GEHL RS6-42 Operators Manual

RS6-42
RS8-42
RS8-44

Telescopic Handlers

Operator’s Manual

Form No.

913218

Revision C

© 2007 Gehl Company • All Rights Reserved. • Printed in USA

Indicator and Operation Symbols

Read Operator’s

Manual

Turn SignalsParking Brake Safety Alert

Fuel

Lights

Volume Half FullVolume Full

Engine Oil

Pressure

Hazard Flasher

Battery

Work Lights

Clutch Disengaged

Transmission

Temperature

Fan

Frame Level Left

Crab Steer

Lower Load

2-Wheel Steer

Raise Load

4-Wheel Steer

Engine Coolant

Temperature

Hourmeter

Retract Load

Volume Empty

Starting Aid

Injection

Tilt Rearward

Wiper/Washer

Extend LoadTilt Forward

Hydraulic OilEngine Start Horn

Frame Level Right

Clutch Engaged

Ignition Off Ignition ON

Outriggers Down

(right side shown)

Outriggers Up

(right side shown)

Brake Failure

Diesel Fuel

PRINTED IN U.S.A. 1 913218/CP0307

Table of Contents

Chapter Description Page

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

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2

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

3

Check Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

4

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

5 Indicators and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

6

Operation and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

7

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

8 Service and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

9 Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Standard Hardware Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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.

MODEL NO.

SERIAL NO.

913218/CP0307 2 PRINTED IN U.S.A.

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

GEHL Company asks that you read and understand the contents of this manual
COMPLETELY and become familiar with the machine, before operating it.

This Telescopic Handler is primarily intended for use as a material handler. However, it may be equipped with an
optional system: the Personnel Work Platform (PWP) System, which is intended for use when lifting personnel.
When there is no other practical option available, this machine, when equipped with the PWP System, is approved
for use to lift personnel, but only

with an approved work platform, with the PWP System activated, and in full com-

pliance with the “Mandatory Work Platform Safety Rules” (see SAFETY chapter).

The use of this Telescopic Handler is subject to certain hazards that cannot be eliminated by mechanical means,
but only by the exercise of intelligence, care and common sense. It is therefore essential to have competent and
careful operators, who are not physically or mentally impaired, and who are thoroughly trained in the safe opera­tion 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 IMPORTANT
or NOTE. Be sure to read carefully and comply with the message or directive given. Following this information
will improve operating and maintenance efficiency, help to avoid breakdowns and damage, and extend the
machine’s life. A chart of standard hardware torques is located in the back of this manual.

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

If this machine was purchased “used,” or if the owner’s addrress has changed, please provide your GEHL dealer
or GEHL Company Service Department with the owner’s name and current address, along with the machine model
and serial number. This will allow the registered owner information to be updated, so that the owner can be noti­fied 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.

The wide GEHL dealership network stands ready to provide any assistance that may be required, including gen­uine GEHL service parts. All parts should be obtained from or ordered through your GEHL dealer. Give complete
information about the part and include the model and serial number of the machine. Record the serial number in
the space provided on the previous page, as a handy record for quick reference.

GEHL Company reserves the right to make changes or improvements in the design or construction of any part
without incurring the obligation to install such changes on any unit previously delivered.

Chapter 1

INTRODUCTION

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

Safety Alert Symbol

to identify potential safety hazards, which, if not properly avoided, could
result in injury. When you see this symbol in this manual or on the
machine itself, you are reminded to BE ALERT! Your personal safety is
involved!

PRINTED IN U.S.A. 3 913218/CP0307

Identification

Operator’s

Seat

Boom Angle

Indicator

Operator’s

Station

Lift

Cylinder

Dash Indicators

and Controls

Tilt

Cylinder

Rear Boom

Access

Rear Lights and

Backup Alarm Access

Quick-attach

System

Extend Cylinder

(inside boom)

Storage

Compartment

Battery
Access

Fuel Tank

Frame Leveling

Cylinder

Telescopic

Boom

Slave

Cylinder

Side View

Mirror

Access Covers

Auxiliary

Hydraulics

Hydraulic
Reservoir

(under cover)

Outriggers

913218/CP0307 4 PRINTED IN U.S.A.

Chapter 2

SPECIFICATIONS

Lifting Performance

Maximum lift capacity:

RS8-44 8000 lbs. (3628 kg)
RS8-42 8000 lbs. (3628 kg)
RS6-42 6600 lbs. (2994 kg)

Maximum lift height:

RS8-44 44’ (13.4 m)
RS8-42 42’ (12.8 m)
RS6-42 42’ (12.8 m)

Capacity at maximum lift height:

RS8-44
Outriggers up 7000 lbs. (3175 kg)
Outriggers down 8000 lbs. (3628 kg)
RS8-42
Outriggers up 7000 lbs. (3175 kg)
Outriggers down 8000 lbs. (3628 kg)
RS6-42
Outriggers up 6600 lbs. (2994 kg)
Outriggers down 6600 lbs. (2994 kg)

Max. forward reach to load center:

RS8-44 30’ 5” (9.3 m)
RS8-42 28’ 3” (8.6 m)
RS6-42 28’ 3” (8.6 m)

Capacity at maximum forward reach:

RS8-44
Outriggers up 1000 lbs. (454 kg)
Outriggers down 3000 lbs. (1360 kg)
RS8-42
Outriggers up 1000 lbs. (454 kg)
Outriggers down 3000 lbs. (1360 kg)
RS6-42
Outriggers up 1000 lbs. (454 kg)
Outriggers down 3000 lbs. (1360 kg)

Maximum below grade reach:

RS8-44 16” (406.4 mm)
RS8-42 14” (355.6 mm)
RS6-42 14” (355.6 mm)

Frame Leveling:

10oleft/10oright

General Dimensions

Based on standard machine equipped with
listed tires, 48” masonry carriage and 48” pal­let forks.

Recommended tire type:

13.00 x 24 12-ply

13.00 x 24/12 PR, foam filled

Overall length, less forks:

RS8-44 19’ 10” (6.04 m)
RS8-42 19’ 1” (5.81 m)
RS6-42 19’ 1” (5.81 m)

Overall width:

8’ (2.4 m)

Overall height:

7’-8” (2.34 m)

Ground clearance: 16” (406.4 mm)
Wheel base: 9’-11 1/2” (3.03 m)
Outside turn radius: 13’-8” (4.2 m)

Machine weight:

RS8-44 23,500 lbs. (10,659 kg)
RS8-42 23,350 lbs. (10,591 kg)
RS6-42 22,000 lbs. (9,979 kg)

Instrumentation

Gauges: Fuel level, hourmeter

and coolant temperature

Monitoring lights:

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

Visual indicators:

Boom angle, frame angle

Steering System

Steer Valve: Fixed displacement rotary
Displacement/Rev: 17.9 cu. in. (293 cc)
System pressure: 2500 psi (172 bar)
Steer cylinders: 1 per axle
Steer mode valve:

3-position, 4-way solenoid with
dash-mounted switch actuation

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

Braking System

Service brakes: Oil-immersed inboard

hydraulic wet-disc type; seperate front

and rear systems;

Manual foot pedal actuation

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

Actuation is electric switch with engine

running, automatic with engine off.

Electrical System

Type: 12-volt, negative ground
Battery: 950 cold cranking amps
Circuit protection: Fuse panel
Backup alarm: 107 dB(A)
Horn: 111 dB(A)

Standard on all models:

Brake lights, rear backup light, neutral start

switch

Alternator: 65-amp

Service Capacities

Cooling System:

4.3 gallons (16.3 L)
50/50 mixture

Anti-freeze protection: -34oF (-31oC)

Pressure cap: 10 psi (69 kPa)
Fuel tank: 47 gallons (178 L)
Hydraulic tank & system:

47 gallons (178 L)
Hydraulic Cooler Flow:

19 gpm (72 L/min)
Transmission & cooler: 24 qts. (22.7 L)

Axles:

Differentials (2): 9.6 qts. (9 L) ea.

Hubs (4): 0.6 qts. (0.5 L) ea.

Transmission

Type: Dana Powershift T12000

Speeds: 3 fwd / 3 rev

Torque converter:

Single-stage, dual-phase

Travel Speeds:

1st gear: 3.3 mph (5.31 km/h)
2nd gear: 7.3 mph (11.75 km/h)
3rd gear: 18.8 mph (30.25 km/h)

Axles (front and rear)

Type: Dana

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

Overall ratio: 22.67:1

Engine

Common to all options:

In-line 4-cycle, 4-cylinder, direct
injection diesel fuel system, in-line
fuel filter w/water trap, positive
pressure lubrication, liquid
pressurized cooling system,
18” (457 mm) blower fan,
dry single-element air cleaner,
spin-on oil filter, 65-amp alternator.

Turbocharged aspiration (RS6 only):

John Deere 4045T
276 cu. in. (4523 cc) displacement
99 hp (74 kW) @ 2500 rpm
Oil capacity: 14 qts. (13.3 L)

Turbocharged aspiration:

John Deere 4045T
276 cu. in. (4523 cc) displacement
115 hp (86 kW) @ 2500 rpm
Oil capacity: 14 qts. (13.3 L)

Hydraulic System

Type: Open-center
Pump: Single-section gear type

Displacement / revolution:

3.72 cu. in. (61 cc)

Flow @ 2500 RPM:

40 gpm (151 L/min)

Main relief pressure:

3000 psi (207 bar)

Steer relief pressure:

2500 psi (172 bar)

Hydraulic filter:

In-tank return type, 10-micron
media, 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, 100-micron media,
replaceable element
Rated flow: 100 gpm (379 L/min)
By-pass pressure: 3 psi (21 kPa)

PRINTED IN U.S.A. 5 913218/CP0307

Chapter 3

CHECKLISTS

PRE-DELIVERY

The following Checklist is an important reminder of inspec­tions that MUST be made before delivering the Telescopic
Handler to the customer. Check off each item after 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 or

loosely secured.



Oil, fuel and air filters are not damaged, leaking or loosely

secured.



All grease fittings have been properly lubricated and no fit-

tings are missing; see LUBRICATION chapter of this man­ual.



Wheel nuts are torqued to 450 ft-lbs (610 Nm).



Tires are inflated to 70 psi (480 kPa) cold.



Hydraulic system reservoir, engine crankcase, engine

coolant, transmission and axles are filled to the proper
operating fluid levels.



All adjustments have been made to comply with the set-

tings given in this manual and in the separate engine man­ual.



All guards, shields and decals are in place and securely

attached.



Model and serial numbers for this unit are recorded in

space provided on this page and page 1.

Check that:



All indicators (lamps, switches, etc.) function properly.



All hand and foot controls operate properly.



The PWP System operates properly (if equipped). Refer to

SERVICE AND STORAGE chapter for the procedure to
check the PWP System.



Boom, Quick-attach System with attachment tool and

frame 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 performed
on 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 valu­able information that MUST be passed on to the customer at
the time the unit is delivered. Check off each item as you
explain it to the customer.



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



The Index at the back, for quickly locating topics;



The Safety, Indicators and Controls, and Operation and
Adjustments chapters for information regarding safe use of
the machine.



The LUBRICATION, SERVICE AND STORAGE chap­ters for information regarding proper maintenance of the
machine. Explain that regular lubrication and maintenance
are required for continued safe operation and long life.



Give this Operator’s Manual and the AEM Safety Manual
to the customer and instruct them to be sure to read and
completely understand their contents before operating the
unit.



Explain that the customer must consult the engine manual
(provided) for related specifications, operating adjustments
and maintenance instructions.



Completely fill out the Owner’s Registration, including
customer’s signature, and return it to the Company.

Customer’s Signature

Date Delivered

Start the machine and test-run the unit while
checking that proper operation is exhibited by all
controls.

(Dealer’s File Copy - Remove at Perforation)

913218/CP0307 6 PRINTED IN U.S.A.

INTENTIONALLY BLANK

(To be removed as Dealer’s file copy)

PRINTED IN U.S.A. 7 913218/CP0307

Chapter 3

CHECKLISTS

PRE-DELIVERY

The following Checklist is an important reminder of inspec­tions that MUST be made before delivering the Telescopic
Handler to the customer. Check off each item after 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 or

loosely secured.



Oil, fuel and air filters are not damaged, leaking or loosely

secured.



All grease fittings have been properly lubricated and no fit-

tings are missing; see LUBRICATION chapter of this man­ual.



Wheel nuts are torqued to 450 ft-lbs (610 Nm).



Tires are inflated to 70 psi (480 kPa) cold.



Hydraulic system reservoir, engine crankcase, engine

coolant, transmission and axles are filled to the proper
operating fluid levels.



All adjustments have been made to comply with the set-

tings given in this manual and in the separate engine man­ual.



All guards, shields and decals are in place and securely

attached.



Model and serial numbers for this unit are recorded in

space provided on this page and page 1.

Check that:



All indicators (lamps, switches, etc.) function properly.



All hand and foot controls operate properly.



The PWP System operates properly (if equipped). Refer to

SERVICE AND STORAGE chapter for the procedure to
check the PWP System.



Boom, Quick-attach System with attachment tool and

frame 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 performed
on 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 valu­able information that MUST be passed on to the customer at
the time the unit is delivered. Check off each item as you
explain it to the customer.



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



The Index at the back, for quickly locating topics;



The Safety, Indicators and Controls, and Operation and
Adjustments chapters for information regarding safe use of
the machine.



The LUBRICATION, SERVICE AND STORAGE chap­ters for information regarding proper maintenance of the
machine. Explain that regular lubrication and maintenance
are required for continued safe operation and long life.



Give this Operator’s Manual and the AEM Safety Manual
to the customer and instruct them to be sure to read and
completely understand their contents before operating the
unit.



Explain that the customer must consult the engine manual
(provided) for related specifications, operating adjustments
and maintenance instructions.



Completely fill out the Owner’s Registration, including
customer’s signature, and return it to the Company.

Customer’s Signature

Date Delivered

Start the machine and test-run the unit while
checking that proper operation is exhibited by all
controls.

(Pages 5 and 6 have been removed at perforation)

913218/CP0307 8 PRINTED IN U.S.A.

Chapter 4

SAFETY

DANGER

“DANGER” indicates an imminently haz­ardous situation which, if not avoided, will
result in death or serious injury.

WARNING

“WARNING” indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.

CAUTION

“CAUTION” indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury. It may also alert to
unsafe practices.

Gehl Company ALWAYS takes the operator’s safety
into consideration when designing its machinery, and
guards exposed moving parts for his/her protection.
However, some areas cannot be guarded in order to
assure proper operation. Further, this Operator’s
Manual,and Safety Manual and decals on the machine
warn of additional hazards and should be read and
observed closely.

REMEMBER! It is the owner’s responsibility for com­municating information on the safe use and proper
maintenance of this machine! This includes providing
understandable interpretations of these instructions
for operators who are not fluent in reading English.

It is the responsibility of the operator to read and
understand the Operator’s Manual and other informa­tion provided and use the correct operating procedure.
Machines should be operated only by qualified opera­tors.

MANDATORY SAFETY SHUTDOWN

PROCEDURE

BEFORE cleaning, adjusting, lubricating or ser­vicing the unit:

1. Stop machine on a level surface. (Avoid parking
on a slope, but if necessary, park across the
slope and block the tires.)

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

3. Place controls in neutral and apply parking
brake.

4. Shut off the engine and remove the key.

ONLY when you have taken these precautions can
you be sure it is safe to proceed. Failure to follow
the above procedure could lead to death or serious
bodily injury.

The above Safety Alert Symbol means ATTENTION!
ALWAYS BE ALERT! YOUR SAFETY IS
INVOLVED! It stresses an attitude of “Heads Up for

Safety” and can be found throughout this Operator’s
Manual and on the machine itself.

Before operating this equipment, read and
study the following safety information. In
addition, be sure that everyone who operates
or works with this equipment is familiar with
these safety precautions.

PRINTED IN U.S.A. 9 913218/CP0307

SAFETY

Additional Safety Reminders

 User/operator safety practices, as established by

industry standards, are included in this Operator’s
Manual and intended to promote safe operation of
the machine. These guidelines do not, of course,
preclude the use of good judgment, care and com­mon sense as may be indicated by the particular
jobsite work conditions.

 It is essential that operators be physically and men-

tally free of mind altering drugs and chemicals and
thoroughly trained in the safe operation of the
machine. Such training should be presented com­pletely to all new operators and not condensed for
those claiming previous experience. Information
on operator training is available from several
sources, including the manufacturer.

 Some illustrations used in this manual may show

doors, guards and shields open or removed for
illustration purposes ONLY. BE SURE that all
doors, guards and shields are in their proper oper­ating positions BEFORE starting the engine.

Before Operation Safety Reminders

 Check brakes, steering, and hydraulic system prior

to starting operation. Operate all controls to ensure
proper operation. Observe all gauges and indica­tors for proper operation. If any malfunctions are
found, correct the cause prior to using the machine.

