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RS6-34 Operator`s Manual

1. L5 Torque Specifications 93 Traffic Flow Patterns 39 Transmission Description See Chapter 2 Temperature Lamp 23 Transmission Oil CHANGING ies exce zio gen dv aus 161 Checking Level 54 Recommended Grades LATI Transporting Loading ERR LES 146 Unloading 1 461 Travel Speed See Controls Troubleshooting 67 Warranty hints Inside Rear Cover Water Trap See Fuel Filter Windshield Wiper Switch 2 251 Work Platform Design Requirements 1 151 PRINTED IN U S A 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 MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT ANY OF THESE LIMITATIONS
2. 54 Changing coolant 165 Flushing and Refilling 165 Relay ACCESS 1 30 Relay Functions 1311 Road Travel 45 5 SAFETY 8 ia bo et ek eee 17 Schematics Electrical 789 Hydraulic 1 85 Seat operators 222222222 2 2 1271 Service and Safety 1 301 Service Intervals Daily 521 Weekly a ae ees 56 100 56 250 Parton asd 1 56 1000 hours 161 2000 ROUFS MC 64 Shields 21 Side View Mirror 1 30 Specifications 14 Steering See Controls Steering Relief Pressure Check 6 eee d 165 Suspended Loads Handling eis x bee Rede CR es s 4 Safety Reminders 1 1 50960083 AP0914 96 Tables Lubrca nts as Rura 1 47 Paint Notice 68 Replacement Filters 148 Theft Deterrents 46 i Tire Pressures
3. L JOYSTICK REET rT F3 JOYSTICK CONTROL OPTION HER or etc T BRN YEL Processor TAN RED BATTERY BATTERY 30 CONOENSOR FAN RELAY EGR SENSOR GROUND EGR SENSOR SV POWER GRN RED EOR SENSOR SIGNAL GRN YEL STARTER RELAY GRO BLK BRN REMAINING INTERCONNEC CU J2 CONNECTIONS SHOWN ON SEPERATE SHEET STARTER RELAY POWER ALTERNATOR PUR REO DEUTZ STARTER RELAY 50960083 0914 ACCESSORY HORN ACCESSORY BLU RED BLU RED m ORG YEL BLU ORO 2 m PEDAL c BRN GRN BRN RED id 2 TEMPERATURE SWITCH YEL RED I WHT BRN Low T CLEANER 01 Sus sens NOT USED BLU FRONT BRAKE PRESSURE SWITCH YEL WMT SERVICE DRAKE 12 OUTPUT IF EITHER REAR BRAKE 5 OR 6 ON 2 12 2 amp 1 PARK BRAKE ENGAGE START UP TURNS ON WHEN INPUT 7 HOT wHT BLU TURNS OFF WHEN INPUT B TURNS OFF PARK BRAKE ON WHEN MACHINE STARTED amp STAYS ON BLK RED TILL MACHINE SHIFTEO IN GEAR In li ATER MEATER OPTION 90 PRINTED IN U S A Load Zone Charts 2 No 553 zm O gt 89 e v Decal 104875 Standard Carriage Decal 104878 8
4. A 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 pres sure and removing the radiator cap If the coolant level is low remove the radiator cap and slowly add a low silicate ethylene glycol based coolant mixed with quality water and supplemental coolant additives SCAs suitable for heavy duty diesel engines untill the sight glass 1s filled with coolant See your engine manual for additional information Replace the radiator cap securely NOTE Do not fill the radiator to the top of the radiator tank NOTE f the engine is operated with a loose radi ator 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 chap ter for the type of oil to use 50960083 AP0914 CHECKING HYDRAULIC OIL LEVEL The machine must be on level ground with boom low ered and completely retracted The fluid MUST be cool when checking the reservoir level to reduce the po
5. 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 odor less 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 park brake before leaving the operator s station NEVER travel with the boom above the carry position attachment tool should be at minimum ground clearance Boom should be fully retract ed 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 PRINTED IN U S A A SAFETY A gt 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 2 NEVER allow any riders on this machine This is strictly a single seat NO passenger machine 2 NEVER use as a lift for personnel unless the machine is equipped with the Personnel Work Platform PWP System gt When road travel
6. 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 1s therefore essential to have competent and careful operators who are not physically or mentally impaired and who are thoroughly trained in the safe opera tion of the equipment and the handling of the loads Throughout this manual information 1 provided that 1 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 or 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 pocke
7. 06 Boom Angle Indicator Properly secured no visible damage bubble is visible 07 Tire and Wheel Assemblies Properly secured no loose or missing lug nuts no visible tire damage cuts or abrasions proper inflation 08 Front and Rear Axles No loose or missing parts no visible damage tie rod end studs locked no evidence of leaking properly lubricated 9 Operator Compartment O Seat belt undamaged operates properly mounting hardware secure Switches and levers undamage no loose or missing parts load charts properly secured and legible levers and switches operate properly control mark ings legible L1 frame level indicator secured and undamaged bub ble 1 visible 010 Lift Cylinder Properly secured no visible damage no evidence of leaking from the cylinder properly lubricated 011 Slave Cylinder Properly secured no visible dam age no evidence of leaking from the cylinder prop erly lubricated 012 Boom Pivot Assembly Properly secured no visible damage or excessive wear properly lubricated PRINTED IN U S A 35 O13 O14 O15 O16 O17 O18 O19 O20 021 022 023 024 025 026 027 028 Boom Hydraulic Hoses No visible damage or exte rior wear no evidence of leaking Rear Light Assembly Properly secured no visible damage no loose or disconnected wires no malfunc tions Hydraulic Control Valve Assembly No loose or m
8. 87 50960083 AP0914 Hydraulic Schematic for Tri Function Joystick with PWP LEVEL CYLINDER LEFT ar RIGHT 3700 PSI FRONT 1 FRONT m BRAKE en CES BRAKE piscs 7 Discs FRONT R R REAR STEER STEER CYLINDER CYLINDER aa FRAME LEVEL CONTROLLER L PRESSURE SWITCH STEER LH LIFT RH LIFT CYLINDER CYLINDER B A e d Xll lk T P LIFT BOOM JOYSTICK CARRIAGE TILT APPLY VALVE ears EXTEND CYLINDER 9 3 000 PSI Ls T SLAVE CYLINDER 4 LAILA amp WI R XC arem AUX IL ARY COUPLERS 1 GUAGE PORT 35025 m P s ZA x amp SAHR APPLY 5 lt gt LES GUAGE 4 PSI 4 SUCTION gt j PORT STRAINER 50960083 0914 88 PRINTED IN U S A Electrical Schematic including options TAN RED PUR RED BC K BLu NOTE REMAINING INTERCONNECTION ANO ECU 52 CONNECTIONS SHOWN ON SEPERATI YEL BLU Kez ORN RED Kaa GRN YEL z BLK BLU STARTER RELAY GROUND BLK BRN x28 zi STARTER RELAY POWER WHT YEL 73 ORG GRN x35 20 Aa RED 2 j BLK GRN x26 FUEL PuwP 5 REO 8L 90 ALTERNATOR RELAY 1 FUEL PUMP 9 8 DEUTZ STARTER RELAY Sri TOW VOCERGTU i RED BR
9. Service Every 2000 Hours or Two Years 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 fac tory Three test ports are provided under the front hood access cover E Test ports under access cover Before conducting any pressure checks check the engine speed Engine speed must be 1000 RPM at idle and 2300 RPM at high idle Steering Relief Pressure Plug a 3000 psi 207 bar oil or liquid filled gauge into the test port labeled SP Turn the steering full to the right or left The gauge should read 2000 psi 138 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 350 psi 24 bar Main Relief Pressure Plug a 3000 psi 207 bar oil or liquid filled gauge into the test port labeled 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 50960083 AP0914 Remove the drain plug and drain oil Wash or blow off any particles collected on the magnetic drain plug IMPORTANT DO NOT discharge oil onto ground Catch and dispose of per
10. Tri Function Joystick Control Two Joystick Control DESCRIPTION WARNING TILT HAZARD GENERAL OPERATOR WARNING CARRY LOAD LOW F N R SHIFT MADE IN USA WARNING PARK BRAKE SEAT BELT PART NO L70306 L65926 L68295 140516 101506 STANDARD CARRIAGE LOAD CHART ROTATING CARRIAGE LOAD CHART BUCKET LOAD CHART TRUSS BOOM LOAD CHART WINCH LOAD CHART PWP LOAD CHART 104875 104876 104877 104878 104879 104880 ATTACHMENT TILT FRAME LEVEL BOOM CONTROL AUXILIARY HYDRAULIC CONTROL Optional IGNITION SWITCH DANGER HIGH VOLT MOVING PARTS L63632 L63631 102718 50304691 L70307 JOYSTICK CONTROL FRAME LEVEL 104215 L63311 PRINTED IN U S A 71 50960083 AP0914 p PWP SYSTEM DECAL LOCATIONS PWP EQUIPPED UNITS DESCRIPTION PART NO WARNING PERSONNEL LIFT L71554 WARNING WORK PLATFORM RULES L71555 PERSONNEL LIFT SAFETY RULES L71700 PWP LOAD CHART 104880 PWP SWITCH 102969 PWP SYSTEM 103028 50960083 AP0914 72 PRINTED IN U S A Chapter 10 MAINTENANCE This Maintenance Interval Chart was developed to match the Service and Storage chapter of this manual Detailed information on each Service Procedure 15 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 procedures is impractical an
11. 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 Ibs 610 Nm Tires are inflated to 60 psi 415 kPa cold Hydraulic system reservoir engine crankcase engine coolant transmission and axles are filled to the proper operating fluid levels OOO D DO DO DO adjustments been made to comply with the set tings given in this manual and in the separate engine man ual 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 Start the machine and test run the unit while checking that proper operation is exhibited by all controls Check that indicators lamps switches etc function properly hand and foot controls operate properly D DO 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 le
12. Be sure you know where you will make load pickups placements lifts and turns Look over the terrain of the jobsite for holes obstacles slippery surfaces and soft or deep mud 6 Check clearances of ramps doorways and passageways 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 must be reported immediately to the user s des ignated authority The machine should not be operated until it has been restored to a safe operating condition A WARNING Exhaust fumes can kill Ensure proper ventila tion when starting indoors or in enclosed areas Use proper hand holds NOT the steering wheel or control levers as handholds 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 PRINTED IN U S A Operate the travel controls gradually and smoothly when starting stopping turning and reversing direc tion Grade and Slope Precautions The Telescopic Handler complies with industry stabil ity test requirements and is stable when properly oper ated However improper operation faulty mainte nance and poor housekeeping can contribute to a con dition of instability The amo
13. 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 POWERTRAIN COMPONENTS The engine and transmission are coupled directly to each other 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 spe cial know how and tools for servicing IMPORTANT f any powertrain components are suspected of faulty operation contact your Gehl dealer for assistance HYDRAULIC SYSTEM COMPONENTS Valves pumps motors and cylinders are sophisticated assemblies which require special know how and tools for servicing cylinders are appropriately designed with particular strokes diameters checks and hose connection provisions unique to the machine applica tion requirements A hydraulic schematic located at the back of this manual can be used as a guide for ser vice reference as required PRINTED IN U S A A WARNING Tilt lift extend and leveling cylinders have counterbalance valves These valves keep hydraulic fluid from entering and exiting the cylinders while not being used and are under extremely high pressure Before removing any of these valves it is REQUIRED to call the your Gehl Service Department Failure to do so may result in serious injury or dea
14. Main Relief Pressure Check 641 Maintenance gj R el MT 74 Handling Non Suspended Loads ide E mo Scheduled Int PEE 73 Picking T EU Rp Carrying the 421 E Bre Mandatory Work Platf fety Rules 14 Load Elevation and Placement 142 bd 0 Bos Handling Suspended Loads Picking Up Suspended Loads 143 Oils See Lubrication Carrying Suspended Loads 143 Operation e Ground Level Suspended Load Placement 143 Starting IA MS E 361 a2 ue Elevated Suspended Load Placement 143 Stopping 36 Hand Signals o n asooo 139 Symbols inside Front Cover Hourmeter 23 Travel 45 Hydraulic Components servicing 5 i Operator s Manual storing Hydraulic Operator Services 511 Changing Sonus 1 64 Station e 1 Checking level 154 Heater Controls 1251 ITE Recommended Type 47 Heater AC Controls 26 Hydraulic Maintenance P Oil Filter
15. A 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 these safety precautions PRINTED IN U S A 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 fingers on the tire bead or rim during inflation Use a clip on tire chuck with a remote hose and gauge which allows standing clear of the tire while inflating it 4 NEVER inflate beyond 35 psi 240 kPa to seat the beads If the beads have not seat ed 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 To ensure proper load carrying capabihty original equipment tires comply with the specifications pub lished in the Tire and Rim Association Yearbook Replacement tires MUST meet the same specifica tions When replacing tires be sure all tires are of the same type quality and load rating and the same size as the original equip
16. Methods See Chapter 6 Axles Description See Chapter 2 Greasing iua eek ea tee nde eee dS 48 See also Service Axle Oil Changing Ix Pons 163 Checking Levels 1 56 Recommended Grades 1 47 Backup Alarm REY 1 301 Battery Charging Lamp 1251 Jump Starting 159 M TC 1 59 Boom Travel Function Controls 1 271 Function Indicators 2 ji Service 6 Capacities See Chapter 2 Checklists delivery and pre delivery Eu Controls 122 Right Side Panel 1271 Floor and Seat 1 26 Cylinders Servicing 50 50960083 0914 Dealer Services 50 Decal Locations 69 Decals applying 68 Dimensions See Chapter 2 E Electrical Components Characteristics See Chapter 2 Controls and Indicators See Chapter 4 Sericihg pne L51 Engine Cold Starting Procedures Description See Chapter 2 Emergency Override 24 Oil Pressure Lamp 231 Engin
17. Ports Battery 50960083 AP0914 Backup Alarm Located inside the rear frame cover this alarm produces a loud warning sound when the machine is in reverse Backup Alarm Side View Mirror Located on the front outside cor ner of the fuel tank this mirror provides the operator with a view toward the rear of the machine Hydraulic Reservoir Oil Level and Fill Cap The dipstick on the fill cap of the reservoir indicates the level of the hydraulic oil in the reservoir Side View Mirror Hydraulic Fill Cap Dipstick Air Filter Restriction This message will appear in the multi function display anytime the air cleaner is restricted Check the air cleaner for a clogged element and replace if neccessary The message will clear when the air cleaner restriction is corrected Fuse and Relay Access Compartment This compart ment 1 located under the load chart panel Remove the four screws to gain access to the fuses and relays Fuse and Relay Access PRINTED IN U S A Fuses and Relays Functions Remove the covers to access the fuses and relays Refer to the illustration and following description for the fuse and relay functions FUSES 1 15 fuse Ignition Switch Horn Brake Lights and Clutch Cutout 2 20 AMP fuse Transmission Park Brake PWP Steer Select and Backup Alarm 3 15 AMP fuse Lights 4 25 AMP fuse Heater and Display 5 25 AMP fuse Top Wiper Motor 6 25 AMP fu
