Form No. RS5...Transmission Type: Clark Powershift T12000 Speeds: 3 fwd / 3 rev Torque converter: Single stage, dual phase Travel Speeds: 1st gear: 3.6 mph (5.8 km/h) 2nd gear: 7.9

Form No.908494Revision

B

OPERATOR’S MANUAL

RS5

TelescopicHandler

®

Indicator and Operation Symbols

Read Operator’sManual

Fasten Seat Belt

Parking Brake Electrical Preheat Safety

Fuel Low Head LightsVolume Half FullVolume Full

Engine Oil Pressure Hazard FlasherBattery

Heater BeaconClutch Disengaged

Hydraulic OilFilter

Clutch Engaged

TransmissionTemperature

Fan Work Lights

Frame Level LeftCrab Steer

Lower LoadFront Wheel Steer

Raise Load4-Wheel Steer

Outrigger(RH Shown)

Engine CoolantTemperature

Frame Level Right

Hourmeter

Air Conditioning Turn Signal

Ignition Key Off Ignition Key On

Retract Load

Diesel Fuel

Engine OilPressure

Volume Empty

Starting AidInjection

Tilt Rearward

Wiper/WasherBrake Malfunction

Extend LoadTilt Forward

Fuse Engine Air Filter

Engine StartHorn

Table of ContentsChapter Description Page

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

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Check Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Indicators and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226 Operation and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .398 Service and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .429 Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5510 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67Standard Hardware Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Back Cover

IDENTIFICATION INFORMATION

Write your Gehl Telescopic Handler Model and Serial Numbers below.Refer to these numbers 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.

RS5

PRINTED IN U.S.A. 1 908494/BP0204

908494/BP0204 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 manual COM-PLETELY and become familiar with the machine BEFORE operating it.

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 your operating and maintenance efficiency, help to avoid breakdowns and damage, and extend themachine’s life. A chart of standard hardware torques is located in the back of this manual.

A storage area is provided on the unit for storing the Operator’s Manual. After using the manual, please return itto the storage area and keep it with the unit at all times! If this machine is resold, GEHL Company recommendsthat this manual be given to the new owner.

If this machine was purchased "used," or if the owner's address has changed, please provide your GEHL dealer orGEHL Company Service Department with the owner's name and current address, along with the machine modeland serial number. This will allow the registered owner information to be updated, so that the owner can be noti-fied directly in case of an 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 you may need, including genuine GEHL ser-vice 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 your machine. Record the serial number in the spaceprovided 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 partwithout incurring the obligation to install such changes on any unit previously delivered.

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

Safety Alert Symbolto pinpoint characteristics which, if NOT properly followed, can createa safety hazard. When you see this symbol in this manual or on themachine itself, you are reminded to BE ALERT! Your personal safetyis involved!

Chapter 1INTRODUCTION


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 temperature

Monitoring lights:Engine oil pressure, alternator,transmission oil temperature,brake failure

Monitoring alarms:Park brake on

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. Separatefront and rear systems.Manual foot pedal actuation.

Parking brake: Mechanical disc type.

Electrical SystemType: 12-volt negative groundBattery: 745 cold cranking amps (CCA)Circuit protection: Circuit breakersBackup alarm: 107 dB(A)Horn: 111 dB(A)

Standard on all models:Brake lights, neutral start switch

Service CapacitiesCooling System: 17.2 qts. (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, 65-amp alternator.

Turbocharged aspiration:John Deere 4045T276 cu. in. (4523 cc) displacement99 hp (74 kW) @ 2500 rpmOil capacity: 10 qts. (9.5 L)

Turbocharged aspiration:John Deere 4045T276 cu. in. (4523 cc) displacement115 hp (86 kW) @ 2500 rpmOil capacity: 10 qts. (9.5 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:2800 psi (194 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 andinspections that MUST be made before delivering theTelescopic Handler to the customer. Check off each itemafter prescribed 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.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 pre-delivery procedures were performedon this unit as outlined above.

Dealership’s Name

Dealer Representative’s Name

Date Checklist filled out

Machine Model # Machine Serial # Engine Serial #

DELIVERY

Check 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 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 Safety Manual to thecustomer and instruct them to be sure to read and com-pletely understand its contents BEFORE operating theunit.

Explain that the customer MUST consult the engine manu-al (provided) for related specifications, operating adjust-ments and 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 andinspections that MUST be made before delivering theTelescopic Handler to the customer. Check off each itemafter prescribed 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.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 pre-delivery procedures were performedon this unit as outlined above.

Dealership’s Name

Dealer Representative’s Name

Date Checklist filled out

Machine Model # Machine Serial # Engine Serial #

DELIVERY

Check 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 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 Safety Manual to thecustomer and instruct them to be sure to read and com-pletely understand its contents BEFORE operating theunit.

Explain that the customer MUST consult the engine manu-al (provided) for related specifications, operating adjust-ments and 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, may result indeath or serious injury.

CAUTION“CAUTION” indicates a potentially hazardoussituation which, if not avoided, may result inminor or moderate injury. Also alerts to unsafepractices.

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 SHUTDOWNPROCEDURE

BEFORE cleaning, adjusting, lubricating or servic-ing the unit:

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

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

3. Place controls in neutral and set parking brake.

4. Shut off engine and remove 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 seriousinjury.

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 operating this equipment, read andstudy the following safety information. Inaddition, be sure that every individual whooperates or works with this equipment,whether family member or employee, is famil-iar with these safety precautions.

The Gehl Company ALWAYS takes the operator’ssafety into consideration when designing its machineryand guards exposed moving parts for his/her protec-tion. However, some areas cannot be guarded orshielded in order to assure proper operation. Further,this Operator’s Manual, the Safety Manual and decalson the machine warn of additional hazards and shouldbe 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 knowl-edge, 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: terrain,engine speed, type of load being carried andplaced, improper tire inflation, weight of theattachment tool, and abrupt movement of any con-trol lever may affect the stability of the machine.IF YOU ARE NOT CAREFUL WHILE OPER-ATING THIS MACHINE, ANY OF THEABOVE FACTORS COULD CAUSE THEMACHINE TO TIP AND THROW YOU OUTOF THE OPERATOR’S STATION, WHICHMAY CAUSE SERIOUS BODILY INJURY ORDEATH!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 tothe rear 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 operatingcapacity 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 provided.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-MENT chapter of the Operator’s Manual.NEVER allow any riders on this machine or use asa lift for personnel. This is strictly a single seat,NO passenger machine!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 grade, 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, and boom 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. Use a piece of paper or cardboard.Escaping fluid under pressure can be invisible andcan penetrate the skin, causing serious injury. Ifany fluid is injected into your skin, see a doctor atonce. Injected fluid MUST be surgically removedby a doctor familiar with this type of injury or gan-grene 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 the hot engine from igniting the fuel if itshould spill or splash.DO NOT smoke while filling the fuel tank, whileworking on the fuel or hydraulic systems, or whileworking around 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 operating. Ifthe engine must be in operation to make certainadjustments, park the equipment in a safe position,place the transmission in neutral, apply the parkingbrake, 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 shall not be performed without themanufacturer’s prior written approval. Where suchauthorization is granted, tags or decals shall bechanged accordingly.All attachment tools MUST be marked to identifythe attachment tool and the total capacity withattachment tool at maximum elevation with loadlaterally centered.ALWAYS be sure all nameplates, caution andinstruction markings are in place and legible.Local government regulations may require specif-ic decals, which then become the responsibility ofthe local owner to provide.

SAFETY


SAFETYSafety Guards and Warning Devices

This 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 over-turn, but it cannot protect against every possiblehazard. Therefore it should not be considered asubstitute for good judgment and safe practices inoperating the machine. If the ROPS/FOPS struc-ture is damaged, it must be replaced to restore theprotection it provides.This machine is equipped with a horn and backupalarm. The user must determine if operating condi-tions require that the machine be equipped withadditional devices (mirrors, rotating beacon, etc.)and be responsible for providing and maintainingsuch devices.