 ALWAYS wear appropriate personal protective

equipment for the job and working conditions.
Hard hats, goggles, protective shoes, gloves,
reflector-type vests, respirators and ear protection
are exampes of types of equipment that may be
required. DO NOT wear loose fitting clothing,
long hair, jewelry or loose personal items while
operating or servicing the machine.

 ALWAYS check the job site for terrain hazards,

obstructions and people. Remove all objects that
do not belong in or on the machine and its equip­ment.

WARNING

U.S. OSHA regulations require employers in
general industry and the construction, ship­yard and cargo-handling industries (excepting
agricultural operations) to ensure that forklift
operators are competent, as demonstrated by
successful completion of a training course.

The training course must consist of a combi­nation of formal instruction and practical
training, including both forklift-related and
workplace-related topics, and evaluation of
the operator’s performance in the workplace.

All operator training and evaluation is to be
conducted by persons who have the know­ledge, training and experience to train and
evaluate operators.

WARNING

ALWAYS maintain a safe distance from elec­tric power lines and avoid contact with any
electrically charged conductor or gas line. It is
not necessary to make direct contact with a
power line for power to ground through the
structure of the machine. Keep the boom at
least 10 ft. (3 m) from all power lines.
Accidental contact or rupture can result in
electrocution or an explosion. Contact the
North American One-Call Referral System at
[phone] for the local “Digger’s Hotline”
number or proper local authorities for utility
line locations BEFORE starting to dig!

913218/CP0307 10 PRINTED IN U.S.A.

 Walk around the machine and warn all personnel

who may be servicing the machine or who are in
the machine path prior to starting. DO NOT start
until all personnel are clearly away from the
machine.

Operation Safety Reminders

 Any or all of the following elements: terrain,

engine speed, type of load being carried and
placed, improper tire inflation, weight of the
attachment tool, and abrupt movement of any con­trol lever may affect the stability of the machine.

IF YOU ARE NOT CAREFUL WHILE OPER­ATING THIS MACHINE, ANY OF THE
ABOVE FACTORS COULD CAUSE THE
MACHINE TO TIP AND THROW YOU OUT
OF THE OPERATOR’S STATION, WHICH
MAY CAUSE SERIOUS BODILY INJURY OR
DEATH!

 ALWAYS wear the seat belt provided to prevent

being thrown from the machine. If you are in an
overturn:

- DO NOT jump!

- Hold on tight and stay with the machine!

- Lean away from the fall!

 ALWAYS keep hands, feet and arms inside of the

operator’s station when operating the machine!

 Always look in the direction of travel. Look to the

rear before backing.

 ALWAYS use the recommended hand holds and

steps with at least three points of support when get­ting on and off the machine. Keep steps and plat­form clean. Face the machine when climbing up
and down.

 DO NOT raise or drop a loaded fork or bucket sud-

denly. Abrupt movements under load can cause
serious instability.

 Study the load chart carefully. It shows maximum

capacity to be lifted and placed at specific outward
and upward distances. ALWAYS be aware of load
weights prior to attempting lift and placement with
this machine.

 DO NOT exceed the machine’s rated operating

capacity for the type of attachment tool being used.

 DO NOT allow minors or any unqualified person-

nel to operate or be near the machine unless prop­erly supervised.

 DO NOT start the engine or operate any controls

unless 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 odor­less and deadly gas. Internal combustion engines
deplete the oxygen supply within enclosed spaces
and may create a serious hazard unless the oxygen
is replaced. This includes the atmosphere within
the cab when equipped.

 DO NOT leave the operator’s station with the

boom and attachment tool raised. ALWAYS lower
the boom and attachment tool to the ground, shut
off the engine and engage the parking brake before
leaving the operator’s station.

 DO NOT drive too close to an excavation or ditch.

BE SURE that the surrounding ground has ade­quate strength to support the weight of the machine
and the load it is carrying.

 DO NOT turn quickly while traveling on a slope or

operate the machine beyond the grade and slope
limits noted in the Operation and Adjustments
chapter of the Operator’s Manual.

 NEVER allow any riders on this machine. This is

strictly a single seat, NO passenger machine

 NEVER use as a lift for personnel unless the

machine is equipped with the Personnel Work
Platform (PWP) Safety System.

 When road travel is required, know and use the

signaling devices on the machine. Provide an
escort and Slow Moving Vehicle (SMV) emblem
when required.

 If necessary to park on a slope, park across the

slope and block the wheels.

SAFETY

PRINTED IN U.S.A. 11 913218/CP0307

Servicing Safety Reminders

 ALWAYS be aware of and avoid pinch point areas

on the machine, such as wheels-to-frame, cylin­ders-to-frame, boom and attachment tool-to-frame.

 NEVER attempt to by-pass the keyswitch to start

the engine. ONLY use the jump-starting procedure
detailed in the SERVICE AND STORAGE chap­ter.

 NEVER use your hands to search for hydraulic

fluid leaks. Use a piece of paper or cardboard.
Escaping fluid under pressure can be invisible and
can penetrate the skin, causing serious injury. If
any fluid is injected into your skin, see a doctor at
once. Injected fluid MUST be surgically removed
by a doctor familiar with this type of injury or gan­grene may result.

 ALWAYS wear safety glasses with side shields

when striking metal against metal. In addition, it is
recommended that a softer (chip-resistant) materi­al be used to cushion the blow. Failure to heed
could lead to serious injury to the eyes or other
parts of the body.

 DO NOT refill the fuel tank when the engine is

hot. Allow engine to cool down before refilling to
prevent hot engine parts from igniting the fuel if it
should spill or splash.

 DO NOT smoke while filling the fuel tank, work-

ing on the fuel or hydraulic systems, or working
around the battery.

 DO NOT fill the fuel tank completely. Allow room

for expansion. Maintain control of the fuel filler
nozzle when filling the tank. Use the correct fuel
grade for the operating season.

 NEVER use fuel for cleaning purposes.
 DO NOT remove the radiator cap after the engine

has reached operating temperature or if it is over­heated. At operating temperatures, the engine
coolant will be extremely HOT and under pressure.

ALWAYS wait for the engine to cool before
attempting to relieve pressure and remove the radi­ator cap. Failure to heed this warning could result
in severe burns.

 DO NOT loosen or disconnect any hydraulic lines,

hoses or fittings without first relieving hydraulic
circuit pressure. Also, be careful not to touch any
hydraulic components that have been in recent
operation because they can be extremely hot and
can burn you!

 Avoid lubrication or mechanical adjustments with

the machine in motion or the engine running. If the
engine must be running to make certain adjust­ments, place the transmission in neutral, apply the
parking brake, place the equipment in a safe posi­tion, securely block the wheels and use extreme
caution.

 To ensure continued safe operation, replace dam-

aged or worn-out parts with genuine GEHL service
parts before using this equipment.

Modifications, Nameplates, Markings
and Capacities

 Modifications and additions that affect capacity or

safe operation must never be performed without
the manufacturer’s prior written approval. Where
such authorization is granted, any applicable mark­ings are to be changed accordingly.

 All attachment tools MUST be marked to identify

the attachment tool and the total capacity with the
attachment tool at maximum elevation with the
load laterally centered.

 ALWAYS be sure all nameplates, warnings and

instruction markings are in place and legible.
Local government regulations may require specif­ic decals, which are the responsibility of the owner
to provide.

SAFETY

913218/CP0307 12 PRINTED IN U.S.A.

Safety Guards and Warning Devices

 This machine is fitted with a Roll-Over Protective

Structure (ROPS) and Falling Object Protective
Structure (FOPS) in accordance with industry stan­dards. It is intended to offer protection to the oper­ator from falling objects and in case of an overturn,
but it cannot protect against every possible hazard.
Therefore it should not be considered a substitute
for good judgment and safe practices in operating
the machine. If the ROPS / FOPS structure is dam­aged, it must be replaced to restore the protection
it provides.

 This machine is equipped with a horn and backup

alarm. The user must determine if operating condi­tions require the machine to be equipped with
additional devices (mirrors, rotating beacon, etc.)
and be responsible for providing and maintaining
such devices.

Personnel Work Platform (PWP)
Safety System

The Mandatory Work Platform Safety Rules must be
adhered to at all times while elevating personnel.
These rules are based on ANSI/ITSDF Standard
B56.6-2005, “Safety Standard for Rough Terrain
Forklift Trucks.” (A copy of this and related standards
can be obtained from the Industrial Truck Standards
Development Foundation, 1750 K Street NW, Suite
460, Washington DC 20009; or downloaded from:
www.itsdf.com.) The rules apply to the owner, opera­tor and the personnel in the work platform.

MANDATORY WORK PLATFORM

SAFETY RULES

1. The work platform must comply with
ANSI/ITSDF B56.6-2005, Sec. 8.24, “Platforms
for Elevating Personnel.” (See page 13, “Work
Platform Design Requirements.”)

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

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

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

5. Personnel on the platform must be provided pro­tection from any moving parts on the forklift that
may present a hazard.

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

7. Be sure that the lifting mechanism is operating
smoothly throughout its entire range, both empty
and loaded, and that any lift-limiting devices and
latches are functional.

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

9. Be sure the platform is horizontal before lifting.

10. Be sure that the forklift has a firm footing.

11. Be sure that any required restraining means (rail­ings, chains, harnesses, etc.) are in place and prop­erly used.

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

13. Before lifting personnel, the area should be
marked to warn others of work by elevated per­sonnel.

14. Be sure the path of platform travel is clear of haz­ards, such as scaffolds, electrical wires and over­head obstructions.

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

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

17. The platform must be lowered fully before moving
the forklift. Do not drive the forklift with person­nel on the platform.

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

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

WARNING

The machine must not be used to lift or carry
personnel, or be fitted with any form of per­sonnel work platform unless fitted with the
optional PWP System.

If fitted with the PWP System, the Mandatory
Work Platform Safety Rules must be followed
at all times while lifting personnel.

PRINTED IN U.S.A. 13 913218/CP0307

20. The combined weight of the platform, personnel
and load must not exceed one-third of the materi­al-handling capacity of the forklift.

21. Platform personnel must maintain firm footing on
the platform floor, unless secured by harness and
lanyard. A harness is to be worn and a lanyard
attached to the platform or boom when working
from an elevated work platform, in accordance
with OSHA regulations. Use of railings, planks,
ladders, etc. on platform for the purpose of achiev­ing additional reach or height is prohibited.

22. Workers on the platform must keep all parts of
their bodies inside the work platform during rais­ing and lowering.

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

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

25. Any harness, body belt, lanyard, or deceleration
device that has sustained permanent deformation
or is otherwise damaged must be replaced.

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

Work Platform Design Requirements

(Per ASME/ITSDF B56.6-2005, Sec. 8.24)

1. A platform floor having a slip resistant surface
located not more than 8 inches (200 mm) above the
normal load supporting surface of the forks.

2. Floor dimensions, which shall not exceed two
times the load center distance of 24 inches (610
mm) listed on the forklift nameplate, measured
parallel to the longitudinal center plane of the
truck, nor have a width greater than the overall
width of the forklift [measured across the load­bearing tires] plus 10 inches (250 mm) on either
side. Minimum space for each person on the plat­form shall not be less than 18 inches (450 mm) in
either direction.

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

4. An overhead protective device, when requested by
the user.

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

6. Information prominently indicated on the plat­form:

a. maximum work load including personnel and

equipment,

b. weight of empty platform.

7. Means so that the platform can only be centered
laterally on the forklift, and retained against the
vertical face of the forks, carriage, or lifting mach­anism.

8. A means to securely attach the platform to the lift­ing mechanism, and to prevent the platform from
inadvertantly pivoting.

WARNING

Use ONLY an approved work platform for ele­vating personnel.

NEVER move the machine with the work plat­form in a raised position or with personnel on
board.

NEVER tilt the platform forward, rearward, or
to the side with personnel on board.

ALWAYS engage the PWP System and follow
the Mandatory Work Platform Safety Rules
when elevating personnel.

Work Platform

Switch

PWP

Remote

Shutdown

Switch

Electrical

Connection

Remote Shutdown Switch

With Coiled Wire Connector

913218/CP0307 14 PRINTED IN U.S.A.

9. Restraining means such as a guardrail or a means
for securing personnel such as a body harness and
lanyard. A guardrail or similar structure shall have
a nominal height to the platform floor of 42 inches
(1066 mm) around its upper periphery and include
a midrail. It may be hinged, removable, or of
chains, and used to provide an access opening if
proper positioning is easily accomplished and a
secure condition is discernable. Such restraining
means shall be capable of withstanding a concen­trated horizontal force of 200 lb. (890 N) applied at
the point of least resistance without permanent
deformation. Abody harness and lanyard is to have
an attachment point provided overhead for free­dom of movement, and its length is to limit free­fall to 5 feet (1500 mm) measured from the point
of attachment to the operator. The complete system
shall be capable of withstanding three consecutive
drop tests to simulate a 250 lb. (113 kg) person
falling 6 feet (1800 mm) without allowing the test
weight to fall free to the ground. A deceleration
device may be included.

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

10. Lanyards, when provided, shall be arranged so as
not to cause a tripping hazard.

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

12. Structural safety factor - all load supporting struc­tural elements of the work platform shall have a
structural safety factor of not less than 2 to 1 based
on the minimum yield strength of the materials
used.

PRINTED IN U.S.A. 15 913218/CP0307

SAFETY

L70307

L70306

101506

L65926

101506

L65926

L70306

L70307

913218/CP0307 16 PRINTED IN U.S.A.

SAFETY

L65927

L70305

L65927

L65932

L65927

L65927

L65933

L70305

L65932

L65928

100359

PRINTED IN U.S.A. 17 913218/CP0307

SAFETY

L65933

L65932

L65927

100359

L70305

L65928

913218/CP0307 18 PRINTED IN U.S.A.

SAFETY

L65926

L65928

L65927

L65927

L66613

PRINTED IN U.S.A. 19 913218/CP0307

SAFETY

RED

L66613

L65928

L65927

L65926

913218/CP0307 20 PRINTED IN U.S.A.

L71554

L71555

L71554

L71700

L71700

L71555

L71554

SAFETY

PWP Safety Decals

102969

102969

PRINTED IN U.S.A. 21 913218/CP0307

GUARDS AND SHIELDS

Whenever possible and without affecting machine
operation, guards and shields are used to protect poten­tially hazardous areas. In many places, decals are also
provided to warn of potential hazards and to display
special operating procedures.

WARNING

Read and thoroughly understand all safety
decals on the Telescopic Handler BEFORE
operating it. DO NOT operate the machine
unless all factory-installed guards and shields
are properly secured in place.

CAUTION

Become familiar with and know how to use
ALL safety devices and controls on the
Telescopic Handler BEFORE operating it.
Know how to stop the machine operation
BEFORE operating it. This GEHL machine is
designed and intended to be used ONLY with
a GEHL Company attachment tool, or a GEHL
Company approved accessory or referral
attachment tool. GEHL Company cannot be
responsible for safety if the machine is used
with an unapproved accessory or attachment
tool.

Chapter 5

INDICATORS AND CONTROLS

Operator’s Compartment and Indicators/Controls Locations

Frame Angle

Indicator

Boom Control

Joystick

Key Switch

Start Button

Boom Angle

Indicator

Brake Pedal

Frame Level and

Attachment Joystick

Auxiliary

Hydraulics

Control

Throttle Pedal

Steering Wheel

Outrigger

Controls

Instrument and

Switch Panel

Load Zone

Charts

Horn Button

Speed and Travel

Direction Lever

Brake Fluid

Reservoir

Tri-Function

Joysticks

Frame Level

Control

913218/CP0307 22 PRINTED IN U.S.A.

Coolant Temperature Gauge: The
upper right gauge in the instrument
panel, it indicates the temperature of
the engine coolant. Under normal
conditions, this gauge should indicate
approximately 185°F (85°C).

Lamp Cluster Gauge: The lower left
gauge in the instrument panel, it con­tains four indicator lamps. The func­tion of these lamps are as follows:

Alternator Lamp: Located in the
upper left section of the lamp
cluster gauge, this lamp indicates
the condition of the electrical
charging system. During normal
operation, this lamp should be
off. If the charge rate is too high or
too low, this lamp will come on.

Engine Oil Pressure Lamp:

Located in the upper right section
of the lamp cluster gauge, this
lamp indicates whether the
engine lubricating oil pressure is
sufficient. During normal opera­tion, with the engine running, this
lamp should be off. During starting and
when the engine is not running, this lamp will be on.

IMPORTANT: If this lamp comes on during nor­mal operation with the engine running, stop the
engine immediately! After allowing the oil to drain
down for a few minutes, check the engine oil
level. Maintain oil level at the FULL mark on the
dipstick.