18. Rotate cylinder pivot pins 2 GREASE FITTINGS LOCATIONS 17 Rotate carriage wear pads 3 18 Rotate pivot bearing 1 Every 50 Hours or weekly 19 Boom slide pads as required front and rear Refer to the illustration on the facing page for loca tions CHASSIS AREA 1 Brake foot linkage 1 2 Wheel spindle pins per axle 4 3 Axle to frame pivot pins per axle 2 4 Drive shaft slip joint per shaft 1 5 Drive shaft u joint per shaft 2 6 Level cylinder pivot pins 2 7 Base end lift cylinder pivot pins 2 8 Base end slave cylinder pivot pins 2 50960083 AP0914 48 PRINTED IN U S A Grease Fittings Locations PRINTED IN U S A 49 50960083 AP0914 Chapter SERVICE AND STORAGE GENERAL INFORMATION A WARNING BEFORE performing any service on the Telescopic Handler unless expressly instruct ed to the contrary exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE 8 Safety chapter After service has been per formed BE SURE to restore all guards shields and covers to their original positions BEFORE resuming machine operation 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 d
19. S A to locate any underground utility lines BEFORE starting to dig Keep all body parts inside the operator s sta tion while operating the machine BE SURE of clearance for the attachment tool when turn ing working around buildings etc Turning corners too fast can tip the machine or cause a load to slide off the attachment Sudden slowing or stopping of the machine may cause the load to fall 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 NEVER leave the operator s station without first lowering the attachment tool to the ground Then set the parking brake place con trols 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 Load Capacity and Reach The machine has flip charts in the operator s station that provide at a glance the load capacity limits at var ious positions of attachment tool extension and eleva tion A set of the load zone charts is reproduced at 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 dis tance in feet from the front of the machine The arc
20. Slide Pads Wear and Clearance Change Transmission Oil and Filter Change Hydraulic Return Filter Element Change Air Filter Element Change Axle Differential and Planetary Oil Check Alternator and Fan Belt Condition Check Exhaust System Check Hydraulic System Relief Pressures Change Hydraulic Reservoir Oil and Strainer Change Radiator Coolant MAINTENANCE LOG Service Procedure 50960083 AP0914 74 PRINTED IN U S A MAINTENANCE LOG Service Procedure PRINTED IN U S A 75 50960083 AP0914 MAINTENANCE LOG Service Procedure 50960083 AP0914 76 PRINTED IN U S A ENGINE DIAGNOSTIC TROUBLE CODES DTCs Engine diagnostic trouble codes are displayed in the multi function display screen Diagnostic trouble codes are displayed as a two part code Suspect Parameter Number SPN and Failure Mode Identifier FMI as shown on the following table The first part is a Suspect Parameter Number SPN followed by a Failure Mode Identifier FMI To deter mine the exact type of failure both parts SPN and of the code are needed The SPN identifies the system or the component that has the failure for example SPN 000110 indicates a failure in t
21. any control lever IF YOU ARE NOT CAREFUL WHILE OPERATING THIS MACHINE ANY OF THE ABOVE FACTORS COULD CAUSE THE MACHINE TO TIP AND YOU COULD BE THROWN OUT OF THE OPERATOR S STATION WHICH COULD RESULT IN SERIOUS 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 DO NOT depend on the backup alarm to clear bystanders out of the path of the machine ALWAYS look in the direction of travel Look to 50960083 AP0914 the rear before backing ALWAYS use the recommended handholds and steps with at least three points of support when get ting on and off the machine Keep steps and plat form clean Face the machine when climbing 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 prop erly supervised
22. battery because a short circuit can result Battery acid is harmful on contact with skin or fabrics If acid spills follow these first aid tips 1 IMMEDIATELY remove any clothing on which acid spilled 2 If acid contacted the skin rinse the affect ed 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 bat tery terminal connection first 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 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 50960083 AP0914 A WARNING The ONLY safe method for jump starting a dis charged battery is for TWO PEOPLE to per form the following procedure The second per son is needed for removing the jumper cables so that the operator does not have to leave the operator s c
23. explosion or fire if ignited Wear a face shield when disassembling spring loaded components or working with battery acid Wear a helmet or goggles with special lenses when welding or cutting with a torch When working beneath a raised machine always use blocks jack stands or other rigid and stable supports Wear appropriate protec tive 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 flu ids 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 positive battery terminal con nection before welding Choose a clean level work area Be sure there 15 suffi cient room clearances and adequate ventilation Clean the walking and working surfaces Remove oil grease and water to eliminate slippery areas Use sand or oil absorbing compound as necessary while servicing the Telescopic Handler Before startin
24. have a width greater than the overall width of the forklift measured across the load bearing 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 Anoverhead 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 plat form a maximum work load including personnel and equipment and 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 mech anism 8 Ameans to securely attach the platform to the lift ing mechanism and to prevent the platform from inadvertently pivoting 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 50960083 AP0914
25. iloa MD Dre 8 Service and Storage 50 9 Decal Locati ns dotes 68 10 Maintenance 4 acad E EXTR dE 173 Engine Diagnostic Trouble Codes LT Hydraulic Schematics 224552 cada 851 Electrical Schematics 5 5 891 Load Zone EQ EE cade 01 Standard Hardware Torque Data 93 AEX HOT 194 b rcu Inside Back Cover IDENTIFICATION INFORMATION Write your Gehl Telescopic Handler serial number below Refer to the model and serial number when inquiring about parts or service from your Gehl dealer MODEL NO RS6 34 The model and serial numbers for this machine are on a decal located inside the operator s station PRINTED IN U S A 1 50960083 AP0914 Chapter 1 INTRODUCTION The information in this Operator s Manual was written to give the owner operator assistance in preparing adjust ing maintaining and servicing of the Telescopic Handler More 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
26. is required know and use the signaling devices on the machine Provide an escort and Slow Moving Vehicle SMV emblem when required gt If necessary to park on a slope park across the slope and block the tires Suspended Load Safety Reminders The handling of suspended loads by means of a truss boom winch boom mounted lift hook or other similar device can introduce dynamic forces affecting the sta bility of the machine that are not considered in the sta bility criteria of industry test standards Grades and sudden starts stops and turns can cause the load to swing and create a hazard Refer to the following guidelines for handling suspended loads A WARNING U S OSHA regulations effective November 8 2010 29 CFR Part 1926 Subpart CC Cranes and Derricks in Construction include require ments for employers that use powered indus trial trucks forklifts configured to hoist by means of a winch or hook and move sus pended loads horizontally In particular this regulation applies to any rough terrain forklift e g telescopic handler equipped with a jib or truss boom with a hook with or without a winch or a hook assembly attached to the forks Note This regulation is in addition to the OSHA regulation that requires specific forklift operator training 1910 178 I When a forklift telescopic handler is config ured and used for hoisting the employer must ensure that PRINTED IN U S A 1 Forkli
27. it may be nec essary to refill the cooling system after a short period of use as the air will naturally bleed out of the system Check the sight glass to verify the coolant level before adding coolant STORING THE MACHINE If the Telescopic Handler will not be operated for a period of three months or more prepare and store it using the following procedure NOTE f the storage area is outdoors or in a harsh environment the storage procedure should be followed if the Telescopic Handler is to be stored for one month Before Storage Perform the following prior to placing the machine in storage 1 Wash 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 1t 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 concentration of anti freeze is adequate to keep 50960083 AP0914 the coolant from freezing Refer to the engine manual for anti freeze recommendations and quantities During Storage 1 About once each month connect the battery che
28. of time e DO NOT operate the engine at maximum power for long periods of time e Vary the engine speed and load e Check the oil level frequently and replenish as necessary with the oil specified in the engine man ual After the first 100 hours of operation change the oil and replace the oil filter Consult the Lubrication chap ter or the engine manual for the type of oil to use in the engine Refer to the Service and Storage chapter for the proper service intervals PRINTED IN U S A PRE START WALK AROUND INSPEC TION It is the operator s responsibility to perform a pre start inspect of the machine before the start of each work day Every pre start 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 pre start inspection is designed to discover if the machine has incurred any damage or is in need of rou tine service Any needed repairs are to be made by a qualified ser vice technician Refer to the illustration and checklist on the next two pages for the Pre Start Walk Around Inspection 50960083 AP0914 Pre Start Walk Around Inspection Illustration PRE START WALK AROUND INSPECTION PROCEDURE Refer to the following illustration and checklist to per form the inspection Begin with item 1 at the left front of the machine and wal
29. on the front hood section Access to the drain plug is from underneath the machine Proceed as follows 1 Remove the drain plug and drain oil Replace the drain plug Transmission 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 50960083 AP0914 3 Refill the transmission with new oil as shown in the Lubrication chapter of this manual z Transmission Filter is too high oil foaming excessively high oil tem perature 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 HYDRAULIC RETURN FIL TER ELEMENT A WARNING Lower the boom to the ground when servicing the hydraulic system The hydraulic return filter element is a cartridge type accessible from a housing on top of the hydraulic reser voir 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 ele ment into the housing and replace the cover Reservoir Filter Removal CHANGING AIR FILTER ELEMENTS IMPORTANT Failure to follow proper filter ser vicing instructions could resul
30. operator when ready to be moved Platform personnel must maintain firm looting on platiorm floor unless secured by harness and lanyard A harness and lanyard attached to platform or boom must be worn when working Do not use railings planks ladders etc on platform to acheive additional reach or height Do not ride in platform when forklift is being moved or re positioned 171700 Platform Installation Precautions Platform must comply with ASME ANSI B56 6b 1998 Addenda Sec 8 24 Modifications to platform that are detrimental 10 its safe use are prohibited Guard any components that may present hazard to platform personnel Platform must be centered on and securely attached 10 carriage or forks Carriage must be securely attached to boom e Carriage and forks must be secured to prevent them from pivoting upward Pre Lift Precautions Be sure lilting mechanism is operating smoothly throughout its range both empty and loaded and that the PWP System is functioning properly Any rotating or swing carriage function must be deactivated Mark area to warn others of work by elevated personnel Combined weight of platlorm personnel and load must not exceed one third 1 3 of capacity of forklift Be sure forklilt has a firm footing Shilt transmission into neutral and apply parking brake Be sure forklilt frame is leveled to insure a vertical lilt Be sure platform is horizontal Be sure path of pl
31. pressure occurs in either system during normal operation with the brake pedal depressed this lamp will come on 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 necessary repairs made immediately E Transmission Oil Temperature Lamp 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 sys tem is at the proper temperature IMPORTANT f this lamp comes on during nor mal operation a problem may exist in the trans mission oil system Stop the machine immediate ly and investigate the cause of the problem F Engine Glow Plug Indicator Lamp When light ed this lamp indicates that the glow plug cold weather starting aid is in use G Alternator Lamp This lamp indicates the condi tion 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 H Coolant Temperature Lamp This lamp indicates if the temperature of the engine coolant is too high IMPORTANT f this lamp comes on during nor mal operation with the engine running STOP the engine as soon as possible and check the engine cooling system I Engine Oil Pressure Lamp This lamp indicates whether the engine lubricating oil pressure is
