off each item as youexplain it to the customer.

Review with the customer the contents of the AEM Safety Manual and this manual for the following:

The Index at the back, for quickly locating topics;

The SAFETY, INDICATORS AND CONTROLS, andOPERATION AND ADJUSTMENTS chapters for infor-mation regarding safe use of the machine.

The LUBRICATION, SERVICE AND STORAGE chap-ters for information regarding proper maintenance of themachine. Explain that regular lubrication and maintenanceare required for continued safe operation and long life.

Give this Operator’s Manual and the AEM Safety Manualto the customer and instruct them to be sure to read andcompletely understand their contents BEFORE operatingthe unit.Remind the customer of U.S. OSHA regulation 1910.178(l), which specifies operator training requirements.

Explain that the customer must consult the engine manual(provided) for related specifications, operating adjustmentsand maintenance instructions.Completely fill out the Owner’s Registration, includingcustomer’s signature, and return it to the Company.

Customer’s Signature

Date Delivered

Start the machine and test-run the unit whilechecking that proper operation is exhibited by allcontrols.

(Pages 5 and 6 have been removed at perforation)


Chapter 4

SAFETY

DANGER“DANGER” indicates an imminently haz-ardous situation which, if not avoided, willresult in death or serious injury.

WARNING“WARNING” indicates a potentially hazardoussituation which, if not avoided, could result indeath or serious injury.

CAUTION“CAUTION” indicates a potentially hazardoussituation which, if not avoided, may result inminor or moderate injury. It may also alert tounsafe practices.

REMEMBER! It is the owner’s responsibility for com-municating information on the safe use and propermaintenance of this machine! This includes providingunderstandable interpretation of these instructions foroperators who are not fluent in reading English.

It is the responsibility of the operator to read andunderstand the Operator’s Manual and other informa-tion provided and use the correct operating procedure.Machines should be operated only by qualified opera-tors.

MANDATORY SAFETY SHUTDOWN

PROCEDUREBEFORE cleaning, adjusting, lubricating or ser-vicing the unit:

1. Stop machine on a level surface. (AVOID park-ing on a slope, but if necessary, park across theslope and block the tires.)

2. Fully retract the boom and lower the attach-ment tool to the ground. Idle engine for gradualcooling.

3. Place controls in neutral and apply parkingbrake.

4. Shut off the engine and remove the key.

ONLY when you have taken these precautions canyou be sure it is safe to proceed. Failure to followthe above procedure could lead to death or seriousbodily injury.

The above Safety Alert Symbol means ATTENTION!ALWAYS BE ALERT! YOUR SAFETY ISINVOLVED! It stresses an attitude of “Heads Up forSafety” and can be found throughout this Operator’sManual and on the machine itself.

Before you attempt to operate thisequipment, read and study the followingsafety information. In addition, be sure thateveryone who operates or works with thisequipment, whether family member oremployee, is familiar with thesesafety precautions.

Gehl Company ALWAYS takes the operator’s safetyinto consideration when designing its machinery, andguards exposed moving parts for his/her protection.However, some areas cannot be guarded in order toassure proper operation. Further, this Operator’sManual and decals on the machine warn of additionalhazards and should be read and observed closely.


SAFETYAdditional Safety Reminders

User/operator safety practices, as established byindustry standards, are included in this Operator’sManual and intended to promote safe operation ofthe machine. These guidelines do not, of course,preclude the use of good judgment, care and com-mon sense as may be indicated by the particularjobsite work conditions.It is essential that operators be physically and men-tally free of mind altering drugs and chemicals andthoroughly trained in the safe operation of themachine. Such training should be presented com-pletely to all new operators and not condensed forthose claiming previous experience. Informationon operator training is available from severalsources, including the manufacturer.Some illustrations used in this manual may showdoors, guards and shields open or removed forillustration purposes ONLY. BE SURE that alldoors, guards and shields are in their proper oper-ating positions BEFORE starting the engine.

Before Operation Safety RemindersCheck brakes, steering, and hydraulic system priorto starting operation. Operate all controls to ensureproper operation. Observe all gauges and indica-tors for proper operation. If any malfunctions arefound, correct the cause prior to using the machine.ALWAYS wear appropriate personal protectiveequipment for the job and working conditions.Hard hats, goggles, protective shoes, gloves,reflector-type vests, respirators and ear protectionare exampes of types of equipment that may berequired. DO NOT wear loose fitting clothing,long hair, jewelry or loose personal items whileoperating or servicing the machine.

ALWAYS check the job site for terrain hazards,obstructions and people. Remove all objects thatdo not belong in or on the machine and its equip-ment.

WARNINGU.S. OSHA regulations require employers ingeneral industry and the construction, ship-yard and cargo-handling industries (exceptingagricultural operations) to ensure that forkliftoperators are competent, as demonstrated bysuccessful completion of a training course.

The training course must consist of a combi-nation of formal instruction and practicaltraining, including both forklift-related andworkplace-related topics, and evaluation ofthe operator’s performance in the workplace.

All operator training and evaluation is to beconducted by persons who have the know-ledge, training and experience to train andevaluate operators.

WARNINGALWAYS maintain a safe distance from elec-tric power lines and avoid contact with anyelectrically charged conductor or gas line. It isnot necessary to make direct contact with apower line for power to ground through thestructure of the machine. Keep the boom atleast 10 ft. (3 m) from all power lines.Accidental contact or rupture can result inelectrocution or an explosion. Contact theNorth American One-Call Referral System at(888) 258-0808 for the local “Digger’s Hotline”number or proper local authorities for utilityline locations BEFORE starting to dig!


Walk around the machine and warn all personnelwho may be servicing the machine or who are inthe machine path prior to starting. DO NOT startuntil all personnel are clearly away from themachine.

Operation Safety RemindersAny or all of the following elements may affect thestability of the machine: terrain, engine speed, typeof load being carried and placed, improper tireinflation, weight of the attachment tool, and abruptmovement of any control lever. IF YOU ARENOT CAREFUL WHILE OPERATING THISMACHINE, ANY OF THE ABOVE FACTORSCOULD CAUSE THE MACHINE TO TIPAND THROW YOU OUT OF THE OPERA-TOR’S STATION, WHICH MAY CAUSESERIOUS BODILY INJURY OR DEATH!

ALWAYS wear the seat belt provided to preventbeing thrown from the machine. If you are in anoverturn:

- DO NOT jump!- Hold on tight and stay with the machine!- Lean away from the fall!

ALWAYS keep hands, feet and arms inside of theoperator’s station when operating the machine!Always look in the direction of travel. Look to therear before backing.ALWAYS use the recommended hand holds andsteps with at least three points of support when get-ting on and off the machine. Keep steps and plat-form clean. Face the machine when climbing upand down.DO NOT raise or drop a loaded fork or bucket sud-denly. Abrupt movements under load can causeserious instability.Study the load chart carefully. It shows maximumcapacity to be lifted and placed at specific outwardand upward distances. ALWAYS be aware of loadweights prior to attempting lift and placement withthis machine.DO NOT exceed the machine’s rated operating

capacity for the type of attachment tool being used.DO NOT allow minors or any unqualified person-nel to operate or be near the machine unless prop-erly supervised.DO NOT start the engine or operate any controlsunless properly seated in the operator’s seat!DO NOT run the engine in an enclosed area with-out providing proper ventilation for the exhaust.Exhaust gases contain carbon monoxide, an odor-less and deadly gas. Internal combustion enginesdeplete the oxygen supply within enclosed spacesand may create a serious hazard unless the oxygenis replaced. This includes the atmosphere withinthe cab when equipped.DO NOT leave the operator’s station with theboom and attachment tool raised. ALWAYS lowerthe boom and attachment tool to the ground, shutoff the engine and engage the parking brakeBEFORE leaving the operator’s station.DO NOT drive too close to an excavation or ditch.BE SURE that the surrounding ground has ade-quate strength to support the weight of the machineand the load it is carrying.DO NOT turn quickly while traveling on a slope oroperate the machine beyond the grade and slopelimits noted in the OPERATION AND ADJUST-MENTS chapter of the Operator’s Manual.NEVER allow any riders on this machine. This isstrictly a single seat, NO passenger machineNEVER use as a lift for personnel unless themachine is equipped with the Personnel WorkPlatform (PWP) Safety System.When road travel is required, know and use thesignaling devices on the machine. Provide anescort and Slow-Moving Vehicle (SMV) emblemwhen required.If necessary to park on a slope, park across theslope and block the wheels.

SAFETY


Servicing Safety RemindersALWAYS be aware of and avoid pinch point areason the machine, such as wheels-to-frame, cylin-ders-to-frame, boom and attachment tool-to-frame.NEVER attempt to by-pass the keyswitch to startthe engine. ONLY use the jump-starting proceduredetailed in the SERVICE AND STORAGE chap-ter.NEVER use your hands to search for hydraulicfluid leaks. Instead use a piece of paper or card-board. Escaping fluid under pressure can be invis-ible and can penetrate the skin, causing seriousinjury. If any fluid is injected into your skin, see adoctor at once. Injected fluid MUST be surgicallyremoved by a doctor familiar with this type ofinjury or gangrene may result.ALWAYS wear safety glasses with side shieldswhen striking metal against metal. In addition, it isalso recommended that a softer (chip-resistant)material be used to cushion the blow. Failure toheed could lead to serious injury to the eyes orother parts of the body.DO NOT refill the fuel tank when the engine ishot. Allow engine to cool down BEFORE refillingto prevent hot engine parts from igniting the fuel ifit should spill or splash.DO NOT smoke while filling the fuel tank, work-ing on the fuel or hydraulic systems, or workingaround the battery.DO NOT fill the fuel tank completely. Allow roomfor expansion. Maintain control of the fuel fillernozzle when filling the tank. Use the correct fuelgrade for the operating season.NEVER use fuel for cleaning purposes.

DO NOT remove the radiator cap after the enginehas reached operating temperature or if it is over-heated. At operating temperatures, the enginecoolant will be extremely HOT and under pressure.

ALWAYS wait for the engine to cool down beforeattempting to relieve pressure and remove the radi-ator cap. Failure to heed this warning could resultin severe burns.DO NOT loosen or disconnect any hydraulic lines,hoses or fittings without first relieving hydrauliccircuit pressure. Also, be careful not to touch anyhydraulic components that have been in recentoperation because they can be extremely hot andcan burn you!Avoid lubrication or mechanical adjustments withthe machine in motion or the engine running. If theengine must be running to make certain adjust-ments, place the transmission in neutral, apply theparking brake, place the equipment in a safe posi-tion, securely block the wheels and use extremecaution.To ensure continued safe operation, replace dam-aged or worn-out parts with genuine Gehl serviceparts BEFORE using this equipment.

Modifications, Nameplates, Markingsand Capacities

Modifications and additions that affect capacity orsafe operation must never be performed withoutthe manufacturer’s prior written approval. Wheresuch authorization is granted, any applicable mark-ings are to be changed accordingly.All attachment tools MUST be marked to identifythe attachment tool and the total capacity with theattachment tool at maximum elevation with theload laterally centered.ALWAYS be sure all nameplates, warnings andinstruction markings are in place and legible.Local government regulations may require specif-ic decals, which are the responsibility of the ownerto provide.

SAFETY


Safety Guards and Warning DevicesThis machine is fitted with a Roll-Over ProtectiveStructure (ROPS) and Falling Object ProtectiveStructure (FOPS) in accordance with industry stan-dards. It is intended to offer protection to the oper-ator from falling objects and in case of an overturn,but it cannot protect against every possible hazard.Therefore it should not be considered a substitutefor good judgment and safe practices in operatingthe machine. If the ROPS / FOPS structure is dam-aged, it must be replaced to restore the protectionit provides.This machine is equipped with a horn and backupalarm. The user must determine if operating condi-tions require the machine to be equipped withadditional devices (mirrors, rotating beacon, etc.)and be responsible for providing and maintainingsuch devices.

Personnel Work Platform (PWP) SafetySystem

The Mandatory Work Platform Safety Rules must beadhered to at all times while elevating personnel.These rules are based on ASME/ANSI StandardB56.6-2002, “Safety Standard for Rough TerrainForklift Trucks.” (A copy of this and related standardscan be obtained from the American National StandardsInstitute, 1819 L Street NW, Washington, D.C. 20036.)The rules apply to the owner, operator and the person-nel in the work platform.

MANDATORY WORK PLATFORMSAFETY RULES

1. The work platform must comply withASME/ANSI B56.6-2002, Sec. 8.24, “Platformsfor Elevating Personnel.” (See page 13, “WorkPlatform Design Requirements.”)

2. The platform must be securely attached to the car-riage or forks, and the carriage securely attached tothe boom.

3. The carriage and forks must be secured to preventthem from pivoting upward.

4. If the machine is equipped with a rotating orswinging carriage, the rotation or swing must bedeactivated. (This occurs automatically when the“PWP System” is switched on.)

5. Personnel on the platform must be provided pro-tection from any moving parts on the forklift thatmay present a hazard.

6. If overhead hazards exist for platform personnel,overhead protection must be provided.

7. Be sure that the lifting mechanism is operatingsmoothly throughout its entire range, both emptyand loaded, and that any lift-limiting devices andlatches are functional.

8. Be sure that the frame is level, to ensure a verticallift.

9. Be sure the platform is horizontal before lifting.10. Be sure that the forklift has a firm footing.11. Be sure that any required restraining means (rail-

ings, chains, harnesses, etc.) are in place and prop-erly used.

12. Before lifting personnel, shift the transmission intoNeutral, apply the parking brake, and activate the"PWP System" mode switch.

13. Before lifting personnel, the area should bemarked to warn others of work by elevated per-sonnel.

14. Be sure the path of platform travel is clear of haz-ards, such as scaffolds, electrical wires and over-head obstructions.

15. The operator must keep hands and feet clear ofcontrols that are not in use.

16. Personnel must be lifted and lowered smoothly andcautiously, and only at their request.

17. The platform must be lowered fully before movingthe forklift. Do not drive the forklift with person-nel on the platform.

18. Elevated personnel must always be alerted beforeraising or lowering the platform.

19. A trained operator must be in position to operatethe forklift and boom controls at all times.

20. The combined weight of the platform, personneland load must not exceed one-third of the materi-

WARNINGThe machine must not be used to lift or carrypersonnel, or be fitted with any form of per-sonnel work platform unless fitted with theoptional PWP System.

If fitted with the PWP System, the MandatoryWork Platform Safety Rules must be adheredto at all times while elevating personnel.


al-handling capacity of the forklift.21. Platform personnel must maintain firm footing on

the platform floor, unless secured by harness andlanyard. A harness is to be worn and a lanyardattached to the platform or boom when workingfrom an elevated work platform, in accordancewith OSHA regulations. Use of railings, planks,ladders, etc. on platform for the purpose of achiev-ing additional reach or height is prohibited.

22. Workers on the platform must keep all parts oftheir bodies inside the work platform during rais-ing and lowering.

23. Be sure that the personnel and equipment on theplatform do not exceed the available space.

24. The platform must be fully lowered for personnelto enter and exit. Personnel must not climb on anypart of the forklift in attempting to enter and exit.

25. Any harness, body belt, lanyard, or decelerationdevice that has sustained permanent deformationor is otherwise damaged must be replaced.

26. Modifications to the platform that are detrimentalto its safe use are prohibited.

Work Platform Design Requirements(Per ANSI/ASME B56.6-2002, Sec. 8.24)1. A platform floor having a slip-resistant surface

located not more than 8 inches (200 mm) above thenormal load supporting surface of the forks.