Brake Failure Lamp: This lamp is
located in the lower left section of
the lamp cluster gauge. The front
and rear brakes are on indepen­dent brake systems. If during
normal operation with the brake
pedal depressed, a loss of pressure
occurs in either system, the brake failure
lamp comes on. During normal operation the lamp
should remain off.

DASH PANEL AREA

Key Switch OFF: When the key is verti­cal in the keyswitch, power from the bat­tery is disconnected to the control and
instrument panel electrical circuits. Also,
this is the only position in which the key can be insert­ed or removed.

Key Switch ON: When the key is turned
one position clockwise from the vertical
(OFF) position, power from the battery is
supplied to all control and instrument
panel electrical circuits.

NOTE: If the engine requires repeated attempts
to start, the key MUST be returned to the OFF
position between starting attempts to prevent bat­tery run down.

Start Button: With key switch in ON
position, press the button to activate the
starter. Release it as soon as the engine
starts.

Horn Button: With the key switch ON,
press the horn button to activate warning
sound.

Load Zone Charts: A series of flip charts show lift
height and reach limits relative to the load weight
being handled with various attachment tools.

Fuel Level Gauge: The upper left
gauge in the instrument panel, it indi­cates the amount of fuel remaining in
the fuel tank.

Instrument and Switch Panel

PRINTED IN U.S.A. 23 913218/CP0307

Failure in one of the brake systems does not affect the
operation of the other system. However, the MANDA-

TORY SAFETY SHUTDOWN PROCEDURE (p.

8) should be followed and any required repairs made

immediately.

Transmission Oil Temperature
Lamp: Located in the lower right

section of the lamp cluster
gauge, this lamp indicates
whether or not the transmission
oil is at the proper temperature.
During normal operation this lamp
should be off, indicating that the trans­mission oil system is at the proper temperature.

IMPORTANT: If this lamp comes on during nor­mal operation, a problem may exist in the trans­mission oil system. Stop the machine immediate­ly and investigate the cause of the problem!

Hourmeter: Located to the right of
the lamp cluster gauge, it indicates
the total operating time of the
machine and should be used for
keeping the maintenance log.

Top Row Switches

Switches have graphic symbols to indicate position
and response. The following mode descriptions start
with the first switch from the left.

NOTE: Some switches are optional and may not
be on machine.

Steer Selector: This 3-position switch is
used to select between three steer modes.
The upper position selects the 4-wheel
steer mode. This mode selects all wheel
steering for making tighter turns, usually
on a jobsite. The center position selects the
2-wheel steer mode. This mode selects front wheel
steering only, used for higher speed travel. The lower
position selects the crab steer mode. This mode is used
when a small amount of side shift is needed for pick­ing or placing a load.

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

Any of the steering position modes can be used in for­ward and reverse travel. The operator should learn to
anticipate changes in machine movement if the steer­ing selector mode must be changed.

Engine Fault Override Shutdown
Switch: Pressing the override shutdown

switch will override an engine shutdown
signal. The switch must be pressed within
30 seconds to prevent undesired shutdown of engine.
The switch can be overridden for 30 seconds at a time
to move the machine to a safe location and to lower the
boom to the ground. If the engine shuts down, the igni­tion switch must be turned off and then back on before
the engine can be restarted.

NOTE: Holding the switch continously “ON” will
not reset the 30-second timer.

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

Clutch Cutout: When activated, it allows
faster engine acceleration and more power
to the hydraulic system, without power to
the drive axles, while the service brake
pedal is pressed.

In the “OFF” position, the clutch mecha­nism of the transmission remains engaged when apply­ing brakes. In the “ON” position, the clutch mecha­nism is disengaged while applying the brakes.

Normal brake force will hold the machine in position
while accelerating the engine to power hydraulic con­trol functions during load placement.

Parking Brake: When the machine is shut
off, this switch should be depressed to
actuate the parking brake mechanism in
the front axle.

WARNING

Unattended machine hazard.

Activate parking brake switch and lower
attachment tool to ground before leaving
machine. An unattended machine can move or
roll and cause death or serious injury to oper­ator or bystanders.

Periodically check the parking brake opera­tion to maintain adequate holding power.
Always be sure the parking brake switch is off
when resuming machine operation.

913218/CP0307 24 PRINTED IN U.S.A.

Middle Row Switches

Switches have graphic symbols to indicate position
and response. The following mode descriptions start
with the first switch from the left.

NOTE: Some switches are optional and may not
be on machine.

Head Lights/Work Lights: Depressing
the top of the switch will illuminate the
lights mounted on the top of the operator’s
station and the red tail lights for forward
travel operations. Depressing the bottom of
the switch will illuminate the lights at the
end of the boom in addition to the lights on the opera­tor’s station for additional lighting in working opera­tions.

Turn Signal: This switch is used to indi­cate the direction of a turn with the tail
lights. Depress the right arrow for a right
turn; depress the left arrow for a left turn.
Return the switch to the center position
after the turn is completed.

Hazard: This switch can be activated to
make the tail lights flash on and off in case
the machine is stalled or temporarily
stopped in a traffic area on the road or job­site.

Personnel Work Platform: This is a red switch used
to activate the Personnel Work Platform System. When
activated, an amber lamp in the switch will light.

NOTE: This lamp will flash on and off, indicating
that the system is not yet fully functional, until the
brakes are held on for three or more seconds.

Bottom Row Switches

Switches have graphic symbols to indicate position
and response. The following mode descriptions start
with the first switch on the left.

NOTE: Some switches are optional and may not
be on machine.

Wiper/Washer: The windshield and top
window of the operator’s station are each
equipped with a wiper and washer mecha­nism. The left switch operates the wiper
and washer on the windshield; the second switch oper­ates the wiper and washer on the top window.

Cold Starting: This switch activates the
injection of an ether agent for faster engine
starts in cold weather.

Heater Controls

Temperature Control: This is the upper knob located
to the left of the steering wheel. This knob is used to
adjust the temperature output of the heater. Turning the
knob clockwise will increase the temperature output of
the cab heater.

Fan Speed: This knob is located below the tempera­ture control knob. Rotating the knob clockwise will
increase the fan speed for increased air circulation.

Travel Lever

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

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

NOTE: Backup alarm automatically sounds with
travel lever in reverse.

Position “F” (FORWARD)

Position “N” (NEUTRAL)

Position “R” (REVERSE)

Fan Speed Knob

Temperature

Control Knob

PRINTED IN U.S.A. 25 913218/CP0307

Speed Range: Twisting the lever end clockwise or
counter-clockwise will change the transmission speed
between low, medium and travel ranges.

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

IMPORTANT: Care should be taken when down­shifting or changing direction, because damage to
the transmission can occur if shifting is forced or
attempted at too high a speed. Allow engine
speed to slow before any downshift or directional
change is attempted.

Steering

The power steering system is designed to provide low
effort steering without shock reaction from the axle
wheels to the steering wheel. Turn the steering wheel
to the right or left to turn the machine in that direction.

FLOOR AND SEAT AREA

Throttle Pedal: This is right-foot operated and con­trols the engine RPM to match increased power
requirements. Pushing down on the pedal increases
engine speed; letting up on the pedal decreases engine
speed.

Service Brake Pedal: Depressing this pedal activates
inboard hydraulic wet-disc-type brakes on all four
wheels. Separate front and rear brake systems allow
bringing the machine to a safe stop if either system
loses pressure.

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

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

Suspension Seat Option: This option is avalable for
addtional operator comfort. It is adjustable for a soft or
firm ride.

RIGHT SIDE PANEL

These controls and indicators are used to position the
frame, boom, attachment and outriggers. Graphic sym­bols on the side panel illustrate the control actions.

This machine is equipped with one of two types of
boom and attachment joystick control configurations.
One being a two joystick configuration and the other is
a single tri-function joystick.

WARNING

Use extreme caution when raising or extend­ing the boom. The Telescopic Handler MUST
be level. Loaded or empty, this machine can
tip if not level.

ALWAYS place the transmission in neutral, set
the parking brake and keep the service brakes
fully applied before raising or extending the
boom.

NEVER exceed the specified lifting and
extending capacities of this machine. Serious
machine damage or personal injury may
result. Refer to the load charts in the opera­tor’s station or this manual.

If a boom circuit hose should burst with the
boom up, with or without a load, shut down
the machine following the MANDATORY
SAFETY SHUTDOWN PROCEDURE (page 8).
DO NOT attempt repairs. Call your Gehl dealer
for assistance.

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

NEVER use winch for lifting or moving of per­sonnel. NEVER exceed the maximum rated
capacity of the winch (3000 lbs./1360 kg) or
exceed the load chart rating for winch appli­cations.

DO NOT tilt the truss boom back more than
45° from horizontal. DO NOT attempt to use

the optional rotating carriage as a load level­ing function. Always level the frame prior to
raising a load.

913218/CP0307 26 PRINTED IN U.S.A.

Two Joystick Configuation

Frame Level/Attachment Tilt Joystick: The machine
may be tilted slowly 10° to the left or right to level the
frame and boom in relation to the ground. Move the
joystick handle to the left to tilt to the left. Move the
joystick handle to the right to tilt to the right.

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

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

Boom Control Joystick: This machine has a hydraulic
type boom with telescopic sections. The sections
extend by means of a hydraulic cylinder and chain sys­tem inside the boom, sequenced for uniform extension
of each section.

To extend the boom, move the joystick handle to the
right. To retract the boom, move the joystick handle to
the left. To raise the boom, move the joystick handle
rearward. To lower the boom, move the joystick handle
forward.

Outrigger Controls: The outriggers are an option
used to provide greater stability in specific applica­tions. The left lever controls the left outrigger. The
right lever controls the right outrigger. Move the levers
forward to lower the outriggers. Move the levers rear­ward to raise the outriggers.

Auxiliary Hydraulics Control: This 2-position lever
is for attachment tools that require additional
hydraulics.

Tri-Function Joystick Configuation

Tri-Function Joystick: This joystick handle is
equipped with two yellow buttons and two blue but­tons on the upper rear of the handle and a trigger
switch on the front of the handle. The yellow buttons
operate the attachment tilt. The blue buttons operate
the auxiliary hydraulics. The trigger switch increases
the function speed of both the attachment tilt and aux­iliary hydraulics.

Boom, Attachment

and Auxilliary

Hydraulic Joystick

Frame Level

Control

Outrigger

Controls

Single Tri-Function Joystick Configuration

WARNING

Be sure NO persons or equipment are where
the outrigger pads will be positioned.

DO NOT travel with the outriggers extended
under any circumstances.

Adequate clearance is required for the outrig­gers in the retracted position when traveling
through doorways or narrow pathways.

DO NOT attempt to use outriggers as a
hydraulic jack for maintenance or frame level­ing or other similar uses.

Failure to heed could result in death or seri­ous injury.

WARNING

DO NOT level the frame with the boom raised
or extended. Only level the frame while
stopped and with the boom fully retracted and
the attachment raised just enough to clear the
ground.

Frame Level and

Attachment Joystick

Boom Control

Joystick

Auxilliary

Hydraulics

Control

Outrigger

Controls

Two Joystick Configuration

PRINTED IN U.S.A. 27 913218/CP0307

To extend the boom, move the joystick right. To retract
the boom, move the joystick left. To raise the boom,
move the joystick rearward. To lower the boom, move
the joystick forward.

To tilt the attachment tool up, depress and hold the
lower yellow button on the left side of the joystick han­dle. To tilt the attachment tool down, depress and hold
the upper yellow button on the left side of the joystick
handle.

To operate the auxiliary attachment hydraulics, depress
and hold either the upper or lower blue button on the
right side of the joystick handle.

Depressing and holding the trigger on the front side of
the joystick handle will increase the speed of the
attachment tilt and auxiliary hydraulic functions.

NOTE: The joystick handle does not need to be
moved to operate the tilt or auxiliary hydraulic
functions.

Speed Control Knobs: The tri-function joystick han­dle also incorporates a manually adjusted speed con­trol. This speed adjustment is accomplished through
the manual adjustment of the pilot pressure apply
valves located on the top rear of the hydraulic reservoir
under the access cover on the front hood section.

If the machine is equipped with auxiliary hydraulics,
there will be two pilot pressure apply valves, each hav­ing two speed-control knobs. The rigth pilot valve con-

trols the auxiliary hydraulics, and the left pilot valve
controls the attachment tilt function. On the attachment
tilt pilot valve, the left knob controls the attachment
tilt-back speed, and the right knob controls the attach­ment tilt-forward speed. On the auxiliary hydraulic
pilot valve, the function of the knobs will depend on
the type of attachment requiring auxiliary hydraulics.

Turning a knob clockwise will increase the speed of its
associated function. Turning a knob counter-clockwise
will decrease the speed of its associated function.

NOTE: There is a locking knob located forward of
the adjusting knob, which must be loosened
before the adjusting knob can be turned. After
adjustment has been made, tighten the locking
knob to maintain the selected speed.

Frame Level Control: This control is located to the
rear of the tri-function joystick. The machine may be
tilted slowly 10° to the left or right to level the frame
and boom in relation to the ground.

AUXILIARY HYDRAULICS

PILOT PRESSURE APPLY

VALV E

ATTACHMENT TILT

PILOT PRESSURE APPLY

VALV E

ATTACHMENT TILT
FORWARD SPEED

CONTROL KNOB

ATTACHMENT TILT

REARWARD SPEED

CONTROL KNOB

AUXILIARY

HYDRAULICS SPEED

CONTROL KNOBS

LOCKING

KNOB

L71378
DECAL

LOCKING

KNOB

L71378
DECAL

FRONT

WARNING

DO NOT level the frame with the boom raised
or extended. Only level the frame while
stopped and with the boom fully retracted and
the attachment raised just enough to clear the
ground.

Attachment and Auxilliary Hydraulics Pilot Pressure Apply Valves

913218/CP0307 28 PRINTED IN U.S.A.

Outrigger Controls: The outriggers are an option
used to provide greater stability in specific applica­tions. The left lever controls the left outrigger. The
right lever controls the right outrigger. Move the levers
forward to lower the outriggers. Move the levers rear­ward to raise the outriggers.

FUNCTION INDICATORS

Frame Level Indicator: Located in front of the oper­ator on the ROPS upper cross tube. Movement of the
bubble shows when the frame is level relative to a slop­ing ground surface.

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

OTHER INDICATORS

The following indicators are for checking fluid levels.

Transmission Oil Level: Dipstick is located below the
rear cover on the front section of the main hood.

Engine Oil Level: Dipstick is located on the right side
of the middle section of the main hood.

Coolant Level: Coolant can be checked and added
through the radiator cap located under the top rear
opening on the main hood.

Hydraulic Reservoir Oil Level and Fill Cap: The
sight gauge on the side of the reservoir indicates the
level of the hydraulic oil. The fill cap is accessible by
removing the front cover of the front hood section.

SERVICE AND SAFETY FEATURES

Hydraulic Pressure Test Ports: A gauge can be
attached to these ports to check main valve, joystick
and steering pressures.

Backup Alarm: Located inside the rear frame cover, it
produces a loud warning sound when the machine is in
reverse.

Boom Angle

Indicator

Frame Level

Indicator

Hydraulic

Test Ports

Transmission

Dipstick

Hydraulic Oil

Fill Cap

Hydraulic Oil Level

Sight Gauge

WARNING

Be sure NO persons or equipment are where
the outrigger pads will be positioned.

DO NOT travel with the outriggers extended
under any circumstances.

Adequate clearance is required for the outrig­gers in the retracted position when traveling
through doorways or narrow pathways.

DO NOT attempt to use outriggers as a
hydraulic jack for maintenance or frame level­ing or other similar uses.

Failure to heed could result in death or seri­ous injury.

PRINTED IN U.S.A. 29 913218/CP0307

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

Battery Compartment: The battery compartment is
below the tool box at the rear of the fuel tank. Remove
the bottom panel of the tool box to check the elec­trolyte level. Remove the access panel on the side of
the battery compartment to remove the battery.

Fuse and Relay Compartment: Located under the
load chart panel in the cab. Remove the four screws to
gain access to the fuses and relays.

ATTACHMENT TOOLS

Gehl offers a versatile range of attachment tools to
meet various lifting and material handling applications.
Contact your Gehl dealer for specifications and order­ing information.

ACCESSORIES

Gehl offers a range of special accessories for this
machine. Contact your Gehl dealer for specifications
and ordering information.

NOTE: All accessories are field-installed unless
otherwise noted. Information and parts for
installing accessories will be provided by the Gehl
Company or Gehl Telescopic Handler dealers.

Electrolyte

Access

Removal

Access

Fuse and

Relay Access

913218/CP0307 30 PRINTED IN U.S.A.

GENERAL INFORMATION

ENGINE BREAK-IN

A new engine does not require extensive “break-in.”
However, for the first 100 hours of operation, follow
these guidelines: Allow the engine to idle for a few
minutes after every cold start. DO NOT idle the engine
for long periods of time. DO NOT operate the engine
at maximum power for long periods of time. Check the
oil level frequently and replenish as necessary with the
oil specified in the engine manual.