32. proper operation Observe all gauges and indica tors for proper operation If any malfunctions are found correct the cause prior to using the machine 2 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 50960083 AP0914 A SAFETY A are examples 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 equip ment Gehl telescopic handlers are designed and intend ed to be used only with Gehl attachments and approved attachments To avoid possible personal injury equipment damage and performance prob lems use attachments that are approved for use on and within the operating capacity of the machine Contact your dealer or Gehl Company for infor mation on attachment approval and compatibility with specific machine models Gehl cannot be responsible if the machine is used with a non approved attachment Operation Safety Reminders gt Any orall of the following elements may affect the stability of the machine terrain engine speed type of load being carried and placed improper tire inflation weight of the attachment tool and abrupt movement of
33. section near the carriage The switch must be accessible by the platform personnel at all times when the platform is to be moved To de activate the PWP System apply and hold the service brakes on for three or more seconds and press the bottom of the PWP System rocker switch The sys tem is de activated when the lamp in the PWP System rocker switch is off NOTE f the lamp in the PWP system rocker switch is flashing apply the service brakes until the lamp goes off PRINTED IN U S A A 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 under stand 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 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 opera tion obtain and install an amber flashing beacon NOTE ALWAYS follow ALL state and local regu lations regarding the operation of equipment on or across public highways Whenever there is an appreciable distance between jobsites or if dr
34. suffi cient During normal operation with the engine run ning this lamp should be off During starting and when the ignition is on but the engine is not running this lamp will be on IMPORTANT f this lamp comes on during nor mal operation 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 50960083 AP0914 Switch Panel The switch panel contains three rows of switches for the operation of standard and optional equipment on the telescopic handler Top Row Switches Switches have graphic symbols to indicate function and effect The following descriptions start with the first switch on the left NOTE Some switches are optional and may not be on machine A Steering Mode This 3 position switch is used to select among the three steering modes The upper posi tion engages the 4 wheel steer mode This mode pro vides all wheel steering used for making tighter turns usually on a jobsite The center position engages the 2 wheel steer mode This mode provides front wheel steering only used for higher speed travel The lower position engages 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 posi tion before changing the steering mode Any of the steer
35. switch lamp flash es when switch is turned OFF Parking brake switch lamp stays ON when PWP System switch is OFF PRINTED IN U S A PWP System is not activated Machine is not level PWP System remote shutdown switch is disengaged PWP System remote shutdown switch is not plugged into the connector at the end of the boom PWP System angle sensor is unplugged or faulty PWP System is not de activated 67 With PWP System switch ON apply service brakes for three seconds until PWP switch lamp is lit continuously Level the machine Engage the PWP System remote shutdown switch Plug in and engage the PWP System remote shutdown switch Contact your Gehl dealer for assistance With engine running apply ser vice brakes for three seconds until PWP switch lamp goes off 50960083 AP0914 Chapter 9 DECAL LOCATIONS GENERAL INFORMATION A CAUTION ALWAYS read and follow the safety precau tions and information shown on decals If any decals are damaged or unreadable or if the unit is repainted the decals must be replaced If repainting BE SURE that all decals that apply to your machine are affixed in their proper locations Decal location information is provided to assist in the proper selection and application of new decals in the event the original decals become damaged or the machine is repainted For correct replacement of decals compare the loca
36. tank 29 gals 110 L Hydraulic reservoir and system 35 gals 133 L Transmission and cooler 24 qts 22 7 L Axles Differentials 9 6 qts 9 L ea Hubs 0 6 qts 0 5 L ea Transmission Type Clark Powershift T12000 Speeds 3 fwd 3 rev Torque converter Single stage dual phase Travel Speeds Ist gear 3 5 mph 5 6 km h 2nd gear 7 4 mph 11 9 km h 3rd gear 18 0 mph 29 km h Axles front and rear Type Dana Drive steer open differential double reduction planetary full time four wheel drive Overall ratio 15 4 1 Engine Options Features Turbocharged 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 20 508 mm suction fan dry dual element air cleaner spin on oil filter Engine make and model Deutz TD3 6 L4 Tier 4 22 cu in 3 621 L displacement 74 3 hp 55 4 kW 2300 rpm Oil capacity w filter 9 5 qts 8 9 L Hydraulic System Type Open center Pump Single section gear type Displacement revolution 2 7 cu in 44 3 cc Flow 2500 RPM 29 gpm 110 L min Main relief pressure 3000 psi 207 bar Steer relief pressure 2000 psi 138 bar Hydraulic filter In tank return type 10 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 straine
37. the engine lubricat ing oil pressure A4 Voltmeter Press button until VOLTS is displayed This indicates the voltage output from the alternator A5 Hourmeter Press button until HRS is dis played It indicates the total operating time of the machine and should be used for keeping the mainte nance log A6 Maintenance Reminder After every 250 hours a reminder will display ROUTINE MAINTENACE IS REQUIRED CHECK OPERATOR S MANU AL Perform the required maintenance and then clear the message by pressing and holding button until the message is cleared NOTE maintenance reminder message must display at least three minutes before it can be cleared by pressing and holding button A7 Air Filter Restriction This message will appear anytime the air cleaner is restricted Check the air cleaner for a clogged element and replace if necces sary The message will clear when the air cleaner restriction is corrected AS Error Fault Code Error codes and a short error description are displayed in this screen The error code will clear when the error is corrected PRINTED IN U S A Indicator Lamps Low Fuel Lamp This lamp indicates a low fuel situation The fuel tank should be filled as soon as pos sible D Brake Failure Lamp This lamp indicates the con dition of the service brake systems The front and rear brakes are on independent systems If a loss of
38. the load A jib or truss boom should ONLY be used to lift and place loads when the machine is sta tionary and the frame is level Transporting suspended loads must ALWAYS be done slow ly and cautiously with the boom and load as low as possible Use taglines to restrict loads from swinging to avoid overturn PRINTED IN U S A HANDLING SUSPENDED LOADS Determine the weight and load center of the load to be handled Refer to the telehandler load chart to deter mine if the load can safely be handled NOTE Refer to the standard carriage load chart when using the boom mounted hook A WARNING NEVER exceed the rated operating capacity of the telehandler as shown on the load zone charts A WARNING Operating conditions can reduce the telehan dler s safe operating capacity Exceeding the capacity when raising or extending the boom will cause the telehandler to tip forward Picking Up Suspended Load 1 Rigging should be in good condition and rated for the load being lifted 2 Rigging should comply with OSHA regulation 1910 184 Slings or 1926 251 Rigging equipment for material handling 3 Be sure the rigging equipment is clear of any part of the machine or machine attachment before lift ing the load 4 Avoid lifting double tiered or any unstable loads 5 Only lift loads vertically and clear from any adja cent obstacles Never drag the load horizontally 6 Use multiple lift points and taglines to
39. tion photographs to the machine before starting to refinish the unit Check off each required decal using the illustration reference number to find the part num ber description and quantity in the list Refer to the appropriate illustration for replacement locations If there is a decal on a part that is being replaced be sure that the decal is applied to the replacement part NOTE Refer to the Safety chapter of this manual for specific information provided on the various safety decals 50960083 AP0914 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 peel off the top covering paper PAINT FINISH Use this list to order paint for refinishing 167788 4 1 qt Cans Yellow 167789 6 12 oz Spray Cans Yellow 167754 4 1 qt Cans Gun Metal Gray 167757 6 12 oz Spray Cans Gun Metal Gray Decal Kits 50220763 RS6 34 Telescopic Handler wit
40. to ground Engine Speed Maximum engine speed exceeded Engine Speed ECU measures a offset angle between crankshaft and camshaft sensor is too large Engine Speed Camshaft Speed Sensor ECU recieves no sig nal uses crankshaft sensor to calculate engine speed Crankshaft Speed Sensor disturbed signal Engine Speed Engine Speed the engine speed calculated by ECU is above the target range the ECU activates a warning threshold Engine Speed Crankshaft Speed Sensor Unavailable ECU uses camshaft speed sensor Speed detection out of range signal disrupted erratic signal Engine Speed Engine Speed the engine speed calculated by ECU is above the target range the ECU activates a engine speed warning threshold ES N EEPROM Error The ECU finds an erroe during the access to its EEPROM memory or works with an alternative value PRINTED IN U S A 79 50960083 AP0914 DTC CAN Bus error CAN Bus BusOff Status Electrical Error Injector Cyl 1 the current drop measure by ECU is above the target range shor circuit to injector 1 Electrical Error Injector Cyl 1 interuption of electrical connection Electrical Error Injector Cyl 3 the current drop measure by ECU is above the target range shor circuit to injector 1 Electrical Error Injector Cyl 3 interuption of electrical connection Electrical Error Injector Cyl 4 the current drop measure by ECU is above the target range shor circuit to injector 1 Electrical
41. you see this symbol in this manual or on the machine itself you are reminded to BE ALERT Your personal safety is involved 50960083 AP0914 2 PRINTED IN U S A Identification Boom Angle Indicator Telescopic Boom Dash Indicators and Controls Slave Cylinder Quick attach System Tilt Cylinder Operator s Station Lift Cylinder Tilt and Auxiliary Hydraulics Hoses Rear Boom Access Cover Exhaust Extend Pipe Cylinder Air Cleaner Frame Leveling Access Cover Cylinder with Rear Lights and Backup Alarm Fuel Tank Hydraulic Side View Reservoir Mirror PRINTED IN U S A 3 50960083 AP0914 EN Chapter 2 Lifting Performance Maximum lift capacity 6000 Ibs 2721 kg Maximum lift height 34 3 10 44 m Capacity at maximum lift height 4000 Ibs 1820 kg Max forward reach to load center 237 3 7 09 m Capacity at maximum forward reach 900 Ibs 408 kg Maximum below grade reach 24 610 mm Frame leveling 10 left 10 right General Dimensions Based on standard machine equipped with listed tires 48 masonry carriage and 48 pallet forks Recommended tire type 15 00 x 19 5 12 ply Inflate to 60 psi 415 kPa Overall length less forks 167 0 4 88 m Overall width 77 10 2 39 m Overall height 77 9 2 36 m Ground clearance 14 356 mm Wheel base 97 2 2 8 m Outside turn radius 12 6 3 81 m Machine weig
42. 20009 or downloaded from www itsdf org The rules apply to the owner operator and the personnel in the work platform 50960083 AP0914 A SAFETY A 15 MANDATORY WORK PLATFORM SAFETY RULES The work platform must comply with ANSI ITSDF B56 6 2005 Sec 8 24 Platforms for Elevating Personnel See page 14 Work Platform Design Requirements The platform must be securely attached to the car riage or forks and the carriage securely attached to the boom The carriage and forks must be secured to prevent them from pivoting upward 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 Personnel on the platform must be provided pro tection from any moving parts on the forklift that may present a hazard If overhead hazards exist for platform personnel overhead protection must be provided 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 Be sure that the frame is level to ensure a vertical lift Be sure the platform is horizontal before lifting Be sure that the forklift has a firm footing Be sure that any required restraining means rail ings chains harnesses etc are in place and prop erly used Before lifting personnel shift the transm
43. 23613 Rail Pressure fuel pressure in rrail exceeds tar get range dependant on engine speed rail pres sure disrupted maximum negative rail pressure deviation with metering unit on lower limit is exceeded Rail Pressure fuel pressure in rail exceeds target rage dependant on engine speed rail pressure disrupted leakage detected based on fuel quanti ty balance power reduction may result Rail Pressurre fuel pressure in rail exceeds tar get range dependant on engine speed rail pres sure disrupted maximum rail pressure exceeded 523613 Rail Pressure Error Rail Pressure fuel pressure in rail calculated by ECU is below the target range which is depen dant on engine speed minimum rail pressure exceeded 523613 Metering Unit Error Rail Pressure fuel pressure in rail calculated by ECU is below the target range which is depen dant on engine speed setpoint of metering unit in overun mode not plausible 523615 Metering Unit Error Fuel Metering Unit current drain measured by ECU is above the target range short circuit to battery high side short circuit to battery low side 523615 Metering Unit Error Fuel Metering Unit current drain measured by ECU is above the target range short circuit to ground high side short circuit to ground low side SCR Error Engine Shut Off request from supervisory moni toring function Timeout Error Timeout Error limp mode activated Passive Timeout Error Passive Timeout Error limp mode act
44. A SAFETY A means shall be capable of withstanding a concen trated horizontal force of 200 Ibs 890 N applied at the point of least resistance without permanent deformation A body harness and lanyard is to have an attachment point provided overhead for free dom of movement and its length is to limit free fall to 5 feet 1500 mm measured from the point of attachment to the operator The complete system shall be capable of withstanding three consecutive drop tests to simulate a 250 pound 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 applic able 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 struc tural 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 50960083 AP0914 16 PRINTED IN U S A A SAFETY A 07 06 _ L70306 ho Lawn L65928 FALL HAZARD DO NOT use this machine to lift people or work platiorms PRINTED IN U S A d L70306 OVERTURN HAZARD Always fasten seat