2. Floor dimensions, which shall not exceed twotimes the load center distance of 24 inches (610mm) listed on the forklift nameplate, measuredparallel to the longitudinal center plane of thetruck, nor have a width greater than the overallwidth of the forklift [measured across the load-bearing tires] plus 10 inches (250 mm) on eitherside. Minimum space for each person on the plat-form shall not be less than 18 inches (450 mm) ineither direction.

3. A 4 inch (100 mm) minimum height toe plate,which may be omitted at the access opening.

4. An overhead protective device, when requested bythe user.

5. Protection for personnel in their normal workingposition on the platform from moving parts of theforklift that may present a hazard.

6. Information prominently indicated on the plat-form:

a.maximum work load including personneland equipment, and

b. weight of empty platform.7. Means so that the platform can only be centered

laterally on the forklift, and retained against thevertical face of the forks, carriage, or lifting mach-anism.

8. A means to securely attach the platform to the lift-ing mechanism, and to prevent the platform frominadvertantly pivoting.

WARNINGUse ONLY an approved work platform for ele-vating personnel.

NEVER move the machine with the work plat-form in a raised position or with personnel onboard.

NEVER tilt the platform forward, rearward, orto the side with personnel aboard.

ALWAYS engage the PWP Safety System andfollow the Mandatory Work Platform SafetyRules when elevating personnel.

Work Platform System Switch

PWPRemote

ShutdownSwitch

ElectricalConnection

Remote Shutdown Switch With Coiled Wire Connector


9. Restraining means such as a guardrail or a meansfor securing personnel such as a body harness andlanyard. A guardrail or similar structure shall havea nominal height to the platform floor of 42 inches(1066 mm) around its upper periphery and includea midrail. It may be hinged, removable, or ofchains, and used to provide an access opening ifproper positioning is easily accomplished and asecure condition is discernable. Such restrainingmeans shall be capable of withstanding a concen-trated horizontal force of 200 lb. (890 N) applied atthe point of least resistance without permanentdeformation. A body harness and lanyard is to havean attachment point provided overhead for free-dom of movement, and its length is to limit free-fall to 5 feet (1500 mm) measured from the pointof attachment to the operator. The complete systemshall be capable of withstanding three consecutivedrop tests to simulate a 250 lb. (113 kg) personfalling 6 feet (1800 mm) without allowing the testweight to fall free to the ground. A decelerationdevice may be included.

NOTE: Fall protection should comply withapplicable U.S. OSHA regulations: 1910.67(c)(2)(v) (for General Industry) or 1926.453(b)(2)(v) (for Construction).

10. Lanyards, when provided, shall be arranged so asnot to cause a tripping hazard.

11. Body harnesses, when provided, should have awidth of at least 1.75 inches (44 mm).

12. Structural safety factor - all load supporting struc-tural elements of the work platform shall have astructural safety factor of not less than 2 to 1 basedon the minimum yield strength of the materialsused.


SAFETY

L70307

L500445

L70306

L65930

101506

L500445101506

L65930

L65926

L70306L70307

L65926


SAFETY

L65932 L65928 100359

L70305

L65927

L65942

L65932

L70305

L65927L65933

072798


SAFETY

L65933

L65932

L65927

100359

L70305

L65928

L65942

072798


SAFETY

L65926

L65928

L66613

L65927

L65927

L65927


SAFETY

L65927

L65926

REDL66613

L65928


L71554 L71555

L71554

L71700

L71700

L71555L71554

SAFETYPWP Safety Decals

102969

102969


Order FormSafety Training for Operators of Rough

Terrain Forklifts

OPERATOR TRAINING KIT (P/N 908405)

Includes: Instructor’s Guide, Agenda, Objectives and Goals Sheet, Instructor’s Resource Guide, Evaluation Test, Evaluation Log Book, Student Material Sets (5), Visual Aids (PowerPoint® Disk, Overheads, Charts), AEM Rough Terrain Forklift Safety Manual

ADDITIONAL STUDENT MATERIALS (P/N 908406)(NOTE: 5 sets included in OPERATOR TRAINING KIT)

Includes: Operator’s Workbooks (5), Operator Certificates of Completion (5),Operator Wallet-Size Completion ID Cards (5)

BILLING INFORMATIONGehl Dealer Code: PO#:

Name:

Company:

Address:

City: State: Zip Code:

Phone No.: ( ) Fax No.: ( )

SHIPPING INFORMATION (if different from billing information)Name:

Company:

Address:

City: State: Zip Code:

Country:

Phone No.: ( ) FAX No.: ( )

* Call for current prices.

FAX or Mail to: Gehl Company143 Water StreetWest Bend, WI 53095-0179U.S.A.

FAX Number: (800) 252-6684Telephone: (262) 334-6653

(Remove this page at perforation to use as Fax or Mail order form)

OrderQty.

$80.00 *ea.

OrderQty.

$160.00 *ea.


INTENTIONALLY BLANK

(May be removed at perforation as Fax or Mail order sheet)


GUARDS AND SHIELDSWhenever possible and without affecting machineoperation, guards and shields are used to protect poten-tially hazardous areas. In many places, decals are alsoprovided to warn of potential hazards and to displayspecial operating procedures.

WARNINGRead and thoroughly understand all safetydecals on the Telescopic Handler BEFOREoperating it. DO NOT operate the machineunless all factory-installed guards and shieldsare properly secured in place.

CAUTIONBecome familiar with and know how to useALL safety devices and controls on theTelescopic Handler BEFORE operating it.Know how to stop the machine operationBEFORE operating it. This Gehl machine isdesigned and intended to be used ONLY witha Gehl Company attachment tool, or a GehlCompany approved accessory or referralattachment tool. The Gehl Company cannot beresponsible for safety if the machine is usedwith an unapproved accessory or attachmenttool.

Chapter 5INDICATORS AND CONTROLS

Operator’s Compartment and Indicators/Controls Locations

Frame LevelIndicator

Boom ControlJoystick

Key SwitchStart Button

Boom AngleIndicator

Brake Pedal

Frame Level andAttachment Joystick

AuxiliaryHydraulics

ControlThrottle Pedal

Steering Wheel Instrument andSwitch Panel

Load ZoneCharts

Horn Button

Speed and TravelDirection Lever

Brake FluidReservoir


Coolant Temperature Gauge: Theupper right gauge in the instrumentpanel. It indicates the temperature ofthe engine coolant. Under normalconditions, this gauge should indicateapproximately 185oF (85oC).

Lamp Cluster Gauge: The lower leftgauge in the instrument panel. Itcontains four indicator lamps. Thefunction of these lamps are as fol-lows:

Alternator Lamp: Located in theupper left section of the lampcluster gauge, this lamp indi-cates the condition of the electri-cal charging system. During nor-mal operation, this lamp shouldbe off. If the charge rate is too highor too low, this lamp will come on.

Engine Oil Pressure Lamp:Located in the upper right sectionof the lamp cluster gauge, thislamp indicates whether theengine lubricating oil pressure issufficient. During normal opera-tion, with the engine running, thislamp should be off. During startingand when the engine is not running, this lamp will beon.

IMPORTANT: If this lamp comes on during nor-mal operation with the engine running, stop theengine immediately! After allowing the oil to draindown for a few minutes, check the engine oillevel. Maintain oil level at the FULL mark on thedipstick

Brake Failure Lamp: This lamp islocated in the lower left sectionof the lamp cluster gauge. Thefront and rear brakes are onindependent brake systems. Ifduring normal operation with thebrake pedal depressed, a loss ofpressure occurs in either system, thebrake failure lamp comes on.

DASH PANEL AREA

Key switch OFF: When the key is verti-cal in the keyswitch, power from the bat-tery is disconnected to the control andinstrument panel electrical circuits. Also,this is the only position in which the keycan be inserted or removed.

Key switch ON: When the key is turnedone position clockwise from the vertical(OFF) position, power from the battery issupplied to all control and instrumentpanel electrical circuits.

NOTE: If the engine requires repeated attemptsto start, the key MUST be returned to the OFFposition between starting attempts to prevent bat-tery run down.

Start Button: With keyswitch in ONposition, press the button to activate thestarter. Release it as soon as the enginestarts.

Horn Button: With the keyswitch ON,press the horn button to activate warningsound.

Load Zone Charts: A series of flip charts show liftheight and reach limits relative to the load weightbeing handled with various attachment tools.

Fuel Level Gauge: Is the upper leftgauge in the instrument panel. Itindicates the amount of fuel remain-ing in the fuel tank.

Instrument and Switch Panel


Failure in one of the brake systems does not affect theoperation of the other system. However, the MANDA-TORY SAFETY SHUTDOWN PROCEDURE (p.8) should be followed and any required repairs madeimmediately.

During normal operation the lamp should remain off.

Transmission Oil Temperature Lamp:Located in the lower right section ofthe lamp cluster gauge, this lampindicates whether or not thetransmission oil is at the propertemperature. During normaloperation this lamp should be off,indicating that the transmission oilsystem is at the proper temperature.

IMPORTANT: If this lamp comes on during nor-mal operation, a problem may exist in the trans-mission oil system. Stop the machine immediate-ly and investigate the cause of the problem!

Hourmeter: Located to the right ofthe lamp cluster gauge, it indicatesthe total operating time of themachine and should be used forkeeping the maintenance log.

Top Row Switches

Switches have graphic symbols to indicate positionand response. The following mode descriptions startwith the first switch on the left.

NOTE: Some switches are optional and may notbe on machine.

Steer Selector: This 3-position switch isused to select between three steer modes.The upper position selects the 4-wheelsteer mode. This mode selects all-wheelsteering for making tighter turns, usuallyon a jobsite. The center position selects the2-wheel steer mode. This mode selects front wheelsteering only, used for higher speed travel. The lowerposition selects the crab steer mode. This mode is usedwhen a small amount of side shift is needed for pick-ing or placing a load.

NOTE: The rear wheels are not self-centering.Make sure all wheels are in a straight ahead posi-tion before changing the steer mode.

Any of the steering position modes can be used in for-ward and reverse travel. The operator should learn toanticipate changes in machine movement if the steer-ing selector mode must be changed.

Engine Fault Shutdown OverrideSwitch: Pressing the shutdown overrideswitch will override an engine shutdownsignal. The switch must be pressed within30 seconds to prevent undesired shutdownof engine. The switch can be overridden for 30 secondsat a time to move the machine to a safe location and tolower the boom to the ground. If the engine shutsdown, the ignition switch must be turned off and thenback on before the engine can be restarted.

NOTE: Holding the switch continously “ON” willnot reset the 30-second timer.

NOTE: Only machines equipped with the engineshutdown protection have this switch.

Clutch Cutout: When activated, it allowsfaster engine acceleration and more powerto the hydraulic system, without power tothe drive axles, while the service brakepedal is depressed.

In the “OFF” position, the clutch mechanism of thetransmission remains engaged when applying brakes.In the “ON” position, the clutch mechanism is disen-gaged while applying the brakes.

Normal brake force will hold the machine in positionwhile accelerating the engine to power hydraulic con-trol functions during load placement.

WARNINGUnattended machine hazard.

Activate parking brake switch and lowerattachment tool to ground before leavingmachine. An unattended machine can move orroll and cause death or serious injury to oper-ator or bystanders.

Periodically check the parking brake opera-tion to maintain adequate holding power.Always be sure the parking brake switch is offwhen resuming machine operation.


Parking Brake: When the machine is shutoff, this switch should be depressed toactuate the parking brake mechanism inthe front axle.

Middle Row Switches

Switches have graphic symbols to indicate positionand response. The following mode descriptions startwith the first switch from the left.


Head Lights/Work Lights: Depressingthe top of the switch will illuminate thelights mounted on the top of the operator’sstation and the red tail lights for forwardtravel operations. Depressing the bottomof the switch will illuminate the lights atthe end of the boom in addition to the lights on theoperator’s station for additional lighting in workingoperations.

Turn Signal: This switch is used to indi-cate the direction of a turn with the taillights. Depress the right arrow for a rightturn; depress the left arrow for a left turn.Return the switch to the center positionafter the turn is completed.

Hazard: This switch can be activated tomake the tail lights flash on and off in casethe machine is stalled or temporarilystopped in a traffic area on the road or jobsite.

Personnel Work Platform: This is a red switch usedto activate the Personnel Work Platform SafetySystem. When activated, an amber lamp lights on theswitch.

NOTE: This lamp will flash on and off, indicatingthat the system is not yet fully functional, until thebrakes are held on for 2 or more seconds.

Bottom Row Switches

Switches have graphic symbols to indicate positionand response. The following mode descriptions startwith the first switch from the left.


Wiper/Washer: The windshield and topwindow of the operator’s station are eachequipped with a wiper and washer mecha-nism. The left switch operates the wiperand washer on the windshield, the secondswitch operates the wiper and washer on the top win-dow.

Cold Starting: This switch activates theinjection of an ether agent for faster enginestarts in cold weather.

Heater Controls

Temperature Control: This is the upper knob locatedto the left of the steering wheel. This knob is used toadjust the temperature output of the heater. Turning theknob clockwise will increase the temperature output ofthe cab heater.

Fan Speed: This knob is located below the tempera-ture control knob. Rotating the knob clockwise willincrease the fan speed for increased air circulation.

Travel Lever

Located on the left side of the steering wheel column,this lever is used to change travel direction (forward orreverse) and speed.

Travel Direction: The lever MUST be in N (Neutral)position before the starter will engage to start theengine.

NOTE: Backup alarm automatically sounds withtravel lever in reverse.

Fan Speed Knob

TemperatureControl Knob


Position “F” (FORWARD)Position “N” (NEUTRAL)Position “R” (REVERSE)

Speed Range: Twisting the lever end clockwise orcounter-clockwise will change the transmission speedbetween low, medium and travel ranges.

Position “3” (TRAVEL RANGE)Position “2” (MEDIUM RANGE)Position “1” (LOW RANGE)

IMPORTANT: Care should be taken whendownshifting or changing direction, because dam-age to the transmission can occur if shifting isforced or attempted at too high a speed. Allowengine RPM to slow before any downshift ordirectional change is attempted.

SteeringThe power steering system is designed to provide loweffort steering without shock reaction from the axlewheels to the steering wheel. Turn the steering wheelto the right or left to turn the machine in that direction.

FLOOR AND SEAT AREAThrottle Pedal: This is right-foot operated and con-trols the engine RPM to match increased powerrequirements. Pushing down on the pedal increasesthe RPM. Letting up on the pedal decreases RPM.

Service Brake Pedal: Depressing this pedal activatesinboard hydraulic wet-disc-type brakes on all fourwheels. Separate front and rear brake systems allowbringing the machine to a safe stop if either systemloses pressure.

Brake Fluid Reservoirs: Located under the hingedcover on the cab floor directly in front of the seat.

Seat Positioning: The seat is mounted on rails for for-ward and rearward repositioning to accommodateoperator’s size. A spring-loaded latch handle under thefront of the seat activates the adjustment mechanism.

Suspension Seat Option: This option is avalable foraddtional operator comfort. It is adjustable for a soft orfirm ride.

RIGHT SIDE PANEL

These controls and indicators are used to position theframe, boom, attachment and outriggers. Graphic sym-bols on the side panel illustrate the control actions.

Frame Level/Attachment Tilt Joystick: The machinemay be tilted slowly 10o to the left or right to level theframe and boom in relation to the ground. Move thejoystick handle to the left to tilt to the left. Move thejoystick handle to the right to tilt to the right.