SAFETY

L65925L65440

L63690

L65930

L65932

L500445

L65932 L500445 L63690

L65440

L65925

L65930


L65928

SAFETY

L65948

L65929

L66042

093475

093475

L65929 L65948

L66042 L65928


SAFETY

L65942

L65926

L65932

L65927

L65924

L65924

L65927

L65926L65942

L65932

L65927

L65927


SAFETY

L65924

L65927

L65933

L65928

072798

072798

L65928

L65924

L65927

L65933


SAFETY

Truss Boom

RotateCarriage

L65927

L66042


NOTES


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) 252-6604Telephone: (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)


NOTES


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 dangers 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 is designed and intendedto be used ONLY with a Gehl Company attach-ment tool, or a Gehl Company approvedaccessory or referral attachment tool. TheGehl Company cannot be responsible for safe-ty if the machine is used with an unapprovedaccessory or attachment tool.

Chapter 5INDICATORS AND CONTROLS

DASH PANEL AREA

Keyswitch and Start Button

Keyswitch 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 key can be insert-ed or removed.

Keyswitch 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 the ONposition, depress the button to activatethe starter. Release it as soon as theengine starts.

KEYSWITCH

STARTBUTTON

CIRCUITBREAKER

HORNBUTTON

BRAKEFAILURE

TRANS.OIL

ENGINEOIL

ALTERNATOR


engine is not running with key in the ON position, thislamp will be on.

IMPORTANT: If this lamp comes ON duringnormal operation with the engine running, STOPthe engine immediately. After allowing the oil todrain down for a few minutes, check the engine oillevel. Maintain oil level at the FULL mark on thedipstick.

Hourmeter: Indicates the operating timeof the machine and should be used forkeeping up the maintenance log.

Coolant Temperature Gauge: Indicatesthe temperature of the engine coolant.Under normal conditions, this gaugeshould indicate approximately 185°F(85°C).

Fuel Level Gauge: Indicates the amountof fuel remaining in the fuel tank.

Load Charts: A series of flip charts show lift heightand reach limits relative to the load weight being han-dled with various attachment tools.

Hydraulic Pressure Test Port: A test gauge can beinserted to check main and steering system pressures,and joystick pressure.

Circuit Breaker: The 15-amp breakerprotects dash and engine electrical cir-cuits. If it is not in the depressed position,the gauges and indicators on the dash willnot work and the engine will shut off.

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

Park Brake ON: A buzzer locatedbehind the dash sounds as long as thepark brake lever is engaged, if the trans-mission is in forward or reverse.

Transmission Oil Temperature: Thislamp indicates whether the transmissionoil is at the proper operating temperature.During normal operation this lampshould be off, indicating that the transmission oil sys-tem is at the proper temperature.

IMPORTANT: If this lamp comes ON duringnormal operation, a problem may exist in thetransmission oil system. Stop the machine imme-diately and investigate the cause of the problem.

Alternator Lamp: Indicates the condi-tion of the electrical charging system.During normal operation this lampshould be off. If the charge rate is toohigh or too low, this lamp will come on.

Brake Failure Lamp: The front and rearbrakes are on independent brake line sys-tems. If during normal operation with thebrake pedal depressed, a loss of pressureoccurs in either system, the brake failure lamp willcome on.

Failure in one line of the system does not affect theoperation of the other system line. However, theMANDATORY SAFETY SHUTDOWN PROCE-DURE (page 8) should be followed and requiredrepairs made immediately.

During normal operation the lamp should remain off.

Engine Oil Pressure Lamp: Indicateswhether sufficient engine lubricating oilpressure is present or not. During normaloperation, with the engine running, thislamp should be off. During starting and when the

FUELGAUGE

COOLANTTEMP.

HOURMETER

LOADCHARTS

JOYSTICKTEST PORT

MAIN and STEERINGTEST PORT

TEST PORTS


Switch Panel

Clutch Cutout: When activated, it allows greaterengine acceleration and power to the hydraulic systemwithout power to the drive axles while the servicebrake pedal is depressed.

In the “off” position, the clutch mecha-nism of the transmission remainsengaged when applying the brakes.

In the “on” position, the clutch mecha-nism is disengaged while applying thebrakes.

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

NOTE: The switch panel also includes controlswitches for the following accessories used withthe cab enclosure option.

Heater: Provides circulating heated airthroughout the cab interior.

Heater/AC: This switchturns on or off either heatingor cooling selection for theoperator’s station interior.Units without air conditioning have only the heatermode switch.

Lights Option: Work lights may be addedto the operator station and boom to provideillumination for forward travel and workoperations.

Windshield Wiper: Wiper motors canbe activated with this switch to maintainproper visibility for the operator throughthe windshield and the top of the opera-tor’s station.

Windshield Washer: Used to applycleansing agent while activating thewindshield wipers.

Turn Signal: This switch is used to indi-cate the direction of a turn. Depress thearrow which indicates the direction ofyour turn.

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

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

Engine Fault Override Shutdown Switch: Pressingthe override shutdown switch will over-ride an engine shutdown signal. Theswitch must be pressed within 30 sec-onds to prevent undesired shutdown ofthe engine. The switch can be overridden for 30 sec-onds at a time to move the machine to a safe locationand to lower the boom to the ground. If the engineshutsdown, the ignition switch must be turned off andthen back 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.

Travel Controls

These controls are used to maneuver the machinearound the jobsite or for road travel. Decals on the dasharea provide graphic representation of the various con-trol actions.

Steering: The power steering motor is designed to pro-vide low-effort steering with no shock reaction fromthe axle wheels to the steering wheel. Turn the steeringwheel to the right or left to turn the machine in thedirection of wheel turn action.

Steer Select: Use “2-wheel mode” for higher speedtravel. Use “4-wheel mode” for making tighter turns,usually on jobsite. Use “crab mode” when a small

SWITCHPANEL


amount of side shift is needed for picking or placingloads.

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

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

Parking Brake: Functions as both a parking brake andemergency brake. The parking brake handle is linkedby a cable to a brake assembly on the transmission out-put shaft.

To adjust the tension, insert a flat blade screwdriverthrough the hole in the top of the hand grip on thebrake lever, and turn the screw until a pull effort of 20lbs. (89 N) is achieved on the hand lever.

The parking brake may be used as an emergency stop-ping system on relatively level terrain if the servicebrakes fail. When properly adjusted and maintained itmeets ANSI test requirements providing 35% of ser-vice brake performance at 20 lbs. (89 N) hand levereffort.

Travel Direction Selector: Changes the direction oftravel between forward and reverse. Theselector MUST be in N (NEUTRAL)position before the engine will start.

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

NOTE: Backup alarm automatically sounds withtravel lever in reverse.

IMPORTANT: Care should be taken whendownshifting or reversing as damage to the trans-mission can occur if shifting is forced or attempt-ed at too high a speed. Allow engine RPM to slowbefore any shift down or directional change isattempted.

Speed Range Selector: Twist the outer end of thedirection selector counter-clockwise or clockwise tochange the transmission speed between low, medium,and high range.

Position “3” HIGH RANGEPosition “2” MEDIUM RANGEPosition “1” LOW RANGE

Adjustable Steering Wheel: The steering wheel canbe adjusted to one of five positions for operator com-fort. Push the small black handle on the left side of thesteering console and re-position the steering wheel.Release the handle to lock in place.

WARNINGUnattended machine hazard.

Set parking brake and lower attachment toolto ground before leaving machine. An unat-tended machine can move or roll and causedeath or serious injury to operator orbystanders.

Periodically check the parking brake tensionand adjust, if required, to maintain adequateholding power. Always be sure the parkingbrake lever is off when resuming machineoperation.