45. Apply Valve Locking Pilot Pressure Knobs Apply Valve IMPORTANT LEOR BROER 5 T PROCEDURE L71378 Decal Speed Control Knobs If the machine is equipped with auxiliary hydraulics there will be two pilot pressure apply valves each hav ing two speed control knobs The top pilot valve con trols the auxiliary hydraulics and the lower 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 attach ment 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 PRINTED IN U S A 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 as much as 10 to the left or right to level the frame and boom in relation to the ground A WARNING DO NOT level the frame with the boom raised or extended Level the frame ONLY while stopped with the boom fully r
46. Ciz HL Form No 50960083 Revision A September 2014 Telescopic Handler Tier 4 Engine Beginning with Serial Number 22451 Operator s Manual Indicator and Operation Symbols A P D Read Operator s Fasten Seat Belt Parking Brake Brake Failure Manual e Ignition Off Ignition ON Engine Start Engine Oil Pressure gt O Starting Aid Volume Full Volume Half Full Volume Empty Injection Transmission Transmission Turn Signals Oil Temperature t Clutch Disengaged Clutch Engaged Crab Steer J lt Raise Load Lower Load Tilt Rearward Tilt Forward S Brake Fluid Frame Level Left Frame Level Right Wiper Washer 5 m SG 7 Hydraulic Oil Female Auxiliary Male Auxiliary Battery Hydraulic Coupler Hydraulic Coupler A Safety Alert Hazard Flasher Engine Oil Engine Coolant Temperature Diesel Fuel 2 e Work Lights 2 Wheel Steer 4 Wheel Steer gt Retract Load Extend Load Hourmeter Transmission Temperature Table of Contents all Chapter Description Page Indicator and Operation Symbols Inside Front Cover 1 liie P pr 2 SPECINCANONE Sh dirt Ai 3 Check 4 eerie 5 Indicators and Controls ori ze eee cca piace acie 21 6 Operation and Adjustments secus sace n aus ex E ERU perdre 1331 7 JE
47. 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 PRINTED IN U S A 97 50960083 AP0914 A WARNING 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 thor oughly understand the contents of the operator s manual Failure to follow safety operating and maintenance instructions could result in seri ous injury to the ope
48. Error Injector Cyl 4 interuption of electrical connection Electrical Error Injector Cyl 2 the current drop measure by ECU is above the target range shor circuit to injector 1 Electrical Error Injector Cyl 2 interuption of electrical connection Starter Relay Error Starter Relay high side power stage The cur rent drop measured by ECU is above the target range starter relay high side short circuit to bat tery Starter Relay high side power stage The cur rent drain measured by ECU is above the target range starter relay low side short circuit to bat tery Error Code Type Error Description e 14 03 05 03 05 03 05 03 05 3 0 Starter Relay Error Starter Relay high side power stage The cur rent drop measured by ECU is above the target range starter relay low side short circuit to ground Starter Relay high side power stage The cur rent drain measured by ECU is above the target range starter relay high side short circuit to ground e Starter Relay Error Starter Relay low side power stage the current drop measured by ECU is above the target range open circuit disconection LowSide Outout Starter Relay Error Starter Relay low side power stage the current drop measured by ECU is above the target range starter relay powerstage over temperature ECU Erro Internal Hardware Monitoring the ECU detects a deviation of the target range of the power supply voltage of sensor outpu
49. Ft Truss Boom Decal 104876 Rotating Carriage 91 50960083 AP0914 PRINTED IN U S A Load Zone Charts Decal 104879 Decal 104880 Winch Boom PWP 50960083 AP0914 92 PRINTED IN U S A Torque Specifications Use these torque values when tightening hardware excluding locknuts and self tapping thread forming and metal screws unless otherwise specified Unified National Grade 2 C Grade 5 O Thread Dry Dry Metric Course Grade 8 8 4 Thread 6 1 24 8 1 25 10 1 5 12 1 75 14 2 16 2 torque values are in lb ft except those marked with which are in Ib in For metric torque value Nm multiply lb ft value x 1 355 or value x 0 113 PRINTED IN U S A 93 50960083 AP0914 Access to Components Chart 1511 131 Adjustments Slide Pads Clearance 61 Wheel Lug Nuts Torque 55 Air Filter Changing Elements 621 Alternator Belt Service 63 Indicator Lamp EL Anti freeze See Radiator Attachment Tools CHANGING suere PERS 137 Operating
50. N 4 29 RED STARTER MOTOR BLK GRA 3 Eo BLK GRA 2E WHT TAN 4 KEG 30 BLK GRA PNK OUTPUTS INPUTS CAN TERMINATORS NOS 120 2 12 12 12 cum GRN GRA KS3 T oe eu Bu TILT LEVEL DISENGAGE SOLENOID HEZ rome LIFT Z EXTEND DISENGAGE SOLENOID gt PROCESSOR STEER STEER eu MODE BLU RED MOOE eu crag SWITCH Ae 5 GRN BLU ACCESSORY BLU RED PEP OPTION ORO WHT 550 8 0 1 4 WHEEL HORN BLK RED BLK GRN our BEACON HORN BUTTON RED GRN AIR REO L TEMPERATURE AUX POWER OUTLET SURE BRAKE T DIFFERENTIAL WARNING 3 ur TS 5 amp 6 DIFFERI PRINTED IN U S A JOYSTICK FRONT BRAKE PRESSURE SWITCH c3 YEL WHT 12 REAR BRAKI gt AR BRAKE PRESSURE SwITCH T BLU 8 K WHT BLU ON PARK 8 BLK REO BLK WHT BLU Oo CAB HEATER OPTION T F3 JOYSTICK CONTROL OPTION 89 50960083 AP0914 Electrical Schematic including options and Radio Remote TAN RED IER e TILT 7 LEVEL ISE SOLENOID LIFT 7 EXTEND DISENGAGE SOLENOID RADIO REMOTE OPTION j TILT BACK SOLENOID eux TILT FORWARD SOLENOIO
51. TEER CYLINDER LH LIFT RH LIFT CYLINDER CYLINDER eum ae SLAVE NDER CYLINDER ROOM P LS T JOYSTIC 3000 PSI 5 AUXILIARY CONTROLLER AUX IL I ARY COUPLERS MALE Q FEMALE FLOW DIVIDER PUMP JOYSTICK RELIEF Y TT 2400 PSI AVI amp SAHR APPLY SP Er B 1 CO 9n GUAGE iat RETURN TION gt Pel PORT SUC STRAINER 50960083 AP0914 86 PRINTED IN U S A Hydraulic Schematic for Tri Function Joystick without PWP LEVEL CYLINDER FRONT R R REAR LEFT oe RIGHT STEER STEER FRONT 1 FRONT CYLINDER CYLINDER BRAKE m 1 BRAKE UE pisces L DISCS FRAME LEVEL CONTROLLER 3700 PSI STEER B A T P STEERING CONTROL UNIT p e SUCT ON STRAINER PRINTED IN U S A pa MEL 3000 PSI LIFT BOOM JOYSTICK i Ki EXTEND CYLINDER CARRIAGE TILT APPLY VALVE T 5 TILT LAVE CYL INDER CYLINDER T3 A AUXILIARY GUAGE COUPLERS MALE PS Fie 350 PSI m T E 5 TA POVSTICK RELIEF amp SAHR APPLY sP PB JP GUAGE PORT GUAGE Bont 4 1256 lt gt Psi RETURN FILTER
52. The joystick control should now be disabled so that boom raise lower and extend retract no longer function e Repeat the procedure with the frame tilted to the left e 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 e The PWP switch lamp and the parking brake switch lamp should both be illuminated 2 Turn the key switch to OFF and then turn the PWP rocker switch to OFF Turn the key switch back to e 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 e The PWP switch lamp and the parking brake switch lamp should go off after approximately 50960083 AP0914 three seconds of brake pedal application If PWP System fails to perform properly troubleshoot using the chart on page 67 Contact your dealer for ser vice information and parts Service Every 50 Hours Weekly LUBRICATE GREASE POINTS Refer to the Lubrication chapter of this manual for grease fitting locations and other related details 100 Hours New Machine Only The following initial oil and filter changes should be performed at 100 hours on a new machine Thereafter these changes should be performed at the regular main tenance intervals Refer to
53. a sheave If this occurs it could result in severe damage to the boom assembly Two Front Boom Chains One Rear Boom Chain X Jf Intermediate Section Outer Section Section Chain Hookup Detail Inspect the leaf chains for wear Run the boom out slowly to inspect Conditions to look for include cracked or broken plates protruding or turned pins and excessive wear With a steel tape measure 16 links PRINTED IN U S A of the strand that flexes over the sheaves If the section measures 10 3 262 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 worn or broken fingers and worn flanges After 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 two chains on the front of the boom to 25 ft Ibs 34 Nm Lubricate with 80W 90 oil CHECKING BOOM SLIDE PAD WEAR AND CLEARANCE fa wo Inner Shim Front Outer Slide Pad Detail The boom is equipped with special nylon low friction slide pads between the telescopic sections see illustra tion These are pre greased and initially worn in at the factory Normally greasing is not required except for maintaining a
54. aks when under pressure DC Listen for abnormal noises or vibrations if detected deter mine their cause and repair as necessary I acknowledge that the pre delivery procedures were per formed on this unit as outlined above Dealership s Name Dealer Representative s Name Date Checklist Filled Out Machine Model Machine Serial DELIVERY Engine Serial V Check that The following Checklist is a reminder of the important infor mation that MUST be passed on to the customer at the time the unit is delivered Check off each item as it is explained to the customer L Review with the customer the contents of this manual and the AEM Safety Manual for the following The Index at the back for quickly locating topics The Safety Indicators and Controls and Operation and Adjustment chapters for information regarding safe use of the machine The Lubrication and 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 L 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 Remind the customer of U S regulation 1910 178 D which specifies operator training requirements Explain that the customer must consult the engine
55. al 3 4 turn Clean and re install the drain plug Re fill the crankcase with new oil Follow specifi cations in the Lubrication chapter for type and vis cosity of new oil NOTE The oil capacity listed is approximate Always verify oil level with the engine oil dipstick 8 Afternew 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 9 Verfy the oil level is at the Full mark on the engine oil dipstick IMPORTANT Low engine oil level and over full engine oil levels can cause engine damage CHECKING THE BATTERY The battery furnished in the machine is a 12 volt wet cell battery The top ofthe 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 foam ing has stopped flush the top of the battery with clean water If the terminals and cable connection clamps are PRINTED IN U S A corroded or have a buildup disconnect the cables and clean the terminals and clamps with the same alkaline solution NOTE The battery in the machine is warranted by the supplier See the punch tag on the top of the battery for warranty information A WARNING Explosive gas is produced while a battery is in use or being charged Keep flames and sparks away from the battery Make sure battery is charged in a well ventilated area NEVER lay a metal object on top of a
56. ard the front of the truck or trailer so that it 1 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 trail er with tie down chains cables 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 lfnecessary 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 50960083 AP0914 WARNING NEVER adjust travel direction even slightly while traveling on the ramps Instead back down 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 to the truck or trailer bed using chain and binders or steel cables to prevent any movement while transporting THEFT DETERRENTS Gehl Company has recorded all major component part numbers and serial numbers Users should take as many of the following actions as possible to discour age theft to aid in the recovery of the machine in the event it 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 mac
57. arge oil onto ground Catch and dispose of per local waste disposal regulations 2 Remove the check and fill plugs Fill the differen tial with oil as specified in the Lubrication chapter When the oil flows out 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 PRINTED IN U S A Check Plug SS Drain Plug SERE Axle Planetary Hubs The axle 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 Plug in drain position 2 2 Re position the hub so the oil level arrow is hori zontal 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 CONDITION Refer to the engine manual for proper fan belt tension adjustment and replacement procedures If the belt 15 worn or cut it should be replaced Order replacement belts from your Gehl dealer CHECKING EXHAUST SYSTEM Examine the muffler and tail pipe for possible holes Re tighten any loose clamps and make sure the mani fold outlet gasket 1s not leaking 50960083 AP0914
58. arking brake switch OFF PWP System switch OFF Remote switch plugged in and ENGAGED DU vost ES Activation Tests To test the PWP System activation logic 1 Start the engine and press the PWP rocker switch to ON e The PWP System lamp in the switch should be flashing 2 Apply the service brakes e The PWP switch lamp should be illuminated continuously after three seconds indicating that the PWP System has been activated e The parking brake should engage as indicated by the lamp in the parking brake switch illumi nating 50960083 AP0914 e The carriage tilt and auxiliary functions should now be disabled The joystick control should continue to function normally for boom raise lower and extend retract Lockout Tests To test the transmission and joystick control lockout logic 1 Shift transmission into Forward and increase the engine speed slightly The transmission should remain de clutched allowing the engine to increase speed easily e Return the transmission selector to N Neutral after the check 2 Have an assistant move the remote shutdown switch to Dis engaged e The joystick control should now be disabled so that boom raise lower and extend retract will no longer function e 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 e
59. atform travel is clear of hazards such as scalfolds electrical wires and overhead obstructions 50960083 AP0914 Provide overhead protection for platform personnel if overhead hazards exist A WARNING TO AVOID INJURY OR DEATH FOLLOW ALL MANDATORY WORK PLATFORM SAFETY RULES Lifting Precautions Be sure personnel and equipment on platform do not exceed available space trained operator must be in position to operate forklift controls at all times Always alert elevated personnel before moving Lift and lower personnel smoothly and cautiously and only at their request Keep hands and leet clear ol controls that are not in use Always lower platform fully before moving forklift Do not move forklilt with personnel on platlorm Platform Personnel Precautions Be sure any required restraining means railings chains harnesses etc are in place and properly used Any harness lanyard or deceleration device that is damaged or permanently delormed must be replaced Platform must be fully lowered for personnel to enter and exit Personnel must not climb on any part of forklift in attempting to enter and exit Platform personnel must maintain firm footing on platlorm floor unless secured by harness or lanyard A harness and lanyard attached to platlorm boom must be worn when working Use ol railings planks ladders etc platiorm to achieve additional reach or height is prohibited Workers on platiorm mu