To tilt the attachment tool up, move the joystick handlerearward. To tilt the attachment tool down, move thejoystick handle forward.

Once the operator tilts the attachment tool to a desiredangle, that angle will be maintained as the boom israised and lowered, extended and retracted, until a newangle is set.

Frame Level Indicator: Located in front of the oper-ator on the ROPS upper cross tube. Movement of thebubble shows when the frame is level relative to a slop-ing ground surface.

WARNINGDO NOT level the frame with the boom raisedor extended. Only level the frame whilestopped and with the boom fully retracted andthe attachment raised just enough to clear theground.

Frame Level andAttachment Joystick

Boom ControlJoystick

AuxilliaryHydraulics

Control

Frame LevelIndicator


The boom inner section nose has an attachment carry-ing device feature called Quick-Attach System. Thisprovides the operator with a convenient means of uti-lizing optional attachment tools. Refer to the OPERA-TION AND ADJUSTMENTS chapter for attachmenttools changing procedure.

Boom Control Joystick: This machine has a hydraulictype boom with telescopic sections. The sectionsextend by means of a hydraulic cylinder and chain sys-tem inside the boom, sequenced for uniform extensionof each section.

To extend the boom, move the joystick handle to theright. To retract the boom, move the joystick handle tothe left. To raise the boom, move the joystick handlerearward. To lower the boom, move the joystick handleforward.

Boom Angle Indicator: Mounted on the left side ofthe outer boom. Movement of a bubble shows theangle of boom elevation relative to the ground.

Auxiliary Hydraulics Control: This 2-position leveris for attachment tools that require additionalhydraulics.

OTHER INDICATORS

The following indicators are for checking fluid levels.

Transmission Oil Level: The dipstick is located underthe access cover on the front hood section.

Engine Oil Level: The dipstick is located on the rightside of the engine.

Coolant Level: The radiator cap is located under theopening toward the rear of the main hood section.

Hydraulic Reservoir Oil Level and Fill Cap: Thedipstick on the fill cap of the reservoir indicates thelevel of the hydraulic oil in the reservoir.

WARNINGUse extreme caution when raising or extend-ing the boom. The Telescopic Handler MUSTbe level. Loaded or empty, this machine cantip if not level.

ALWAYS place the transmission in neutral, setthe parking brake and keep the service brakepedal fully depressed before raising orextending the boom.

NEVER exceed the specified lifting andextending capacities of this machine. Seriousmachine damage or personal injury mayresult. Refer to the load charts in the opera-tor’s station or this manual.

If a boom circuit hose should burst with theboom up, with or without a load, shut downthe machine following the MANDATORYSAFETY SHUTDOWN PROCEDURE (page 8).DO NOT attempt repairs. Call your Gehl dealerfor assistance.

The truss boom and winch attachment toolsshould ONLY be used to lift and place loadswhen the machine is in a stationary position.DO NOT use to transport loads around thejobsite. This can cause the load to swing,resulting in either load dropping or machinetipover.

NEVER use winch for lifting or moving of per-sonnel. NEVER exceed the maximum ratedcapacity of the winch (3000 lbs./1360 kg) orexceed the load chart rating for winch appli-cations.

DO NOT tilt the truss boom back more than45o from horizontal. DO NOT attempt to usethe optional rotating carriage as a load level-ing function. Always level the frame prior toraising a load.

TransmissionDipstick

Hydraulic FillCap/Dipstick

BOOM ANGLEINDICATOR


SERVICE AND SAFETY FEATURES

Hydraulic Pressure Test Ports: A gauge can beattached to these ports to check main valve, joystickand steering pressures.

Side View Mirror: Located on the front outside cornerof the fuel tank. It provides the operator with a view tothe rear of the machine.

Battery Compartment: The battery is located underthe access cover on the front hood section.

Backup Alarm: Located inside the rear frame cover, itproduces a loud warning sound whenever the machineis in reverse.

HydraulicTest Ports

Fuse and Relay Compartment: Located under theloadchart panel in the cab. Remove the four screws togain access to the fuses and relays.

ATTACHMENT TOOLS

Gehl offers a versatile range of attachment tools tomeet various lifting and material handling applications.Contact your Gehl dealer for specifications and order-ing information.

ACCESSORIES

Gehl offers a range of special accessories for thismachine. Contact your Gehl dealer for specificationsand ordering information.

NOTE: All accessories are field-installed unlessotherwise noted. Information and parts forinstalling accessories will be provided by the GehlCompany or Gehl Telescopic Handler dealers.

Engine Oil Dipstick

Fuse andRelay Access

Side ViewMirror

BatteryCompartment

Backup Alarm


GENERAL INFORMATION

ENGINE BREAK-INA new engine does not require extensive “break-in.”However, for the first 100 hours of operation, followthese guidelines: Allow the engine to idle for a fewminutes after every cold start. DO NOT idle the enginefor long periods of time. DO NOT operate the engineat maximum power for long periods of time. Check theoil level frequently and replenish as necessary with theoil specified in the engine manual.

John Deere engines use a “break-in” oil for the first100 hours of operation. After the first 100 hours ofoperation, change the oil and replace the oil filter.Consult the LUBRICATION chapter for the type andgrade of oil to use. Refer to the SERVICE AND STOR-AGE chapter for the proper service intervals.

PRESTART INSPECTIONIt is the operator’s responsibility to inspect the machinebefore the start of each workday. Every prestart inspec-tion must include more than simply checking the fueland oil levels. It is a good practice to personally inspectany machine you are assigned to use, even though ithas already been put into service by other personnel.

The most efficient method of checking a machine is byconducting a “Walk-Around Inspection.”

Before mounting the operator’s compartment, walkcompletely around the machine to be sure no one isunder, on, or close to it. Let others in the area knowyou are going to start up and wait until everyone isclear of the machine.

Chapter 6OPERATION AND ADJUSTMENTS

BEFORE STARTING ENGINEBefore starting the engine and running the machine,refer to the INDICATORS AND CONTROLS chapterand become familiar with the various operating con-trols, indicators and safety features.

STARTING THE ENGINE

The following procedure is recommended for startingthe engine:

1. Carefully step up and grasp the hand holds to stepinto the operator’s compartment.

2. Adjust the seat and fasten the seatbelt.3. Check that all controls are in their “neutral” posi-

tions, except the parking brake switch, whichshould be in the “ON” position.

4. Turn the keyswitch to “ON” position and press thestart button. If the button is released before theengine starts, turn the keyswitch to “OFF” posi-tion, and allow the starter to stop before attemptingto start again.

IMPORTANT: Crank the starter until the enginestarts. If the engine fails to start within 30 sec-onds, return the key to the “OFF” position, wait 2minutes, and try again to start the engine.Cranking the engine for longer than 30 secondswill result in premature failure of the starter.5. After the engine starts, allow a sufficient warm-up

time before attempting to operate the controls.6. Check that indicators are in normal condition.7. Check that there are no fuel, oil or engine coolant

leaks, and no abnormal noises or vibrations.

CAUTIONBEFORE starting the engine and operating theTelescopic Handler, review and comply withALL safety recommendations in the SAFETYchapter of this manual. Know how to STOP themachine before starting it. Also, BE SURE tofasten and properly adjust the seatbelt. WARNING

ALWAYS fasten your seat belt BEFORE start-ing the engine. Leave the parking brakeapplied until the engine is running and you areready to operate the machine.


COLD STARTING PROCEDURESA block heater or radiator lower hose heater is recom-mended for starting in temperatures of 20oF (-7oC) orlower. See your Gehl dealer for recommended heater.

If prevailing temperature is 40oF (4oC) or below, itmay be necessary to use a cold weather starting aid tostart the diesel engine. For proper use of starting aids,check instructions in the engine manual.If the battery becomes discharged and does not havesufficient power to start the engine, jumper cables canbe used for starting assistance. Refer to the jump start-ing instructions in the SERVICE AND STORAGEchapter of this manual for safe jump starting proce-dures.

STOPPINGThe following procedure is the recommendedsequence for stopping the machine:1. Bring the machine to a stop on a level surface.

Avoid parking on a slope, but if necessary parkacross the slope and block the wheels.

2. Fully retract the boom and lower the attachment tothe ground. Idle the engine for gradual cooling.

3. Place controls in neutral. Apply the parking brake. 4. Turn the ignition switch key to the “OFF” position.

Remove the key.5. Unfasten the seatbelt, and grasp the hand holds

while climbing out of the operator’s compartment.

FIRST TIME OPERATIONMake sure the engine is warm and then go through thefollowing procedures:

Select the travel direction and the speed range. Turn offthe parking brake switch and move ahead slowly, whiletesting the steering and brakes. Stop and operate allboom, attachment tool functions and frame levelingcontrols, checking for smooth response.

Apply the service brakes, stop the machine and movethe direction lever to the opposite direction.

Shifting to the next higher gear may be done at anyengine RPM while the machine is in motion.

DO NOT overspeed the engine when down-shifting.Allow the machine to slow down before shifting to thenext lower gear.

ENGINE SHUTDOWN PROTECTIONNOTE: Only machines that have the engine faultshutdown override switch described on page 25have this feature.The engine is equipped with a WARNING and SHUT-DOWN feature to warn of low engine oil pressure andhigh engine coolant temperature. If the problem is notcorrected, the engine power will be reduced automati-cally, or the engine will shut down.

Engine Oil PressureThere are two low oil pressure protection features:Low Oil Pressure WARNING, and Low Oil PressureSHUTDOWN.

At the Low Oil Pressure WARNING set-point, thewarning lamp in the engine override switch will flashand a slow engine power derate will begin. But if theoil pressure rises above the Low Oil Pressure WARN-ING set-point, power will slowly increase until theengine is back to full power. The lamp will continue toflash until the power has returned to normal, even if thefault condition has been corrected and the recovery isin process.

At the Low Oil Pressure SHUTDOWN set-point, thelamp in the engine override switch will light conti-nously, and a fast engine power derate will begin. If theoil pressure does not rise above the SHUTDOWN set-point within 30 seconds, the engine will shut down.However, if the oil pressure rises above the Low OilPressure SHUTDOWN set-point within 30 seconds,then the power derate speed will revert to the Low OilPressure WARNING speed of reaction.

CAUTIONBe sure the area used for test-running is clearof spectators and obstructions. Initially, oper-ate the machine with an empty attachmenttool.


Engine Coolant TemperatureThere are two coolant temperature features: HighCoolant Temperature WARNING, and High CoolantTemperature SHUTDOWN.

At the High Coolant Temperature WARNING set-point, the warning lamp in the engine override switchwill flash and a slow engine power derate will begin.But if the coolant temperature drops below the HighCoolant Temperature WARNING set-point, the powerwill increase slowly until the engine is back to fullpower. The lamp will continue to flash until the powerhas returned to normal even if the fault condition hasbeen corrected and the recovery is in process.

At the High Coolant Temperature SHUTDOWN set-point, the lamp in the engine override switch will lightcontinously, and a fast engine power derate will begin.If the coolant temperature does not drop below theSHUTDOWN set-point within 30 seconds, the enginewill shut down. However, if the coolant temperaturedrops below the High Coolant Temperature SHUT-DOWN set-point within 30 seconds, then the powerderate speed will revert to the High CoolantTemperature WARNING speed of reaction.

PARKING BRAKENOTE: The parking brake mechanism within thefront axle is NOT designed for, OR intended to beused as, the primary means of stopping move-ment of the machine. Hydraulic braking providedthrough the service brakes within the axles is theprimary means for stopping movement. The axle-by-axle split brake system is the secondarymeans of stopping movement.

The proper sequence for correct machine operation isto always engage the parking brake switch before shut-ting off the engine; and to disengage the parking brakeONLY after the engine is running. In an EMER-GENCY, if it becomes necessary to STOP movement,activate the parking brake switch to “ON.”

CHANGING ATTACHMENT TOOLSThe Telescopic Handler boom nose will accept Quick-attach System Gehl attachment tools. The Quick-attachSystem has a quick-release hookup and locking mech-anism for mounting framing-type or masonry-typeattachment tools to the boom nose.

AttachingTo pick up the attachment tool proceed as follows:

1. Raise the boom slightly and extend it 2 to 3 feet(0.6 to 0.9 m) for better visibility and tilt theQuick-attach System forward.

2. Align the Quick-attach System squarely with theback of the attachment tool.

3. Slowly extend the Quick-attach System and lowerthe hooks under the attachment tool hookup bar.

4. Tilt the Quick-attach System back so that the lockplate engages the attachment tool. This secures theattachment tool to the quick-attach system.

5. For an attachment tool with auxiliary hydraulics,connect hoses to the quick-disconnect connectorson the boom nose.

DetachingTo detach attachment tool, proceed as follows:

1. Raise the boom slightly and extend it 2 to 3 feet(0.6 - 0.9 m) for better visibility. Lower the boomuntil the attachment tool is approximately 12” (0.3m) off the ground.

Quick-attach System Attaching Detail

Attachment Tool Shown Lockedto Quick-attach System

Quick-attach System TiltedForward for Hookup

AttachmentTool


2. Roll the carrier rearward as far as it will go. Oncethe carrier is rolled all the way back, perform theMANDATORY SAFETY SHUTDOWN PROCE-DURE (p. 8, Safety chapter).

3. With the engine off, leave the operator’s station.Manually raise the lock spring and flip the lockplate up and outward at least 180o so it is in posi-tion to re-lock on the next attachment tool.

4. Tilt the Quick-attach System forward to allow theattachment tool to roll out, then lower the boom sothe hook ears clear the hookup bar on the attach-ment tool.

NOTE: One side of the lock plate has a brightred decal to indicate the unlocked position.

5. If the attachment tool has auxiliary hydraulics, dis-connect the hoses from the quick-disconnects onthe boom nose.

6. Start the engine and tilt the Quick-attach Systemforward, then slowly back the machine until theattachment tool is free from the boom nose.

SELF-LEVELINGThe machine is equipped with a hydraulic self-levelingfeature. This feature is designed to keep the attachmenttool level while the boom is being raised.

GENERAL MACHINE OPERATIONTake time to check the Telescopic Handler to be sureall systems are in good operating condition. Performthe following steps before starting the machine for thefirst time each day:

1. Check the engine oil and coolant, transmission oiland hydraulic oil levels.

2. Be sure weekly lubrication has been done.3. Visually inspect for leaks, broken or malfunction-

ing parts. Be sure all caps, covers and safetyshields are in place.

4. Check tires for cuts, bulges, nails, correct pressure,loose wheel nuts, etc.

5. Inspect the work area. Be sure you know whereyou will make load pickups, lifts, and turns. Lookover the terrain of the jobsite for holes, obstacles,slippery surfaces, soft or deep mud.

6. Check clearances of ramps, doorways andpassage-ways. Check overhead clearances if youwill travel and place loads near power or telephonelines.

If the machine is found to be in need of repair or in anyway unsafe, or contributes to an unsafe condition, thematter shall be reported immediately to the user’s des-

WARNINGExhaust fumes can kill. Ensure proper ventila-tion when starting indoors or in enclosedareas.

Use proper hand holds, NOT the steeringwheel or control levers when mounting anddismounting.

NEVER operate the machine with safetyguards or covers removed.

Over-inflated tires can explode and causeinjury or death. Tire repairs MUST be madeonly by authorized personnel using propertools and equipment.

Quick-attach System Detaching Detail

WARNINGModifications, alterations to, or use of attach-ment tools NOT authorized by Gehl (or themanufacturer) in writing can void warrantyand cause machine damage and/or seriouspersonal injury or death.