STEERING WHEEL ADJUSTMENT

SPEED SELECTOR

STEERING

STEERSELECTOR

PARKINGBRAKE

SPEED and TRAVELDIRECTION SELECTOR


FLOOR AND SEAT AREA

Throttle Pedal: This is right-foot operated and con-trols the engine RPM to match increased powerrequirements. Pushing down on the pedal increases theRPM. 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 allowbrake power to bring the machine to a safe stop, ifeither system loses pressure.

Seat Positioning: The seat is mounted on rails for for-ward or rearward repositioning to accommodate oper-ator’s size and comfort. A spring-loaded latch handleunder the front of the seat activates the adjustmentmechanism.

Suspension Seat Option: Option is available for addi-tional operator comfort. It is adjustable for a soft orfirm ride.

Brake Fluid Reservoirs: Located under hinged coveron the cab floor.

RIGHT SIDE PANELThese controls and indicators are used to position theframe, boom and attachment. Graphic symbols on theside panel illustrate the control actions.

Frame Level/Tilt Joystick: The machine may be tilt-ed slowly 10o to the left or right to level the frame andboom in relation to the ground. Move the joystick han-dle to the left to level the frame to the left. Move thejoystick handle to the right to level the frame to theright.

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

Bubble Indicator: Located in front of the operator onthe ROPS/FOPS upper cross tube. Movement of thebubble shows when the frame is level relative to slop-ing ground surface.

The inner boom nose section has an attachment carry-ing device feature called the 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 changingattachment tools procedures.

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

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

THROTTLEPEDAL

BRAKEPEDAL

SEATPOSITION

BRAKEFLUID

BUBBLE INDICATOR

BOOMJOYSTICK

FRAME LEVEL andATTACHMENT TILT

JOYSTICK

OPTIONALJOYSTICK(not shown)


DO NOT tilt the truss boom back more than45o from horizontal.

DO NOT attempt to use the optional rotatingcarriage as a load leveling function.

Always level the frame prior to raising a load.

Boom Joystick: This machine has a hydraulic typeboom with telescopic sections. The sections extend bymeans of a hydraulic cylinder and chain system insidethe boom, sequenced for uniform extension of eachsection.

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. The position of the bubble in theBoom Angle Indicator, shows the angle of the boomrelative to the ground surface.

Optional Attachments Joystick: For other attachmentoptions that require additional hydraulics, a 2-positionjoystick is provided.

OTHER OPERATION INDICATORS

The following indicators are for fluid level and opera-tor rear vision/safety.

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

Side Mirror: Located on the front outside corner ofthe hydraulic reservoir, provides the operator with aview of the right side and rear area of the machine.

BOOM ANGLEINDICATOR

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 applied before raising or extending theboom.

NEVER exceed the specified lifting or extend-ing capacities of this machine. Seriousmachine damage or personal injury mayresult. Refer to the load zone charts in theoperator’s station or this manual.

If a boom circuit hose should break with theboom up, with or without a load, shut downthe machine following the MANDATORYSAFETY SHUTDOWN PROCEDURE. DO NOTattempt repairs. Call your Gehl dealer immedi-ately for 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 the job-site. This can cause the load to swing, result-ing in either the load dropping or machinetipover.

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

MIRRORHYDRAULICFILL CAP/DIPSTICK

HYDRAULICRESERVOIR

ACCESSCOVER


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

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

Engine Oil Level: The dipstick is located on the left-side of the engine.

Engine Coolant Level: The radiator cap is locatedunder the opening toward the rear of the main hoodsection.

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

ATTACHMENT TOOLS

Gehl offers a versatile range of attachment tools tomeet various lifting and material handling applicationsfor this machine. Contact your area Gehl dealer forspecifications and ordering information.

ACCESSORIES

Gehl offers a versatile range of special accessories forthis machine. Contact your area Gehl dealer for speci-fications and ordering information.

NOTE: All accessories are field-installed unlessotherwise noted. Information and parts for fieldinstalling of accessories will be provided by theGehl Company or Gehl Telescopic Handler deal-ers.

TRANS. DIPSTICK BATTERY

BACKUP ALARM


GENERAL INFORMATION

ENGINE BREAK-INYour new engine does not require extensive “break-in.” However, for the first 100 hours of operation, keepthe following in mind: Allow the engine to idle for afew minutes after every cold start. DO NOT idle theengine for long periods of time. DO NOT operate theengine at maximum power for long periods of time.Check the oil level frequently and replenish, as neces-sary.

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 or your enginemanual for the type and grade of oil to use. Refer to theSERVICE AND STORAGE chapter for the proper ser-vice intervals.

PRESTART INSPECTIONIt is the operator’s responsibility to inspect the machinebefore the start of each workday. Every PrestartInspection must include more than simply checking thefuel and oil levels. It is a good practice to personallyinspect any machine you are assigned to use, eventhough it has already been put into service by otherpersonnel.

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

BEFORE STARTING ENGINEBefore starting the engine and running the machine,refer to the INDICATORS AND CONTROLS chapterand familiarize yourself with the various operatingcontrols, indicators and safety features.

STARTING THE ENGINEBefore 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.

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 lever, which shouldbe in the “ON” position.

4. Adjust the position of the steering wheel tilt to pro-vide comfortable handling.

5. Turn the keyswitch to the “ON” position and pressthe start button. If the button is released before theengine starts, turn the keyswitch to the “OFF”position, and allow the starter to stop beforeattempting to start again.

CAUTIONBEFORE starting the engine and operating theTelescopic Handler, review and comply withALL safety recommendations set forth in theSAFETY chapter of this manual. Know how toSTOP the machine before starting it. Also, BESURE to fasten and properly adjust the seatbelt.

WARNINGALWAYS fasten your seatbelt BEFORE start-ing the engine. Leave the parking brake“engaged” until the engine is running and youare ready to operate the machine.

Chapter 6OPERATION AND ADJUSTMENTS


IMPORTANT: Crank the starter until the engineis started. If the engine fails to start within 30 sec-onds, return the key to the “OFF” position, wait 2minutes, and try to restart the engine. Crankingthe engine for longer than 30 seconds will resultin premature failure of the starter.

6. After the engine starts, allow a sufficient warm-uptime before attempting to operate the controls.

7. Check that indicators are in normal condition.

8. Check that there are no fuel, oil or engine coolantleaks, and no abnormal noises or vibrations.

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

If prevailing temperature is 40o F (4° C) 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 fails to have suf-ficient power to start the engine, jumper cables can beused to obtain starting assistance. Refer to the jumpstarting instructions in the SERVICE AND STORAGEchapter of this manual for safe jumpstart procedure.

STOPPING The 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 neccessary parkacross the slope and block the tires.

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

3. Place controls in neutral. Set the parking brakelever to “ON.”

4. Turn the keyswitch key to the “OFF” position.Remove the key.

5. Unlatch the seat belt, and grasp the hand holdswhile climbing out of the operator’s compartment.

FIRST TIME OPERATIONBe sure the engine is warm and then go through the fol-lowing procedures.

Place the travel lever in a speed range and in forwardor reverse direction. Release the parking brake leverand move slowly, while testing the steering and brakes.Stop and operate all boom functons and frame levelingcontrols, checking for smooth response.

Apply the service brakes, stop the machine and movethe travel selector to the opposite direction (forward orreverse).

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 PROTECTION

NOTE: Only machines that have the engine faultoverride shutdown switch described on page 24have this feature.

The engine is equipped with a WARNING and SHUT-DOWN feature to warn of low engine oil pressure andof high engine coolant temperature. If the problem isnot corrected, engine power will derate, or the enginewill shutdown.

Engine Oil PressureThere are two low oil protection features: Low OilPressure WARNING, and Low Oil Pressure SHUT-DOWN.

At the Low Oil Pressure WARNING set-point, thewarning light in the engine override switch will flashand a slow engine power derate will begin. If the oilpressure rises above the Low Oil Pressure WARNINGset-point, power will slowly increase until the engine isback to full power. The light will continue to flash untilthe power has returned to normal, even if the fault con-dition has been corrected and the recovery is inprocess.