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

PRESTART INSPECTION

It is the operator’s responsibility to inspect the machine
before the start of each workday. Every prestart inspec­tion must include more than simply checking the fuel
and oil levels. It is a good practice to personally inspect
any machine you are assigned to use, even though it
has already been put into service by other personnel.

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

Before mounting the operator’s compartment, walk
completely around the machine to be sure no one is
under, on, or close to it. Let others in the area know
you are going to start up and wait until everyone is
clear of the machine.

Chapter 6

OPERATION AND ADJUSTMENTS

BEFORE STARTING ENGINE

Before starting the engine and running the machine,
refer to the Indicators and Controls chapter and
become familiar with the various operating controls,
indicators and safety features.

STARTING THE ENGINE

The following procedure is recommended for starting
the engine:

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

2. Adjust the seat and fasten the seatbelt.

3. Check that all controls are in their “neutral” posi­tions, except the parking brake switch, which
should be in the “ON” position.

4. Turn the key switch to “ON” position and press the
start button. If the button is released before the
engine starts, turn the key switch to “OFF” posi­tion, and allow the starter to stop before attempting
to start again.

IMPORTANT: Crank the starter until the engine

starts. If the engine fails to start within 30 sec­onds, return the key to the “OFF” position, wait 2
minutes, and try again to start the engine.
Cranking the engine for longer than 30 seconds
will result in premature failure of the starter.

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

7. Check that indicators are in normal condition.

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

CAUTION

BEFORE starting the engine and operating the
Telescopic Handler, review and comply with
ALL safety recommendations in the SAFETY
chapter of this manual. Know how to STOP the
machine before starting it. Also, BE SURE to
fasten and properly adjust the seatbelt.

WARNING

ALWAYS fasten the seat belt BEFORE starting
the engine. Leave the parking brake applied
until the engine is running and you are ready
to operate the machine.

PRINTED IN U.S.A. 31 913218/CP0307

COLD STARTING PROCEDURES

A block heater or radiator lower hose heater is recom­mended for starting in temperatures of 20

o

F (-7oC) or

lower. See your Gehl dealer for recommended heater.

If prevailing temperature is 40

o

F (4oC) or below, it
may be necessary to use a cold weather starting aid to
start the diesel engine. For proper use of starting aids,
check instructions in the engine manual.

If the battery becomes discharged and does not have
sufficient power to start the engine, jumper cables can
be used for starting assistance. Refer to the jump start­ing instructions in the Service and Storage chapter of
this manual for safe jump starting procedures.

STOPPING

The following procedure is the recommended
sequence for stopping the machine:

1. Bring the machine to a stop on a level surface.

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

2. Fully retract the boom and lower the attachment to

the ground. Idle the engine for gradual cooling.

3. Place controls in neutral. Apply the parking brake.

4. Turn the ignition switch key to the “OFF” position.

Remove the key.

5. Unfasten the seatbelt, and grasp the hand holds

while climbing out of the operator’s compartment.

FIRST TIME OPERATION

Make sure the engine is warm and then go through the
following procedures:

Select the travel direction and the speed range. Turn off
the parking brake switch and move ahead slowly, while
testing the steering and brakes. Stop and operate all
boom, attachment tool functions and frame leveling
controls, checking for smooth response.

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

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

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

ENGINE SHUTDOWN PROTECTION

NOTE:

Only machines that have the engine fault
override shutdown switch described on page 23
have this feature.

The engine is equipped with a WARNING and SHUT­DOWN feature to warn of low engine oil pressure and
high engine coolant temperature. If the problem is not
corrected, the engine power will be reduced automati­cally, or the engine will shut down.

Engine Oil Pressure

There are two low oil pressure protection features:
Low Oil Pressure WARNING, and Low Oil Pressure
SHUTDOWN.

At the Low Oil Pressure WARNING set-point, the
warning lamp in the engine override switch will flash
and a slow engine power derate will begin. But if the
oil pressure rises above the Low Oil Pressure WARN­ING set-point, power will slowly increase until the
engine is back to full power. The lamp will continue to
flash until the power has returned to normal, even if the
fault condition has been corrected and the recovery is
in process.

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

CAUTION

Be sure the area used for test-running is clear
of spectators and obstructions. Initially, oper­ate the machine with an empty attachment
tool.

913218/CP0307 32 PRINTED IN U.S.A.

Engine Coolant Temperature

There are two coolant temperature features: High
Coolant Temperature WARNING, and High Coolant
Temperature SHUTDOWN.

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

At the High Coolant Temperature SHUTDOWN set­point, the lamp in the engine override switch will light
continously, and a fast engine power derate will begin.
If the coolant temperature does not drop below the
SHUTDOWN set-point within 30 seconds, the engine
will shut down. Howerver, if the coolant temperature
drops below the High Coolant Temperature SHUT­DOWN set-point within 30 seconds, then the power
derate speed will revert to the High Coolant
Temperature WARNING speed of reaction.

PARKING BRAKE

NOTE: The parking brake mechanism within the

front axle is NOT designed for, OR intended to be
used as, the primary means of stopping move­ment of the machine. Hydraulic braking provided
through the service brakes within the axles is the
primary means for stopping movement. The axle­by-axle split brake system is the secondary
means of stopping movement.

The proper sequence for correct machine operation is
to always engage the parking brake switch before shut­ting off the engine; and to disengage the parking brake
ONLY after the engine is running. In an EMER­GENCY, if it becomes necessary to STOP movement,
activate the parking brake switch to “ON.”

CHANGING ATTACHMENT TOOLS

The Telescopic Handler boom nose will accept Quick­attach System Gehl attachment tools. The Quick-attach
System has a quick-release hookup and locking mech­anism for mounting framing-type or masonry-type
attachment tools to the boom nose.

Attaching

To pick up the attachment tool proceed as follows:

1. Raise the boom slightly and extend it 2 to 3 feet
(600 to 900 mm) for better visibility and tilt the
Quick-attach System forward.

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

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

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

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

Detaching

To detach attachment tool, proceed as follows:

1. Raise the boom slightly and extend it 2 to 3 feet
(600 to 900 mm) for better visibility. Lower the
boom until the attachment tool is approximately
12” (0.3 m) off the ground.

Quick-attach System Attaching Detail

Attachment Tool Shown Locked

to Quick-attach System

Quick-attach System Tilted

Forward for Hookup

Attachment

Tool

PRINTED IN U.S.A. 33 913218/CP0307

2. Roll the carrier rearward as far as it will go. Once
the carrier is rolled all the way back, perform the
MANDATORY SAFETY SHUTDOWN PROCE­DURE (p. 8, Safety chapter).

3. With the engine off, leave the operator’s station.
Manually raise the lock spring and flip the lock

plate up and outward at least 180oso it is in posi­tion to re-lock on the next attachment tool.

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

NOTE: One side of the lock plate has a bright

red decal to indicate the unlocked position.

5. If the attachment tool has auxiliary hydraulics, dis­connect the hoses from the quick-disconnects on
the boom nose.

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

SELF-LEVELING

The machine is equipped with a hydraulic self-leveling
feature. This feature is designed to keep the attachment
tool level while the boom is being raised.

GENERAL MACHINE OPERATION

Take time to check the Telescopic Handler to be sure
all systems are in good operating condition. Perform
the following steps before starting the machine for the
first time each day:

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

2. Be sure weekly lubrication has been done.

3. Visually inspect for leaks, broken or malfunction­ing parts. Be sure all caps, covers and safety
shields are in place.

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

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

6. Check clearances of ramps, doorways and
passage-ways. Check overhead clearances if you
will travel and place loads near power or telephone
lines.

If the machine is found to be in need of repair or in any
way unsafe, or contributes to an unsafe condition, the
matter shall be reported immediately to the user’s des­ignated authority. The machine must NOT be operated
until it has been restored to a safe operating condition.

WARNING

Exhaust fumes can kill. Ensure proper ventila­tion when starting indoors or in enclosed
areas.

Use proper hand holds, NOT the steering
wheel or control levers when mounting and
dismounting.

NEVER operate the machine with safety
guards or covers removed.

Over-inflated tires can explode and cause
injury or death. Tire repairs MUST be made
only by authorized personnel using proper
tools and equipment.

Quick-attach System Detaching Detail

WARNING

Modifications, alterations to, or use of attach­ment tools NOT authorized by GEHL (or the
manufacturer) in writing can void warranty
and cause machine damage and/or serious
personal injury or death.

Attachment Tool Shown

Unlocked for Release from

Quick-attach System

913218/CP0307 34 PRINTED IN U.S.A.

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

When ascending or descending grades in excess of 5%
or 3°, the machine should be driven with the load
upgrade. An unloaded machine should be operated on
all forward grades with the load handling attachment
tool downgrade, tilted back if applicable, and raised
only as far as necessary to clear the road surface.

Avoid turning if possible and use extreme caution on
grades, ramps and inclines. Normally travel straight up
and down the slope.

Traffic Flow Patterns

Know and understand the traffic flow patterns of your
jobsite. Know all Telescopic Handler hand signals for
safety. Utilize signal persons and be sure you can see
the signal person and acknowledge the signals given.

When ramps must be used in transporting loads with
the machine, the following are the minimum widths for
safe travel:

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

Permanent aisles, roadways and passageways, floors
and ramps must be clearly defined or marked.
Permanent or temporary protrusion of loads, equip­ment, material and construction facilities into the usual
operating area must be guarded, clearly and distinc­tively marked, or clearly visible.

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

Operate the travel controls gradually and smoothly
when starting, stopping, turning and reversing direc­tion.

Grade and Slope Precautions

The Telescopic Handler complies with industry stabil­ity test requirements and is stable when properly oper­ated. However, improper operation, faulty mainte­nance, and poor housekeeping can contribute to a con­dition of instability and defeat the purpose of the stan­dard.

The amount of forward and rearward tilt to be used is
governed by the application. Although use of maxi­mum rearward tilt is allowable under certain condi­tions, such as traveling with the load fully lowered, the
stability of the machine, as determined by the industry
standard tests, does not encompass consideration for
excessive tilt at high elevations, or the handling of off­center loads.

Handle only loads within the capacity limits of the
machine, and which are stable and safely arranged.
When attachments are used, extra care should be taken
in securing, manipulating, positioning and transporting
the load.

Grade Limits

NOTE:

Grade limits are based on ASME

/ITSDFstandard B56.6-2005.

This telescopic handler meets or exceeds the safety
standard (ASME/ITSDF B56.6) stability limits for
rough terrain forklifts. The stability tipping limits
cover specific, controlled test conditions, which are
extremes, and which are not intended to be achieved
during normal worksite operations. The following
specifications are provided only as information to the
operator, and must not be used as a guideline for oper­ating the telescopic handler. For safe operation, always
follow the instructions and warnings provided in this
manual.

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

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

3. DO NOT place or retrieve loads on a side hill with
a slope or grade that exceeds 12% or 7°.
Regardless of terrain or position of wheels, the
FRAME MUST BE LEVEL, as indicated by the
level indicator on the ROPS/FOPS cross member.

WARNING

DO NOT level the frame with the boom raised
or extended. Only level the frame while
stopped, and with the boom fully retracted
and the attachment tool raised just enough to
clear the ground.

PRINTED IN U.S.A. 35 913218/CP0307

Controlled lighting of adequate intensity should be
provided in operating areas. Where operating condi­tions indicate, the operator/user is responsible for hav­ing the machine equipped with lights.

Provisions must be made to prevent trucks, semi-trail­ers and railroad cars from being moved during loading
and unloading.

Wheel stops, parking brakes, or other positive holding
means must be used to prevent movement during load­ing and unloading.

DO NOT move railroad cars and trailers with the
Telescopic Handler.

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

IMPORTANT: DO NOT lower boom at high

engine RPM when attachment tool is at maximum
rearward tilt. Damage to slave cylinders may
result.

GENERAL LOAD HANDLING

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

Safety Hand Signals

Stop

Rotate Forks

Right

Tilt Forks Down

Rotate Forks

Left

Tilt Forks Up

Lower LoadRaise Load

Load Back Load Forward

Operation of the hydraulic system depends on engine
speed and the distance the controls are moved. When
operating these controls it is important to develop a
technique called “feathering.” Feathering the control
means you start the desired motion by moving the con­trol a small amount away from neutral. Then after
movement has started, the control can be eased to full
movement. Use the same feathering technique to stop
the motion.

WARNING

Excessive speed can be hazardous. ALWAYS
exercise caution and good judgement while
operating the machine.

Twice daily, increase the engine speed (to fast
idle) and extend and retract the frame leveling
cylinder to the stroke limit. This removes any
air trapped in the circuit, which could cause
the machine to lean to one side or the other.

ALWAYS maintain a safe distance from elec­tric power lines and avoid contact with any
electrically charged conductor and gas line. It
is not necessary to make direct contact with a
power line for power to ground through the
structure of the machine. Keep the boom at
least 10 ft. (3 m) from all power lines.
Accidental contact or rupture can result in
electrocution or an explosion. Contact the
North American One-Call Referral System at
[phone] for the local “Digger’s Hotline”
number or proper local authorities for utility
line locations BEFORE starting to dig!

Keep all body parts inside the operator’s sta­tion while operating the machine. BE SURE of
clearance for the attachment tool when turn­ing, 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 machine
may cause the load to drop off the attachment
tool.

Be certain you can control both speed and
direction before moving. Always place the
machine in neutral and set the parking brake
before raising or extending the boom. NEVER
drive the machine up to someone standing in
front of the load.

913218/CP0307 36 PRINTED IN U.S.A.

Load Capacity and Reach

This machine has flip-charts in the operator’s station
that provide, at a glance, the load capacity limits at var­ious positions of attachment tool extension and eleva­tion. A set of the load zone charts is reproduced at the
end of this manual for reference.

A typical load zone chart is shown on this page. The
scale on the left indicates height in feet above the
ground level. The scale on the bottom shows the dis­tance in feet out from the front of the machine. The arc
lines noted by the numbers “1” through “5” correspond

with the position extension markers on the operator
side of the intermediate boom section.

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

Example: The operator, using a standard carriage

attachment tool, wants to raise a 3000 lb. load 20 feet
high, but can only get to within 15 feet of the load
placement point. Can it be done within the capacity of
the machine?

Analysis: See “Typical Load Zone Chart” below.

Projecting up from the 15-foot mark on the horizontal
axis to intersect a line through the 20-foot mark on the
vertical axis shows that the load can be placed in the
3000 lb. zone.

During placement, the operator observes when the arc
reference number “3” on the boom is visible and stops.
He knows the maximum safe distance of extension
with this load has been reached.

Typical Load Zone Chart

HEIGHT ABOVE GROUND

BOOM

EXTENSION

MARKERS

REFERENCE

DISTANCE LOAD IS EXTENDED

NEVER leave the operator’s station without
first lowering the attachment tool to the
ground. Then set the parking brake, place con­trols in neutral, shut off engine and remove
the key. AVOID parking the machine on a
slope, but if necessary, park across the slope
and block the tires.

0

1

2

3

4

5

73°

60°

50°

40°

30°

20°

0°

10°

-4°

PRINTED IN U.S.A. 37 913218/CP0307

LIFTING ATTACHMENT TOOL
APPLICATIONS

Picking Up the Load

Inspect the load. If it appears unstable, DO NOT
attempt to move it. DO NOT attempt lifting double­tiered loads, or straddling side-by-side pallets with one
on each fork. NEVER add extra unauthorized counter­weights to this machine. Consider the additional
weight of any attachment tool as part of the picking
load capacity of the machine.

Approach the load squarely and slowly with the
machine straight and level. Adjust the space between
forks, if necessary. Engage the load equally on both
forks until the load touches the carriage backrest. Tilt
the forks back to position the load for travel.

Carrying the Load

If the load obstructs your view, get someone to direct
you. Maintain ground speeds consistent with ground
conditions and that permit stopping in a safe manner.

Load Elevation and Placement

For ground level load placement, be sure the area
under the load and around the machine is clear of
equipment and personnel. Lower the load to the
ground, tilt the forks to the horizontal position, and
then carefully back away to disengage the forks from
the load.

For elevated or overhead placement, bring the machine
as close as possible to the landing point, and then:

1. Level the machine BEFORE raising the load. Use
extreme caution for high placement. Be sure per­sonnel are clear of the area where the load or the
machine could tip or fall.

2. Set the parking brake, hold the service brake pedal
in fully applied position and slowly raise the load,
maintaining a slight rearward tilt to cradle the load.

3. As the load approaches the desired height, feather
the boom control at minimum speed until the load
is slightly higher than the landing point.