Attachment Tool ShownUnlocked for Release from

Quick-attach System


Regardless of terrain or position of wheels, theFRAME MUST BE LEVEL, as indicated by thelevel indicator on the ROPS/FOPS cross member.

4. DO NOT travel across a side hill that exceeds 18%or 10° grade. Regardless of the terrain or positionof the wheels, the FRAME MUST BE LEVEL,as indicated by the level indicator on theROPS/FOPS cross member. The attachment toolMUST be maintained at the “carry” position withthe boom fully retracted, and attachment tool atminimum ground clearance.

When ascending or descending grades in excess of 5%or 3°, the machine should be driven with the loadupgrade. An unloaded machine should be operated onall forward grades with the load handling attachmenttool downgrade, tilted back if applicable, and raisedonly as far as necessary to clear the road surface.

Avoid turning if possible and use extreme caution ongrades, ramps and inclines. Normally travel straight upand down the slope.

Traffic Flow Patterns Know and understand the traffic flow patterns of yourjobsite. Know all Telescopic Handler hand signals forsafety. Utilize signal persons and be sure you can seethe signal person and acknowledge the signals given.

When ramps must be used in transporting loads withthe machine, the following are the minimum widths forsafe travel:

Compacted dirt, gravel, etc. 12 ft. (3.6 m)Woodboard, concrete, etc. 10 ft. (3.0 m)

Permanent aisles, roadways and passageways, floorsand ramps must be clearly defined or marked.Permanent or temporary protrusion of loads, equip-ment, material and construction facilities into the usualoperating area must be guarded, clearly and distinc-tively marked, or clearly visible.

ignated authority. The machine must NOT be operateduntil it has been restored to a safe operating condition.

Operate the travel controls gradually and smoothlywhen starting, stopping, turning and reversing direc-tion.

Grade and Slope PrecautionsThe Telescopic Handler complies with industry stabil-ity test requirements and is stable when properly oper-ated. However, improper operation, faulty mainte-nance, and poor housekeeping can contribute to a con-dition of instability and defeat the purpose of the stan-dard.

The amount of forward and rearward tilt to be used isgoverned by the application. Although use of maxi-mum rearward tilt is allowable under certain condi-tions, such as traveling with the load fully lowered, thestability of the machine, as determined by the industrystandard tests, does not encompass consideration forexcessive tilt at high elevations, or the handling of off-center loads.

Handle only loads within the capacity limits of themachine, and which are stable and safely arranged.When attachments are used, extra care should be takenin securing, manipulating, positioning and transportingthe load.

Grade Limits

NOTE: Grade limits are based on ANSI/ASMEstandard B56.6-2002.

This telescopic handler meets or exceeds the safetystandard (ANSI/ASME B56.6) stability limits forrough terrain forklifts. The stability tipping limitscover specific, controlled test conditions, which areextremes, and which are not intended to be achievedduring normal worksite operations. The followingspecifications are provided only as information to theoperator, and must not be used as a guideline for oper-ating the telescopic handler. For safe operation, alwaysfollow the instructions and warnings provided in thismanual.

1. DO NOT place or retrieve loads on an up or downslope or grade that exceeds 7% or 4°.

2. DO NOT travel up or down a grade or slope thatexceeds 22% or 12° while loaded.

3. DO NOT place or retrieve loads on a side hill witha slope or grade that exceeds 12% or 7°.

WARNINGDO NOT level the frame with the boom raisedor extended. Only level the frame whilestopped, and with the boom fully retractedand the attachment tool raised just enough toclear the ground.


Maintain a safe distance from the edge of ramps, plat-forms and other similar working surfaces.

Controlled lighting of adequate intensity should beprovided in operating areas. Where operating condi-tions indicate, the operator/user is responsible for hav-ing the machine equipped with lights.

Provisions must be made to prevent trucks, semi-trail-ers and railroad cars from being moved during loadingand unloading.

Wheel stops, parking brakes, or other positive holdingmeans must be used to prevent movement during load-ing and unloading.

DO NOT move railroad cars and trailers with theTelescopic Handler.

DO NOT use the boom and attachment for leverage topush the machine out of mud.

IMPORTANT: DO NOT lower boom at highengine RPM when attachment tool is at maximumrearward tilt. Damage to slave cylinders mayresult.

GENERAL LOAD HANDLINGNEVER attempt to work controls except from theoperator’s seat. NEVER jerk or use fast movements.Avoid sudden stops, starts and changes in direction.

Safety Hand Signals

Stop

Rotate ForksRight

Tilt Forks Down

Rotate ForksLeft

Tilt Forks Up

Lower LoadRaise Load

Load Back Load Forward

Operation of the hydraulic system depends on enginespeed and the distance the controls are moved. Whenoperating these controls it is important to develop atechnique called “feathering.” Feathering the controlmeans you start the desired motion by moving the con-trol a small amount away from neutral. Then aftermovement has started, the control can be eased to fullmovement. Use the same feathering technique to stopthe motion.

WARNINGExcessive speed can be hazardous. ALWAYSexercise caution and good judgement whileoperating the machine.

Twice daily, increase the engine speed (to fastidle) and extend and retract the frame levelingcylinder to the stroke limit. This removes anyair trapped in the circuit, which could causethe machine to lean to one side or the other.

ALWAYS maintain a safe distance from elec-tric power lines and avoid contact with anyelectrically charged conductor and gas line. Itis not necessary to make direct contact with apower line for power to ground through thestructure of the machine. Keep the boom atleast 10 ft. (3 m) from all power lines.Accidental contact or rupture can result inelectrocution or an explosion. Contact theNorth American One-Call Referral System at(888) 258-0808 for the local “Digger’s Hotline”number or proper local authorities for utilityline locations BEFORE starting to dig!

Keep all body parts inside the operator’s sta-tion while operating the machine. BE SURE ofclearance for the attachment tool when turn-ing, working around buildings, etc.

Turning corners too fast can tip the machine,or cause a load to tip off the attachment.Sudden slowing or stopping of the machinemay cause the load to drop off the attachmenttool.

Be certain you can control both speed anddirection before moving. Always place themachine in neutral and set the parking brakebefore raising or extending the boom. NEVERdrive the machine up to someone standing infront of the load.


Load Capacity and Reach This machine has flip-charts in the operator’s stationthat provide, at a glance, the load capacity limits at var-ious positions of attachment tool extension and eleva-tion. A set of the load zone charts is reproduced at theend of this manual for reference.

A typical load zone chart is shown on this page. Thescale on the left indicates height in feet above theground level. The scale on the bottom shows the dis-tance in feet out from the front of the machine. The arclines noted by the numbers “1” through “5” correspond

with the position extension markers on the operatorside of the intermediate boom section.

The following example illustrates proper use of theload zone charts for the Telescopic Handler:

Example:The operator, using a standard carriage attachmenttool, wants to raise a 2000 lb. load 20 feet high, and canonly get to within 15 feet of the load placement point.Can it be done within the capacity of the machine?

Analysis: See “Typical Load Zone Chart” below.

Projecting up from the 15-foot mark on the horizontalaxis to intersect a line through the 20-foot mark on thevertical axis shows the load can be placed in the 2000-lb. zone.During placement, the operator observes when theextension reference number “3” on the boom is visibleand stops. The maximum safe distance of extensionwith this load has been reached.

NEVER leave the operator’s station withoutfirst lowering the attachment tool to theground. Then set the parking brake, place con-trols in neutral, shut off engine and removethe key. AVOID parking the machine on aslope, but if necessary, park across the slopeand block the tires.

Typical Load Zone Chart

HEI

GH

T A

BO

VE G

RO

UN

D

BOOMEXTENSIONMARKERS

REFERENCE

DISTANCE LOAD IS EXTENDED


LIFTING ATTACHMENT TOOLAPPLICATIONS

Picking Up the Load

Inspect the load. If it appears unstable, DO NOTattempt to move it. DO NOT attempt lifting double-tiered loads, or straddling side-by-side pallets with oneon each fork. NEVER add extra unauthorized counter-weights to this machine. Consider the additionalweight of any attachment tool as part of the pickingload capacity of the machine.

Approach the load squarely and slowly with themachine straight and level. Adjust the space betweenforks, if necessary. Engage the load equally on bothforks until the load touches the carriage backrest. Tiltthe forks back to position the load for travel.

Carrying the LoadIf the load obstructs your view, get someone to directyou. Maintain ground speeds consistent with groundconditions and that permit stopping in a safe manner.

Load Elevation and PlacementFor ground level placement, be sure the area under theload and around the machine is clear of equipment andpersonnel. Lower the load to the ground, tilt the forksto the horizontal position, and then back away careful-ly to disengage the forks from the load.

For elevated or overhead placement, bring the machineas close as possible to the landing point. Level themachine BEFORE raising the load. Use extreme cau-tion for high placement. Be sure personnel are clear ofthe area where the load or the machine could tip or fall.

Set the parking brake, hold the service brake pedalfully applied and slowly raise the load, maintaining aslight rearward tilt to cradle the load. As the loadapproaches the desired height, feather the boom con-trol at minimum speed until the load is slightly higherthan the landing point.

Continue the feathering technique and lower the loadin place, until the forks are free. Level the forks andretract clear of the load. Lower the forks to travelheight before moving the machine.

Installation of a Personnel Work Platform (PWP)

1. Center the forks on the carriage, spaced apart tomatch the distance required to engage the PWP.

2. After the forks are fully engaged in the PWP,secure the PWP to the forks. This can be accom-plished by means of a retaining pin behind the heelof the forks as shown on the next page.

3. Secure the forks from pivoting upward in case thePWP is lowered onto an obstruction. This can beaccomplished by using the chain supplied with

WARNINGOperating conditions can reduce themachine’s safe operating capacity. Exceedingthe capacity when raising or extending theboom will cause the machine to tip forward.

WARNINGNEVER travel with the boom above the carryposition (attachment tool should be at mini-mum ground clearance). Boom should be fullyretracted.

Use lower gear when traveling down anincline. NEVER coast with the transmission inneutral. Travel up and down grades slowly.

DO NOT operate the machine on a slope orgrade that exceeds 22% or 12o.

WARNINGNEVER exceed the rated operating capacity ofthe Telescopic Handler as shown on the loadzone charts.

WARNINGThe machine must not be used to lift or carrypersonnel, or be fitted with any form of per-sonnel work platform unless fitted with theoptional PWP System.

If fitted with the PWP System, the MandatoryWork Platform Safety Rules (p. 12) must be fol-lowed at all times while ligting personnel.


PWPs, to secure the lower portion of the PWP tothe bottom of the carriage, as shown below.

NOTE: The PWP must meet ANSI/ASME B56.6-2002, Section 8.24. (See page 13 in the Safetychapter for PWP design requirements.) If thePWP being used does not offer means to securethe PWP to the forks and to secure the forks frompivoting, as shown in Steps 2 and 3, then an alter-nate method must be used.

4. Connect the coiled wire from the remote shutdownswitch to the connector on the end of the boom.Secure the remote shutdown switch to the PWPusing the strap attached to the switch as shownbelow.

5. Secure the lanyard from the body harness to thePWP or the boom. Each person in the PWP should have a body harness with a lanyard attached to the PWP.

Elevating PersonnelThis Telescopic Handler is primarily intended for useas a material handler. It should only be used to elevatepersonnel if it is equipped with the (optional) PWPSystem when there is no other practical option. If thismachine is to be used to elevate personnel, then useonly an approved work platform, lift personnel onlywith the (optional) PWP System activated, and followthe “Mandatory Work Platform Safety Rules” (p. 12Safety chapter).

If this Telescopic Handler is equipped with a PWPSystem, and is to be used for elevating personnel, thesystem must be activated, by the "PWP System" modeswitch, which is located in the instrument and switchpanel. To activate the system, apply and hold the ser-vice brakes on for 2 or more seconds, and press the topof the PWP rocker switch. The system is activatedwhen the lamp in the PWP rocker switch is on conti-nously.

When the PWP System is active:transmission is de-clutched into Neutral,parking brake is applied,rear axle stabilizer cylinder is locked,auxiliary hydraulic and carriage tilt and swingfunctions are disabled,machine inclination sensor is activated, withthe result that the Telescopic Handler must be levellaterally (side-to-side) and longitudinally (front-to-back) to the factory preset limits before the boomcontrol joystick will function, andremote shutdown switch is activated, with theresult that the switch must be connected and in the“on” position for the boom control joystick tofunction.Depressing the switch will disengage the boomcontrol joystick, and stop all platform movement.The remote shutdown switch box is supplied witha coiled electrical cable that must be connected tothe outlet on the front of the innermost boom sec-tion near the carriage. The switch must be accessi-ble by the platform personnel any time the plat-form is to be moved.

Chain

PWPRemote

ShutdownSwitch

ElectricalConnection

Remote Shutdown Switch with Coiled Wire Connector

WARNINGALWAYS check the PWP System for properoperation prior to use. (See page 50 for PWPSystem checking procedure.)

RetainingPin


To de-activate the system, apply and hold the servicebrakes on for 2 or more seconds, and press the bottomof the PWP System rocker switch. The system is de-activated when the lamp in the PWP System rockerswitch is off.

NOTE: If the lamp in the PWP system rockerswitch is flashing, apply the service brakes untilthe lamp goes off.

SUSPENDED LOADS

The handling of suspended loads by means of the trussboom or other similar device can introduce dynamicforces affecting the stability of the machine that are notconsidered in the stability criteria of industry test stan-dards. Grades, sudden starts, stops and turns can causethe load to swing and create a hazard.

DO NOT exceed the Telescopic Handler capacity forhandling suspended loads. Only lift the load vertically;NEVER drag it horizontally. Use tag lines to restrainload swing whenever possible.

Guidelines for “Free Rigging /Suspended Loads”1. The rigging equipment must be in good condition

and comply with the applicable U.S. OSHA regu-lation, 1910.184, “Slings,” or 1926.251, “Riggingequipment for material handling.”

2. The rigging equipment must be secured to theforks such that it cannot slip or slide either side-ways or fore and aft.

3. The capacity of the fork(s) and the machine(whichever is less) must not be exceeded.

4. The load center must remain at 24” (610 mm) orless.

5. No lifting of material may be done when anyone ison the load, rigging or forks.

6. Multiple pickup points on the load are preferred toprevent the load from rotating, but a single pickuppoint may be used if one or more tag lines are uti-lized. And, of course, the load must never be posi-tioned over personnel at any time.

ROAD TRAVELFor short distance highway travel, attach a Slow-Moving Vehicle (SMV) emblem (purchased locally) tothe rear of the Telescopic Handler. For highway opera-tion, obtain and install an amber flashing beacon.

NOTE: ALWAYS follow ALL state and local reg-ulations regarding the operation of equipment onor across public highways. Whenever there is anappreciable distance between jobsites, or ifdriving on public highway is prohibited, transportthe machine using a vehicle of appropriate sizeand capacity.

WARNINGNEVER use frame leveling to position an ele-vated load. Always lower the load to theground and reposition the machine.

If a hydraulic boom circuit hose bursts withthe boom up, shut down the machine. DO NOTattempt to lower the boom or make repairs.Call your Gehl dealer.

As lift height increases, depth perceptiondecreases. High elevation placements mayrequire a signal person to guide the operator.The machine becomes less stable as the loadis raised higher.

DO NOT ram the lift cylinders to the end of thestroke. The resulting jolt could spill the load.