At the Low Oil Pressure SHUTDOWN set-point, the

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


light 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. Ifthe oil pressure rises above the Low Oil PressureSHUTDOWN set-point within 30 seconds, then thepower derate speed will revert to the Low Oil PressureWARNING speed of reaction.

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 light in the engine override switchwill flash and a slow engine power derate will begin. Ifthe coolant temperature drops below the High CoolantTemperature WARNING set-point, the power willincrease slowly until the engine is back to full power.The light will continue to flash until the power hasreturned to norma,l even if the fault condition has beencorrected and the recovery is in process.

At the High Coolant Temperature SHUTDOWN set-point, the light 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. If the coolant temperature drops belowthe High Coolant Temperature SHUTDOWN set-pointwithin 30 seconds, the power derate speed will revertto the High Coolant Temperature WARNING speed ofreaction.

PARKING BRAKE

NOTE: The parking brake mechanism is NOTdesigned for, OR intended to be used as, the pri-mary means of stopping movement of themachine. Hydraulic braking provided through theservice brakes within the axle is the primarymeans for stopping movement.

The proper sequence for correct machine operation isto always engage the parking brake lever before shut-ting off the engine, and to disengage the parking brakeONLY after the engine is running. In an EMER-GENCY, if it becomes necesary to STOP movement,pull the parking brake lever 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, masonry, and materialhandling-type attachment tools to the boom nose.

Attaching - Using Quick-Attach System

To attach the attachment tool, proceed as follows:

1. Raise the boom slightly and extend it 2 or 3 feet(0.6-0.9 m) for better visibility and tilt the Quick-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 attachment tools with auxiliary hydraulics,connect the hoses to the quick-connect connectorson the boom nose.

Quick-Attach System Attaching Detail

Hookup Ear

Hookup Bar

TiltedForward For

HookupAttachment

Tool

AttachmentTool Locked


6. Start the engine and roll the Quick-attach Systemforward, and then slowly back the machine awayuntil the attachment tool is free from the boomnose.

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

GENERAL MACHINE OPERATION

Take 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. Make sure all caps, covers and safetyshields are in place.

Detaching - Using Quick-AttachSystem

To detach the attachment tool, proceed as follows:

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

2. Roll the carrier back as far as it will go. Once thecarrier is rolled back all the way, perform theMANDATORY SAFETY SHUTDOWN PROCE-DURE (page 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-connect connec-tors on the boom nose.

WARNINGModifications, alterations to, or use of attach-ment tools not authorized by Gehl Companycan void the warranty and cause machinedamage, and may result in serious personalinjury or death.

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

Use proper grab handles, NOT the steeringwheel or control levers as hand holds whenmounting and dismounting.

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

AttachmentTool Released

AttachmentTool UnlockedManually For

Release


work site operations. The following specifications areprovided only as information to the operator, and mustnot be used as a guideline for operating the telescopichandler. For safe operation, always follow the instruc-tions and warnings provided in this manual.

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

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

3. DO NOT place or retrieve loads on a side hill witha slope or grade that exceeds 12% or 7° grade.Regardless of terrain or position of wheels, theFRAME MUST BE LEVEL as indicated by thebubble indicator on the ROPS/FOPS cross mem-ber.

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 asindicated by the bubble indicator on theROPS/FOPS upper cross member. Furthermore theattachment tool MUST be maintained in the“carry” position, with the boom fully retracted, andthe attachment tool at minimum 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.

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.

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 jobsite for holes, obstacles, slippery sur-faces, soft terrain or deep mud.

6. Check clearances of ramps, doorways and passageways. Check overhead clearances if you will trav-el and place loads near power or telephone lines.

If the machine is found to be in need of repair or in anyway unsafe, or contributes to an unsafe condition, thematter must be reported immediately to the appropriateauthority. The machine must NOT be operated until ithas 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 tests 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 that are stable and safely arranged. Whenattachments are used, extra care should be taken insecuring, 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 (ASME B56.6) stability limits for rough ter-rain forklifts. The stability tipping limits cover specif-ic, controlled test conditions, which are extremes, andwhich are not intended to be achieved during normal

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


DO NOT move railroad cars and trailers with the fork-lift truck.

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 tllt. 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.

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 away from neutral a small amount. After move-ment has started, the control can be eased to full move-ment. Use the same technique to stop the motion.

The backup alarm automatically sounds with the trav-el direction selector in reverse. Care should be takenwhen down shifting or reversing, because damage tothe transmission can occur if shifting is forced orattempted while traveling.

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 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.

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.

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

Twice daily, increase the engine speed (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.

The machine must not be used to lift or carrypersonnel, or be fitted with any form of per-sonnel work platform.

ALWAYS 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!

Safety Hand Signals

Stop

Rotate ForksRight

Tilt Forks Down

Rotate ForksLeft

Tilt Forks Up

Lower LoadRaise Load

Load Back Load Forward


Load Capacity and Reach This machine has flip-charts in the operator’s stationthat provide, at a glance, the capacity limits at variouspositions of attachment tool extension and elevation. Aset of load zone charts is reproduced at the end of thismanual for reference.

A typical load zone chart is shown below. The scale onthe left indicates height in feet above ground level. Thescale on the bottom shows the distance in feet out fromthe front of the machine. The arc lines noted by thenumbers “1” through “5” correspond with the positionextension markers on the operator side of the interme-diate 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.

Typical Load Zone Chart

HEI

GH

T A

BO

VE G

RO

UN

D

BOOMEXTENSIONMARKERS

REFERENCE

DISTANCE LOAD IS EXTENDED

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.

NEVER leave the operator’s station withoutfirst lowering the attachment tool to theground. Set the parking brake, place controlsin neutral, shut off the engine and remove thekey. AVOID parking the machine on a slope,but if necessary, park across the slope andblock the tires.


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 2000lb. 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.

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 all forksuntil the load touches the carriage backrest. Tilt theforks 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, then back away carefully todisengage forks from the load. For elevated or over-head placement, bring the machine as close as possibleto the landing point.

Level the machine BEFORE raising the load. Useextreme caution for high placement. Be sure personnelare clear of the area where the load or the machinecould 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 loadinto place, until the forks are free. Level the forks andretract clear of the load. Lower the forks to travelheight before moving the machine.

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 should breakwith the boom up, shut down the machine. DONOT attempt to bring down the boom or makerepairs. Call your Gehl dealer immediately.

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 thecapacity decal.

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


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 and sudden starts, stops and turns cancause the load to swing and create a hazard.

DO NOT exceed the Telescopic Handler capacity asequipped for handling suspended loads. Only lift theload vertically and NEVER drag it horizontally. Usetag lines to restrain load swing whenever possible.

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

and comply with the applicable U.S. OSHARegulation 1910.184, “Slings,” or 1926.251“Rigging equipment 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 anyoneis on the load, rigging or forks.

6. Multiple pickup points on the load are preferredto prevent the load from rotating, but a singlepickup point may be used if one or more tag linesare utilized. And, of course, the load must never

be positioned over personnel at any time.

ROAD TRAVELFor short distance highway travel, attach an SMV(Slow-Moving Vehicle) emblem (purchased locally) tothe back of the Telescopic Handler. Activate hazardlights on the machine. For highway operation, obtainand 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 if oper-ation on public highway is prohibited, transportthe machine using a vehicle of appropriate sizeand weight.

TRANSPORTING BETWEENJOBSITESWhen transporting the Telescopic Handler, know theoverall height to allow clearance of obstructions.Remove or tape over the Slow Moving Vehicle (SMV)emblem if it will be visible to traffic.

ALWAYS abide by the following recommended proce-dures and guidelines when using ramps to load themachine onto (or 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 Ramps

NOTE: A matched pair of ramps is required.