60. ations require employers in general industry and the construction ship yard 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 combi nation 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 know ledge training and experience to train and evaluate operators WARNING ALWAYS maintain a safe distance from elec tric 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 and load at least 10 ft 3 m from all power lines Accidental contact or rupture can result in electrocution or an explosion Contact the Call Before You Dig referral system number at 8 1 1 in the U S or 888 258 0808 in the U S and Canada to locate any underground utility lines BEFORE starting to dig PRINTED IN U S A Additional Safety Reminders gt User operator safety practices as indicated by industry standards are included in this Operator s Manual and intended to promote safe operation of the machine These guideli
61. belt Inspect worksite to be able sure ground is stable Bal 12 a Consult load charts e Apply park brake e Shift into Neutral Level DO NOT exceed rated capacity DO NOT ition load using Irae ievelng 00 NOT move machine with boom raised 00 NOT transport load with jb or winch To avoid rear overturn T tilt 0 boom or winch back more than 45 when main boom is taised above 45 machine overturns 00 NOT Instead hold on tight and igan away from tall 101506 TO AVOID INJURY ln t machine balore operating it Be swe work tool is securely attached Start and operate only trom opetator s seat Use 2 wheel steer for high spaad travel Be sure backup alarm i functioning Look in direction ol travel and clear path belors moving DO NOT use hands 10 lind od teak can inject into skin See a if injured Before ace oa Tollow f Stop in level area 2 Fully retract boom lower work tool 3 Shift into Neutral apply park break 4 Shut off engine femova key 100359 L70307 ELECTROCUTION HAZARD Keep machine boom and load 10 leet 3 m or more away tom power lines CRUSH HAZARD 00 NOT remove fight side window of panel e Replace il broken damaged or missing 170307 Read Operator s Manual in seat pouch and ail Salety signs belore using 04 servicing machine Owner employar is
62. can be accomplished by using the chain supplied with the PWP to secure the lower portion of the PWP to the bottom of the carriage as shown below ORE 0 7 50960083 AP0914 A WARNING The PWP must meet ANSI ITSDF B56 6 2005 Section 8 24 See page 15 in the Safety chap ter 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 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 Electrical Connection Shutdown Switch Remote Shutdown Switch with Coiled Wire Connector 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 The Telescopic Handler 15 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 14 Safety chapter If the Telescopic Handler is equipped wit
63. ck all fluid levels to make sure they are at the proper level and start the engine IMPORTANT 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 if the machine is to be returned to stor age recoat the cylinder rods with grease 2 Allow the engine to run until it warms up Then move the machine a short distance to help relubri cate the internal parts Run the engine until the bat tery is recharged and then shut it off After Storage After removing the machine from storage and BEFORE operating it perform the following 1 Change engine oil and filter to remove any con densation and residues 2 Wipe off grease from cylinder rods Lubricate ALL grease fittings 4 Follow the start up and warm up procedures out lined in the Operation and Adjustments chapter of this manual 50960083 AP0914 66 PRINTED IN U S A PWP SYSTEM TROUBLESHOOTING Possible Cause Problem PWP System switch lamp flash es when switch is pressed ON Parking brake does not engage when the PWP System switch is pressed ON Carriage tilt and auxiliary func tions continue operating when the PWP System switch is pressed 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
64. d 1s therefore not recommended IMPORTANT Under severe operating conditions more frequent service than the recommended inter vals may be required Users must decide if the severity of their operation requires more frequent service than normal MAINTENANCE INTERVAL CHART SERVICE PROCEDURE Every 10 Every 50 First 100 Every 250 Hours Hours Hours Hours or or Daily or Weekly Quarterly Check Fuel Tank Level Check Fuel Filter Drain Water If Required Check Engine Oil Level Check Radiator Coolant Level Check Transmission Oil Level Check Hydraulic Oil Level Check Brake Reservoir Level Check Tire Pressures Check Wheel Nut Torque Check Instruments Operation Check General Machine Operation and Condition Check Personnel Work Platform Safety System Lubricate Grease Points Change Engine Oil and Filter Change Transmission Oil and Filter Change Hydraulic Oil Filter Check Axle Oil Levels Change Fuel Filter Change Engine Oil and Filter Check Battery Check and Torque Boom Leaf Chains 1 On new machines or when a wheel has been removed until 450 ft lbs 610 Nm is maintained 2 New machines only 3 On new machines or when a chain has been replaced Chains should be torqued to 25 ft lbs 34 Nm PRINTED IN U S A 73 50960083 AP0914 MAINTENANCE INTERVAL CHART CONT SERVICE PROCEDURE Every 250 Every 1000 Every 2000 Hours or Hours or Hours or Quarterly Yearly Two Years Check Boom
65. d 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 L 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 Remind the customer of U S regulation 1910 178 D which specifies operator training requirements 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 Explain that a copy of the product warranty is included on the inside back cover of this Operator s Manual Customer s Signature Date Delivered Dealer s File Copy Remove at Perforation PRINTED IN U S A 50960083 AP0914 INTENTIONALLY BLANK To be removed as Dealer s file copy 50960083 AP0914 6 PRINTED IN U S A Chapter CHECKLISTS PRE DELIVERY The following Checklist is an important reminder of the inspections that MUST be made before delivering the Telescopic Handler to the customer Check off each item after the prescribed action 1s taken 4 Check that NO parts of machine have been damaged in shipment Check for such things as dents and loose or missing parts
66. e Level Control Tri Function Joystick Load Zone Tri Function Joystick Control Operator s Compartment and Indicators Controls Locations PRINTED IN U S A 50960083 AP0914 DASH PANEL AREA Ignition Switch the ignition switch power is disconnected from the battery to the control and instrument panel electrical circuits This is the only position in which the key can be inserted and removed Key Switch OFF When the key is vertical in position clockwise from the vertical OFF posi tion power from the battery 1s supplied to all controls and multi function display panel electrical cir cuits All indicators lamps in the multi function display will illuminate momentarily as a lamp check Key Switch ON When the key 15 turned one When the key is in this position the engine glow plug indicator will stay on until the engine 1s pre heated In colder temperatures the glow plug indicator will stay lit for 3 30 seconds When the glow plug indicator light goes out the engine can be started Start Turn the ignition switch to this position to activate the starter Release the ignition switch as soon as the engine starts NOTE f the engine requires repeated attempts to start the key MUST be returned to the OFF position between starting attempts to prevent bat tery run down WARNING Do not use starting fluid ether with engine glow plug preheat systems An explosion can result which can caus
67. e Shutdown Protection Starting ele UE 36 Temperature Gauge 2 T Engine Oil Changing 158 Checking Level 1531 Recommended Grades L47 Engine Oil Filter replacing 158 Exhaust System checking 163 F Fan Belt See Alternator Belt Frame Angle Indicator 1 29 Frame Level Control and Indicator 28 29 Fuel See Separate Engine Manual Fuel Filter Checking and Draining 53 Replacing Rp E 57 Fuel Gauge 123 Fuse Access 301 Fuse Functions PRINTED IN U S A L General Load Handling Light Switch 1 251 Load Capacity and Reach 1411 Load Zone Charts 221911 General Machine Operation Lubrication Grade and Slope Precautions 391 See also Service Intervals Grade Limits 39 LOCATIONS spezi oieee 149 Grease Fittings LUBNCANS x eb oie rr pP bee hth eas 471 149 M Types of Grease 147 T 21
68. e engine damage injury or death Horn Located in the center of the steering wheel 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 50960083 AP0914 Instrumentation and Switch Panel Located to the right of the steering wheel this panel contains the multi function display with indicator lamps and the function rocker switches Multi Function Display with Indicator A Multi Function Display Screen This screen dis plays the following functions e fuel level displayed at all times on the lower por tion of the display PRINTED IN U S A e engine coolant temperature e engine oil pressure e voltmeter e hourmeter 250 hour maintenance reminder e air filter restriction message e error fault codes B Scroll Button Pressing this button changes the function displayed in the gauge display panel 1 Fuel Level Gauge The fuel level is displayed at all times in the lower portion of the display It indicates the amount of fuel remaining in the fuel tank A2 Engine Coolant Temperature Press button until TEMP is displayed It indicates the temperature of the engine coolant Under normal conditions this should indicate approximately 185 F 85 C Engine Oil Pressure Press button until OIL is displayed This indicates
69. e out of mud IMPORTANT DO NOT lower boom at high engine speed when attachment tool is at maxi mum rearward tilt Damage to slave cylinders may result GENERAL LOAD HANDLING NEVER operate controls except from the operator s seat NEVER jerk or use fast movements Avoid sud den stops starts and changes in direction 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 starting the desired motion by moving the con trol a small distance away from neutral Then after movement has started the control can be eased to full travel Use the same feathering technique to slow and stop the motion WARNING Excessive speed can be hazardous ALWAYS exercise caution and good judgement while operating the machine ALWAYS maintain a safe distance from elec tric 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 and load at least 10 ft 3 m from all power lines Accidental contact with a power line or rup ture of a gas line can result in electrocution or an explosion Contact the Call Before You Dig referral system number at 8 1 1 in the U S or 888 258 0808 in the U S and Canada PRINTED IN U
70. e under the front of the seat actuates the adjustment mechanism Slide Adjustment Lever Suspension Seat Option This option is available for additional operator comfort It 15 adjustable for a soft or firm ride Slide Adjustment Lever Ride Adjustment Knob Seat Belt This machine has a retractable seat belt Grasp the belt on the left side of the seat pull the belt over your lap and insert the belt into the buckle on the right side of the seat until you hear it lock in place Seat Belt RIGHT SIDE PANEL Joystick Controls These controls and indicators are used to position the frame boom and attachment Graphic symbols on the side panel indicate the control actions and effect PRINTED IN U S A A WARNING Use extreme caution when raising or extend ing the boom The Telescopic Handler MUST be level Loaded or empty the machine can tip over if it is not level ALWAYS place the transmission in neutral apply the parking brake and keep the service brakes fully applied before raising or extend ing the boom NEVER exceed the specified lift and reach capacities of the machine or serious machine damage and personal injury may result Refer to the load charts at the operator s station or this manual If a boom circuit hose fails with the boom up with or without a load shut down the machine following the MANDATORY SAFETY SHUT DOWN PROCEDURE DO NOT attempt repairs Instead call your Gehl deal
71. each fork NEVER add extra unauthorized counterweights to the machine 50960083 AP0914 Approach the load slowly and squarely with the machine straight and level Adjust the space between forks if necessary Engage the load equally on the forks until the load touches the carriage backrest Tilt the forks back to position the load for travel A WARNING Operating conditions such as slopes or soft ground can reduce the machine s safe operat ing capacity Exceeding the capacity when raising or extending the boom will cause the machine to tip forward 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 WARNING NEVER travel with the boom above the carry position attachment tool should be at mini mum 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 129 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 50960083 AP0914 For elevated or overhead placement br
72. eased before the engine starts turn the key switch to the OFF position and wait one minute before attempting to start again IMPORTANT Crank the starter until the engine starts If the engine fails to start within 20 sec onds return the key to the OFF position wait one minute and try to start the engine Cranking the engine for longer than 20 seconds will result in premature failure of the starter 5 After the engine starts allow several minutes warm up time before operating the controls Allow a longer warm up time in cold weather 50960083 AP0914 6 Check that indicators are in their normal operating conditions 7 Verify that there are no fuel oil or engine coolant leaks and no abnormal noises or vibrations COLD STARTING PROCEDURES The engine is equipped with a block heater This block heater or other starting aid is required for starting in temperatures below 32 F 0 See your Gehl dealer for additional starting aids WARNING Do not use starting fluid ether with engine glow plug preheat systems An explosion can result which can cause engine damage injury or death If the battery becomes discharged and has insufficient 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 s