The truss boom attachment tool should ONLYbe used to lift and place loads when themachine is in a stationary position. DO NOTuse to transport loads around the jobsite. Thiscan cause the load to swing, resulting in eitherthe load dropping or the machine tipping over.

WARNINGIn an emergency, if the platform worker hasactivated the remote shut-off switch and thenis not able to re-activate the switch, such as ifthe worker fainted, then the TelescopicHandler operator is permitted to turn off thePWP System to regain control of the boomfunctions, in order to lower the work platformand come to the aid of the worker. But, under-stand this is only permitted in case of anemergency. Otherwise, the PWP System mustbe used at all times when there are workers onthe platform. This is the only exception!


TRANSPORTING BETWEEN JOBSITESALWAYS abide by the following recommended proce-dures and guidelines when using ramps to load themachine onto (and unload it from) a truck or trailer.Failure to heed can result in damage to equipment andserious personal injury or death!

Tie-down hooks are provided for inserting chainsthrough to secure the machine while transporting.

Loading Machine Using RampsNOTE: A matched pair of ramps is required.

1. The ramps MUST be of sufficient strength to sup-port the machine. Whenever possible, the use ofstrong steel ramps is recommended as well assome type of center supporting block.

2. The ramps MUST be firmly attached to the truckor trailer bed with NO step between the bed andthe ramps.

3. Incline of ramps MUST be less than 15 degrees.Ramp length MUST be at least 16 feet (4.9 m)long.

NOTE: A matched pair of ramps is required.

4. Ramp width MUST be at least 1-1/2 times the tirewidth.

5. Block the front and rear of the tires on the truck ortrailer. Engage the parking brake.

6. Position the machine with the boom facing towardthe front of the truck or trailer so that it is straightin line with the ramps. Tie-down slots are provid-ed on the front and rear sides of the frame struc-ture. Slowly (at the lowest engine speed possible)and carefully drive the machine up the ramps.

Unloading Machine Using RampsNOTE: A matched pair of ramps is required.

Repeat Steps 1 through 4 and proceed as follows tounload the machine:

5. If necessary, adjust the machine so that the wheelsare in line and centered with the ramps.

6. Slowly (at the lowest engine speed possible) andcarefully drive the machine down the ramps.

THEFT DETERRENTSGehl has recorded all component part numbers and ser-ial numbers. Users should take as many of the follow-ing actions as possible to discourage theft, to aid in therecovery in the event the machine is stolen, and toreduce vandalism:

1. Remove keys from unattended machines.2. Attach, secure, and lock all anti-vandalism and

anti-theft devices on the machine.

Ramp Placement

WARNINGNEVER adjust travel direction (even slightly)while on the ramps. Instead, back off theramps, and then realign the machine with theramps.

WARNINGNEVER transport the machine with the boomraised or extended. BE SURE to secure themachine (including boom) to the truck or trail-er bed using chain and binders or steelcables, to prevent any movement while trans-porting.


3. Lock doors of cabs when not in use.4. Inspect the gates and fences of the equipment stor-

age yard. If possible, keep machines in well-light-ed areas. Ask the local law enforcement agency tomake frequent checks around the storage and worksites, especially at night, during weekends, and onholidays.

5. Report any theft to your dealer and insurance com-pany. Provide the model and all serial numbers.Request your dealer to forward this information toGehl Company.


INTENTIONALLY BLANK


Hydraulic System Reservoir

Use Mobil DTE 15M, or an equivalent thatcontains anti-rust, anti-foam and anti-oxida-tion additives and conforms to ISO VG46.

Capacity:35 Gallons (133 liters)

All Grease Fittings

Use No. 2 Lithium-based Grease

Engine Crankcase Oil

Ambient Temperature Grade*-22°F - 86°F (-30°C - 30°C) SAE 5W-30-4°F - 104°F (-20°C - 40°C) SAE 10W-405°F - 122°F (-15°C - 50°C) SAE 15W-40

*API Service Classification: CH-4/Cl-4*API Service Classification for first 100 hours on new or

rebuilt John Deere engines: CC or CD

Capacity: 14 Quarts (13.3 liters)

Axle Gear Oil

MobilFluid® 422/423 (recommended)Super Tractor Oil Universal

API GL5 80W90or equivalent

Differential Capacity:9.6 quarts (9.0 liters)

Planetary Capacity (each side):0.6 quarts (0.5 liters)

Transmission Oil

Use Sunco Multi-ATF or equivalentCapacity:

24 quarts (23.0 liters)

Brake System

Use Sunco Multi-ATF or equivalent

GENERAL INFORMATION

NOTE: The MAINTENANCE chapter in thismanual has provisions for recording the dates andhourmeter readings after lubrication or other ser-vice has been performed; use those spaces tokeep a log for maintaining a current service inter-val record. Proper routine lubrication is an impor-tant factor in preventing excessive part wear andearly failure.

LUBRICANTSThe chart on this page lists the locations, temperatureranges and recommended types of lubricants to be usedwhen servicing this machine. Also refer to the separateengine manual for additional information regardingrecommended engine lubricants, quantities requiredand grades.

NOTE: Refer to “Operator Services” in the SER-VICE AND STORAGE chapter of this manual fordetailed information regarding periodic checkingand replenishing of lubricants.

Chapter 7LUBRICATION

WARNINGNEVER lubricate or service this unit when anypart of the machine is in motion. ALWAYSexercise the MANDATORY SAFETY SHUT-DOWN PROCEDURE (p. 8 SAFETY chapter)before lubricating or servicing this equipment.


GREASINGRefer to the illustrations and listings for fitting loca-tions. Wipe dirt from the fittings before greasing themto prevent contamination. Replace any missing or dam-aged fittings. To minimize dirt build-up, avoid exces-sive greasing.

BASIC MACHINEGREASE FITTING LOCATIONS

Every 50 Hours (or weekly)

Refer to the illustration on the facing page for loca-tions.

CHASSIS AREA1 Brake foot pedal linkage . . . . . . . . . . . . . . .12 Wheel spindle pins (per axle) . . . . . . . . . . . .43 Axle to frame pivot pins (per axle) . . . . . . .14 Drive shaft, slip joint (per shaft) . . . . . . . . .15 Drive shaft, U-Joint (per shaft) . . . . . . . . . .26 Level cylinder pivot pins . . . . . . . . . . . . . . .27 Base end lift cylinder pivot pins . . . . . . . . .28 Base end slave cylinder pivot pins . . . . . . . .2

REPLACEMENT FILTER CHARTAIR FUEL ENGINE HYDRAULIC TRANS.

ENGINE TYPE FILTER FILTER OIL FILTER STRAINER OIL

JOHN DEERE Primaryw/ Mechanical Throttle 137498 L98978 102173 L97489 L49327 L99184

Safety137501

JOHN DEERE Primaryw/ Electronic Throttle 137498 102174 102173 L97489 L49327 L99184

Safety137501

BOOM AREA9 Boom to frame upright pivot pins . . . . . . . .210 Rod end slave cylinder pivots pins . . . . . . .211 Rod end lift cylinder pins . . . . . . . . . . . . . . .212 Extend cylinder pivot pins . . . . . . . . . . . . . .213 Chain sheave pins . . . . . . . . . . . . . . . . . . . . .214 Quickattach to boom nose pivot pins . . . . . .215 Tilt cylinder pivot pins . . . . . . . . . . . . . . . . .216 Rotate cylinder pivot pins . . . . . . . . . . . . . .217 Rotate carriage wear pads . . . . . . . . . . . . . .318 Rotate pivot bearing . . . . . . . . . . . . . . . . . . .119 Boom slide pads - as required, front and rear

17

16

18FRONTSIDE


Grease Fittings Locations

2

6

4

5

10

9

13

8UNDERCOVER

11

7

12

12

14

15

15

19

13

19

1

3


GENERAL INFORMATION

NOTE: All service routines, with the exception ofthose described under the “Dealer Services”topic, are owner-operator responsibilities. Alloperator services described under the subtopicsare also referred to on a decal located on theinside right side panel of the operator’s station.Refer to the LUBRICATION chapter of this manu-al for lubrication information.

NOTE: This SERVICE AND STORAGE chapterdescribes procedures to follow for making routinemaintenance checks, adjustments and replace-ments. Most of the procedures are also referred toin the MAINTENANCE chapter of this manual. Forengine related adjustments and servicing proce-dures, refer to the engine manual provided.

PRECAUTIONS

DO NOT perform any maintenance or repair withoutthe owner’s prior authorization. Allow only trainedpersonnel to service the machine.

Warranty repairs can only be done by an authorizedGehl dealer. Dealers know what portions of themachine are covered under the terms of the GehlWarranty and what portions are covered by other ven-dor warranties.

When a problem occurs, do not overlook simple caus-es such as an empty fuel tank. Check for leaks and bro-ken connections. Make note of any specific symptoms,noises, etc. and contact your local Gehl dealer.

IMPORTANT: Always dispose of waste lubri-cating oils, anti-freeze and hydraulic fluidsaccording to local regulations or take them to arecycling center for disposal. DO NOT pour themonto the ground or into a drain.

DEALER SERVICESThe following areas of internal components servicereplacement and operating adjustments should only beby (or under the direction of) an authorized GehlTelescopic Handler dealer.

IMPORTANT: DO NOT service or repair majorcomponents, unless authorized to do so by yourGehl dealer. Any unauthorized repair will void thewarranty.

POWER TRAIN COMPONENTS

The engine and transmission are coupled directly toeach other. All service routines related to the internalcomponents are precise and critical to proper powertrain operation. The axle differential and planetaryends are also sophisticated assemblies that require spe-cial know-how and tools for servicing.

IMPORTANT: If any power train componentsare suspected of faulty operation, contact yourGehl dealer for assistance.

HYDRAULIC SYSTEM COMPONENTS

Valves, pumps, motors and cylinders are also sophisti-cated assemblies which require special know-how andtools for servicing. All cylinders are appropriatelydesigned with particular strokes, diameters, checks andhose connection provisions unique to the machineapplication requirements. A schematic (MAINTE-NANCE chapter) can be used as a guide for servicereference, as required.

Chapter 8SERVICE AND STORAGE

WARNINGBEFORE performimg any service on theTelescopic Handler, unless expressly instruct-ed to the contrary, exercise the MANDATORYSAFETY SHUTDOWN PROCEDURE (p. 8,Safety chapter). After service has been per-formed, BE SURE to restore all guards,shields and covers to their original positionsBEFORE resuming machine operation.


Internal service on any of these components shouldonly be performed by (or under the direction of) anauthorized Gehl Telescopic Handler dealer.

WARNINGTilt, lift, extend and leveling cylinders havecounterbalance valves. These valves keephydraulic fluid from entering and exiting thecylinders while they are not being activated,and they are under extremely high pressure.Before removing one of these valves, youARE REQUIRED to call your Gehl dealer orGehl Service Department. Failure to do somay result in serious injury or death.

ELECTRICAL COMPONENTS

An electrical system schematic is provided, whichincludes instrumentation, electrical components andswitch connections. It is located at the back of thismanual and can be used as a guide for service refer-ence, as required.

OPERATOR SERVICESSome of the operator-related services will requireaccess to components located inside the superstructure,under shields, hoods and covers. The chart on this pagenotes the components accessed in each particular area.

Component Operator’s Frame Front Mid-RearStation Cover Hood

Axle (underside)

Engine

Transmission (center area)

Drive Shafts (underside)

Main Control Valve (rear)

Muffler (underside)

Air Cleaner (top fuel tank)

Battery

Radiator

Brake Valve (underside)

Travel Controls (dash area)

Boom Controls (right side)

Hydraulic Test Ports

Hourmeter (dash)

Switches/Indicators (dash)

Hydraulic Pump

Hydraulic Filter (Reservoir)

Misc. Hydraulic Valves

Heater (lower front)

ACCESS TO COMPONENTS CHART


Choose a clean, level work area. Make sure you havesufficient room, clearances, and adequate ventilation.Clean the walking and working surfaces. Remove oil,grease and water to eliminate slippery areas. Utilizesand or oil absorbing compound, as necessary, whileservicing the Telescopic Handler.

Before starting inspection and repair, move themachine onto a level surface, shut down engine, andrelease all hydraulic pressure. Always block the boomsecurely, or lower it to full ground contact. Place allcontrols in neutral.

Block the wheels. Remove the ignition key. Removeonly guards or covers that provide needed access. Wipeaway excess grease and oil.

Excessively worn or damaged parts can fail and causeinjury or death. Replace any cracked or damaged parts.Use only genuine Gehl parts for service.

Use care not to damage machined and polished sur-faces. Clean or replace all damaged or painted-overplates and decals that cannot be read.

After servicing, check the work performed, that noparts are left over, etc. Install all guards and covers.

CHECK FUEL TANK LEVEL

After operation each day, the fuel tank should be filledto prevent water from condensing in the tank. To fill,remove the filler cap and add fuel.

CHECK ENGINE OIL LEVEL

With the machine on level ground, and the enginestopped for ten minutes or more, slide open the sideengine panel and remove the engine dipstick. Wipe itclean, re-insert it and remove to obtain a reading. If theoil level is down, or below the ADD mark, fill with therequired amount of oil to bring the level to the FULLmark. See the LUBRICATION chapter for the type ofoil to use.

CHECK RADIATOR COOLANT LEVEL

WARNINGDO NOT smoke or allow any open flames inthe area while checking or servicinghydraulic, battery or fuel systems; all containhighly flammable liquids or explosive gases,which can cause an explosion or fire if ignited.

Wear a face shield when you disassemblespring-loaded components or work with bat-tery acid. Wear a helmet or goggles with spe-cial lenses when you weld or cut with a torch.

When working beneath a raised machine,always use blocks, jack-stands or other rigidand stable supports. Wear appropriate protec-tive clothing, gloves, and shoes. Keep feet,clothing, hands and hair away from movingparts.

Always wear safety glasses or goggles for eyeprotection from electric arcs from shorts, flu-ids under pressure, and flying debris or loosematerial when the engine is running or toolsare used for grinding or pounding.

NEVER weld on bucket, forks, boom, supportframe or ROPS/FOPS without the consent ofthe manufacturer. These components may bemade with metals that require special weldingtechniques, or with designs that do not allowweld repairs. NEVER cut or weld on fuel linesor tanks.

If repair welding is ever required, BE SURE toattach the ground (-) cable from the welder asclose as possible to the area to be repaired.Also, remove battery positive (+) terminal con-nection before welding.

Service Every 10 Hours or Daily

WARNINGNEVER leave guards off or access doors openwhen the machine is unattended. Keepbystanders away if access doors are open.

WARNINGDO NOT remove the radiator cap when theengine is running hot or overheated. Coolantis extremely hot and under pressure and it canburn your skin. Allow sufficient time for theradiator to cool BEFORE relieving the pres-sure and removing the radiator cap.


With the machine on level ground, remove the radiatorcap. If the coolant level is below the filler neck, add alow-silicate ethylene glycol base coolant mixed withquality water and supplemental coolant additives(SCAs) suitable for heavy duty diesel engines. Seeyour engine manual for additional information.Replace the radiator cap securely.

NOTE: If the engine is operated with a looseradiator cap, the pressure bypass will not workand the engine will run hot.

CHECK TRANSMISSION OIL LEVEL

The machine must be on level ground. With the engineand transmission at operating temperature parkingbrake on, transmission in neutral and engine speed atlow idle, remove the access cover to the transmissionand hydraulic pump. Remove the dipstick and checkthe oil level. Add the required amount of oil to bringthe level to the FULL mark. See the LUBRICATIONchapter for the type of oil to use.