Ramp Placement

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 tools shouldONLY be 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 machine tipover.


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.

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 Ramps

NOTE: A matched pair of ramps is required.

Repeat Steps 1 through 5 and proceed as follows tounload the machine:

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

WARNINGNEVER adjust travel direction (even slightly)while traveling on the ramps. Instead, backdown off the ramps, and then realign themachine with the ramps.

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 steel cablesto prevent any movement while transporting.

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

THEFT DETERRENTS

Gehl has recorded all part numbers and serial numbers.Users should take as many of the following actions aspossible to discourage theft, to aid in the recovery inthe event that the machine is stolen, and to reduce van-dalism:

1. Remove keys from unattended machines.

2. Attach, secure, and lock all anti-vandalism andanti-theft devices on the machine.

3. Lock doors of cabs when not in use.

4. Inspect the gates and fences of the vehicle storageyard. If possible, keep machines in well lightedareas. Ask the law enforcement agency havingjurisdiction to make frequent checks around thestorage and work sites, especially at night, duringweekends, and on holidays.

5. Report any theft to your dealer and insurance com-pany. Provide the model and all serial numbers.Request that your dealer forward this same infor-mation to Gehl Company


GENERAL INFORMATION

NOTE: The Maintenance chapter in this manualhas 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 types of lubricants to be used when servic-ing this machine. Also refer to the separate enginemanual for additional information regarding recom-mended engine lubricants, quantities required andgrades.

NOTE: Refer to Operator Services topic in the“Service and Storage” chapter of this manual fordetailed information regarding periodic checkingand replenishing of lubricants.

GREASINGRefer to the illustration and listing on the next page forfitting locations. Wipe dirt from the fittings beforegreasing them to prevent contamination. Replace anymissing or damaged fittings. To minimize dirt build-up, avoid excessive greasing.

Chapter 7LUBRICATION

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

Hydraulic System Reservoir

Use Mobil DTE 15M, or equivalent that contains anti-rust, anti-foam and anti-

oxidation 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: 10 Quarts (9.5 liters)

Axle Gear Oil

Use MobilFluid® 423 or 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 (22.7 liters)

Brake System

Use Sunco Multi-ATF or equivalent


BASIC MACHINEGREASE FITTING LOCATIONS

Every 50 Hours (or weekly)

Refer to the illustration below for locations.

CHASSIS AREA1 Brake foot pedal linkage . . . . . . . . . . . . . . .12 Wheel spindle pins (per axle) . . . . . . . . . . . .43 Tie rod ends (per axle) . . . . . . . . . . . . . . . . .24 Axle to frame pivot pins (per axle) . . . . . . .15 Drive shaft, slip joint (per shaft) . . . . . . . . .16 Drive shaft, U-Joint (per shaft) . . . . . . . . . .27 Level cylinder pivot pins . . . . . . . . . . . . . . .28 Base end lift cylinder pivot pins . . . . . . . . .29 Base end slave cylinder pivot pins . . . . . . . .2

BOOM AREA10 Boom to frame upright pivot pins . . . . . . . .211 Rod end slave cylinder pivots pins . . . . . . .212 Rod end lift cylinder pins . . . . . . . . . . . . . . .213 Extend cylinder pivot pins . . . . . . . . . . . . . .214 Chain sheave pins . . . . . . . . . . . . . . . . . . . . .215 Quickattach to boom nose pivot pins . . . . . .216 Tilt cylinder pivot pins . . . . . . . . . . . . . . . . .217 Rotate cylinder pivot pins . . . . . . . . . . . . . .218 Rotate carriage wear pads . . . . . . . . . . . . . .319 Rotate pivot bearing . . . . . . . . . . . . . . . . . . .120 Boom slide pads - as required, front and rear

Ref.No. Description Qty.

Ref.No. Description Qty.

18

17

19FRONTSIDE

REPLACEMENT FILTER CHARTAIR FUEL ENGINE HYDRAULIC TRANS.

ENGINE TYPE FILTER FILTER OIL FILTER STRAINER OIL

JOHN DEEREw/ Mechanical Throttle L120054 L98978 L99420 L97489 L49327 L99184

JOHN DEEREw/ Electronic Throttle L120054 102174 102173 L97489 L49327 L99184


2

4

6

3

1

5

6

11

10

14

9UNDERCOVER

12

8

13

13

15

16

16

20

14

20


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 dailysubtopics are also referred to on a decal locatedon the inside right side panel of the operator’s sta-tion. Refer to the LUBRICATION chapter of thismanual for lubrication information.

NOTE: This SERVICE AND STORAGE chapterdescribes procedures to follow for making routinemaintenance checks, adjustments and replace-ments. The majority of the procedures are alsoreferred to in the MAINTENANCE chapter of thismanual. For engine-related adjustments and ser-vicing procedures, refer to the engine manual pro-vided.

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 autho-rized Gehl 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, don’t overlook simple causessuch as an empty fuel tank. Check for leaks and brokenconnections. Make note of any specific problem symp-toms, 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 service,replacement and operating adjustments should only beperformed by (or under the direction of) an authorizedGehl Telescopic 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 power train components aresuspected of faulty operation, contact your Gehldealer for further assistance.

HYDRAULIC SYSTEM COMPONENTS

Valves, pumps, motors and cylinders are also sophisti-cated assemblies that 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 performing any service on theTelescopic Handler, unless expressly instruct-ed to the contrary, exercise the MANDATORYSAFETY SHUTDOWN PROCEDURE (Safetychapter, pg. 8). 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 any of these valves, you AREREQUIRED to call Gehl Service. Failure to doso may result in serious injury or death.

ELECTRICAL COMPONENTS

An electrical system schematic is provided (MAINTE-NANCE chapter) which includes instrumentation,electrical components and switch connections. It canbe used as a guide for service reference, as required.

OPERATOR SERVICESSome of the operator-related services will requireaccess to components located inside the superstructureunder shields, hoods and covers. The reference charton this page notes components accessed in each partic-ular area.

Component Operator Frame Front Mid-RearStation Cover Hood

Axle (underside)

Engine

Transmission (mid 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 (mid area)

Hourmeter (dash)

Switches/Indicators (dash)

Hydraulic Pump

Hydraulic Filter (Reservoir)

Misc. Hydraulic Valves

Air Conditioner (rear)

Heater (lower front)

ACCESS TO COMPONENTS REFERENCE CHART


Choose a clean, level work area. Be sure you have suf-ficient 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. Remove

only 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.Care should be taken to assure that all replacementparts are interchangeable with original parts and ofequal quality.

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, no partsleft 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.

A drain plug is provided in the bottom of the fuel tankfor removing condensation and other foreign materials.Whenever contamination is present in the tank, openthe plug and allow water and fuel to drain into a con-tainer until only clear fuel is flowing from the tank.

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 flowingfrom the outlet.

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, shoes. Keep feet, cloth-ing, hands and hair away from moving parts.

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 overhead guards without the consentof the manufacturer. Special metals may beused that require special welding techniques,or that should not have weld repairs. NEVERcut or weld on fuel lines or 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.


CHECK ENGINE OIL LEVEL

With the machine on level ground, and the enginestopped for ten minutes or more, remove the enginedipstick. Wipe it clean, re-insert it and remove toobtain a reading. If the oil level is down, or below theADD mark, fill with the required amount of oil to bringthe level to the FULL mark. See the LUBRICATIONchapter for the type of oil to use.

CHECK RADIATOR COOLANT LEVEL

With the machine on level ground, remove the radiatorcap. Add a 50/50 water and anti-freeze mixture if thecoolant level is below the filler neck. Replace the radi-ator cap securely.

IMPORTANT: If the engine is operated with aloose radiator cap, the pressure bypass will notwork and the engine will run hot.