4. Continue the feathering technique and lower the
load into place.

5. Free the forks from the load by alternately retract­ing and raising the boom. If this process is not pos­sible, very slowly and carefully reverse the tele­scopic handler to free the forks from the load.

6. Lower the forks to travel height.

Installation of a
Personnel Work Platform (PWP)

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

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

WARNING

Operating conditions can reduce the
machine’s safe operating capacity. Exceeding
the capacity when raising or extending the
boom will cause the machine to tip forward.

WARNING

NEVER travel with the boom above the carry
position (attachment tool should be at mini­mum ground clearance). Boom should be fully
retracted.

Use lower gear when traveling down an
incline. NEVER coast with the transmission in
neutral. Travel up and down grades slowly.

DO NOT operate the machine on a slope or
grade that exceeds 22% or 12

o

.

WARNING

NEVER exceed the rated operating capacity of
the Telescopic Handler as shown on the load
zone charts.

WARNING

The machine must not be used to lift or carry
personnel, or be fitted with any form of per­sonnel work platform unless fitted with the
optional PWP System.

If fitted with the PWP System, the Mandatory
Work Platform Safety Rules (p. 12) must be
adhered to at all times while elevating person­nel.

913218/CP0307 38 PRINTED IN U.S.A.

3. Secure the forks from pivoting upward in case the
PWP is lowered onto an obstruction. This can be
accomplished by using the chain supplied with
PWP’s, to secure the lower portion of the PWP to
the bottom of the carriage, as shown.

4. Connect the coiled wire from the remote shutdown
switch to the connector on the end of the boom.
Secure the remote shutdown switch to the PWP
using the strap attached to the switch as shown
below.

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

Elevating Personnel

This Telescopic Handler is primarily intended for use
as a material handler. It should only be used to elevate
personnel if it is equipped with the (optional) PWP
System when there is no other practical option. If this
machine is to be used to elevate personnel, then use
only an approved work platform, lift personnel only
with the PWP System activated, and follow the
“Mandatory Work Platform Safety Rules” (p. 12 Safety
chapter).

If this Telescopic Handler is equipped with a PWP
System and is to be used for elevating personnel, the
system must be activated, by the "PWP System" mode
switch, which is located in the instrument and switch
panel. To activate the system, apply and hold the ser­vice brakes on for three or more seconds, and press the
top of the PWP rocker switch. The system is activated
when the lamp in the PWP rocker switch is on conti­nously.

NOTE: If the light is flashing, apply the service
brakes until the light stops flashing.

When the PWP System is active:

z transmission is de-clutched into Neutral
z parking brake is applied
z rear axle stabilizer cylinder is locked
z auxiliary hydraulic and carriage tilt and swing

functions are disabled

z machine inclination sensor is activated, with

the result that the Telescopic Handler must be level
laterally (side-to-side) and longitudinally (front-to­back) to within the factory preset limits before the
boom control joystick will function

z remote shutdown switch is activated, with the

result that the switch must be connected and in the
“on” position for the boom control joystick to
function. Depressing the switch will disengage the
boom control joystick, and stop all platform move­ment. The remote shutdown switch box is supplied

Chain

PWP

Remote

Shutdown

Switch

Electrical

Connection

Remote Shutdown Switch

with Coiled Wire Connector

WARNING

ALWAYS check the PWP System for proper
operation prior to use. (See page 50 for PWP
System checking procedure.)

Retaining

Pin

WARNING

The PWP must meet ANSI/ITSDF B56.6-2005,
Section 8.24. (See page 14 in the Safety chap­ter for PWP design requirements.) If the PWP
being used does not offer means to secure the
PWP to the forks and to secure the forks from
pivoting, as shown in Steps 2 and 3, then an
alternate method must be used.

PRINTED IN U.S.A. 39 913218/CP0307

with a coiled electrical cable that must be connect­ed to the outlet on the front of the innermost boom
section near the carriage. The switch must be
accessible by the platform personnel any time the

platform is to be moved.
To de-activate the system, apply and hold the service
brakes on for three or more seconds, and press the bot­tom of the PWP System rocker switch. The system is
de-activated when the lamp in the PWP System rocker
switch is off.

NOTE: If the lamp in the PWP system rocker

switch is flashing, apply the service brakes until
the lamp goes off.

Stabilizer System

This is an additional safety function while elevating
loads for placement. At a pre-determined angle, the
stabilizer cylinder on the rear axle will lock up. When
this happens, the parking brake is activated. The
machine will not be able to move until the boom is
lowered below the pre-determined angle.

SUSPENDED LOADS

The handling of suspended loads by means of the truss
boom or other similar device can introduce dynamic
forces affecting the stability of the machine that are not
considered in the stability criteria of industry test stan­dards. Grades, sudden starts, stops and turns can cause
the load to swing and create a hazard.

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

Guidelines for “Free
Rigging/Suspended Loads”

1. The rigging equipment must be in good condition
and comply with the applicable U.S. OSHA regu­lation, 1910.184, “Slings,” or 1926.251, “Rigging
equipment for material handling.”

2. The rigging equipment must be secured to the
forks such that it cannot slip or slide either side­ways 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) or
less.

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

6. Multiple pickup points on the load are preferred to
prevent the load from rotating, but a single pickup
point may be used if one or more tag lines are uti­lized. And, of course, the load must never be posi­tioned over personnel at any time.

WARNING

NEVER use frame leveling to position an ele­vated load. Always lower the load to the
ground and reposition the machine.

If a hydraulic boom circuit hose bursts with
the boom up, shut down the machine. DO NOT
attempt to lower the boom or make repairs.
Call your Gehl dealer.

WARNING

In an emergency, if the platform worker has
activated the remote shut-off switch and then
is not able to re-activate the switch, such as if
the worker fainted, then the Telescopic
Handler operator is permitted to turn off the
PWP System to regain control of the boom
functions, in order to lower the work platform
and come to the aid of the worker. But, under­stand this is only

permitted in case of an
emergency. Otherwise, the PWP System must
be used at all times when there are workers on
the platform. This is the only exception!

As lift height increases, depth perception
decreases. High elevation placements may
require a signal person to guide the operator.
The machine becomes less stable as the load
is raised higher.

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

The truss boom attachment tool should ONLY
be used to lift and place loads when the
machine is in a stationary position. DO NOT
use to transport loads around the jobsite. This
can cause the load to swing, resulting in either
the load dropping or the machine tipping over.

913218/CP0307 40 PRINTED IN U.S.A.

ROAD TRAVEL

For short distance highway travel, attach a Slow
Moving Vehicle (SMV) emblem (purchased locally) to
the rear of the Telescopic Handler. For highway opera­tion, obtain and install an amber flashing beacon.

NOTE: ALWAYS follow ALL state and local reg-

ulations regarding the operation of equipment on
or across public highways. Whenever there is an
appreciable distance between jobsites, or if
driving on public highway is prohibited, transport
the machine using a vehicle of appropriate size
and capacity.

TRANSPORTING BETWEEN JOBSITES

ALWAYS abide by the following recommended proce­dures and guidelines when using ramps to load the
machine onto (and unload it from) a truck or trailer.
Failure to heed can result in damage to equipment and
serious personal injury or death!

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

Loading Machine Using Ramps

NOTE:

A matched pair of ramps is required.

1. The ramps MUST be of sufficient strength to sup­port the machine. Whenever possible, the use of
strong1. The ramps MUST be of sufficient
strength to support the machine. The use of strong
steel ramps is recommended, as well as center sup­porting blocks.

2. The ramps MUST be firmly attached to the truck
or trailer bed with NO step between the bed and
the ramps.

3. The incline of the 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 tire
width.

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

6. Position the machine with the boom facing toward
the front of the truck or trailer so that it is straight
in line with the ramps.

7. Slowly (at the lowest engine speed possible) and
carefully drive the machine up the ramps.

8. Secure the machine to the bed of the truck or trail­er.

Unloading Machine Using Ramps

NOTE:

A matched pair of ramps is required.

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

6. Remove the tie-down chains/cables.

7. If necessary, adjust the machine so that the wheels
are in line and centered with the ramps.

8. Slowly (at the lowest engine speed possible) and
carefully drive the machine down the ramps.

THEFT DETERRENTS

GEHL has recorded all component part numbers and
serial numbers. Users should take as many of the fol­lowing actions as possible to discourage theft, to aid in

Ramp Placement

WARNING

NEVER adjust travel direction (even slightly)
while on the ramps. Instead, back off the
ramps, and then realign the machine with the
ramps.

WARNING

NEVER transport the machine with the boom
raised or extended. BE SURE to secure the
machine (including boom) to the truck or trail­er bed using chain and binders or steel
cables, to prevent any movement while trans­porting.

PRINTED IN U.S.A. 41 913218/CP0307

the recovery in the event the machine is stolen, and to
reduce vandalism:

1. Remove keys from unattended machines.

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

3. Lock doors of cabs when not in use.

4. Inspect the gates and fences of the equipment stor­age yard. If possible, keep machines in well-light­ed areas. Ask the local law enforcement agency to
make frequent checks around the storage and work
sites, especially at night, during weekends, and on
holidays.

5. Report any theft to your dealer and insurance com­pany. Provide the model and all serial numbers.
Request your dealer to forward this information to
Gehl Company.

913218/CP0307 42 PRINTED IN U.S.A.

INTENTIONALLY BLANK

PRINTED IN U.S.A. 43 913218/CP0307

Hydraulic System Reservoir

Use Mobil DTE 15M, or an equivalent that
contains anti-rust, anti-foam and anti-oxida­tion additives and conforms to ISO VG46.

Capacity:

47 Gallons (178 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-40
5°F - 122°F (-15°C - 50°C) SAE 15W-40

*API Service Classification: CH-4/Cl-4

*API Service Classification for first 100 hours on new or

rebuilt John Deere engines: CC or CD

Capacity:

14 Quarts (13.3 liters)

Axle Gear Oil

MobilFluid®422/423 (recommended)

Super Tractor Oil Universal

API GL5 80W-90

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 equivalent

Capacity:

24 quarts (23.0 liters)

Brake System

Use Sunco Multi-ATF or equivalent

GENERAL INFORMATION

NOTE:

The Maintenance chapter in this manual
has provisions for recording the dates and
hourmeter readings after lubrication or other ser­vice has been performed; use those spaces to
keep a log for maintaining a current service inter­val record. Proper routine lubrication is an impor­tant factor in preventing excessive part wear and
early failure.

LUBRICANTS

The chart on this page lists the locations, temperature
ranges and recommended types of lubricants to be used
when servicing this machine. Also refer to the separate
engine manual for additional information regarding
recommended engine lubricants, quantities required
and grades.

NOTE: Refer to “Operator Services” in the

Service and Storage chapter of this manual for
detailed information regarding periodic checking
and replenishing of lubricants.

Chapter 7

LUBRICATION

WARNING

NEVER lubricate or service this unit when any
part of the machine is in motion. ALWAYS
exercise the MANDATORY SAFETY SHUT­DOWN PROCEDURE (p, 8, SAFETY chapter)
before lubricating or servicing this equipment.

913218/CP0307 44 PRINTED IN U.S.A.

GREASING

Refer to the illustrations and listings for fitting loca­tions. Wipe dirt from the fittings before greasing them
to prevent contamination. Replace any missing or dam­aged fittings. To minimize dirt build-up, avoid exces­sive greasing.

BASIC MACHINE
GREASE FITTING LOCATIONS

Every 50 Hours (or weekly)

Refer to the illustration on the facing page for loca­tions.

--- BOOM AREA ---

1. Boom to frame upright pivot pins (2)

2. Rod end slave cylinder pivot pins (2)

3. Rod end lift cylinder pins (2)

4. Extend cylinder pin

5. Chain sheaves pins, (2)

6. Dynattach to boom nose pivot pins

7. Tilt cylinder pivot pins (2)

8. Boom slide pads - as required, front and rear

REPLACEMENT FILTER CHART

AIR FUEL ENGINE HYDRAULIC TRANS.

ENGINE TYPE FILTER FILTER OIL FILTER STRAINER OIL

JOHN DEERE
w/ Mechanical Throttle L120037 L98978 102173 L97489 L49327 L99184

JOHN DEERE
w/ Electronic Throttle L120037 102174 102173 L97489 L49327 L99184

--- CHASSIS AREA ---

9. Brake pedal linkage

10. Wheel spindle pins (4 per axle)

11. Stabilizer cylinder pivot pins (3)

12. Axle pivot pins (2 per axle)

13. Drive shafts (3 per drive shaft)

14. Leveling cylinder pivot pins (2)

15. Base end lift cylinder pivot pins (2)

16. Base end slave cylinder pivot pins (2)

--- OUTRIGGERS ---

Refer to the illustration below.

17. Outrigger pad (2 per pad)

18. Outrigger cylinder (2 per cylinder)

19. Outrigger leg pivot (1 per leg)

17

19

18

PRINTED IN U.S.A. 45 913218/CP0307

Grease Fittings Locations

1

2

5

4

3

6

7

8

8

5

9

14

10

16

12

13

15

11

913218/CP0307 46 PRINTED IN U.S.A.

GENERAL INFORMATION

NOTE: All service routines, with the exception of

those described under the “Dealer Services”
topic, are owner-operator responsibilities. All
operator services described under the subtopics
are also referred to on a decal located on the
inside right side panel of the operator’s station.
Refer to the Lubrication chapter of this manual for
lubrication information.

NOTE: This Service and Storage chapter

describes procedures to follow for making routine
maintenance checks, adjustments and replace­ments. Most of the procedures are also referred to
in the Maintenance chapter of this manual. For
engine related adjustments and servicing proce­dures, refer to the engine manual provided.

PRECAUTIONS

DO NOT perform any maintenance or repair without
the owner’s prior authorization. Allow only trained
personnel to service the machine.

Warranty repairs can only be done by an authorized
GEHL dealer. Dealers know what portions of the
machine are covered under the terms of the GEHL
Warranty and what portions are covered by other ven­dor warranties.

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

IMPORTANT: Always dispose of waste lubri-

cating oils, anti-freeze and hydraulic fluids
according to local regulations or take them to a
recycling center for disposal. DO NOT pour them
onto the ground or into a drain.

DEALER SERVICES

The following areas of internal components service
replacement and operating adjustments should only be
by (or under the direction of) an authorized GEHL
Telescopic Handler dealer.

IMPORTANT: DO NOT service or repair major

components, unless authorized to do so by your
GEHL dealer. Any unauthorized repair will void
the warranty.

POWER TRAIN COMPONENTS

The engine and transmission are coupled directly to
each other. All service routines related to the internal
components are precise and critical to proper power
train operation. The axle differential and planetary
ends are also sophisticated assemblies that require spe­cial know-how and tools for servicing.

IMPORTANT: If any power train components

are suspected of faulty operation, contact your
GEHL dealer for assistance.

HYDRAULIC SYSTEM COMPONENTS

Valves, pumps, motors and cylinders are also sophisti­cated assemblies which require special know-how and
tools for servicing. All cylinders are appropriately
designed with particular strokes, diameters, checks and
hose connection provisions unique to the machine
application requirements. A schematic (Maintenance
chapter) can be used as a guide for service reference, as
required.

Chapter 8

SERVICE AND STORAGE

WARNING

BEFORE performimg any service on the
Telescopic Handler, unless expressly instruct­ed to the contrary, exercise the MANDATORY
SAFETY SHUTDOWN PROCEDURE (p. 8,
Safety chapter). After service has been per­formed, BE SURE to restore all guards,
shields and covers to their original positions
BEFORE resuming machine operation.

PRINTED IN U.S.A. 47 913218/CP0307

Internal service on any of these components should
only be performed by (or under the direction of) an
authorized Gehl Telescopic Handler dealer.

WARNING

Tilt, lift, extend and leveling cylinders have
counterbalance valves. These valves keep
hydraulic fluid from entering and exiting the
cylinders while they are not being activated,
and they are under extremely high pressure.
Before removing one of these valves, you
ARE REQUIRED to call your GEHL dealer or
GEHL Service Department. Failure to do so
may result in serious injury or death.

ELECTRICAL COMPONENTS

An electrical system schematic is provided, which
includes instrumentation, electrical components and
switch connections. It is located at the back of this
manual and can be used as a guide for service refer­ence, as required.

OPERATOR SERVICES

Some of the operator-related services will require
access to components located inside the superstructure,
under shields, hoods and covers. The chart on this page
notes the components accessed in each particular area.

Component Operator’s Frame Front Mid-Rear

Station Cover Hood

Axle (underside) z

Engine z

Transmission (center area) z

Drive Shafts (underside) z

Main Control Valve (rear) z

Muffler (underside) z

Air Cleaner (top front hood) z

Battery z

Radiator z

Brake Valve (underside) z

Travel Controls (dash area) z

Boom Controls (right side) z

Hydraulic Test Ports z

Hourmeter (dash) z

Switches/Indicators (dash) z

Hydraulic Pump z

Hydraulic Filter (Reservoir) z

Misc. Hydraulic Valves z

Heater (lower front) z

ACCESS TO COMPONENTS CHART

913218/CP0307 48 PRINTED IN U.S.A.