CHECK HYDRAULIC OIL LEVEL

The machine must be on level ground with boom low-ered and completely retracted. The fluid MUST be coolwhen checking the reservoir level, to reduce the possi-bility of overfilling the hydraulic system.

Locate the filler cap next to the side view mirror on theright side od the machine. Remove the filler cap andcheck the level on the dipstick. If the oil level is down,or below the ADD mark, fill with the required amountof oil to bring the level to the FULL mark. See theLUBRICATION chapter for the type of oil to use.

IMPORTANT: Be careful when removing thereservoir filler cap so that no dirt or other foreignmatter enters the hydraulic system. DO NOTOVERFILL.

CHECK BRAKE RESERVOIR LEVELS

Flip up the cover on the cab floor in front of the seat.Remove both reservoir covers to check the fluid levels.If low, fill to the proper level with the correct fluid. Seethe LUBRICATION chapter for the type of fluid touse.

CHECK TIRE PRESSURES

Proper tire pressure should be maintained for all fourtires to enhance operating stability and extend tire life.

When installing tires on the machine, be sure that alltires are of the same size and style. ALWAYS replacetires with the same size furnished as original equip-ment. Replacement tires must be purchased locally.

Check the tire pressure “cold.” All 12-ply tires shouldbe inflated to 55 PSI (380 kPa).

NOTE: If the tires have been filled with water orcalcium chloride for balast, a calcium chloride tirepressure gauge MUST be used to check the tirepressure.

When removing tires, follow industry safety practices.Deflate completely prior to removal. After assembly ofthe tire onto the rim, use a safety cage or restrainingdevice while inflating.

WARNINGInflating or servicing tires can be dangerous.Whenever possible, trained personnel shouldservice and mount tires. To avoid possibledeath or serious injury, follow the safety pre-cautions below:1. BE SURE the rim is clean and free of rust.2. Lubricate both the tire beads and rim

flanges with a soap solution. DO NOT useoil or grease.

3. DO NOT place your fingers on the tire beador rim during inflation. Use a clip-on tirechuck with a remote hose and gauge,which allows you to stand clear of the tirewhile inflating it.

4. NEVER inflate beyond 35 PSI (240 kPa) toseat the beads. If the beads have NOTseated by the time the pressure reaches 35PSI (240 kPa), deflate the assembly, repo-sition the tire on the rim, relubricate bothparts and re-inflate. Inflation pressurebeyond 35 PSI (240 kPa) with unseatedbeads may break the bead or rim withexplosive force sufficient to cause deathor serious injury.

5. After seating the beads, adjust the inflationpressure to the recommended operatingpressure listed.

6. DO NOT weld, braze, or otherwise attemptto repair and use a damaged rim.


CHECK PERSONNEL WORK PLATFORMSAFETY SYSTEM (if to be used)

The following must be performed before begining thePWP System checking procedures:1. Machine on level surface, and boom fully lowered,2. Frame level,3. Transmission in “NEUTRAL”,4. Parking brake switch “OFF”,5. Work platform system switch “OFF”, and remote

switch plugged in and “ENGAGED”.Procedure to test the PWP System mode enable logic:1. Start the engine and turn the PWP switch “ON”.

PWP mode lamp in the switch should be flashing.

2. Apply the service brakes.After two seconds, the PWP mode lamp

should be on continously, indicating that the sys-tem has been activated.

Parking brake should engage, as indicated bythe lamp on the parking brake switch lighting.

The carriage tilt and auxiliary functions shouldnow be disabled. The hydraulic joystick shouldfunction as normal for boom raise/lower andextend/retract.

Procedure to test the transmission and joystick controllockout:3. Shift transmission into “FORWARD” and increase

the engine speed slightly.The transmission should remain de-clutched

and allow the engine to gain rpm easily.Return the transmission selector to “NEU-

TRAL” to complete the check.4. Have an assistant move the remote switch to “DIS-

ENGAGED”.The hydraulic joystick should now be disabled

such that boom raise/lower and extend/retract nolonger function.

Have the assistant move the remote switch to“ENGAGED” after completion of the check.

5. Tilt the frame to the right slightly more than 2degrees.

The hydraulic joystick should now be disabled

CHECK WHEEL NUT TORQUE

On new machines, or any time a wheel has beenremoved, re-torque until 450 ft-lbs (610 Nm) is main-tained.

CHECK INSTRUMENTS OPERATION

Allow the engine to warm up for about five minutesbefore beginning operation. Indicator lamps should beOFF and gauges should register normal readings. Tiltthe frame from side to side with the frame levelingcontrol and note the angle indicator movement.

CHECK GENERAL MACHINE OPERATIONAND CONDITION, INCLUDING PROPERINSTALLATION OF PERSONNEL WORKPLATFORM (if applicable)

Are any decals missing or damaged? Are all guards,shields and covers in place? Do all controls functionsmoothly and properly? Are there any abnormal vibra-tions or noises? Are any hose or fitting connectionsleaking? Is the engine exhaust color normal?

WARNINGManufacturers of push-pull control cablesadvise taking the following operation andmaintenance precautions:

Do not adjust the control cable with the enginerunning.

A gradual or sudden increase in the no-loadfriction (cable disconnected at both ends) of acontrol cable is an indication of an impendingor present performance problem. The controlcable should be replaced.

A gradual or sudden decrease in the useabletravel is a indication of an impending or pre-sent performance problem. The cable shouldbe replaced.

Control cables that have moisture inside ofthem and/or have frozen should be replaced.Do not apply heat to thaw or dry controlcables.

Control cable are lubricated for the life of thecontrol cable. Do not remove the seals orlubricate the control cable.

Control cables are designed to be non-repairable. Do not attempt to repair controlcables.

Failure to heed could result in death or seri-ous injury.


such that boom raise/lower and extend/retract nolonger function.

Repeat the procedure with the frame tilted tothe left.

Return the frame to a level position after com-pletion of the check.

Procedure to test the PWP mode disable logic:6. Turn the ignition key switch to “OFF” and wait for

the engine to stop completely. Then turn the keyswitch to “ON”.

The PWP mode lamp and the parking brakelamp should be illuminated.

7. Turn the key switch “OFF” and then turn the PWProcker switch “OFF”. Turn the key switch back“ON”.

The PWP mode lamp should be flashing and thepark brake lamp should be on continously.

8. Start the engine and apply the service brakes.The PWP mode lamp and the parking brake

lamp should go off after approximately two sec-onds of service brake application.

LBRICATE GREASE POINTS

Refer to the LUBRICATION chapter of this manualfor weekly grease fitting locations and other relateddetails.

CHECK FUEL FILTER

NOTE: The fuel filter will require occasionalreplacement to maintain a clean and adequatefuel flow for maximum engine horsepower. Thefrequency of filter replacement will be determinedby the cleanliness of available fuel, the care usedin storing fuel supplies and the operating condi-tions in which the machine is used.

Small amounts of water can be drained from the fuelfilter. The drain plug should be removed weekly todrain off water accumulation until clear fuel is flowing

from the outlet.

A drain plug is also provided in the bottom of the fueltank for removing condensation and other foreignmaterials. Open the plug and allow water and fuel todrain into a container until only clear fuel is flowingfrom the tank.

The following initial oil and filter changes should bemade at 100 hours on a new machine. Thereafter thesechanges should be made at the regular maintenanceschedule listed below. Refer to those schedules for thenecessary procedures.

Engine Oil and Filter (250 Hours)Transmission Oil and Filter (1000 Hours)Hydraulic Return Filter Element (1000 Hours)

NOTE: Perform all other service requirementsup to this point, as well as the following:

CHECK AXLE OIL LEVELS

Differential

NOTE: The Telescopic Handler should be on alevel surface for this procedure.

See illustration. Remove the oil check plug. Oil shouldflow from the hole. If low, remove the oil fill plug andadd oil until it flows from the check hole. Replace theplug, wait 10 to 15 minutes and repeat the fill proce-dure. Continue this process until the differential is full.See the LUBRICATION chapter for the proper oilspecification. Replace the check and fill plugs.

Service Every 50 Hours or Weekly

Service Every 250 Hours or Quarterly

100 Hours (New Machine Only)

WARNINGIf the PWP System fails to operate properlyduring any of the PWP System checks, DONOT USE the machine until the cause hasbeen corrected. Contact your dealer (or GehlCompany) for service information and parts.

Drain Plug

Fill PlugCheck Plug


Planetary Hubs

NOTE: The planetary hubs can be checked with-out jacking up the machine.

See illustration below. The planetary hubs have oneplug each used for filling and draining. For checkingthe level and filling, position the wheel until the oillevel arrow is horizontal. Remove the plug. If oil doesnot run out, add oil until it overflows. Check theremaining hubs the same way. Refer to the oil specifi-cations found in the LUBRICATION chapter of thismanual.

CHANGE FUEL FILTER

The frequency of filter replacement will be determinedby the cleanliness of available fuel, the care used instoring fuel supplies and the operating conditions inwhich the machine is used.

NOTE: For proper replacement procedures referto the engine manual for your machine.

After fuel filter replacement, bleed the air out of thefuel system following the procedures in the enginemanual.

Fuel Bleeding Procedures

When the fuel filter is removed and replaced, or theengine runs out of fuel, air must be bled from the sys-tem. Refer to the engine manual for proper bleedingprocedures.

If the engine still will not start, consult your authorizedengine dealer.

NOTE: Only an authorized engine dealer canperform warranty service on the engine.

Diesel Fuel Injectors

Whenever faulty or plugged injectors are indicated, seeyour authorized engine dealer.

Diesel Injection Pump Timing

Whenever injection pump timing, or other pump ser-vice is indicated by abnormal engine operation, contactyour engine dealer.

CHANGE ENGINE OIL AND FILTER

Change the engine oil and filter using the followingprocedure:

1. With the engine warm, remove the crankcase drainplug. Some plugs are equipped with a magnet togather metal particles. Completely clean and flushaway all metallic filings from the plug and re-install it.

IMPORTANT: DO NOT discharge oil ontoground. Catch and dispose of per local waste dis-posal regulations.

2. The engine oil filter should be changed at every oilchange interval. Remove and discard the disposi-ble filter canister. Wipe the gasket sealing area ofthe block with a clean cloth.

IMPORTANT: Your OEM engine oil filters havespecial by-pass valves built in. Use only genuineOEM engine replacement filters.

3. Apply a thin coat of clean oil to the new oil filtergasket. Hand tighten. Refill the crankcase withnew oil. Follow specifications in the LUBRICA-TION chapter for type and viscosity of new oil.

WARNINGNEVER service the fuel system while smok-ing, while near an open flame, or after theengine has been operated and is hot.

Plug in fill andcheck position.

WARNINGEscaping diesel fuel under pressure can havesufficient force to penetrate the skin. Beforeapplying pressure to the fuel system, BESURE all connections are tight and lines andhoses are not damaged. Use a piece of woodor cardboard to search for suspected leaks. Ifinjured by escaping fuel, see a doctor familiarwith this type of injury at once or gangrenemay result.


4. After new oil has been added, run the engine at idlespeed until the oil pressure lamp is OFF. Check forleaks at the filter and drain plug. Re-tighten only asmuch as necessary to eliminate leakage.

CHECK THE BATTERY

The battery furnished in the machine is a 12-volt, wet-cell battery.

Handling Battery Safely

The top of the battery must always be kept clean. Cleanthe battery with a brush dipped in an alkaline solution(ammonia or baking soda and water). After the foam-ing has stopped, flush the top of the battery with cleanwater. If the terminals and cable connection clamps arecorroded or have a buildup, disconnect the cables andclean the terminals and clamps with the same alkalinesolution.

NOTE: The battery in this machine is warrantedby the supplier. See the punch tag on the top ofthe battery for warranty information.

Jump Starting

If the battery becomes discharged or does not haveenough power to start the engine, use jumper cablesand the following procedure to jump-start the engine.

IMPORTANT: BE SURE that the jumper batteryis also a 12-volt D. C. battery, and the vehicleused for jump starting has a negative-groundelectrical system.

1. Turn the keyswitches on both vehicles to “OFF”.Be sure that both vehicles are in “Neutral” andNOT touching.

2. Connect one end of the positive (+) jumper cableto the positive (+) battery terminal on the disabledmachine first. DO NOT allow the positive (+)jumper cable clamps to touch any metal other thanthe positive (+) battery terminals. Connect theother end of the positive jumper cable to thejumper battery positive (+) terminal.

WARNINGThe ONLY safe method for jump-starting adisharged battery is for TWO PEOPLE to per-form the following procedure. The second per-son is needed for removing the jumper cablesso that the operator does not have to leave theoperator’s compartment while the engine isrunning. NEVER connect the jumper cablesdirectly to the starter solenoid of eitherengine. DO NOT start the engine from anyposition other than the operator’s seat, andthen ONLY after making sure all controls are in“neutral.”

Closely follow the jump-start procedures, inthe order listed, to avoid personal injury. Inaddition, wear safety glasses to protect youreyes, and avoid leaning over the batterieswhile jump-starting.

DO NOT attempt to jump-start the machine ifthe battery is frozen, because this may causeit to rupture or explode.

4. To neutralize acid spilled on the floor, useone of the following mixtures:

a. 1 pound (0.5 kg) of baking soda in 4quarts (4 liters) of water.

b. 1 pint (0.4 liters) of household ammo-nia in 4 quarts (4 liters) of water.

Whenever battery is removed from the unit,BE SURE to disconnect the negative (-) bat-tery terminal connection first.

WARNINGExplosive gas is produced while a battery is inuse or being charged. Keep flames or sparksaway from the battery area. Make sure batteryis charged in a well-ventilated area.

NEVER lay a metal object on top of a batteryas a short circuit can result.

Battery acid is harmful on contact with skin orfabrics. If acid spills, follow these firstaid tips:

1. IMMEDIATELY remove any clothing onwhich acid spills.

2. If acid contacts the skin, rinse the affectedarea with running water for 10 to 15 min-utes.

3. If acid comes in contact with the eyes,flood the eyes with running water for 10 to15 minutes. See a doctor at once. NEVERuse any medication or eye drops unlessprescribed by the doctor.


Extend the boom to its maximum length. Then retractthe boom slowly until the chain slack allows the chainto rest on the top of the boom. Torque the chains on thefront of the boom to 25 ft-lb (34 Nm). Lubricate with80W90 oil.

CHECK BOOM SLIDE PADS WEAR AND CLEARANCE

The boom is equipped with special nylon low frictionslide pads between the telescopic sections (see illus-tration). These are pre-greased and initially worn-in atthe factory. Normally greasing is not required, exceptfor maintaining a light film of grease on the pad track-ing areas of the boom sections. An exception would beif a boom section has been replaced.

Visually check for loose pad bolts. The bolts aretorqued to 30 ft-lb (40 Nm). If the bolts are re-torquedat any time, Loctite® thread lock must be re-applied tothe bolts.

If the boom starts to chatter under load, grease the slidepads and wipe off the excess. If a top or side slide pad

3. Connect one end of the negative (-) jumper cableto the jumper battery negative (-) terminal.

4. Make the final negative (-) jumper cable connec-tion to the disabled machine’s engine block orframe (ground) -- NOT to the disabled battery neg-ative post. If making the connection to the engine,keep the jumper clamp away from the battery, fuellines, or moving parts.

NOTE: Twist the jumper cable clamps on thebattery terminals to ensure a good electrical con-nection.