CHECK TRANSMISSION OIL LEVEL

The machine must be on level ground with the boomlowered and retracted. With engine and transmission atoperating temperature; parking brake on, transmissionin neutral and engine speed at low idle, remove theaccess cover to the transmission and hydraulic pump.Remove the dipstick and check the oil level. Add therequired amount of oil to bring the level to the FULLmark. See the LUBRICATION chapter for the type ofoil to use.

CHECK HYDRAULIC OIL LEVEL

The machine must be on level ground with the boomlowered and retracted. The fluid MUST be cool whenchecking the reservoir level. By doing this, you willreduce the possibility of overfilling the hydraulic sys-tem, and also reduce potential injury due to hot fluid.

Remove the front cover from the front hood section.Loosen the filler cap to release pressure. Remove thefiller cap and check the level on the dipstick. If the oillevel 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.

IMPORTANT: Be careful when removing thereservoir filler cap so that no dirt or other foreignmatter enters the hydraulic system while the capis removed. DO NOT OVERFILL.

CHECK BRAKE RESERVOIR LEVELS

Flip up the floor cover under the seat mount. Removeboth reservoir covers to check the levels. If low, fill tothe proper level with correct fluid. See LUBRICA-TION chapter for the type of fluid used.

CHECK PARK BRAKE LEVER

Check the tension when applied. Adjust, if necessary,to an application force of 20 lbs. (89 N).

CHECK TIRE PRESSURES

Proper tire pressure should be maintained equally forall four tires to enhance operating stability and extendtire 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 weight, a calcium chloride tirepressure gauge MUST be used to check the tirepressure.

When removing tires, follow industry safety practices.Deflate completely prior to removal. Following assem-bly of the tire on the rim, use a safety cage or restrain-ing device while inflating.

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.


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 (light greyor colorless)?

LUBRICATE GREASE POINTS

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

CHECK WHEEL NUT TORQUE

On NEW machines, or anytime 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 MACHINEOPERATION AND CONDITION

Are any decals missing or damaged? Are all guards,

Service Every 50 Hours or Weekly

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 rimflanges with a soap solution. DO NOT use oilor grease.

3. DO NOT place your fingers on the tire beador rim during inflation. Use a clip-on tire chuckwith a remote hose and gauge, which allowsyou to stand clear of the tire while inflating it.

4. NEVER inflate beyond 35 PSI (240 kPa) toseat the beads. If the beads have not seatedby the time the pressure reaches 35 PSI (240kPa), deflate the assembly, reposition the tireon the rim, relubricate both parts and re-inflate. Inflation pressure beyond 35 PSI (240kPa) with unseated beads may break the beador rim with explosive force sufficient to causedeath or serious injury.

5. After seating the beads, adjust the inflationpressure to the recommended operating pres-sure listed.

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

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 a pending orpresent performance problem. The controlcable should be replaced.

A gradual or sudden decrease in the useabletravel is a indication of a pending or presentperformance problem. The cable should bereplaced.

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.


The following initial oil and filter changes should bemade at this time on a new machine. Thereafter thesechanges should be made at the regular maintenanceschedule listed. Refer to those schedules for proce-dures necessary.

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

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

CHANGE AIR FILTER ELEMENT

This air filter contains a single dry element. Wipe theoutside of the body with a rag or cloth. Blow off excessdirt and dust with compressed air. Refer to illustrationon the next page.

1. Loosen the clamp ring and remove the dust cup.Remove the baffle. Wipe the cup and baffle com-pletely clean. Reassemble the dust cup.

2. Remove the element wing bolt and slide out theelement. Avoid knocking the element against thehousing. Dirt accidentally transferred to the insideof the outlet tube will reach the engine and causewear.

Service Every 250 Hours or Quarterly

100 Hours (New Machine Only) 3. Wipe the entire inside of the main body and inletcap screen.

A streak of dust on the clean air side of the old elementindicates a leakage problem. Be sure to remove thecause before installing a new element.

4. Inspect the new element for possible damage.Placing a bright light inside the element andinspecting the outside will show up any holes ortears. Discard the element if such damage appears.

IMPORTANT: NEVER use an element that isdamaged. Severe engine wear and eventual fail-ure can result if dirt gets through a hole in the ele-ment.

5. Install the element and reassemble the end cup tohousing. Make sure the large o-ring is in placebetween the end cup and the main body.

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

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 minute and repeat the fill proce-dure. Continue this process until the differential is full.

Axle Oil Plugs LocationAir Cleaner Assembly

Dust Cup& Clamp Ring

Inlet Cap

MountBand

Element

CHECKDRAIN

FRONT AXLE SHOWN

FILL

CHECK PLUG LOCATED ONTHE BACK SIDE OF AXLE.


See the LUBRICATION chapter of this manual for theproper oil specification. Replace the oil level check/fillplug.

Planetary Hubs

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

See illustrations below. The planetary hubs have oneplug each used for filling and draining. For checkingthe level and filling, position the Wheel until the arrowpoints down. Remove the plug. If oil does not run out,add oil until it flows from the hole. Check the remain-ing hubs the same way. Refer to the oil specificationsfound in the LUBRICATION chapter of this manual.

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 the proper bleed-ing procedures.

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

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

Diesel Fuel Injectors

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

Diesel Injection Pump Timing

Whenever injection pump timing, or other pump ser-vice is indicated by abnormal engine operation, contactyour nearest authorized 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 onto theground. 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 throwaway filter canister. Wipe the gasket sealing area ofthe block with a clean cloth.

NOTE: Your OEM engine oil filters have specialby-pass valves built in. Use only genuine OEMengine replacement filters.

3. Apply a thin coat of clean oil to the new oil filtergasket and spin tighten. Refill the crankcase withnew oil. Follow specifications in the LUBRICA-

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

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.

PLUG IN FILL ANDCHECK POSITION.


TION chapter for type and viscosity of new oil toput in.

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

CHECK BATTERY

The battery furnished with this 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 battery isalso a 12-volt D. C. battery, and the vehicle usedfor jump starting has a negative ground electricalsystem.

1. Turn the keyswitches on both vehicles to OFF. Besure that both vehicles are in “Neutral” and NOTtouching.

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 first aid 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.

WARNINGThe ONLY safe method for jump-starting adischarged 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 cabledirectly to the starter solenoid of eitherengine. DO NOT start the engine from anyposition other than the operator’s seat, andthen ONLY after being 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.

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.

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 cable first.


boom. A third is accessible from inside the rear of theboom (see illustration). Run the boom out slowly toinspect. Conditions to look for include cracked or bro-ken plates, protruding or turned pins, and excessivewear. With a steel tape, measure 16 links of the strandthat flexes over the sheaves. When the distance mea-sures 10.3” (262 mm), the chain should be discarded.DO NOT repair sections of a chain. Replace the com-plete chain.

Chain anchors and sheaves also require inspection forwear or broken fingers and worn flanges. If a chain hasbeen replaced, operate under load conditions and re-check the torque. Adjust the chains per the followingprocedure.

Extend the boom straight out to its maximum length.Then retract the boom slowly until the chain slackallows the chain to rest on the top of the boom. Torquethe chains on the front of the boom to 25 ft.-lbs. (34Nm). Lubricate with 80/90W oil.

CHECK BOOM SLIDE PADSWEAR AND CLEARANCE

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

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 Telescopic Handler’s engineblock or frame (ground)NOT to the disabledbattery negative post. If making the connection tothe engine, keep the jumper clamp away from thebattery, fuel lines, and 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 attempting to operate themachine or shut off the engine.

NOTE: If the battery frequently becomes dis-charged, have the battery checked for possibledead cells, or troubleshoot the entire electricalsystem for possible short circuits or damaged wireinsulation.

CHECK ALTERNATOR ANDFAN BELT TENSION

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 BOOM LEAF CHAINSAND SHEAVES

Inspect the leaf chains for wear and proper tension.Two of the chains and sheaves are on the top of the Slide Pad Detail

Rear Inner

Shim

Pad

FrontOuter

Chain Hookup Detail

InnerSection

OuterSection

IntermediateSection

Two FrontBoom ChainsOne Rear

Boom Chain


gasket. Spin 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 seal couldresult.