73. ecal 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 details procedures to follow for making routine mainte nance checks adjustments and replacements The majority of the procedures are also referred to in the Maintenance chapter of this manual For engine related adjustments and servicing proce dures 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 a Gehl dealer Dealers know what portions of the machine are cov ered under the terms of the Gehl Warranty and what portions are covered by other vendor warranties 50960083 AP0914 When a problem occurs do not overlook simple caus es such as an empty fuel tank Check for leaks and bro ken connections Make note of any specific symptoms noises etc and contact your local Gehl dealer IMPORTANT A ways dispose of waste lubricating oils anti freeze and hydraulic fluids according to local regulations or take them to a recycling cen ter 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 performed by or under the direction of an authorized
74. ected range Maximum rail pressure in limp home mode exceeded monitoring for maximum rail pressure in limp home mode with PRV Rail pressure relief valve can t be opened due to rail pressure PRV error rail pressure out of toler ance range average rail pressure is outside the expected tolerance range Rail pressure relief valve open PRV forced to open system reaction initiated fault path indicat ing shutoff condition in case of open PRV power reduction may result Rail pressure relief valve open PRV is open PRV in rail is open power reduction may result Terminal 50 ECU receives a permanent signal T50 start switch active for too long Start informa tion to starter T50 Switch erratic defect Internal Hardware Monitoring the ECU detects a deviation of the target range of the power supply voltage of sensor output 3 ECU Internal software error power reduction may result Internal ECU monitoring detection reported error Internal Hardware Monitoring ECU CPU reset and cause is logged internally no item created in error memory software reset CPU software visi bility resets in DSM 50960083 AP0914 Error Code Error Description Rail Pressure Error Rail Pressure fuel pressure in rail below target range dependant on engine speed rail pressure disrupted Positive governor deviation maximum positive rail pressure deviation exceeded con cerning set fuel flow power reduction may result 5
75. ent Tilt Cylinder Properly secured no vis Ible damage no evidence of leaking from the cylin der properly lubricated Date Initials 50960083 AP0914 BEFORE STARTING ENGINE 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 Wait until everyone is clear of the machine before starting it up Before starting the engine and running the machine refer to the ndicators and Controls chapter and become familiar with the various operating controls indicators and safety features STARTING THE ENGINE A WARNING ALWAYS fasten your seat belt BEFORE start ing the engine Leave the parking brake applied until the engine is running and you are ready to operate the machine The following procedure is recommended for starting the engine 1 Grasp the handholds and step up into the opera tor s compartment 2 Adjust the seat and fasten the seatbelt 3 Check that all controls are in their neutral posi tions except the parking brake switch which should be in the ON position 4 Turn the key switch clockwise one position to the ON position When the pre heat indicator lamp in the multi function display goes out the engine can be started 5 Tum the key switch clockwise until the engine starter activates Release the key switch when the engine starts If the key switch is rel
76. er 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 Transporting suspended loads must ALWAYS be done slowly and cautiously with the boom and load as low as possible Use taglines to restrict loads from swinging to avoid over turn NEVER use winch for lifting or moving per sonnel NEVER exceed the maximum rated capacity of the winch 3000 Ibs 1360 kg or exceed the load chart rating for winch appli cations DO NOT tilt the truss boom back more than 459 from horizontal DO NOT attempt to use the optional rotating carriage as a load level ing function ALWAYS level the frame prior to raising a load Failure to heed could result in death or seri ous injury This machine is equipped with one of two types of boom and attachment joystick control configurations either a two joystick configuration or a single tri func tion joystick 50960083 AP0914 Two Joystick Configuration Boom Control Joystick Frame Level and Attachment Joystick E Auxiliary Hydraulics Control Two Joystick Configuration Frame Level Attachment Tilt Joystick The machine may be tilted slowly as much as 10 to the left or right to level the frame and boom 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 WARNING DO NOT leve
77. etracted and the attachment raised just enough to clear the ground 12 Volt Accessory Power Port Use this power port to power small electrical devices 12 Volt Power Port FUNCTION INDICATORS Frame Angle Indicator Located in front of the oper ator on the ROPS upper cross tube the position of the ball indicates when the frame is level relative to a slop ing ground surface Frame Angle Indicator Boom Angle Indicator Mounted on the left side of the outer boom the movement of a ball indicates the angle of boom elevation relative to the ground Indicator 50960083 AP0914 SERVICE AND SAFETY FEATURES Coolant Level Visually check the level of the engine coolant through the sight gauge located on the back of the radiator as shown Remove the radiator cap to add coolant Radiator Cap A Coolant Level Su Gauge END j Engine Oil Level The dipstick is located on the right side of the engine Open the door to gain access to the engine oil dipstick filter and filler Engine Oil Filter Engine Oil Filler Engine Oil Dipstick Hydraulic Pressure Test Ports A gauge can be attached to these ports to check main valve joystick and steering pressures Transmission Oil Level The dipstick is located under the access cover on the front hood section Battery Compartment The battery is located under the access cover on the front hood section Transmission Dipstick Hydraulic Test
78. f the filter head several turns 3 Loosen drain plug B until fluid runs out Let drain until pure diesel fuel flows from the drain 4 When fuel starts to drain out tighten drain plug securely 5 the water level sensor electrical con nector 6 Tighten vent screw 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 CHECKING ENGINE OIL LEVEL Engine Oil Filler Engine Oil Dipstick With the machine on level ground and the engine stopped for ten minutes or more remove the engine oil dipstick Wipe it clean re insert it and remove to obtain a reading If the oil level is below the crosshatch pattern on the dipstick fill with the required amount of oil to bring the level to within the crosshatch pattern Oil levels anywhere within the crosshatch are consid ered full See the Lubrication chapter for the type of oil to use IMPORTANT Low engine oil level and overfilling engine oil can lead to engine damage 50960083 AP0914 CHECKING RADIATOR COOLANT LEVEL Radiator D Cap tte yi Coolant Level Sight Gauge af With the machine on level ground visually check the level of the engine coolant through the sight gauge located on the back of the radiator as shown Coolant should fill the sight gauge
79. f 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 After fuel filter replacement start the engine and oper ate approximately 5 minutes at low idle Check for fuel leaks Diesel Fuel Injectors Whenever faulty or plugged injectors are indicated see your authorized engine dealer NOTE Only an authorized engine dealer can per form warranty service on the engine 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 located on the left side of the engine oil pan IMPORTANT DO NOT discharge oil onto ground Catch and dispose of per local waste disposal regulations PRINTED IN U S A Engine Oil Filter Engine Oil Filler Engine Oil Dipstick 2 The engine oil filter should be changed at every oil change interval Using a suitable filter wrench remove and discard the filter IMPORTANT Filtration of oils is critical to proper lubrication Always change filter with every oil change Use only genuine OEM engine replace ment filters 3 Apply a thin coat of clean engine oil to the sealing gasket of the new oil filter 4 Wipe the filter sealing surface on the engine with a clean cloth 5 Turn new oil filter by hand until filter contacts the sealing surface then turn the filter an addition
80. forward to allow the attachment tool to roll out then lower the boom so that 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 Ifthe attachment tool has auxiliary hydraulics dis connect the hoses from the quick disconnects on the boom nose 6 Start the engine and roll the Quick attach System forward Slowly back the machine until the attach ment tool 15 free from the boom nose A WARNING Modifications alterations to or use of attach ment tools not authorized by Gehl or the man ufacturer in writing can void warranty and cause machine damage and or serious per sonal injury or death 50960083 AP0914 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 Check the Telescopic Handler to be sure all systems are in good operating condition Perform the following steps before starting the machine the first time each day 1 Check the engine oil coolant transmission oil and hydraulic oil levels 2 Make sure weekly lubrication has been done Visually inspect for leaks broken or malfunction ing parts Make 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
81. ft lift equipment and rigging have been inspected each shift month and year and are in good safe condition and properly installed 2 An operator s manual and applicable load charts are on the forklift 3 Work zone ground conditions can support the equipment and load Any hazardous conditions in the work area have been identified and the operator notified 4 Equipment is being used within its rated capacity and in accordance with the manu facturer s instructions 5 Operator and crew members have been trained in the safe use and operation of the equipment including how to avoid electro cution 6 During use no part of the equipment load line or load will be within the minimum clearance distance specified by OSHA 10 feet 3 0 m and more for lines rated over 50 kV of any energized power line and any taglines used are non conductive 7T n addition for lift equipment with a rated capacity greater than 2000 Ibs 907 kg the employer must ensure that a An accessible fire extinguisher is on the forklift b Monthly and annual inspections are performed and documented and records retained three months for monthly one year for annual c Before November 10 2014 operators must have had the additional training and qualification certification required by OSHA regulations 1926 1427 and 1926 1430 Note Refer to the full text of the OSHA crane regulation 29 CFR Part 1926 Subpart CC for a de
82. g L65928 FALL HAZARD DO NOT use this machine to lift people or work platiorms 165928 166613 RED PRINTED IN U S A 19 50960083 AP0914 A SAFETY A PWP Safety Decals 102969 WORK PLATFORM SYSTEM To activate deactivate work platform system 1 Actuate red switch 2 Apply service brakes for 3 or more seconds until lamp in switch stops flashing 102969 171950 d 171554 171700 171700 WARNING FALL HAZARD Lilt personnel ONLY with an approved work platiorm using the Work Platform Safety System Check the Work Platform Safety System belore use Follow ALL Mandatory Work Platiorm Safety Rules 171554 171555 AVOID INJURY OR DEATH FOLLOW ALL WORK PLATFORM SAFETY RULES Connect and secure PWP System upper control before being lifted Personnel and equipment on platlorm must not exceed available space Be sure that any required restraining means guardrails Chains harnesses lanyards etc are in place and properly used Any harness lanyard or deceleration device that is damaged or permanently deformed must be replaced Platform must be fully lowered for personnel to enter and exit Do not climb on any part of forklift in attempting to enter and exit Workers on platform must keep all parts of their bodies inside platform during raising and lowering Signal
83. g Safety Reminders 2 ALWAYS be aware of and avoid pinch point areas on the machine such as wheels to frame cylin ders to frame boom attachment tool to frame gt NEVER attempt to by pass the keyswitch to start the engine ONLY use the jump starting procedure 50960083 AP0914 12 detailed in the Service and Storage chapter NEVER use your hands to search for hydraulic fluid leaks Instead use a piece of paper or card board Escaping fluid under pressure can be invis ible 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 materi al 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 while working on the fuel or hydraulic systems or while 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 opera
84. g 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 50960083 AP0914 Block the tires 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 sur faces Clean or replace all plates and decals that are damaged or painted over and cannot be read A WARNING NEVER leave guards off or access doors open when the machine is unattended Keep bystanders away if access doors are open After servicing check the work performed that no parts are left over etc Install all guards and covers Service Every 10 Hours or Daily WARNING Static electricity can produce dangerous sparks at the fuel filling nozzle Do not wear polyester or polyester blend clothing while fueling Before fueling touch the metal sur face of the machine away from the fuel fill to dissipate any built up static electricity Do not re enter the machine but stay near the fuel fill ing point during refueling to minimize the build up of static electricity Do not use cell phones while fueling Make sure the static line is connected from the machine to t
85. g the engine intake manifold 3 Inspectthe replacement primary filter for any dam age before installation Replace the primary ele ment if any damage is found PRINTED IN U S A NOTE Cleaning the primary filter element is not recommended Secondary Element NOTE Replace the secondary element only if it is visibly dirty or if the primary element has been replaced three times Before removing the secondary element from the hous ing clean out any dirt in the housing Leave the sec ondary element installed during this step to prevent debris from entering the engine intake manifold Remove the secondary element Reinstallation IMPORTANT NEVER use an element that is damaged Severe engine wear and eventual fail ure can result if dirt gets through a hole in the ele ment 1 Check inside 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 end cap to the housing with the three latches 5 Check the hose connections and make sure they are all clamped and tightened properly 6 Air filter restriction message in the mult function display will clear when the air filter s are replaced CHANGING AXLE DIFFERENTIAL AND PLANETARY OIL Differential 1 Remove the three drain plugs and drain the oil Replace the drain plugs see illustration IMPORTANT DO NOT disch