5. Proceed to start the machine. If it does not startimmediately, start the jumper vehicle engine toavoid excessive drain on the booster battery.

6. After the machine is started and running smoothly,have the second person remove the jumper cables(negative (-) jumper cable first) from the jumpervehicle battery, and then from the disabledmachine, while ensuring NOT to short the twocables together.

Allow sufficient time for the alternator to build up acharge in the battery before operating the machine orshutting off the engine.

NOTE: If the battery frequently becomes dis-charged, have the battery checked for possibledead cells, or troubleshoot the electrical systemfor possible short circuits or damaged wire insula-tion.

CHECK AND TORQUE BOOM LEAFCHAINS

Inspect the leaf chains for wear and proper tension.Two of the chains are on the top front of the boom. Athird chain is accessible from inside the rear of theboom (see boom illustration).

Run the boom out slowly to inspect. Conditions to lookfor include cracked or broken plates, protruding orturned pins, excessive wear. With a steel tape, measure16 links of the strand that flexes over the sheaves.When the distance measures 10.3” (262 mm), the chainshould be replaced. DO NOT repair sections of a chain.Replace the complete chain.

Chain anchors and sheaves also require inspection forwear or broken fingers and worn flanges. If any chainhas been replaced, operate under loaded conditions andre-check the torque. Adjust the chains per the follow-ing procedure.

Chain Hookup Detail

InnerSection

OuterSection

IntermediateSection

Two FrontBoom ChainsOne Rear

Boom Chain

Slide Pad Detail

Rear Inner

Shim

Pad

FrontOuter


4. Start and run the machine long enough for the oilto circulate and warm slightly. Recheck the levelwith the dipstick.

CHANGE RADIATOR COOLANT

Drain, flush and refill the cooling system as follows:

IMPORTANT: DO NOT discharge coolant ontoground. Catch and dispose of per local waste dis-posal regulations.

1. Loosen the radiator cap to its stop. This willrelease any system pressure. Remove the cap whenall pressure is bled off.

2. Open the radiator drain cock. Remove the waterjacket drain plug from the engine block. When allcoolant is drained, flush the system with cleanfresh water. Allow the flush to drain completely.

3. Replace all drain plugs and tighten the radiatordrain cock. Clean the cooling fins in the radiatorwith water pressure or steam.

IMPORTANT: Fill the cooling system with alow-silicate ethylene glycol base coolant mixedwith quality water and supplemental coolant addi-tives (SCAs) suitable for heavy-duty dieselengines. See your engine manual for additionalinformation.

4. Inspect the radiator cap seal before installing it.Replace it if it appears to be damaged. The 10 PSI(70 kPa) pressure cap and engine thermostat workin conjunction with each other to maintain properengine cooling.

NOTE: Check the engine temperature gaugeevery minute or two after coolant has beenchanged. Air pockets can form and it may be nec-essary to refill the cooling system after a shortperiod of use, as the air will naturally bleed out ofthe system.

shows excessive wear, loosen bolts and insert shims toeach side or top and bottom for even distribution ofclearance. Re-apply Loctite® thread lock to the boltsand re-torque to 30 ft-lbs (40 Nm). Bottom slide padsshould be replaced when the thickness is worn down to3/8” (9.5 mm).

CHECK PERSONNEL WORK PLATFORMSYSTEM

Follow the procedure for checking the PWP System asoutlined on page 50.

NOTE: Perform all other service requirementsup to this point, as well as the following:

CHANGE TRANSMISSION OIL AND FILTER

Operate the machine long enough to warm up thetransmission oil. Shut down the engine. Access to filterand drain plug is from underneath the machine.Proceed as follows:

1. Remove the drain plug and drain old oil. Replacethe drain plug.


2. Remove and discard the oil filter. Wipe the sealingsurface on the transmission with a clean cloth.Apply a thin coat of clean oil to the new oil filtergasket. Hand tighten.

3. Refill the transmission with new oil as shown inthe LUBRICATION chapter of this manual.

IMPORTANT: DO NOT OVERFILL! lf the oillevel is too high, oil foaming, excessively high oiltemperature and oil leakage at the seals couldresult.

WARNINGRemove the radiator cap only when the engineis cool, or painful burns could result.

Service Every 1000 Hours or Yearly

WARNINGFailure to maintain proper slide pad clearanceand thickness could cause damage to theboom, resulting in sudden boom failure.


CHANGE HYDRAULIC RETURNFILTER ELEMENT

This element is a cartridge type accessible from a hous-ing on top of the hydraulic reservoir. Initial replace-ment is after the first 100 hours. See illustration.Remove the top cover of the housing. Remove the ele-ment and discard. Insert the new element into the hous-ing and replace the cover.

CHANGE AIR FILTER ELEMENT

IMPORTANT: Failure to follow proper filter ser-vicing instructions could result in catastrophicengine damage.

The air cleaner assembly consists of an outer (primary)filter element and an inner (secondary) filter element.An air filter restriction indicator for monitoring thecondition of the elements is located in the rubber elbowat the rear of the air cleaner. If the air filter becomesrestricted, this indicator turns red to warn the operatorthat the air cleaner requires service. Push the reset but-ton located at the end of the indicator after replacingthe element

NOTE: Before replacing the filter element(s),push the reset button on the indicator. Start theengine and run at full throttle. If the indicator doesnot turn red, do not replace the element(s).

The outer element should be replaced only when therestriction indicator turns red. The inner elementshould be replaced every third time the outer elementis replaced, unless the outer element is damaged or theinner element is visibly dirty. Along with a daily checkof the restriction indicator, check that the air cleanerintake hose and clamps, and the mounting brackethardware are properly secure.

1. Unlatch the three latches on the air cleaner andremove the cover. Clean out any dirt built up in thecover assembly.

2. Carefully pull the outer element out of the housing.Never remove the inner element unless it is to bereplaced.

3. Clean out any dirt built up in the housing. Leavethe inner element installed during this step to pre-vent debris from entering the engine intake mani-fold.

4. Use a trouble light inside the new outer element toinspect for bad spots, pinholes or ruptures.

IMPORTANT: NEVER use an element that isdamaged. Severe engine wear and eventualfailure can result if dirt gets through a hole inthe element. Cleaning the outer element is notrecommended.

NOTE: Replace the inner element only if it is vis-ibly dirty or if the outer element has beenreplaced three times.

Before removing the inner element from the housing,clean out any dirt built up in the housing. Leave theinner element installed during this step to preventdebris from entering the engine intake manifold.Remove the inner element.

5. Check the inside of the housing for any damagethat may interfere with the elements.Air Cleaner Assembly

WARNINGBefore servicing the hydraulic system, lowerthe boom to the ground.

Reservoir Filter Removal

Housing Top

Filter Element

Filter Housing

TOP OFRESERVOIR

Inlet Cap

Inner SafetyElementOuter Filter

Element

MountingBandElement

Cover

RestrictionIndicator

DustEjector



2. Re-position the hub so the oil level arrow is hori-zontal. Fill with fresh oil as specified in theLUBRICATION chapter. When the oil runs out,install the drain/fill plug. Repeat this procedure onthe three remaining hubs.

CHECK ALTERNATOR ANDFAN BELT CONDITON

Refer to the engine manual for proper belt tensionadjustment and replacement procedures. If the beltshows wear or cuts, it should be replaced. Orderreplacement belt from your engine dealer.

CHECK EXHAUST SYSTEM

Examine the muffler and tail pipe for possible holes.Re-tighten any loose clamps and make sure the mani-fold outlet gasket is not leaking.

NOTE: Perform all other service requirementsup to this point, as well as the following.

CHECK HYDRAULIC SYSTEMRELIEF PRESSURES

Pressure settings for relief valves are pre-set at the fac-tory. Three test ports are provided under the front hoodaccess cover.

6. Be sure that the element sealing surfaces are clean.7. Insert the element(s), making sure that they are

seated properly.8. Secure the cover to the housing with the three

clamps.9. Check the hose connections and make sure they

are all clamped and tightened properly.

NOTE: Keep spare elements on hand to elimi-nate down time.

CHANGE AXLE DIFFERENTIALAND PLANETARY OIL

Differentials

1. Remove the three drain plugs and drain out the oldoil. Replace the drain plugs (see illustration).


2. Remove the check and fill plugs. Fill the differen-tial with oil as specified in the LUBRICATIONchapter. When the oil flows the check hole, replacethe plug. Wait 10 to 15 minutes and repeat thisprocess until the axle is full. Repeat this procedurewith the other axle.

Axle Planetary Hubs

The hubs have one plug each used for draining and fill-ing (see illustration).

1. Position the wheel until the oil level arrow pointsdown. Remove the drain/fill plug and allow the oilto drain out. Replace the plug.

Service Every 2000 Hours or Two Years

Drain Plug

Fill Plug Check Plug

Plug in drainposition.

Test ports underaccess cover.


Before conducting any test port pressure checks, checkthe engine RPM. Engine speed must be 800 RPM atidle and 2500 to 2550 RPM at high idle.

Steering Relief Pressure

Plug a 3000 PSI (207 bar) oil-or liquid-filled gaugeinto the test port labeled ”SP”. Cramp the steering fullyto the right or left. The gauge should read 2000 PSI(138 bar).

Joystick and Parking Brake ReleasePressure

Plug a 1000 PSI (70 bar) gauge into the port labeled“JP”. With the engine running, the gauge should read400-425 PSI (27-29 bar).

Main Relief Pressure

Plug a 3000 PSI (207 bar) oil-or liquid-filled gaugeinto the test port labeled “MP”. Fully retract the boomover the relief valve. The gauge should read 3000 PSI(207 bar).

CHANGE HYDRAULIC RESERVOIROIL AND STRAINER

Clean all dirt and debris from around the top of thereservoir, especially around the access cover. Refer toillustration and use the following procedure:

1. Remove the drain plug and drain out all used oil.Wash or blow off all particles collected on themagnetic drain plug.


2. Remove the access cover and wash the inlet screenwith clean solvent. Remove the sump filter strain-er from the bottom inside of the reservoir. Wash italso. If the strainer has any damage, holes, etc., itshould be replaced.

3. Flush out the bottom of the tank with cleanhydraulic oil. Re-install all cleaned componentsand put the access cover back on the reservoir witha new gasket. Clean the filter/breather cap.

4. Fill the tank with fresh oil. Follow specificationsfound in the LUBRICATION chapter of this man-ual.

IMPORTANT: Hydraulic fluid and filters shouldbe replaced any time contamination is presentbefore the normally scheduled change.

Hydraulic Reservoir Sump Strainer Removal

Fill CapDipstick

AccessCover

Gasket

Element

TOP OFRESERVOIR

WARNINGEscaping hydraulic oil under pressure canhave sufficient force to penetrate the skin.Before applying pressure to the hydraulic sys-tem, be sure all connections are tight andlines and hoses are not damaged. Use a pieceof wood or cardboard to search for suspectedleaks. If injured by escaping hydraulic oil, seea doctor familiar with this type of injury atonce or gangrene may result.


STORAGE

If the Telescopic Handler will not be operated for along period of time, prepare and store it using the fol-lowing procedure:

Before Storage

Perform the following prior to placing the machine instorage:

1 Wash off the entire machine.2. Lubricate all grease fittings as described in the

LUBRICATION chapter of this manual.3. Change engine oil as outlined in the SERVICE

AND STORAGE chapter of this manual.4. Apply grease to all exposed hydraulic cylinder rod

areas.5. Disconnect the battery cable clamps and cover the

battery or remove the battery from the machineand store it separately.

6. If the ambient temperature (at any time during thestorage period) is expected to drop below freezing,make sure the engine coolant is either completelydrained from the radiator and engine block or thatthe amount of anti-freeze in it is adequate to keepthe coolant from freezing. Refer to the separateengine manual provided for anti-freeze recommen-dations and quantities.

During Storage1. About once each month, connect the battery and

check all fluid levels to make sure they are at theproper level before starting the engine.

2. Start the engine and allow it to run until it warmsup and then move the machine a short distance tohelp relubricate the internal parts. Run the engineuntil the battery has a chance to recharge and thenshut it off.

IMPORTANT: If it is desired to operate thehydraulic cylinders at this time, BE SURE to wipethe protective grease (and any adhering dirt) fromthe cylinder rods prior to starting the engine. Afteroperating, BE SURE to recoat the cylinder rodswith grease if the machine is to be returned tostorage.

After Storage

After removing the machine from storage andBEFORE operating it, perform the following:

1. Change engine oil and filter to remove condensa-tion or other residues.

2. Wipe off grease from cylinder rods.3. Lubricate ALL grease fittings.4. Review and re-familiarize yourself with all safety

precautions as outlined in the SAFETY chapter ofthis manual.

5. Follow the starting and warm-up procedures asoutlined in the OPERATION AND ADJUST-MENTS chapter of this manual.


Problem

PWP System mode lamp flash-es when switch is turned “ON”.

Parking brake did not engagewhen the PWP System switch isturned “ON”.

Carriage tilt and auxiliary func-tions continue operating whenthe PWP System switch isturned “ON”.

Transmission does not remainde-clutched when shifted into“FORWARD or REVERSE”when the PWP switch is “ON”.

Boom control functions do notoperate.

PWP System mode lamp flash-es when switch is turned “OFF”.

Parking brake lamp stays “ON”when PWP System switch isturned “OFF”.

Possible Cause

PWP System not activated.

Machine is not level.

Remote PWP System switch isde-activated.

Remote PWP System switch isnot plugged into the connector atthe end of the boom.

PWP System level sensorunplugged or faulty.

PWP System is not de-activated.

Remedy

With PWP System switch “ON”,apply service brakes for two sec-onds until PWP mode lamp is oncontinously.

Level the machine.

Activate the remote PWPSystem switch.

Plug in and engage the remotePWP System switch.

Contact your Gehl dealer forassistance.

With engine running, apply ser-vice brakes for two seconds untilPWP mode lamp goes off.

PWP SYSTEM OPERATIONAL TROUBLESHOOTING


GENERAL INFORMATION

Decal locations information is provided to assist in theproper selection and application of new decals, in theevent the original decals become damaged or themachine is repainted.

For correct replacement of decals, compare the loca-tion illustrations to your machine before starting torefinish the unit. Check off each required decal usingthe illustration reference number to find the part num-ber, description and quantity in the list. Refer to theappropriate illustrations for replacement locations.

NEW DECAL APPLICATIONBefore applying the new decals, surfaces must be freefrom dirt, dust, grease and other foreign material. Toapply a solid-formed decal, remove the smaller portionof the decal backing paper and apply this part of theexposed adhesive backing to the clean surface whilemaintaining proper position and alignment. Slowlypeel off the other portion of the backing paper whileapplying hand pressure to smooth out decal surface. Toapply a die-cut decal, first remove the backing paper.Then, properly orient and position the decal onto theclean mounting surface. After the decal is firmlyapplied and smoothly pressed down, remove the frontcovering paper.

PAINT FINISH

Use this list to order paint for refinishing:

906213 One Gallon Yellow906214 6 (12 oz. Spray Cans) Yellow184765 One Gallon Gun Metal Gray910100 6 (12 oz. Spray Cans) Gun Metal Gray

Decal Kits

103369 RS5-34 Telescopic Handler without PWP103372 RS5-34 Telescopic Handler with PWP

NOTE: Decals may be purchased in kits or indi-vidually.

Chapter 9DECAL LOCATIONS

CAUTIONALWAYS read and follow the safety precau-tions on decals. Replace decals if they aredamaged, or if the unit is repainted. If repaint-ing, BE SURE that all applicable decals areaffixed in their proper locations.