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 out the cooling fins in the radia-tor with 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 defective. The 10 PSI (69kPa) pressure cap and engine thermostat work inconjunction with each other to maintain properengine cooling.

This boom is equipped with special nylon low-frictionslide pads between the telescopic sections (see illustra-tion). These are pre-greased and initially worn-in at thefactory. Normally greasing is not required, except formaintaining a light film of grease on the pad trackingareas of the boom sections. An exception would be if aboom section has been replaced.

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

If the boom starts to chatter under load, grease the slidepads and wipe off the excess. If a top or side slide padshows excessive wear, loosen bolts. 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).

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

CHANGE TRANSMISSION OILand 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 out old oil.Replace the drain plug.

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

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 filter

Service Every 1000 Hours or Yearly

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

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


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.

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 onto thehousing and replace the cover.

CHANGE AXLE DIFFERENTIALAND PLANETARY OIL

Differential

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 from the check hole,replace the plug. Wait 10 to 15 minutes and repeatthis process until the axle is full Repeat the proce-dure with the other axle.

Axle Planetary Hubs

The hubs have one plug each used for both drainingand filling (see illustration).

1. Position the wheel until the arrow points to the left.Remove the drain/fill plug and allow the oil todrain out. Replace the plug.


2. Re-position the hub so the arrow points down. Fillwith fresh oil as specified in the LUBRICATIONchapter. When the oil runs out, install the drain/fillplug. Repeat this procedure on the three remaininghubs.

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.

PLUG IN DRAINPOSITION.

Axle Oil Plugs Location

CHECKDRAIN

FRONT AXLE SHOWN

Reservoir Filter Removal

Housing Top

Filter Element

Filter HousingTOP OF

RESERVOIR

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

FILL

CHECK PLUG LOCATED ONTHE BACK SIDE OF AXLE.


3. Flush out the bottom of the tank with cleanhydraulic oil. Re-install all cleaned componentsand put the top back on the reservoir with a newgasket. Clean the filter/breather cap.

4. Fill the tank with fresh oil. Follow specificationsfound in LUBRICATION chapter of this manual.

IMPORTANT: Hydraulic fluid and filters should

be replaced any time contamination is presentbefore the normally scheduled change.

NOTE: Perform all other service requIrements

up to this point, as well as the following:

CHECK HYDRAULIC SYSTEMRELIEF PRESSURES

Pressure settings for relief valves are pre-set at the fac-tory. Later units have two test ports located under thehood center section access cover. The second test portis used to check the joystick relief pressure.

Before conducting any test port pressure checks, checkthe engine RPM. Engine speed must be 950 to 1000RPM at idle and 2500 RPM at high idle.

Steering Relief Pressure

Plug a 3000 PSI (207 bar) oil or liquid filled gauge inthe test port. Cramp the steering full to the right or left.The gauge should read 2000 PSI (138 bar).

Check Main Relief Pressure

With the gauge in the test port and the boom extended,retract the boom fully. The gauge should read 3000 PSI(207 bar).

Joystick Relief Pressure

Plug a 1000 PSI (69 bar) gauge in the joystick test port.Start the engine. The gauge should read 400 PSI (28bar) with the engine at any RPM.

CHANGE HYDRAULIC RESERVOIR OIL AND STRAINER

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

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

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 excaping hydraulic oil, seea doctor familiar with this type of injury atonce or gangrene may result.

Service Every 2000 Hours or Two Years

Hydraulic Reservoir Sump Strainer Removal

Fill CapDipstick

AccessCover

TOP OFRESERVOIR

Gasket

Element


STORAGE

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

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 theLUBRICATION chapter of this manual.

3. Change engine oil as outlined in the SERVICEAND STORAGE chapter of this manual.

4. Apply grease to all exposed hydraulic cylinder rodareas.

5. Disconnect the battery cable clamps and cover thebattery 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 residuals.

2. Wipe off grease from cylinder rods.

3. Lubricate ALL grease fittings.

4. Review and refamiliarize yourself with all safetyprecautions 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.


GENERAL INFORMATION

Decal locations information is provided to assist in theproper selection and application of new decals, in theevent original decals become damaged or the machineis 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 illustration 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) Yellow420-36230 One Gallon Gray910100 6 (12 oz. Spray Cans) Gray

DECAL KITS

L500965 Model RS5 Telescopic Handler

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

Chapter 9DECAL LOCATIONS

CAUTIONALWAYS follow the safety precautions ondecals. Replace decals if they are damaged, orif the unit is repainted. If repainting, be surethat all applicable decals are affixed in theirproper locations.


REF. DESCRIPTION PART NO.NO.

01 DANGER - ROTATING FAN L6592402 GEHL - 4 1/2” (solid color decal) L6656502 GEHL - 5” (3-D style decal) 10202703 TURBO 10165704 GEHL - 6 3/8” (solid color decal) 10146604 GEHL - 6- 3/4” (3-D style decal) 184069

05 WARNING - PINCH POINT L6592706 WARNING - NO RIDERS L6593207 WARNING - JUMP START L6593308 RS5 10156809 BRAKE FLUID LEVEL L6347410 OPERATOR MANUAL INSIDE 100359

DECAL LOCATIONS - LEFT SIDE OF MACHINE

8

4

6

3 7

1

2

9 5

10


DECAL LOCATIONS - RIGHT SIDE OF MACHINE


01 DANGER - ROTATING FAN L6592402 TURBO 10165703 GEHL - 6 3/8” (solid color decal) 10146603 GEHL - 6- 3/4” (3-D style decal) 18406904 WARNING - PINCH POINT L6592705 RS5 101568

06 WARNING - HOT SURFACE L6594207 WARNING - NO RIDERS L6593208 GEHL - 2” (solid color decal) 10146808 GEHL - 2” (3-D style decal) 10202609 DYNATTACH UNLOCK RED STRIPE L6661310 DANGER - PERSONNEL L65928

14

8

2

10

6

4

9

3

5

7

4

4


DECAL LOCATIONS


01 HALF ZONE EXTENSION MARKER L6258302 NO. “0” EXTENSION MARKER L6771802 NO. “1” EXTENSION MARKER L6771902 NO. “2” EXTENSION MARKER L6772002 NO. “3” EXTENSION MARKER L67721

02 NO. “4” EXTENSION MARKER L6772202 NO. “5” EXTENSION MARKER L6772303 QUICKATTACH DIAGRAM L6593704 WARNING - PINCH POINT L6592705 WARNING - CARRY LOAD LOW L65926

06 COOLANT UNDER PRESSURE 07279807 ANTI-FREEZE NOTE 05685908 DIESEL FUEL 13763409 HYDRAULIC OIL 137632

498

6

7212

4

53


DECAL LOCATIONS - DETAILS IN OPERATOR STATION


01 GEHL - 2” DIA. 10154502 WARNING - SEAT BELT L6544003 STEER SELECTOR L6361804 F-N-R CONTROL L6829505 IGNITION/HORN L68513

06 MADE IN USA 09495107 WARNING - PARK BRAKE L6592508 WARNING - OPERATOR L6369009 WARNING CARRY LOAD LOW 09347510 WARNING - BACKUP ALARM L500445

11 LOADCHART-ROTATING CARRIAGE 10166611 LOADCHART-TRUSS BOOM 10157411 LOADCHART-STANDARD CARRIAGE 10157011 LOADCHART-BUCKET 10157211 LOADCHART - WINCH 101573

9

4

6

8

3 2

5

11

7

1

10


DECAL LOCATIONS - DETAILS IN OPERATOR STATION

2 89

46 75312

11

10

1


01 DANGER - PERSONNEL L6592802 WARNING - TRUSS BOOM L6604203 WARNING - MACHINE LEVEL L6593004 MAINTENANCE CHART L6354205 TILT/LEVEL CONTROL L6363206 BOOM CONTROL L63631