86. gnals given Safety Hand Signals Rotate Forks Left Rotate Forks Right Safety Hand Signals Continued on Next Page 50960083 AP0914 Safety Hand Signals Continued Tilt Forks Up Tilt Forks Down Load Back Load Forward When ramps must be used in transporting loads with the machine the following shall be the minimum widths for safe travel Compacted dirt gravel etc Woodboard concrete etc 12 ft 3 6 m 10 ft 3 0 m Permanent aisles roadways passageways floors and ramps should be marked or defined in some fashion Permanent or temporary protrusion of loads equip ment material and construction facilities into the usual operating area should be guarded clearly and distinc tively marked or clearly visible Maintain a safe distance from the edge of ramps plat forms and other similar working surfaces Controlled lighting of adequate intensity should be 50960083 AP0914 provided in operating areas Where operating condi tions dictate the operator user is responsible for hav ing the machine equipped with lights Provisions should 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 should 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 machin
87. h 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 press the top of the PWP rocker switch apply and hold the service brakes on for three or more seconds The system is activated when the lamp in the PWP rocker switch is on continuously PRINTED IN U S A NOTE the light is flashing apply the service brakes until the light stops flashing A WARNING ALWAYS check the PWP System for proper operation prior to use See page 55 for PWP System checking procedure When the PWP System is active transmission is de clutched into Neutral parking brake is applied e auxiliary hydraulic and carriage tilt and swing functions are disabled machine inclination sensor is activated with the result that the Telescopic Handler must be level laterally side to side and longitudinally front to back to within the factory pre set limits before the boom control joystick will function and e remote shutdown switch is activated meaning that the switch must be connected and in the posi tion for the boom control joystick to function Pressing the shutdown switch will disengage the boom control joystick and stop all platform move ment The remote shutdown switch box is supplied with a coiled electrical cable that must be connect ed to the outlet on the front of the innermost boom
88. he tool carrier forward 2 Alignthe tool carrier squarely with the back of the attachment tool 3 Slowly extend the tool carrier and lower the hooks under the attachment tool hookup bar Attachment Quick attach System Tilted Tool Forward for Hookup 4 Tilt the tool carrier back so that the lock plate engages the attachment tool This secures the attachment tool to the Quick attach System Attachment Tool Shown Locked to Quick attach System Quick attach System Attaching Detail 5 For an attachment tool with auxiliary hydraulics connect the hoses to the quick disconnect connec tors on the boom nose 50960083 AP0914 Detaching Procedure To detach the attachment tool proceed as follows 1 Raise the boom slightly and extend it two to three feet 600 to 900 mm for better visibility Lower the boom until the attachment tool 1s approximate ly 12 0 3 m off the ground 2 Tilt the carrier rearward as far as it will go Once the carrier is tilted back all the way perform the Mandatory Safety Shutdown Procedure Safety chapter page 8 3 With the engine off leave the operator s station and manually raise the lock spring and flip the lock plate up and outward at least 180 so it 1s in posi tion to re lock onto the next attachment tool Attachment Tool Shown Unlocked for Release from Quick attach System Quick attach System Detaching Detail 4 Tilt the Quick attach System
89. he engine coolant temperature sensor The FMI identifies the type of failure that has occurred for example FMI 03 indicates a value above normal Combining SPN 000110 with FMI 03 means the engine coolant temperature input voltage 1 too high This example would display in the multi function display as error code 000110 03 Always contact your servicing engine dealer for help in correcting the diagnostic trouble codes that are dis played for the engine The fault code listing in the following tables are in ascending SPN FMI codes Actuator of the external EGR valve the ECU detects a short circuit to battery short cut to bat tery on ECU pin A19 or pin A20 Actuator of the external EGR valve The ECU detects a short circuit to ground Short cut to ground on ECU pin A19 is detected measured voltage by ECU is under limit Actuator error EGR Valve signal range check low measuredcurrent is blow target open load on ECU output is detected Actuator error EGR Valve signal range check high measured current by ECU is over target too high current is going into the actuator output is switched off overload by short circuit EGR Valve Actuator Error Actuator position for EGR Valve is not plausible internal error angular misalignment of the flap Valve Actuator Error Accelerator Pedal Sensor Error Analog accelerator pedal sensor 1 the voltage measured by ECU is out of the target Accelerator Pedal Sensor Error Analog acce
90. he fuel truck before fueling begins Ultra Low Sulfur Diesel ULSD poses a greater static ignition hazard than earlier diesel formulations Avoid death or serious injury from fire or explosion consult with your fuel or fuel system supplier to ensure the entire fuel delivery system is in compliance with fueling standards for proper grounding and bonding practices PRINTED IN U S A CHECKING FUEL TANK LEVEL The fuel level is shown by the fuel level gauge in the multi function display on instrument panel After oper ation 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 See the Lubrication chapter for the diesel fuel requirements CHECKING FUEL FILTER NOTE The primary fuel filter water separator A and secondary fuel filter B will require occasion al 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 condi tions in which the machine is used Check the primary fuel filter water separator A for water and debris Primary Fuel Filter Water Separator PRINTED IN U S A IMPORTANT Drain water into a suitable contain er and dispose of properly 1 Disconnect the water level sensor electrical con nector A 2 Loosen vent screw on the top o
91. he load 4 the load approaches the landing point feather the boom control at minimum speed until the load is just above the landing point 5 With the assistance of a signal person continue the feathering technique to lower the load into place A WARNING NEVER place the signal person between the load and the telehandler or other stationary objects 50960083 AP0914 6 Once the load is stationary the landing point and the rigging is loose from the load have the signal person disconnect the rigging from the load 7 Raise boom enough to clear the rigging from the load Slowly and carefully reverse the telehandler till the rigging is clear of the load 8 Lower the boom to travel height Installing a Personnel Work Platform PWP A WARNING The machine must not be used to lift or carry personnel or be fitted with any form of per sonnel work platform unless fitted with the optional PWP System If fitted with the PWP System the Mandatory Work Platform Safety Rules p 14 must be fol lowed at all times while lifting personnel 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 accom plished by means of a retaining pin behind the heel of the forks as shown 3 Secure the forks from pivoting upward in case the PWP 15 lowered onto an obstruction This
92. hine Lock doors of cabs when not in use 4 Inspect the gates and fences of the equipment stor age yard If possible keep machines in well light ed areas Ask the local law enforcement agency 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 com pany Provide the model and serial numbers Request your dealer to forward this information to Gehl Company PRINTED IN U S A Chapter 7 LUBRICATION GENERAL INFORMATION A WARNING NEVER lubricate or service this unit when any part of the machine is in motion ALWAYS exercise the MANDATORY SAFETY SHUT DOWN PROCEDURE p 8 SAFETY chapter before lubricating or servicing this equipment NOTE The Maintenance chapter Chapter 10 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 ser vice 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 the machine Refer to the separate engine manual for additional information regarding recommended engine lubricants quantities and grades required NOTE Refer to Opera
93. hout PWP 50220764 RS6 34 Telescopic Handler with PWP NOTE Decals may be purchased in kits or indi vidually PRINTED IN U S A DECAL LOCATIONS FRAME AND BOOM DESCRIPTION PART NO DANGER HANDS OUT L70305 WARNING PINCH POINT L65927 WARNING JUMP START L65933 GEHL 5 00 102027 QUICK ATTACH DIAGRAM L65937 GEHL 6 75 184069 ANTI FREEZE 056859 HALF ZONE MARKER 5 ea L62583 NO 0 EXTENSION MARKER 1 ea L67718 1 EXTENSION MARKER 1 ea L67719 2 EXTENSION MARKER 1 ea L67720 3 EXTENSION MARKER 1 ea L67721 4 EXTENSION MARKER 1 ea L67722 5 EXTENSION MARKER 1 ea L67723 COOLANT UNDER PRESSURE 072798 WARNING NO RIDERS L65932 BRAKE FLUID L63474 OPERATOR MANUAL WARNING 100359 DANGER PERSONNEL INJURY units without PWP L65928 CARRY LOAD LOW L65926 LUBE CHART 50305007 RS6 34 LH 104871 GEHL 3 75 184043 PRINTED IN U S A 69 50960083 0914 DECAL LOCATIONS FRAME AND DESCRIPTION DANGER HANDS OUT WARNING PINCH POINT GEHL 6 75 HYDRAULIC OIL FILL WARNING NO RIDERS PART NO L70305 L65927 184069 137632 L65932 Gehl 2 00 DANGER PERSONNEL INJURY units without PWP QUICK ATTACH UNLOCKED DIESEL FUEL RS6 34 RH 102026 L65928 L66613 50301416 104872 HOT SURFACE L65942 50960083 AP0914 70 PRINTED IN U S A DECAL LOCATIONS OPERATOR STATION
94. ht 15 100 Ibs 6855 kg Instrumentation Multi Function Display Screen Fuel level Engine coolant temperature Engine oil pressure Voltmeter Hourmeter Maintenance reminder Air filter restriction and Error fault codes Indicator Lamps Low fuel Brake failure Transmission oil temperature Engine pre heat indi cator Alternator Engine coolant tem perature and Engine oil pressure Visual indicators Boom angle frame angle 50960083 AP0914 SPECIFICATIONS Steering System Steer Valve Fixed displacement rotary Displacement Rev 17 9 cu in 293 cc System pressure 2000 psi 138 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 separate front and rear systems Manual foot pedal actuation Parking brake Spring applied hydraulic release disc type in front axle Actuation is electric switch with 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 features Brake lights rear backup light neutral start switch Alternator 95 amp Service Capacities Cooling System 4 3 gallons 16 3 L 50 50 mixture Anti freeze protection 349F 319C Pressure cap 16 psi 110 kPa Fuel
95. ieve loads on an up or down slope or grade that exceeds 7 or 4 PRINTED IN U S A 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 the terrain or position of the wheels the FRAME MUST BE LEVEL as indicated by the frame angle indicator on the ROPS FOPS crossmember 4 DO NOT travel across a side hill that exceeds 1896 or 10 grade Regardless of the terrain or position of the wheels the FRAME MUST BE LEVEL as indicated by the frame angle indicator on the ROPS FOPS crossmember The attachment tool MUST be maintained at the 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 On grades ramps and inclines use extreme caution and avoid turning if possible 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 si
96. ing its machinery and guards exposed moving parts for his her protection However some areas cannot be guarded or shielded in order to assure proper operation Further this Operator s Manual the Safety Manual and decals on the machine warn of additional hazards and should be read and observed closely It is the responsibility of the operator to read and understand the Operator s Manual and other informa tion provided and use the correct operating procedures Machines should be operated only by qualified opera tors REMEMBER It is the owner s responsibility for com municating 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 MANDATORY SAFETY SHUTDOWN PROCEDURE BEFORE cleaning adjusting lubricating or ser vicing 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 attach ment 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 PRINTED IN U S A A SAFETY A A WARNING U S OSHA regul
97. ing modes can be used in forward and reverse travel The operator should learn to anticipate changes in machine movement if the steering mode must be changed B Clutch Cutout When activated this switch allows faster engine acceleration and more power to the hydraulic system without power to the drive axles while the service brake pedal 1s pressed In the OFF position the clutch mechanism of the transmission remains engaged when the brakes are applied In the ON position the clutch mechanism is disengaged when the brakes are applied Normal brake force will hold the machine in position while accelerating the engine to power hydraulic con trol functions during load placement 50960083 AP0914 C Engine Emergency Override Switch Pressing and holding the bottom of the engine emergency over ride switch will override an ECU engine shutdown sig nal The switch must be pressed within 30 seconds of the engine shutdown signal from the ECU to prevent unde sired shutdown of the engine Pressing the switch will override the engine shutdown 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 igni tion switch must be turned off for 30 seconds and then back on before the engine can be restarted NOTE Holding the switch continously ON will not reset the 30 second timer Refer to the error fault code displayed in the multi function display to deter
98. ing power reduction or a shutdown threshold PRINTED IN U S A bte Error Description 03 Coolant Temperature Sensor Error Coolant Temperature sensor the voltage of the sensor measured by ECU is out of the target range high Coolant Temperature Sensor Error Coolant Temperature sensor the voltage of the sensor measured by ECU is out of the target range low Coolant Level Coolant Level the coolant level calculated by the ECU is underneath the allowed minimum Rail Pressure Sensor Error Rail Pressure Sensor the voltage of sensor mea sured by ECU is out of target range high e Rail Pressure Sensor Error Rail Pressure Sensor the voltage of sensor mea sured by ECU is out of target range low Battery Voltage Sensor Error Battery Voltage the voltage measured by ECU is out of the target range high Battery Voltage Sensor Error Battery Voltage the voltage measured by ECU is out of the target range low Battery Voltage Sensor Error Battery Voltage the voltage measured by ECU is out of the target range battery voltage above warning threshold N Co Battery Voltage Sensor Error Battery Voltage the voltage measured by ECU is out of the target range battery voltage above warning threshold short cut to battery Battery Voltage Sensor Error Battery Voltage the voltage measured by ECU is out of the target range battery voltage above warning threshold short cut