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

Before starting inspection and repair, move the
machine onto a level surface, shut down engine, and
release all hydraulic pressure. Always block the boom
securely, or lower it to full ground contact. Place all
controls in neutral.

Block the wheels. Remove the ignition key. Remove
only guards or covers that provide needed access. Wipe
away excess grease and oil.

Excessively worn or damaged parts can fail and cause
injury or death. Replace any cracked or damaged parts.
Use only genuine GEHL parts for service.

Use care not to damage machined and polished sur­faces. Clean or replace all damaged or painted-over
plates and decals that cannot be read.

After servicing, check the work performed, that no
parts are left over, etc. Install all guards and covers.

CHECKING FUEL TANK LEVEL

The fuel level is shown by the fuel level gauge on the
instrument panel. After operation each day, the fuel
tank should be filled to prevent water from condensing
in the tank. To fill, remove the filler cap and add fuel.

CHECKING ENGINE OIL LEVEL

With the machine on level ground, and the engine
stopped for ten minutes or more, slide open the side
engine panel and remove the engine dipstick. Wipe it
clean, re-insert it and remove to obtain a reading. If the
oil level is down, or below the ADD mark, fill with the
required amount of oil to bring the level to the FULL
mark. See the Lubrication chapter for the type of oil to
use.

CHECKING RADIATOR COOLANT LEVEL

WARNING

DO NOT smoke or allow any open flames in
the area while checking or servicing
hydraulic, battery or fuel systems; all contain
highly flammable liquids or explosive gases,
which can cause an explosion or fire if ignited.

Wear a face shield when you disassemble
spring-loaded components or work with bat­tery acid. Wear a helmet or goggles with spe­cial lenses when you weld or cut with a torch.

When working beneath a raised machine,
always use blocks, jack-stands or other rigid
and stable supports. Wear appropriate protec­tive clothing, gloves, and shoes. Keep feet,
clothing, hands and hair away from moving
parts.

Always wear safety glasses or goggles for eye
protection from electric arcs from shorts, flu­ids under pressure, and flying debris or loose
material when the engine is running or tools
are used for grinding or pounding.

NEVER weld on bucket, forks, boom, support
frame or ROPS/FOPS without the consent of
the manufacturer. These components may be
made with metals that require special welding
techniques, or with designs that do not allow
weld repairs. NEVER cut or weld on fuel lines
or tanks.

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

Service Every 10 Hours or Daily

WARNING

NEVER leave guards off or access doors open
when the machine is unattended. Keep
bystanders away if access doors are open.

WARNING

DO NOT remove the radiator cap when the
engine is running hot or overheated. Coolant
is extremely hot and under pressure and it can
burn your skin. Allow sufficient time for the
radiator to cool BEFORE relieving the pres­sure and removing the radiator cap.

PRINTED IN U.S.A. 49 913218/CP0307

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

NOTE: If the engine is operated with a loose

radiator cap, the pressure bypass will not work
and the engine will run hot.

CHECKING TRANSMISSION OIL LEVEL

The machine must be on level ground. With the engine
and transmission at operating temperature parking
brake on, transmission in neutral and engine speed at
low idle, remove the access cover to the transmission
and hydraulic pump. Remove the dipstick and check
the oil level. Add the required amount of oil to bring
the level to the FULL mark. See the Lubrication chap­ter for the type of oil to use.

CHECKING HYDRAULIC OIL LEVEL

The machine must be on level ground with boom low­ered and completely retracted. The fluid MUST be cool
when checking the reservoir level, to reduce the possi­bility of overfilling the hydraulic system.

Visually check the level of the hydraulic oil through
the sight gauge located on the right side of the front
hood. If low, remove the front access cover from the
front hood to replenish the oil through the filler cap.
See the Lubrication chapter for the type of oil to use.

IMPORTANT: Be careful when removing the

reservoir filler cap so that no dirt or other foreign
matter enters the hydraulic system. DO NOT
OVERFILL.

CHECKING BRAKE RESERVOIR LEVELS

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

the Lubrication chapter for the type of fluid to use.

CHECKING TIRE PRESSURES

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

When installing tires on the machine, be sure that all
tires are of the same size and style. ALWAYS replace
tires with the same size furnished as original equip­ment. Replacement tires must be purchased locally.

Check the tire pressure “cold.” All 12-ply tires should
be inflated to 70 psi (480 kPa).

NOTE: If the tires have been filled with water or

calcium chloride for balast, a calcium chloride tire
pressure gauge MUST be used to check the tire
pressure.

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

WARNING

Inflating or servicing tires can be dangerous.
Whenever possible, trained personnel should
service and mount tires. To avoid possible
death or serious injury, follow the safety pre­cautions below:

1. BE SURE the rim is clean and free of rust.

2. Lubricate both the tire beads and rim
flanges with a soap solution. DO NOT use
oil or grease.

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

4. NEVER inflate beyond 35 psi (240 kPa) to
seat the beads. If the beads have NOT
seated by the time the pressure reaches 35
psi (240 kPa), deflate the assembly, reposi­tion the tire on the rim, relubricate both
parts and re-inflate. Inflation pressure
beyond 35 psi (240 kPa) with unseated
beads may break the bead or rim with
explosive force sufficient to cause death
or serious injury.

5. After seating the beads, adjust the inflation
pressure to the recommended operating
pressure listed.

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

913218/CP0307 50 PRINTED IN U.S.A.

CHECKING PERSONNEL WORK PLAT­FORM (PWP) SYSTEM (if used)

Machine Position

The following must be performed before begining the
PWP System checking procedures:

1. Machine on level surface,

2. Boom fully lowered,

3. Frame level,

4. Transmission in “N” (Neutral),

5. Parking brake switch “OFF,”

6. PWP System switch “OFF,”

7. Remote switch plugged in and “ENGAGED.”

Activation Tests

To test the PWP System activation logic:

1. Start the engine and press the PWP rocker switch
“ON.”

z The PWP System lamp in the switch should be

flashing.

2. Apply the service brakes.

z The PWP switch lamp should be illuminated

continuously after three seconds, indicating that
the PWP System has been activated.

z The parking brake should engage, as indicated

by the lamp on the parking brake switch illumi­nating.

z The carriage tilt and auxiliary functions, should

now be disabled. The hydraulic joystick should
continue to function normally for boom
raise/lower and extend/retract.

CHECKING WHEEL NUT TORQUE

On new machines, or any time a wheel has been
removed, re-torque until 450 ft.-lbs. (610 Nm) is main­tained.

CHECKING INSTRUMENTS OPERATION

Allow the engine to warm up for about five minutes
before beginning operation. Indicator lamps should be
OFF and gauges should register normal readings. Tilt
the frame from side to side with the frame leveling
control and note the angle indicator movement.

CHECKING GENERAL MACHINE
OPERATION AND CONDITION

Are any decals missing or damaged? Are all guards,
shields and covers in place? Do all controls function
smoothly and properly? Are there any abnormal vibra­tions or noises? Are any hose or fitting connections
leaking? Is the engine exhaust color normal?

WARNING

Manufacturers of push-pull control cables
advise taking the following operation and
maintenance precautions:

Do not adjust the control cable with the engine
running.

A gradual or sudden increase in the no-load
friction (cable disconnected at both ends) of a
control cable is an indication of an impending
or present performance problem. The control
cable should be replaced.

A gradual or sudden decrease in the useable
travel is a indication of an impending or pre­sent performance problem. The cable should
be replaced.

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

Control cable are lubricated for the life of the
control cable. Do not remove the seals or
lubricate the control cable.

WARNING

If the PWP System fails to operate properly
during any of the PWP System checks, DO
NOT USE the machine until the cause has
been corrected. Contact your dealer (or Gehl
Company) for service information and parts.

Control cables are designed to be non­repairable. Do not attempt to repair control
cables.

Failure to heed could result in death or seri­ous injury.

PRINTED IN U.S.A. 51 913218/CP0307

Lockout Tests

To test the transmission and joystick control lockout
logic:

1. Shift transmission into “F” (Forward) and increase
the engine speed slightly.

z The transmission should remain de-clutched,

allowing the engine to increase speed easily.

z Return the transmission selector to “N”

(Neutral) after the check.

2. Have an assistant move the remote shutdown
switch to “Dis-engaged.”

z The hydraulic joystick should now be disabled,

so that boom raise/lower and extend/retract will
no longer function.

z Have the assistant move the remote shutdown

switch to “Engaged” after the check.

3. Tilt the frame to the right slightly more than two
degrees.

z The hydraulic joystick should now be disabled

so that boom raise/lower and extend/retract no
longer function.

z Repeat the procedure with the frame tilted to

the left.

z Return the frame to a level position after the

checks.

De-activation Tests

To test the PWP System de-activation logic:

1. Turn the key switch to “OFF” and wait for the
engine to stop. Then turn the key switch back to
“ON.”

z The PWP switch lamp and the parking brake

switch lamp should both be illuminated.

2. Turn the key switch “OFF” and then turn the PWP
rocker switch to “OFF.” Turn the key switch back
“ON.”

z The PWP switch lamp should be flashing and

the parking brake switch lamp should be on
continuously.

3. Start the engine and apply the service brakes.

z The PWP switch lamp and the parking brake

switch lamp should go off after approximately
three seconds of brake pedal application.

If PWP System fails to perform properly, troubleshoot
using the chart on page 56. Contact your dealer for ser­vice information and parts.

Refer to the Lubrication chapter of this manual for
weekly grease fitting locations and other related
details.

CHECKING FUEL FILTER

NOTE: The fuel filter will require occasional

replacement to maintain a clean and adequate
fuel flow for maximum engine horsepower. The
frequency of filter replacement will be determined
by the cleanliness of available fuel, the care used
in storing fuel supplies and the operating condi­tions in which the machine is used.

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

A drain plug is also provided in the bottom of the fuel
tank for removing condensation and other foreign
materials. Open the plug and allow water and fuel to
drain into a container until only clear fuel is flowing
from the tank.

The following initial oil and filter changes should be
made at 100 hours on a new machine. Thereafter these
changes should be made at the regular maintenance
schedule listed below. Refer to those schedules for the
necessary procedures.

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

NOTE: Perform all other service requirements

up to this point, as well as the following:

CHECKING AXLE OIL LEVELS

Differential

NOTE: The Telescopic Handler should be on a

level surface for this procedure.

Service Every 50 Hours or Weekly

Service Every 250 Hours or Quarterly

100 Hours (New Machine Only)

913218/CP0307 52 PRINTED IN U.S.A.

See illustration. Remove the oil check plug. Oil should
flow from the hole. If low, remove the oil fill plug and
add oil until it flows from the check hole. Replace the
plug, wait 10 to 15 minutes and repeat the fill proce­dure. Continue this process until the differential is full.
See the Lubrication chapter for the proper oil specifi­cation. Replace the check and fill plugs.

Planetary Hubs

NOTE: The planetary hubs can be checked with-

out jacking up the machine.

See illustration below. The planetary hubs have one
plug each used for filling and draining. For checking
the level and filling, position the wheel until the oil
level arrow is horizontal. Remove the plug. If oil does
not run out, add oil until it overflows. Check the
remaining hubs the same way. Refer to the oil specifi­cations found in the Lubrication chapter of this manu­al.

CHANGING FUEL FILTER

The frequency of filter replacement will be determined
by the cleanliness of available fuel, the care used in
storing fuel supplies and the operating conditions in
which the machine is used.

NOTE: For proper replacement procedures refer

to the engine manual for your machine.

After fuel filter replacement, bleed the air out of the
fuel system following the procedures in the engine
manual.

Fuel Bleeding Procedures

When the fuel filter is removed and replaced, or the
engine runs out of fuel, air must be bled from the sys­tem. Refer to the engine manual for proper bleeding
procedures.

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

NOTE: Only an authorized engine dealer can

perform warranty service on the engine.

Diesel Fuel Injectors

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

Diesel Injection Pump Timing

Whenever injection pump timing, or other pump ser­vice is indicated by abnormal engine operation, contact
your engine dealer.

WARNING

NEVER service the fuel system while smok­ing, while near an open flame, or after the
engine has been operated and is hot.

Plug in fill and

check position.

WARNING

Escaping diesel fuel under pressure can have
sufficient force to penetrate the skin. Before
applying pressure to the fuel system, BE
SURE all connections are tight and lines and
hoses are not damaged. Use a piece of wood
or cardboard to search for suspected leaks. If
injured by escaping fuel, see a doctor familiar
with this type of injury at once or gangrene
may result.

Drain Plug

Fill Plug

Check Plug

PRINTED IN U.S.A. 53 913218/CP0307

CHANGING ENGINE OIL AND FILTER

Change the engine oil and filter using the following
procedure:

1. With the engine warm, remove the crankcase drain
plug. Some plugs are equipped with a magnet to
gather metal particles. Completely clean and flush
away all metallic filings from the plug and re­install it.

IMPORTANT: DO NOT discharge oil onto

ground. Catch and dispose of per local waste dis­posal regulations.

2. The engine oil filter should be changed at every oil
change interval. Remove and discard the disposi­ble filter canister. Wipe the gasket sealing area of
the block with a clean cloth.

IMPORTANT: Your OEM engine oil filters have

special by-pass valves built in. Use only genuine
OEM engine replacement filters.

3. Apply a thin coat of clean oil to the new oil filter
gasket. Hand tighten. Refill the crankcase with
new oil. Follow specifications in the Lubrication
chapter for type and viscosity of new oil.

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

CHECKING THE BATTERY

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

The top of the battery must always be kept clean. Clean
the battery with a brush dipped in an alkaline solution
(ammonia or baking soda and water). After the foam­ing has stopped, flush the top of the battery with clean
water. If the terminals and cable connection clamps are
corroded or have a buildup, disconnect the cables and
clean the terminals and clamps with the same alkaline
solution.

Jump Starting

If the battery becomes discharged or does not have
enough power to start the engine, use jumper cables
and the following procedure to jump-start the engine.

WARNING

The ONLY safe method for jump-starting a
disharged battery is for TWO PEOPLE to per­form the following procedure. The second per­son is needed for removing the jumper cables
so that the operator does not have to leave the
operator’s compartment while the engine is
running. NEVER connect the jumper cables
directly to the starter solenoid of either
engine. DO NOT start the engine from any
position other than the operator’s seat, and
then ONLY after making sure all controls are in
“neutral.”

Closely follow the jump-start procedures, in
the order listed, to avoid personal injury. In
addition, wear safety glasses to protect your
eyes, and avoid leaning over the batteries
while jump-starting.

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

1. IMMEDIATELY remove any clothing on
which acid spills.

2. If acid contacts the skin, rinse the affected
area with running water for 10 to 15 min­utes.

3. If acid comes in contact with the eyes,
flood the eyes with running water for 10 to
15 minutes. See a doctor at once. NEVER
use any medication or eye drops unless
prescribed by the doctor.

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

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

quarts (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 (-) bat­tery terminal connection first.

WARNING

Explosive gas is produced while a battery is in
use or being charged. Keep flames or sparks
away from the battery area. Make sure battery
is charged in a well-ventilated area.

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

913218/CP0307 54 PRINTED IN U.S.A.

CHECKING AND TORQUING BOOM LEAF
CHAINS

Inspect the leaf chains for wear and proper tension.
Two of the chains are on the top front of the boom. A
third chain is accessible from inside the rear of the
boom (see “Chain Hook Detail” illustration).

Run the boom out slowly to inspect. Conditions to look
for include cracked or broken plates, protruding or
turned pins, excessive wear. With a steel tape, measure
16 links of the strand that flexes over the sheaves.
When the distance measures 12-3/8” (314 mm) or
more, the chain should be replaced. DO NOT repair
sections of a chain. Replace the complete chain.

Chain anchors and sheaves also require inspection for
wear or broken fingers and worn flanges. If any chain
has been replaced, operate under loaded conditions and
re-check the torque. Adjust the chains per the follow­ing procedure.

Extend the boom to its maximum length. Then retract
the boom slowly until the chain slack allows the chain
to rest on the top of the boom. Torque the chains on the
front of the boom to 30 ft.-lbs. (40 Nm). Lubricate with
80/90W oil.

CHECKING BOOM SLIDE PAD WEAR
AND CLEARANCE

The boom is equipped with special nylon low friction
slide pads between the telescopic sections (see “Slide
Pad Detail” illustration). These are pre-greased and
initially worn-in at the factory. Normally greasing is
not required, except for maintaining a light film of
grease on the pad tracking areas of the boom sections.
An exception would be if a boom section has been
replaced.

IMPORTANT: BE SURE that the jumper battery

is also a 12-volt D. C. battery, and the vehicle
used for jump starting has a negative-ground
electrical system.