07 FILTER CHART L6808408 DANGER - PANEL IN PLACE L6594809 DANGER - POWER LINES L6592910 BRAKE FLUID LEVEL L6347411 OPERATOR MANUAL INSIDE 10035912 WARNING - PINCH POINT L65927


This Maintenance Chart was developed to match the Service chapter of this manual. Detailed information on eachService Procedure may be found in the Service chapter. A Maintenance Log follows the Interval Chart for record-ing the maintenance procedures performed. Recording the 10 Hour (or Daily) service intervals would be imprac-tical 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 or Hours or Hours Hours orDaily Weekly Quarterly

Check Fuel Tank Level

Check Fuel Filter (Drain Water As Required)

Check Engine Oil

Check Radiator Coolant Level

Check Transmission Oil Level

Check Hydraulic Oil Level

Check Brake Reservoir Levels

Check Parking Brake

Check Tire Pressures

Check Wheel Nut Torque 1

Check Instruments Operation

Check General Machine Operation and Condition

Lubricate Weekly Grease Points

Change Hydraulic Return Filter Element

Change Transmission Filter

Change Engine Oil and Filter

Check Axle Oil Levels

Change Fuel Filter

Check Battery

Check Boom Leaf Chains and Torque

1 - Only Until 450 Ft-Lbs (610 Nm) Is Maintained.

MAINTENANCE INTERVAL CHART


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

Change Air Filter Element

Check Alternator and Fan Belt Tension

Check Boom Slide Pads Wear and Clearance

Change Transmission Oil and Filter

Change Radiator Coolant

Change Hydraulic Return Filter Element

Change Axle Differential and Planetary Oil

Check Exhaust System

Check Hydraulic System Relief Pressures

Change Hydraulic Reservoir Oil and Strainer

MAINTENANCE INTERVAL CHART (CONT.)

Date Hours Service Procedure

MAINTENANCE LOG


Date Hours Service Procedure

MAINTENANCE LOG


Hydraulic Schematic

A

GAUGEPORT

GAUGEPORT


Hydraulic Schematic (cont.)

A


Electrical Schematic


Load Zone Charts

RS5101570 - Standard Carriage

RS5101666 - Rotating Carriage

RS5101572 - 1.3 Cu. Yd. Bucket

RS5101574 - 8 Ft. Truss Boom


RS5101573 - Winch 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) muiltiply lb-ft x 1.355 or lb-in value x 0.113.


AAccess To Components Chart . . . . . . . . . . . . . . . . . . . . . 43Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Adjustments

Slide Pads Clearance . . . . . . . . . . . . . . . . . . . . . . . . .50Wheel Lug Nuts Torque . . . . . . . . . . . . . . . . . . . . . . . .46

Air FilterService Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

AlternatorBelt Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Anti-freeze - See RadiatorAttachment Tools

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Operating Methods - See Chapter 6

AxlesDescription - See Chapter 2Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39See Also Service

Axle OilChange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Check Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .39

BBackup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,28Battery

Charging Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Boom TravelFunction Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Function Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . .27Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

CCapacities - See Chapter 2Carriage Lifting Applications

Load Capacity and Reach . . . . . . . . . . . . . . . . . . . . . .35Load Carry, Elevation and Placement . . . . . . . . . . . . .36

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

Controls,Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Right Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Floor and Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Other Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . .27

CylindersServicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

DDealer Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Decals, applying new . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Dimensions - See Chapter 2

EElectrical Components

Characteristics - See Chapter 2Controls and Indicators - See Chapter 4Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

EngineCold Weather Start Procedures . . . . . . . . . . . . . . . . .30Description - See Chapter 2Oil Pressure Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .23Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . .23

Engine OilChanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48Check Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .39

Engine Shutdown ProtectionEngine Coolant Temperature . . . . . . . . . . . . . . . . . . . .31Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .30Engine Override Shutdown Switch . . . . . . . . . . . . . . . .24

Engine Oil Filter, replacing . . . . . . . . . . . . . . . . . . . . . . . .48Exhaust System, check . . . . . . . . . . . . . . . . . . . . . . . . . .52

FFan Belt - See Alternator BeltFrame Level Control and Indicator . . . . . . . . . . . . . . . . . .26Fuel - See Separate Engine Manual

Index


Fuel FilterCheck and Drain Water . . . . . . . . . . . . . . . . . . . . . . . .44Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

GGrease Fittings

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Types Of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Grade and Slope Precautions . . . . . . . . . . . . . . . . . . . . .33Grade Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

HHand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Hydraulic Components, servicing . . . . . . . . . . . . . . . . . . .42Hydraulic Oil

Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Check level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Recommended type . . . . . . . . . . . . . . . . . . . . . . . . . .39

Hydraulic MaintenanceOil Filters, replacing . . . . . . . . . . . . . . . . . . . . . . . . . .52Oil Sump Strainer, replacing . . . . . . . . . . . . . . . . . . . .53Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Hydraulic Pump, servicing . . . . . . . . . . . . . . . . . . . . . . . .42Hydraulic Valves, servicing . . . . . . . . . . . . . . . . . . . . . . . .42

IIdentification Reference . . . . . . . . . . . . . . . . . . . . . . . . . . .3Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Indicator Symbols . . . . . . . . . . . . . . . . . .Inside Front CoverIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

JJoystick Relief Pressure Check . . . . . . . . . . . . . . . . . . . .53

LLight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Lubrication,

See also Service IntervalsLocations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

MMain Relief Pressure Check . . . . . . . . . . . . . . . . . . . . . . .53

MaintenanceRecording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62Scheduled Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Mandatory SAFETY Shutdown Procedure . . . . . . . . . . .8

OOils - See LubricationOperation

Load Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Symbols . . . . . . . . . . . . . . . . . . . . . . .Inside Front CoverTravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Operator Manual, storing . . . . . . . . . . . . . . . . . . . . . . . . . .2Operator Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19Operator’s Station

Environment Controls . . . . . . . . . . . . . . . . . . . . . . . . .24

PPark Brake

Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Paint, refinish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Pump, Delivery Rates - See Chapter 2

QQuickattach System

Attach Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Detach Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

RRadiator

Check coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Flushing and Refilling . . . . . . . . . . . . . . . . . . . . . . . . .51

Road Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

SSAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Schematics

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Seat, operator’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Service Intervals

Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44


Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46100 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .512000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Side View Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Steering - See ControlsSteering Relief Pressure Check . . . . . . . . . . . . . . . . . . . .53Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Suspended Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

TTables

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Paint Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Replacement Filters . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Theft Deterrents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .69Traffic Flow Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Transmission

Description - See Chapter 2Temperature Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Transmission OilChanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Check level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .39

TransportingLoading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Travel Speed - See Controls

WWarranty . . . . . . . . . . . . . . . . . . . . . . . . . Inside Rear CoverWater Trap - See Fuel FilterWindshield Wiper/Washer Switch . . . . . . . . . . . . . . . . . .24

GEHLNEW CONSTRUCTION EQUIPMENT

TELESCOPIC HANDLER

WARRANTY

GEHL CONSTRUCTION DIVISION of the GEHL COMPANY, hereinafter referred to as GEHL, warrants newGEHL Telescopic Handlers, to the Original Retail Purchaser to be free from defects in material and workmanshipfor a period 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 specif-ically 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 profits and expenses of acquiring replacement equipment.

GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND,EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MER-CHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT ASEXPRESSLY STATED IN THIS 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

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.

908494/BP0204 2004 Gehl Company PRINTED IN U.S.A.All Rights Reserved.

Documents

Form No. RS5...Transmission Type: Clark Powershift T12000 Speeds: 3 fwd / 3 rev Torque converter: Single stage, dual phase Travel Speeds: 1st gear: 3.6 mph (5.8 km/h) 2nd gear: 7.9