REF. DESCRIPTION PART NO.NO.

01 DANGER - HANDS OUT L7030502 WARNING - PINCH POINT L6592703 WARNING - JUMP START L6593304 GEHL, 5.00” 10202705 QUICKATTACH DIAGRAM L65937

06 GEHL, 6.75” 18406907 ANTI-FREEZE 05685908 HALF ZONE MARKER (5 ea.) L6258309 NO. “0” EXTENSION MARKER (1 ea.) L67718

NO. “1” EXTENSION MARKER (1 ea.) L67719

NO. “2” EXTENSION MARKER (1 ea.) L67720NO. “3” EXTENSION MARKER (1 ea.) L67721NO. “4” EXTENSION MARKER (1 ea.) L67722NO. “5” EXTENSION MARKER (1 ea.) L67723

10 COOLANT UNDER PRESSURE 072798

11 WARNING - NO RIDERS L6593212 BRAKE FLUID L6347413 OPERATOR MANUAL WARNING 10035914 DANGER-PERSONNEL INJURY (units without PWP) L6592815 CARRY LOAD LOW L6592616 LUBE CHART 10322917 ROPS & FOPS CERTIFICATION 10332618 RS5-34 LH 103328

DECAL LOCATIONS - FRAME AND BOOM

52

2

15

69

89

4

10

7

14

11

12

13

16

1718

3

1

2



01 DANGER - HANDS OUT L7030502 WARNING - PINCH POINT L6592703 GEHL, 6.75” 18406904 HYDRAULIC OIL FILL 13763205 WARNING - NO RIDERS L65932

06 Gehl 2.00” 10202607 DANGER-PERSONNEL INJURY (units without PWP) L6592808 QUICKATTACH UNLOCKED L6661309 DIESEL FUEL 13763410 RS5-34, RH 103329

11 HOT SURFACE L65942

DECAL LOCATIONS - FRAME AND BOOM

2

94

2

3

12

7

6

11

5

8

10



01 WARNING-TILT HAZZARD/GENERAL OPERATOR L7030602 WARNING-MACHINE LEVEL L6593003 WARNING - CARRY LOAD LOW L6592604 F-N-R SHIFT L6829505 MADE IN USA 14051606 WARNING - PARK BRAKE/SEAT BELT 101506

07 STANDARD CARRIAGE LOAD CHART 101570ROTATING CARRIAGE LOAD CHART 101666BUCKET LOAD CHART 101572TRUSS BOOM LOAD CHART 101574WINCH LOAD CHART 101573

08 ATTACHMENT TILT/FRAME LEVEL L63632

09 BOOM CONTROL L6363110 AUXILIARY HYDRAULIC CONTROL (Optional) 10271811 IGNITION/START/HORN 10271712 WARNING-BACKUP ALARM L50044513 DANGER-HI VOLT./MOVING PARTS L70307

DECAL LOCATIONS - OPERATOR STATION

2

1

12

11

6

7 8 9 10

3

13

4

5



01 WARNING-PERSONNEL LIFT L7155402 WARNING-WORK PLATFORM RULES L7155503 PERSONNEL LIFT SAFETY RULES L7170004 PWP LOAD CHART 10333405 PWP SWITCH 10296906 PWP SYSTEM 103028

DECAL LOCATIONS - PWP EQUIPPED UNITS

21

4

6

5

1

3


This Maintenance Interval Chart was developed to match the SERVICE AND STORAGE chapter of this manual.Detailed information on each Service Procedure may be found in the SERVICE AND STORAGE chapter. AMaintenance Log follows the Maintenance Interval Chart for recording the maintenance procedures performed.Recording the 10-Hour (or Daily) service procedures would be impractical and is therefore not recommended.

IMPORTANT: Under extreme operating conditions, more frequent service than the recommendedintervals may be required. You must decide if your operation requires more frequent service.

Chapter 10MAINTENANCE

SERVICE PROCEDURE Every 10 Every 50 First 100 Every 250Hours Hours Hours Hours (or(or Daily) (or Weekly) Quarterly)

Check Fuel Tank Level

Check Engine Oil Level

Check Radiator Coolant Level

Check Transmission Oil Level

Check Hydraulic Oil Level

Check Brake Reservoir Level

Check Tire Pressures

Check Wheel Nut Torque 1,2

Check Instruments Operation

Check General Machine Operation and Condition

Check Personnel Work Platform Safety System

Lubricate Grease Points

Check Fuel Filter (Drain Water If Required)

Change Engine Oil and Filter 2

Change Transmission Oil and Filter 2

Change Hydraulic Oil Filter 2

Check Axle Oil Levels

Change Fuel Filter

Change Engine Oil and Filter

Check Battery1 - On new machines or when a wheel has been removed until 450 Ft-Lbs (610 Nm) is maintained.2 - Only New Machines.

MAINTENANCE INTERVAL CHART


SERVICE PROCEDURE Every 250 Every 1000 Every 2000Hours (or Hours (or Hours (orQuarterly) Yearly) Two Years)

Check and Torque Boom Leaf Chains

Check Boom Slide Pads Wear and Clearance

Check Personnel Work Platform System

Change Transmission Oil and Filter

Change Radiator Coolant

Change Hydraulic Return Filter Element

Change Air Filter Element

Change Axle Differential and Planetary Oil

Check Alternator and Fan Belt Condition

Check Exhaust System

Check Hydraulic System Relief Pressures

Change Hydraulic Reservoir Oil and Strainer

MAINTENANCE INTERVAL CHART (CONT.)

Date Hours Service Procedure

MAINTENANCE LOG



MAINTENANCE LOG


Hydraulic Schematic w/o PWP(continued on next page)

“B”

“A”


Hydraulic Schematic w/o PWP(continued from previous page)

“B”

“A”


Hydraulic Schematic with PWP(continued on next page)

“A”

“B”

“C”


Hydraulic Schematic with PWP(continued from previous page)

“A”

“B”

“C”


Electrical Schematic

“I”“H”“G”

“F”“E”“D”

“C”“B”

“A”

“K”

“J”


Load Zone Charts

Decal 101570Standard Carriage

Decal 101666Rotating Carriage

Decal 1015721.3 Cu. Yd. Bucket

Decal 1015748 Ft. Truss Boom


Decal 103334PWP

Decal 101573Winch Boom

Load Zone Charts


Dry Lubed Dry Lubed Dry Lubed

Grade 2 Grade 5 Grade 8Unified NationalThread

Torque SpecificationsUse these torque values when tightening Gehl hardware (excluding: locknuts and self-tapping, thread-forming and metalscrews) unless otherwise specified.

8-32 19* 14* 30* 22* 41* 31*8-36 20* 15* 31* 23* 43* 32*

10-24 27* 21* 43* 32* 60* 45*10-32 31* 23* 49* 36* 68* 51*1/4-20 66* 50* 9 75* 12 91/4-28 76* 56* 10 86* 14 10

5/16-18 11 9 17 13 25 185/16-24 12 9 19 14 25 203/8-16 20 15 30 23 45 353/8-24 23 17 35 25 50 35

7/16-14 32 24 50 35 70 557/16-20 36 27 55 40 80 601/2-13 35 35 75 55 110 801/2-20 40 40 90 65 120 90

9/16-12 55 55 110 80 150 1109/16-18 60 60 120 90 170 1305/8-11 75 75 150 110 220 1705/8-18 85 85 180 130 240 1803/4-10 130 130 260 200 380 2803/4-16 150 150 300 220 420 3207/8-9 125 125 430 320 600 460

7/8-14 140 140 470 360 660 5001-8 190 190 640 480 900 680

1-14 210 210 710 530 1000 740

Dry Lubed Dry Lubed Dry Lubed

Grade 8.8 Grade 10.9 Grade 12.9Metric CourseThread

M6-1 8 6 11 7 13.5 10*24M8-1.25 19 14 27 20 32.5 24*M10-1.5 37.5 28 53 39 64 47M12-1.75 65 48 91.5 67.5 111.5 82

M14-2 103.5 76.5 145.5 108 176.5 131M16-2 158.5 117.5 223.5 165.5 271 200

* All torque values are in lb-ft except those marked with an *, which are in lb-in.For metric torque value (Nm), multiply lb-ft x 1.355 or lb-in value x 0.113.


AAccess To Components Chart . . . . . . . . . . . . . . . . . . . . . 47

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Adjustments

Slide Pads Clearance . . . . . . . . . . . . . . . . . . . . . . . . .54

Wheel Lug Nuts Torque . . . . . . . . . . . . . . . . . . . . . . . .50

Air Filter

Service Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Alternator

Belt Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Anti-freeze - See Radiator

Attachment Tools

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Operating Methods - See Chapter 6

Axles

Description - See Chapter 2

Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

See Also Service

Axle Oil

Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Check Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .43

BBackup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Battery

Charging Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Boom Travel

Function Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Function Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

CCapacities - See Chapter 2

Carriage Lifting Applications

Load Capacity and Reach . . . . . . . . . . . . . . . . . . . . . .36

Load Carry, Elevation and Placement . . . . . . . . . . . . .37

Checklists, delivery and pre-delivery . . . . . . . . . . . . . . . .5,7

Controls,

Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Right Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Floor and Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Other Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . .28

Cylinders

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

DDealer Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Decals, applying new . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Dimensions - See Chapter 2

EElectrical Components

Characteristics - See Chapter 2

Controls and Indicators - See Chapter 4

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Engine

Cold Weather Start Procedures . . . . . . . . . . . . . . . . .31


Oil Pressure Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . .24

Engine Oil

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Check Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48


Engine Shutdown Protection

Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . .32

Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Engine Override Shutdown Switch . . . . . . . . . . . . . . . .25

Engine Oil Filter, replacing . . . . . . . . . . . . . . . . . . . . . . . .52

Exhaust System, check . . . . . . . . . . . . . . . . . . . . . . . . . .57

FFan Belt - See Alternator Belt

Frame Level Control and Indicator . . . . . . . . . . . . . . . . . .27

Fuel - See Separate Engine Manual

Fuel Filter

Check and Drain Water . . . . . . . . . . . . . . . . . . . . . . . .51

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Fuse Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Index


GGrease Fittings

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Types Of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Grade and Slope Precautions . . . . . . . . . . . . . . . . . . . . .34

Grade Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

HHand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Hydraulic Components, servicing . . . . . . . . . . . . . . . . . . .46

Hydraulic Oil

Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Check level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Recommended type . . . . . . . . . . . . . . . . . . . . . . . . . .43

Hydraulic Maintenance

Oil Filters, replacing . . . . . . . . . . . . . . . . . . . . . . . . . .56

Oil Sump Strainer, replacing . . . . . . . . . . . . . . . . . . . .58

Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Hydraulic Pump, servicing . . . . . . . . . . . . . . . . . . . . . . . .46

Hydraulic Valves, servicing . . . . . . . . . . . . . . . . . . . . . . . .46

IIdentification Reference . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Indicator Symbols . . . . . . . . . . . . . . . . . .Inside Front Cover

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

JJoystick Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . .58

LLight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Lubrication,

See also Service Intervals

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

MMain Relief pressure check . . . . . . . . . . . . . . . . . . . . . . .58

Maintenance

Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Scheduled Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Mandatory SAFETY Shutdown Procedure . . . . . . . . . . .8Mandatory Work Platform Safety Rules . . . . . . . . . . . .12

OOils - See Lubrication

Operation

Load Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Symbols . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover

Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Operator Manual, storing . . . . . . . . . . . . . . . . . . . . . . . . . .2

Operator Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Operator’s Station

Environment Controls . . . . . . . . . . . . . . . . . . . . . . . . .26

PPark Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Park Brake Pressure Setting . . . . . . . . . . . . . . . . . . . . . . .58

Paint, refinish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Pump, Delivery Rates - See Chapter 2

Personnel Work Platform Safety Decals . . . . . . . . . . . . . .20

Personnel Work Platform Safety Rules . . . . . . . . . . . . . . .12

Personnel Work Platform Switch . . . . . . . . . . . . . . . . . . . .26

Personnel Work Platform Safety System . . . . . . . . . . . . .12

Personnel Work Platform Checking Procedure . . . . . . . . .50

QQuickattach System

Attach/Detach Mechanism . . . . . . . . . . . . . . . . . . . . . .32

RRadiator

Check coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Flushing and Refilling . . . . . . . . . . . . . . . . . . . . . . . . .55

Relay Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Road Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

SSAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Schematics

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70


Seat, operator’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Service and safety Features . . . . . . . . . . . . . . . . . . . . . . .29

Service Intervals

Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

100 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

2000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Side View Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Steering - See Controls

Steering Relief Pressure Check . . . . . . . . . . . . . . . . . . . .58

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Suspended Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Guidelines For Free Rigging / Suspended Loads . . . .39

TTables

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Paint Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Replacement Filters . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Theft Deterrents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Traffic Flow Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Transmission


Temperature Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Transmission Oil

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Check Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49


Transporting

Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Travel Speed - See Controls

Troubleshooting, PWP . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

WWarranty . . . . . . . . . . . . . . . . . . . . . . . . . Inside Rear Cover

Water Trap - See Fuel Filter

Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . .26

Work Platform Design Requirements . . . . . . . . . . . . . . . .13


NOTES


GEHLNEW CONSTRUCTION EQUIPMENT

RS5-34 TELESCOPIC HANDLER

WARRANTY

GEHL CONSTRUCTION DIVISION of the GEHL COMPANY, hereinafter referred to as Gehl, warrants new GehlTelescopic Handlers, to the Original Retail Purchaser to be free from defects in material and workmanship for aperiod of twelve (12) months from the Warranty Start Date.

GEHL CONSTRUCTION WARRANTY SERVICE INCLUDES:

No agent, employee or representative of Gehl has any authority to bind Gehl to any warranty except as specifi-cally set forth herein. Any of these limitations excluded by local law shall be deemed deleted from this warranty;all other terms will continue to apply.

Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer’sbusiness location.

GEHL CONSTRUCTION WARRANTY SERVICE DOES NOT INCLUDE:

1. Transportation to selling dealer’s business location or, at the option of the Original RetailPurchaser, the cost of a service call.

2. Used equipment.

3. Components covered by their own non-Gehl warranties, such as tires, trade accessories andengines.

4. Normal maintenance service and expendable, high-wear items.

5. Repairs or adjustments caused by: improper use; failure to follow recommended maintenanceprocedures; use of unauthorized attachments; accident or other casualty.

6. Liability for incidental or consequential damages of any type, including, but not limited to lost prof-its and expenses of acquiring replacement equipment.

Gehl MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESSOR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITYAND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED INTHIS WARRANTY STATEMENT.

THIS OPERATOR’S MANUAL ISPROVIDED FOR OPERATOR USE

DO NOT REMOVEFROM THIS MACHINE

Do not start, operate or work on this machine until you have carefully read and thor-oughly understand the contents of the operator’s manual.

Failure to follow safety, operating and maintenance instructions could result in seri-ous injury to the operator or bystanders, poor operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or maintenance of thismachine, contact your dealer or the service department of Gehl Company before starting or continuing operation.

Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 U.S.A.www.gehl.com

913227/AP0505 ©2005 Gehl Company PRINTED IN U.S.A.All Rights Reserved.

California Proposition 65 WarningsDiesel engine exhaust and some of its constituents are known to the State ofCalifornia to cause cancer and birth defects or other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead com-pounds, chemicals known to the State of California to cause cancer and birthdefects or other reproductive harm. Wash hands after handling battery.

rs5-34 operator manual - midtn equipment & services

Documents