1. Turn the keyswitches on both vehicles to “OFF”.
Be sure that both vehicles are in “Neutral” and
NOT touching.

2. Connect one end of the positive (+) jumper cable
to the positive (+) battery terminal on the disabled
machine first. DO NOT allow the positive (+)
jumper cable clamps to touch any metal other than
the positive (+) battery terminals. Connect the
other end of the positive jumper cable to the
jumper battery positive (+) terminal.

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

4. Make the final negative (-) jumper cable connec­tion to the disabled machine’s engine block or
frame (ground) - NOT to the disabled battery neg­ative post. If making the connection to the engine,
keep the jumper clamp away from the battery, fuel
lines, or moving parts.

NOTE: Twist the jumper cable clamps on the

battery terminals to insure a good electrical con­nection.

5. Proceed to start the machine. If it does not start
immediately, start the jumper vehicle engine to
avoid 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 jumper
vehicle battery, and then from the disabled
machine, while ensuring NOT to short the two
cables together.

Allow sufficient time for the alternator to build up a
charge in the battery before operating the machine or
shutting off the engine.

NOTE: If the battery frequently becomes dis-

charged, have the battery checked for possible
dead cell(s), or troubleshoot the electrical system
for possible short circuits or damaged wire insula­tion.

Chain Hookup Detail

Inner

Section

Outer

Section

Intermediate

Section

Two Front

Boom Chains

One Rear

Boom Chain

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

PRINTED IN U.S.A. 55 913218/CP0307

transmission oil. Shut down the engine. Access to filter
and drain plug is from underneath the machine.
Proceed as follows:

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

IMPORTANT: DO NOT discharge oil onto

ground. Catch and dispose of per local waste dis­posal regulations.

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

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

IMPORTANT: DO NOT OVERFILL! lf the oil

level is too high, oil foaming, excessively high oil
temperature and oil leakage at the seals could
result.

4. Start and run the machine long enough for the oil
to circulate and warm slightly. Recheck the level
with the dipstick.

CHANGING RADIATOR COOLANT

Drain, flush and refill the cooling system as follows:

IMPORTANT: DO NOT discharge coolant onto

ground. Catch and dispose of per local waste dis­posal regulations.

1. Loosen the radiator cap to its stop. This will
release any system pressure. Remove the cap when
all pressure is bled off.

2. Open the radiator drain cock. Remove the water
jacket drain plug from the engine block. When all
coolant is drained, flush the system with clean
fresh water. Allow the flush to drain completely.

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

Visually check for loose pad bolts. The bolts are
torqued to 30 ft.-lbs. (40 Nm). If the bolts are re­torqued at any time, Loctite

®

thread lock must be re-

applied to the bolts.

If the boom starts to chatter under load, grease the slide
pads and wipe off the excess. If a top or side slide pad
shows excessive wear, loosen bolts and insert shims to
each side or top and bottom for even distribution of
clearance. Re-apply Loctite

®

thread lock to the bolts
and re-torque to 30 ft.-lbs. (40 Nm). Bottom slide pads
should be replaced when the thickness is worn down to
3/8” (9.5 mm).

CHECK PERSONNEL WORK PLATFORM
SYSTEM

Follow the procedure for checking the PWP System as
outlined on page 50.

NOTE: Perform all other service requirements

up to this point, as well as the following:

CHANGING TRANSMISSION OIL
AND FILTER

Operate the machine long enough to warm up the

WARNING

Remove the radiator cap only when the engine
is cool, or painful burns could result.

Service Every 1000 Hours or Yearly

Slide Pad Detail

Rear Inner

Shim

Pad

Front
Outer

WARNING

Failure to maintain proper slide pad clearance
and thickness could cause damage to the
boom, resulting in sudden boom failure.

913218/CP0307 56 PRINTED IN U.S.A.

IMPORTANT: Fill the cooling system with a

low-silicate ethylene glycol base coolant mixed
with quality water and supplemental coolant addi­tives (SCAs) suitable for heavy-duty diesel
engines. See your engine manual for additional
information.

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

NOTE: Check the engine temperature gauge

every minute or two after coolant has been
changed. Air pockets can form and it may be nec­essary to refill the cooling system after a short
period of use, as the air will naturally bleed out of
the system.

CHANGING HYDRAULIC RETURN
FILTER ELEMENT

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

CHANGING AIR FILTER ELEMENT(S)

These machines have been equipped with two types of
air cleaner assemblies. The early-type air cleaner used

a single dry element. Later machines used dual dry ele­ments. Refer to the following illustrations.

Single-Element Air Cleaner Assembly

1. Loosen the clamp ring and remove the dust cup.
Remove the baffle. Wipe the cup and baffle com­pletely clean. Reassemble the dust cup.

2. Remove the element wing bolt and slide out the
element. Avoid knocking the element against the
housing. Dirt accidentally transferred to the inside
of the outlet tube will reach the engine and cause
wear.

3. Wipe the entire inside of the main body and inlet
cap screen.

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

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

IMPORTANT: NEVER use an element that is

damaged. Severe engine wear and eventual fail­ure can result if dirt gets through a hole in the ele­ment.

5. Install the element and reassemble the dust cup to
housing. Be sure the large o-ring is in place
between the dust cup and the main body.

NOTE: Keep spare elements on hand to elimi-

nate down time.

Dual-Element Air Cleaner Assembly

The air cleaner assembly consists of an outer (primary)

Single-Element Air Cleaner Assembly

WARNING

When servicing the hydraulic system, lower
the boom to the ground.

Reservoir Filter Removal

Housing Top

Filter Element

Filter Housing

Inlet Cap

Element

Mount

Band

End Cap and

Clamp Ring

PRINTED IN U.S.A. 57 913218/CP0307

Inner Element

NOTE: Replace the inner element only if it is vis-

ibly dirty or if the outer element has been replaced
three times.

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

Reinstallation

1. Check the inside of the housing for any damage
that may interfere with the elements.

2. Be sure that the element sealing surfaces are clean.

3. Insert the element(s), making sure that they are
seated properly.

4. Secure the cover to the housing with the three
clamps.

5. Check the hose connections and make sure they
are all clamped and tightened properly.

6. Reset the indicator by pressing the reset button.

CHANGING AXLE DIFFERENTIAL
AND PLANETARY OIL

Differentials

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

IMPORTANT: DO NOT discharge oil onto

ground. Catch and dispose of per local waste dis­posal regulations.

2. Remove the check and fill plugs. Fill the differen­tial with oil as specified in the Lubrication chapter.
When the oil flows the check hole, replace the
plug. Wait 10 to 15 minutes and repeat this process
until the axle is full. Repeat this procedure with the
other axle.

filter element and an inner (secondary) filter element.
An air filter restriction indicator for monitoring the
condition of the elements is located on the front of the
air cleaner. If the air filter becomes restricted, this indi­cator turns red to warn the operator that the air cleaner
requires service. Push the reset button located at the
end of the indicator after fitting a clean element.

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

The outer element should be replaced only when the
restriction indicator turns red. The inner element
should be replaced every third time the outer element
is replaced, unless the outer element is damaged or the
inner element is visibly dirty. Along with a daily check
of the restriction indicator, check that the air cleaner
intake hose and clamps, and the mounting bracket
hardware are properly secure.

Unlatch the three latches on the air cleaner and remove
the cover. Clean out any dirt built up in the cover
assembly.

Outer Element

1. Carefully pull the outer element out of the housing.
Never remove the inner element unless it is to be
replaced.

2. Clean out any dirt built up in the housing. Leave
the inner element installed during this step to pre­vent debris from entering the engine intake mani­fold.

3. Use a trouble light inside the outer element to
inspect for bad spots, pinholes or ruptures. Replace
the outer element if any damage is noted. The outer
element must be replaced if it is oil- or soot-laden.

NOTE: Cleaning the outer element is not recom­mend.

Drain Plug

Fill Plug

Check Plug

Secondary

Element

Mounting

Band

End Cap and

Dust Ejector

Primary

Element

Housing

Inlet Cap

Dual-Element Air Cleaner Assembly

913218/CP0307 58 PRINTED IN U.S.A.

Axle Planetary Hubs

The hubs have one plug each used for draining and fill­ing (see illustration).

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

IMPORTANT: DO NOT discharge oil onto

ground. Catch and dispose of per local waste dis­posal regulations.

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

CHECKING ALTERNATOR AND
FAN BELT CONDITON

Refer to the engine manual for proper belt tension
adjustment and replacement procedures. If the belt
shows wear or cuts, it should be replaced. Order
replacement belt from your engine dealer.

CHECKING EXHAUST SYSTEM

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

NOTE: Perform all other service requirements

up to this point, as well as the following.

CHECKING HYDRAULIC SYSTEM
RELIEF PRESSURES

Pressure settings for relief valves are pre-set at the fac­tory. Three test ports are provided under the front hood
rear access cover.

Before conducting any test port pressure checks, check
the engine rpm. Engine speed must be 800 rpm at idle
and 2500 to 2550 rpm at high idle.

Steering Relief Pressure

Plug a 3000 psi (207 bar) oil-or liquid-filled gauge into
the test port labeled ”SP.” Cramp the steering fully to
the right or left. The gauge should read 2500 psi (172
bar).

Joystick and Parking Brake Release
Pressure

Plug a 1000 psi (70 bar) gauge into the port labeled
“JP.” With the engine running, the gauge should read
400-425 psi (27-29 bar).

Main Relief Pressure

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

CHANGING HYDRAULIC RESERVOIR
OIL AND STRAINER

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

Hydraulic Reservoir Sump Strainer Removal

Element

TOP OF

RESERVOIR

Service Every 2000 Hours or Two Years

Test ports under

rear access cover.

Plug in drain

position.

Gasket

Access

Cover

Fill Cap
Dipstick

PRINTED IN U.S.A. 59 913218/CP0307

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

IMPORTANT: DO NOT discharge oil onto ground.
Catch and dispose of per local waste disposal
regulations.

2. Remove the access cover and wash the inlet screen
with clean solvent. Remove the sump filter strain­er from the bottom inside of the reservoir. Wash it
also. If the strainer has any damage, holes, etc., it
should be replaced.

3. Flush out the bottom of the tank with clean
hydraulic oil. Re-install all cleaned components
and put the access cover back on the reservoir with
a new gasket. Clean the filter/breather cap.

4. Fill the tank with fresh oil. Follow specifications
found in the Lubrication chapter of this manual.

IMPORTANT: Hydraulic fluid and filters should be
replaced any time contamination is present before
the normally scheduled change.

STORAGE

If the Telescopic Handler will not be operated for a
long period of time, prepare and store it using the fol-

lowing procedure:

Before Storage

Perform the following prior to placing the machine in
storage:

1 Wash off the entire machine.

2. Lubricate all grease fittings as described in the
Lubrication chapter of this manual.

3. Change engine oil as outlined in the Service and
Storage chapter of this manual.

4. Apply grease to all exposed hydraulic cylinder rod
areas.

5. Disconnect the battery cable clamps and cover the
battery or remove the battery from the machine
and store it separately.

6. If the ambient temperature (at any time during the
storage period) is expected to drop below freezing,
make sure the engine coolant is either completely
drained from the radiator and engine block or that
the amount of anti-freeze in it is adequate to keep
the coolant from freezing. Refer to the separate
engine manual provided for anti-freeze recommen­dations and quantities.

During Storage

1. About once each month, connect the battery and
check all fluid levels to make sure they are at the
proper level before starting the engine.

2. Start the engine and allow it to run until it warms
up and then move the machine a short distance to
help relubricate the internal parts. Run the engine
until the battery has a chance to recharge and then
shut it off.

IMPORTANT: If it is desired to operate the

hydraulic cylinders at this time, BE SURE to wipe
the protective grease (and any adhering dirt) from
the cylinder rods prior to starting the engine. After
operating, BE SURE to recoat the cylinder rods
with grease if the machine is to be returned to
storage.

After Storage

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

1. Change engine oil and filter to remove condensa­tion or other residues.

2. Wipe off grease from cylinder rods.

3. Lubricate ALL grease fittings.

4. Follow the starting and warm-up procedures as
outlined in the Operation and Adjustments chapter
of this manual.

WARNING

NEVER use your hands to search for hydraulic
fluid leaks. Escaping hydraulic oil under pres­sure can have sufficient force to penetrate the
skin. Before applying pressure to the
hydraulic system, be sure all connections are
tight and lines and hoses are not damaged.
Use a piece of wood or cardboard to search
for suspected leaks. If injured by escaping
hydraulic oil, see a doctor familiar with this
type of injury at once or gangrene may result.

913218/CP0307 60 PRINTED IN U.S.A.

Problem

PWP System mode lamp flash­es when switch is turned “ON.”

Parking brake did not engage
when the PWP System switch is
turned “ON.”

Carriage tilt and auxiliary func­tions continue operating when
the PWP System switch is
turned “ON.”

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

Boom control functions do not
operate.

PWP System mode lamp flash­es when switch is turned “OFF.”

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

Possible Cause

PWP System not activated.

Machine is not level.

Remote PWP System switch is
de-activated.

Remote PWP System switch is
not plugged into the connector at
the end of the boom.

PWP System level sensor
unplugged or faulty.

PWP System is not de-activated.

Remedy

With PWP System switch “ON,”
apply service brakes for two sec­onds until PWP mode lamp is on
continously.

Level the machine.

Activate the remote PWP
System switch.

Plug in and engage the remote
PWP System switch.

Contact your Gehl dealer for
assistance.

With engine running, apply ser­vice brakes for two seconds until
PWP mode lamp goes off.

PWP SYSTEM OPERATIONAL TROUBLESHOOTING

PRINTED IN U.S.A. 61 913218/CP0307

GENERAL INFORMATION

Decal locations information is provided to assist in the
proper selection and application of new decals, in the
event the original decals become damaged or the
machine is repainted.

For correct replacement of decals, compare the loca­tion illustrations to your machine before starting to
refinish the unit. Check off each required decal using
the illustration reference number to find the part num­ber, description and quantity in the list. Refer to the
appropriate illustrations for replacement locations.

NEW DECAL APPLICATION

Before applying the new decals, surfaces must be free
from dirt, dust, grease and other foreign material. To
apply a solid-formed decal, remove the smaller portion
of the decal backing paper and apply this part of the
exposed adhesive backing to the clean surface while
maintaining proper position and alignment. Slowly
peel off the other portion of the backing paper while
applying hand pressure to smooth out decal surface. To
apply a die-cut decal, first remove the backing paper.
Then, properly orient and position the decal onto the
clean mounting surface. After the decal is firmly
applied and smoothly pressed down, remove the front
covering paper.

PAINT FINISH

Use this list to order paint for refinishing:

184768 One Gallon Yellow
167789 6 (12 oz. Spray Cans) Yellow
167754 One Gallon Gun Metal Gray
167753 6 (12 oz. Spray Cans) Gun Metal Gray

Decal Kits

102808 RS8-44 Telescopic Handler without PWP
102809 RS8-44 Telescopic Handler with PWP
102967 RS8-42 Telescopic Handler without PWP
102966 RS8-42 Telescopic Handler with PWP
102810 RS6-42 Telescopic Handler without PWP
102811 RS6-42 Telescopic Handler with PWP

NOTE: Decals may be purchased in kits or indi-

vidually.

Chapter 9

DECAL LOCATIONS

CAUTION

ALWAYS read and follow the safety precau­tions on decals. Replace decals if they are
damaged, or if the unit is repainted. If repaint­ing, BE SURE that all applicable decals are
affixed in their proper locations.

913218/CP0307 62 PRINTED IN U.S.A.

REF. DESCRIPTION RS8-44 RS8-42 RS6-42
NO. PART NO. PART NO. PART NO.

01 DANGER - HANDS OUT L70305 L70305 L70305
02 WARNING - PINCH POINT L65927 L65927 L65927
03 WARNING - JUMP START L65933 L65933 L65933
04 GEHL, 5.00” 102027 102027 102027
05 QUICKATTACH DIAGRAM L65937 L65937 L65937

06 GEHL, 8.00” 102025 102025 102025
07 ANTI-FREEZE 056859 056859 056859
08 HALF ZONE MARKER (5 ea.) L62583 L62583 L62583
09 NO. “1” EXTENSION MARKER (1 ea.) L67719 L67719 L67719

NO. “2” EXTENSION MARKER (1 ea.) L67720 L67720 L67720

NO. “3” EXTENSION MARKER (1 ea.) L67721 L67721 L67721
NO. “4” EXTENSION MARKER (1 ea.) L67722 L67722 L67722

NO. “5” EXTENSION MARKER (1 ea.) L67723 L67723 L67723
10 COOLANT UNDER PRESSURE L072798 072798 072798
11 WARNING - NO RIDERS L65932 L65932 L65932

12 BRAKE FLUID L63474 L63474 L63474
13 OPERATOR MANUAL WARNING 100359 100359 100359
14 DANGER-PERSONNEL INJURY (units without PWP) L65928 L65928 L65928
15 CARRY LOAD LOW L65926 L65926 L65926
16 LUBE CHART 102801 102801 102801
17 ROPS & FOPS CERTIFICATION 102800 102800 102800
18 RS8 or RS6 LH 102804 102916 102802

DECAL LOCATIONS - FRAME AND BOOM

1

5

3

2

2

2

15

6

8

9

8

4

10

7

14

11

12

13

16

17

18

PRINTED IN U.S.A. 63 913218/CP0307

REF. DESCRIPTION RS8-44 RS8-42 RS6-42
NO. PART NO. PART NO. PART NO.

01 DANGER - HANDS OUT L70305 L70305 L70305
02 WARNING - PINCH POINT L65927 L65927 L65927
03 GEHL, 8.00” 102025 102025 102025
04 HYDRAULIC OIL FILL 137632 137632 137632
05 WARNING - NO RIDERS L65932 L65932 L65932

06 GEHL 2.00” 102026 102026 102026
07 DANGER-PERSONNEL INJURY (units without PWP) L65928 L65928 L65928
08 QUICKATTACH UNLOCKED L66613 L66613 L66613
09 DIESEL FUEL 137634 137634 137634
10 RS8 or RS6 RH 102805 102917 102803

DECAL LOCATIONS - FRAME AND BOOM

2

9

4

5

8

2

3

2

1

2

2

7

6

10

913218/CP0307 64 PRINTED IN U.S.A.

REF. DESCRIPTION RS8-44 RS8-42 RS6-42
NO. PART NO. PART NO. PART NO.

01 WARNING-TILT HAZZARD/GENERAL OPERATOR L70306 L70306 L70306
02 WARNING - CARRY LOAD LOW L65926 L65926 L65926
03 F-N-R SHIFT L68295 L68295 L68295
04 STEERING WHEEL 2.0” DIA. (early models only) 101545 101545 101545
05 MADE IN USA 140516 140516 140516

06 WARNING - PARK BRAKE/SEAT BELT 101506 101506 101506
07 STANDARD CARRIAGE LOAD CHART 102795 102918 102790

ROTATING CARRIAGE LOAD CHART 102796 102919 102791

BUCKET LOAD CHART 102797 102920 102792

TRUSS BOOM LOAD CHART 102798 102921 102793

WINCH LOAD CHART 102799 102922 102794

SWING CARRIAGE LOAD CHART 102806 102923 NA

180° SWING CARRIAGE 103770 103769 103768
08 ATTACHMENT TILT/FRAME LEVEL L63632 L63632 L63632
09 BOOM CONTROL L63631 L63631 L63631

10 OUTRIGGER CONTROL (Optional) 101658 101658 101658
11 AUXILIARY HYDRAULIC CONTROL (Optional) 102718 102718 102718
12 IGNITION/START/HORN 102717 102717 102717
13 DANGER-HI VOLT./MOVING PARTS L70307 L70307 L70307
14 JOYSTICK CONTROL 104215 104215 104215

15 FRAME LEVEL L63311 L63311 L63311

DECAL LOCATIONS - OPERATOR STATION

6

1

7

8

9

10

11

2

13

3

5

4

12

11

15

14

Tri-function Joystick Control

Dual Joystick Control

PRINTED IN U.S.A. 65 913218/CP0307

REF. DESCRIPTION RS8-44 RS8-42 RS6-42
NO. PART NO. PART NO. PART NO.

01 WARNING-PERSONNEL LIFT L71554 L71554 L71554
02 WARNING-WORK PLATFORM RULES L71555 L71555 L71555
03 PERSONNEL LIFT SAFETY RULES L71700 L71700 L71700
04 PWP LOAD CHART 102788 102924 102787
05 PWP SWITCH 102969 102969 102969
06 PWP SYSTEM 103028 103028 103028

DECAL LOCATIONS - PWP EQUIPPED UNITS

3

1

2

1

4

6

5

913218/CP0307 66 PRINTED IN U.S.A.

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

IMPORTANT: Under extreme operating conditions more frequent service than the recommended

intervals may be required. You must decide if your operation requires more frequent service.

Chapter 10

MAINTENANCE

SERVICE PROCEDURE Every 10 Every 50 First 100 Every 250

Hours Hours Hours Hours (or
(or Daily) (or Weekly) Quarterly)

Checking Fuel Tank Level z

Checking Engine Oil Level z

Checking Radiator Coolant Level z

Checking Transmission Oil Level z

Checking Hydraulic Oil Level z

Checking Brake Reservoir Level z

Checking Tire Pressures z

Checking Wheel Nut Torque z

1,2

Checking Instruments Operation z

Checking General Machine Operation and Condition z

Checking Personnel Work Platform Safety System z

Lubricate Grease Points z

Checking Fuel Filter (Drain Water If Required) z

Changing Engine Oil and Filter z

2

Changing Transmission Oil and Filter z

2

Changing Hydraulic Oil Filter z

2

Checking Axle Oil Levels z

Changing Fuel Filter z

Changing Engine Oil and Filter z

Checking Battery z

1 - On new machines or when a wheel has been removed, until 450 ft.-lbs. (610 Nm) is maintained.
2 - Only New Machines.

MAINTENANCE INTERVAL CHART

PRINTED IN U.S.A. 67 913218/CP0307

SERVICE PROCEDURE Every 250 Every 1000 Every 2000

Hours (or Hours (or Hours (or
Quarterly) Yearly) Two Years)

Checking and Torquing Boom Leaf Chains z

Checking Boom Slide Pads Wear and Clearance z

Checking Personnel Work Platform System z

Changing Transmission Oil and Filter z

Changing Radiator Coolant z

Changing Hydraulic Return Filter Element z

Changing Air Filter Element z

Changing Axle Differential and Planetary Oil z

Checking Alternator and Fan Belt Condition z

Checking Exhaust System z

Checking Hydraulic System Relief Pressures z

Changing Hydraulic Reservoir Oil and Strainer z

MAINTENANCE INTERVAL CHART (CONT.)

Date Hours Service Procedure

MAINTENANCE LOG

913218/CP0307 68 PRINTED IN U.S.A.

Date Hours Service Procedure

MAINTENANCE LOG

PRINTED IN U.S.A. 69 913218/CP0307

Date Hours Service Procedure

MAINTENANCE LOG

913218/CP0307 70 PRINTED IN U.S.A.

Hydraulic Schematic w/o PWP

with Dual Joystick Control

(continued on next page)

“B”

“A”

PRINTED IN U.S.A. 71 913218/CP0307

Hydraulic Schematic w/o PWP

with Dual Joystick Control

(continued from previous page)

“B”

“A”

913218/CP0307 72 PRINTED IN U.S.A.

Hydraulic Schematic with PWP

with Dual Joystick Control

(continued on next page)

“A”

“B”

“C”

PRINTED IN U.S.A. 73 913218/CP0307

Hydraulic Schematic with PWP

with Dual Joystick Control

(continued from previous page)

“A”

“B”

“C”

913218/CP0307 74 PRINTED IN U.S.A.

Hydraulic Schematic w/o PWP

with Tri-Function Joystick Control

(continued on next page)

“A”

“B”

PRINTED IN U.S.A. 75 913218/CP0307

Hydraulic Schematic w/o PWP

with Tri-Function Joystick Control

(continued from previous page)

“A”

“B”

913218/CP0307 76 PRINTED IN U.S.A.

Hydraulic Schematic with PWP

with Tri-Function Joystick Control

(continued on next page)

“A”

“B”

“C”

PRINTED IN U.S.A. 77 913218/CP0307

Hydraulic Schematic with PWP

with Tri-Function Joystick Control

(continued from previous page)

“A”

“B”

“C”

913218/CP0307 78 PRINTED IN U.S.A.

Electrical Schematic

with Dual Joystick Control

(continued on next page)

“I”

“H”

“G”

“F”

“E”

“D”

“C”

“B”

“A”

“L”

“K”

“J”

“N”

“M”

PRINTED IN U.S.A. 79 913218/CP0307

Electrical Schematic

with Dual Joystick Control

(continued on next page)

“I”

“H”

“G”

“F”

“E”

“D”

“C”

“B”

“A”

“L”

“K”

“J”

“N”

“M”

913218/CP0307 80 PRINTED IN U.S.A.

Electrical Schematic

with Tri-Function Joystick Control

(continued on next page)

“F”

“E”

“D”

“C”

“B”

“A”

“I”

“H”

“G”

“J”

“L”

“K”

“M”

“N”

PRINTED IN U.S.A. 81 913218/CP0307

Electrical Schematic

with Tri-Function Joystick Control

(continued on next page)

“N”

“M”

“L”

“K”

“J”

“I”

“H”

“G”

“F”

“E”

“D”

“A”

“C”

“B”

913218/CP0307 82 PRINTED IN U.S.A.

RS8-44 Load Zone Charts

Decal 102795

Standard Carriage

Decal 102796

Rotating Carriage

Decal 102797

1 Cu. Yd. Bucket

Decal 102798

15 Ft. Truss Boom

PRINTED IN U.S.A. 83 913218/CP0307

RS8-44 Load Zone Charts

Decal 102799

Winch Boom

Decal 102806

Swing Carriage

Decal 103770

180° Swing Carriage

Decal 102788

PWP

913218/BP0706 84 PRINTED IN U.S.A.

RS8-42 Load Zone Charts

Decal 102918

Standard Carriage

Decal 102919

Rotating Carriage

Decal 102920

1 Cu. Yd. Bucket

Decal 102921

15 Ft. Truss Boom

PRINTED IN U.S.A. 85 913218/CP0307

RS8-42 Load Zone Charts

Decal 102922

Winch Boom

Decal 102923

Swing Carriage

Decal 103769

180° Swing Carriage

Decal 102924

PWP

913218/CP0307 86 PRINTED IN U.S.A.

RS6-42 Load Zone Charts

Decal 102790

Standard Carriage

Decal 102791

Rotating Carriage

Decal 102792

1 Cu. Yd. Bucket

Decal 102793

12 Ft. Truss Boom

PRINTED IN U.S.A. 87 913218/CP0307

RS6-42 Load Zone Charts

Decal 102794

Winch Boom

Decal 103768

180° Swing Carriage

Decal 102787

PWP

913218/CP0307 88 PRINTED IN U.S.A.

Dry Lubed Dry Lubed Dry Lubed

Grade 2

Grade 5

Grade 8

Unified National

Thread

Torque Specifications

Use these torque values when tightening GEHL hardware (excluding: locknuts and self-tapping, thread-forming
and metal screws) 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 9
1/4-28 76* 56* 10 86* 14 10

5/16-18 11 9 17 13 25 18
5/16-24 12 9 19 14 25 20

3/8-16 20 15 30 23 45 35
3/8-24 23 17 35 25 50 35

7/16-14 32 24 50 35 70 55
7/16-20 36 27 55 40 80 60

1/2-13 35 35 75 55 110 80
1/2-20 40 40 90 65 120 90

9/16-12 55 55 110 80 150 110
9/16-18 60 60 120 90 170 130

5/8-11 75 75 150 110 220 170
5/8-18 85 85 180 130 240 180

3/4-10 130 130 260 200 380 280
3/4-16 150 150 300 220 420 320

7/8-9 125 125 430 320 600 460

7/8-14 140 140 470 360 660 500

1-8 190 190 640 480 900 680

1-14 210 210 710 530 1000 740

Dry Lubed Dry Lubed Dry Lubed

Grade 8.8

Grade 10.9

Grade 12.9

Metric Course

Thread

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 47

M12-1.75 65 48 91.5 67.5 111.5 82

M14-2 103.5 76.5 145.5 108 176.5 131

M16-2 158.5 117.5 223.5 165.5 271 200

* All torque values are in ft.-lbs except those marked with an * which are in lb.-in.

For metric torque value (Nm) multiply ft.-lbs x 1.355 or lb.-in. value x 0.113.

PRINTED IN U.S.A. 89 913218/CP0307

A

Access To Components Chart . . . . . . . . . . . . . . . . . . . . . 47

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

Adjustments

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

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

Air Filter

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

Alternator

Belt Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Anti-freeze - See Radiator

Attachment Tools

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

Operating Methods - See Chapter 6

Axles

Description - See Chapter 2

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

See Also Service

Axle Oil

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

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

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

B

Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Battery

Charging Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

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

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

Boom Travel

Function Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

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

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

C

Capacities - See Chapter 2

Carriage Lifting Applications

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

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

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

Controls,

Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Right Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Floor and Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Other Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Cylinders

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

D

Dealer Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

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

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

Dimensions - See Chapter 2

E

Electrical Components

Characteristics - See Chapter 2

Controls and Indicators - See Chapter 4

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

Engine

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

Description - See Chapter 2

Oil Pressure Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .22

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

Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . .22

Engine Oil

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

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

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

Engine Shutdown Protection

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

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

Engine Override Shutdown Switch . . . . . . . . . . . . . . . .23

Engine Oil Filter, replacing . . . . . . . . . . . . . . . . . . . . . . . .53

Exhaust System, check . . . . . . . . . . . . . . . . . . . . . . . . . .58

F

Fan Belt - See Alternator Belt

Frame Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Frame Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Fuel - See Separate Engine Manual

Fuel Filter

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

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

Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

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

Index

913218/CP0307 90 PRINTED IN U.S.A.

G

Grease Fittings

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

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

Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

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

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

H

Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

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

Hydraulic Oil

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

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

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

Hydraulic Maintenance

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

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

Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

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

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

I

Identification Reference . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

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

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

J

Joystick Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . .58

L

Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Lubrication,

See also Service Intervals

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

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

M

Main Relief pressure check . . . . . . . . . . . . . . . . . . . . . . .58

Maintenance

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

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

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

Mandatory Work Platform Safety Rules . . . . . . . . . . . .12

O

Oils - See Lubrication

Operation

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

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

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

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

Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

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

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

Operator’s Station

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

Outriggers Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .26, 28

P

Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

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

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

Pump, Delivery Rates - See Chapter 2

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

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

Personnel Work Platform Switch . . . . . . . . . . . . . . . . . . . .24

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

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

Q

Quickattach System

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

R

Radiator

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

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

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

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

Road Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

S

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

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

Schematics

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

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

PRINTED IN U.S.A. 91 913218/CP0307

Seat, operator’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Service and safety Features . . . . . . . . . . . . . . . . . . . . . . .28

Service Intervals

Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

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

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

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

2000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

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

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

Steering - See Controls

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

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

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

Guidelines For Free Rigging / Suspended Loads . . . .39

T

Tables

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

Paint Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Replacement Filters . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Theft Deterrents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Traffic Flow Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Transmission

Description - See Chapter 2

Temperature Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Transmission Oil

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Check Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

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

Transporting

Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Travel Speed - See Controls

Troubleshooting, PWP . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

W

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . Inside Rear Cover

Water Trap - See Fuel Filter

Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . .24

Work Platform Design Requirements . . . . . . . . . . . . . . . .13

913218/CP0307 92 PRINTED IN U.S.A.

NOTES

PRINTED IN U.S.A. 93 913218/CP0307

GEHL COMPANY

WARRANTY

GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl equipment to the

Original Retail Purchaser to be free from defects in material and workmanship for a period of
twelve (12) months from the Warranty Start Date.

GEHL WARRANTY SERVICE INCLUDES:

Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer's
business location.

GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND,
EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS
EXPRESSLY STATED IN THIS WARRANTY STATEMENT.

ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL BE DEEMED
DELETED FROM THIS WARRANTY; ALL OTHER TERMS WILL CONTINUE TO APPLY.

SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE
WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW.

GEHL WARRANTY DOES NOT INCLUDE:

1. Transportation to selling dealer's business location or, at the option of the Original Retail
Purchaser, the cost of a service call.

2. Used equipment.

3. Components covered by their own non-Gehl warranties, such as tires, batteries, trade
accessories and engines.

4. Normal maintenance service and expendable, high-wear items.

5. Repairs or adjustments caused by: improper use; failure to follow recommended
maintenance procedures; 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 or expenses of acquiring replacement equipment.

No agent, employee or representative of Gehl has any authority to bind Gehl to any warranty
except as specifically set forth herein.

THIS OPERATOR’S MANUAL IS

PROVIDED FOR OPERATOR USE

DO NOT REMOVE

FROM THIS MACHINE

Do not start, operate or work on this machine until you have carefully read and thor­oughly understand the contents of the operator’s manual.

Failure to follow safety, operating and maintenance instructions could result in seri­ous injury to the operator or bystanders, poor operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or maintenance of this
machine, 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

913218/CP0307 ©2007 Gehl Company PRINTED IN U.S.A.

All Rights Reserved.

California Proposition 65 Warnings

Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer and birth defects or other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead com­pounds, chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm. Wash hands after handling battery.