99. ing 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 per sonnel are clear of the area where the load or the machine could fall or tip 2 Setthe parking brake hold the service brake pedal fully applied and slowly raise the load maintain ing 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 Continuing the feathering technique lower the load into place 5 Free the forks from the load by alternately retract ing and raising the boom If this process is not pos sible very slowly and carefully reverse the tele scopic handler to free the forks from the load 6 Lower the forks to travel height A WARNING The machine becomes less stable as the load is raised higher NEVER use frame leveling to position an ele vated load Always lower the load to the ground and reposition the machine If a hydraulic boom circuit hose should break with the boom up shut down the machine DO NOT attempt to bring down the boom or make repairs Call your Gehl dealer immediately As lift height increases depth perception decreases High elevation placement may require a signal person to guide the operator DO NOT ram the lift cylinders to the end of the stroke The resulting jolt could spill
100. ise will increase the temperature output of the cab heater Fan Speed This knob 15 located below the tempera ture control knob Rotating the knob clockwise will increase the fan speed for increased air circulation 50960083 AP0914 Heater Controls Fan Speed Knob Fan Speed This is the upper knob located to the left of the steering wheel The fan is in the off position when the knob is rotated completely to the left Rotating the knob clockwise will switch the fan on and increase the fan speed for increased air circulation Temperature Control This knob is located below the fan speed knob It is used to adjust the temperature out put of the heater A C unit Turning the knob clockwise from the midpoint position will increase the tempera ture output ofthe cab heater Turning the knob counter clockwise from the midpoint position will switch the A C unit on and decrease the temperature output of the cab A C 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 50960083 AP0914 Position Forward F Position N Neutral N Position Reverse R Speed Range Twisting the lever end clockwise
101. issing parts no evidence of leaking no damaged or leaking hoses Exhaust System No loose or missing parts no visi ble damage no obstructions to the outlet Engine Air Filter No loose or missing parts no vis Ible damage no obstructions to the evacuator pre cleaner free from dirt restriction indicator proper reading Boom Hose Guards Properly secured no visible damage Engine Compartment O Engine oil level add if needed O Coolant level add if needed No evidence of engine oil or coolant leaks Belts and hoses in good condition properly secured and adjusted Fuel Tank No visible damage no evidence of leak ing level of fuel breather cap secure and working Hydraulic Oil Reservoir No visible damage no evidence of leaking recommended oil level breather cap secure and working Battery Compartment under cover Proper elec trolyte level no loose or damaged cables no visible damage or corrosion Mirror Assembly No loose or missing parts no vis ible damage properly adjusted Cowling and Latches All cowling doors and latch es in working condition properly secure no loose or missing parts all components operate properly Frame No visible damage no cracked welds no loose or missing parts Frame Tilt Cylinder Properly secured no evidence of leaking properly lubricated Tilt and Auxiliary Hydraulic Hoses No visible damage or excessive wear no evidence of leaking Attachm
102. ission into Neutral apply the parking brake and activate the PWP System mode switch Before lifting personnel the area should be marked to warn others of work by elevated per sonnel Be sure the path of platform travel is clear of haz ards such as scaffolds electrical wires and over head obstructions 50960083 AP0914 16 17 18 19 20 21 22 23 24 25 26 The operator must keep hands and feet clear of controls that are not in use Personnel must be lifted and lowered smoothly and cautiously and only at their request The platform must be lowered fully before moving the forklift Do not drive the forklift with person nel on the platform Elevated personnel must always be alerted before raising or lowering the platform A trained operator must be in position to operate the forklift and boom controls at all times The combined weight of the platform personnel and load must not exceed one third of the materi al handling capacity of the forklift Platform personnel must maintain firm footing on the platform floor A harness is to be worn and a lanyard attached to the platform or boom when working from an elevated work platform in accor dance with OSHA regulations Use of railings planks ladders etc on platform for the purpose of achieving additional reach or height is prohibited Workers on the platform must keep all parts of their bodies inside the work
103. ity water mix ture suitable for heavy duty diesel engines Coolant should be a phosphate free silicate free nitrite free and borate free formula with corrosion inhibitors to provide wet sleeve liner cavitation and corrosion pro tection of all cooling system metals Factory filled with FINAL CHARGE PRE DILUTED Global Extended Coolant Antifreeze Life Axle Gear Oil Factory filled with CHS Cenex Qwiklift HTB XO Alternative oil MobilFluid 424 or equivalent Differential capacity 9 6 quarts 9 0 liters Planetary capacity 0 6 quarts each 0 5 liters 50 50 Grease Fittings Use No 2 lithium based grease 47 50960083 AP0914 REPLACEMENT FILTER CHART AIR FUEL ENGINE HYDRAULIC TRANS FILTER OIL FILTER STRAINER OIL Safety Separator 50352455 Filter 50303847 50352454 50302441 132023 L97489 L49327 L99184 GREASING BOOM AREA 9 Boom to frame upright pivot pins 2 Refer to the illustrations and listings for fitting loca 10 Rod end slave cylinder pivot pins 2 tions Wipe dirt from the fittings before greasing them 11 Rod end lift cylinder pins 2 to prevent contamination Replace any missing or dam 12 Extend cylinder pivot pins 2 aged fittings To minimize dirt build up avoid exces 13 2 sive greasing 14 Quickattach to boom nose pivot pins 2 15 Tilt cylinder pivot pins 2 BASIC MACHINE 16
104. ivated Injector Adjustment Error Missing or wrong injector adjustment value pro gramming IMA injector 1 Injector Adjustment Error Missing or wrong injector adjustment value pro gramming IMA injector 3 Injector Adjustment Error Missing or wrong injector adjustment value pro gramming IMA injector 4 Injector Adjustment Error Missing or wrong injector adjustment value pro gramming IMA injector 2 523698 523776 523777 523895 523896 523897 11 13 13 13 3 523898 1 50960083 AP0914 82 PRINTED IN U S A _____ Error Description 523906 Fuel Pump Error ECU detects short cut to battery in fuel feed pump circuit electric fuel pre supply pump short circuit to battery 523906 04 Fuel Pump Error ECU detects short cut to ground in fuel feed pump circuit electric fuel pre supply pump short circuit to ground 523906 05 Fuel Pump Error ECU detect open load on the electric fuel feed pump output electric fuel pre supply pump open load cable break 523906 12 Fuel Pump Error ECU detects to high temperature in powerstage of fuel pump circuit electric fuel pre supply pump powerstage over temperature 523982 Powerstage Diagnosis Disabled Powerstage Diagnosis Disabled high battery volt age 523982 Powerstage Diagnosis Disabled Powerstage Diagnosis Disabled low battery volt age 524057 0 Fuel Pressure Error Electric Fuel Pump fuel pressure build up error 524108 Timeout Er
105. iving on public highway is prohibited transport the machine using a vehicle of appropriate size and capacity TRANSPORTING BETWEEN JOB SITES ALWAYS abide by the following recommended proce dures 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 eyes are provided for inserting chains through to secure the machine during transporting Rear Tie Down Front Tie Down 50960083 AP0914 Loading Machine Using Ramps NOTE A matched pair of ramps is required TRUCK BED amp TOP MIN RAMP LENGTH OF RAMP MUST BE EVEN MUST BE 3 9 TIMES X HEIGHT uo E T Je a tire lt STURDY LESS TIRE BLOCKING CENTER THAN 15 FRONT amp BACK SUPPORT Ramp Placement 1 The ramps MUST be of sufficient strength to sup port 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 For a four foot high truck bed 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 tow
106. k toward the rear of the machine on the left side and around the back and toward the front on the right side of the machine Any needed repairs or service noted during the inspec tion must be performed by a qualified service techni cian before operating the machine The illustration and checklist page can be copied for future pre start walk around inspections 50960083 AP0914 34 PRINTED IN U S A Pre Start Walk Around Inspection Checklist Note the condition of safety decals during the walk around inspection Replace missing or illegible safety decals Lli Attachment Tool Check for broken missing or damaged parts When using a personnel work plat form check to see if the platform meets ANSI ITSDF standards and that it 18 secured to the forks and fork carriage When using forks check for welds cracks or misalignment Replace the forks in sets when the condition of the forks is questionable IMPORTANT DO NOT use forks that have been repaired by welding 02 Attachment Tool Mount No loose or missing parts no visible damage 03 Attachment Tool Mounting Pins No visible dam age pin fit is secure and properly lubricated 04 Boom Chain No loose or missing parts no visible damage sheave pin fit 1 secure and properly lubri cated 5 Boom Sections and Wear Pads No loose or missing parts no visible damage or excessive wear NOTE Wear pads that measure 3 8 9 5 mm thick or less need to be replaced
107. l not to touch any hydraulic components that have been in recent operation because they can be extremely hot and can burn you 2 DO NOT use the boom to lift or support the machine for maintenance or service gt Avoid lubrication or mechanical adjustments with the machine in motion or the engine operating If the engine must be running to make certain adjust ments place the transmission in neutral apply the parking brake place the equipment in a safe posi tion securely block the tires and use extreme cau tion 2 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 gt Modifications and additions that affect capacity or safe operation shall not be performed without the manufacturer s prior written approval Where such authorization is granted any applicable markings are to be changed accordingly 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 2 ALWAYS be sure all nameplates warnings and instruction markings are in place and legible Local government regulations may require specif ic decals which then become the responsibility of the owner or user to provide PRINTED IN U S A Safety Guards and Warning Devices 55 This machine is fitted with a Roll Over P
108. l the frame with the boom raised or extended Level the frame ONLY while stopped with the boom fully retracted and the attachment raised just enough to clear the ground To tilt the attachment tool up move the Joystick handle rearward To tilt the attachment tool down move the joystick handle forward After 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 sec tions 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 50960083 AP0914 Auxiliary Hydraulics Control This two position lever is for attachment tools that require additional hydraulics Tri Function Joystick Configuration Boom Attachment and Auxiliary Hydraulic Joystick mm Frame Level Control Single Tri Function Joystick Configuration Tri Function Joystick This joystick handle is equipped with two yellow buttons and two blue but tons on the upper rear of the handle and a trigger switch on the front of the handle The yellow buttons o
109. lerator pedal sensor 1 the voltage measured ECU is out of the target Accelerator Pedal Sensor Error Pedal Sensor Error LE Low Fuel Pressure Sensor Error Low Fuel Pressure Sensor Error PRINTED IN U S A Actuator EGR valve temperature limit in power stage of the actuator is reached due to high cur rent Accelerator Pedal Sensor Eror Plausibility error between APP1 and idle switch error between APP1 and idle switch Low fuel pressure the low fuel pressure calculat ed by ECU is underneath the target range the ECU activates a system reaction Low fuel pressure the voltage of sensor mea sured by ECU is out of the target range high 50960083 AP0914 DTC lt A e 3 Water in Fuel Sensor Error Water in Fuel Sensor Error 12 01 03 04 Charge Air Pressure Sensor Error Charge Air Pressure Sensor Error Charge Air Pressure Sensor Error Charge Air Temperature Sensor Error Charge Air Temperature Sensor Error e Charge Air Temperature Sensor Error Air Filter Differential Pressure Sensor Error Coolant Temperature Sensor Error 50960083 AP0914 78 Error Code Type Error Description 04 Low Fuel Pressure Sensor Error Low fuel pressure the voltage of sensor mea sured by the ECU is out of the target range low Fuel filter water level sensor the voltage of sen sor measured by ECU is out of the target range high Fuel filter water level sensor the v
110. light film of grease on the pad tracking areas of the boom sections An exception is if a boom section has been replaced Visually check for loose pad bolts The bolts are torqued to 30 ft lbs 40 Nm If the bolts are re torqued at any time Loctite thread lock must be re applied to the bolts If the boom starts to chatter under load grease the slide pads and wipe off the excess grease Maintain a clear ance of 1 16 between the top or side slide pads and the boom Shims can be added to achieve the proper clear ance Loosen the bolts and insert shims until proper clearance is obtained PRINTED IN U S A NOTE When inserting shims in the side slide pads be sure to place equal shims on both sides of the boom for even distribution of clearance Re apply Loctite 271 red thread lock or equivalent to the bolts and re torque to 30 ft lbs 40 Nm Bottom slide pads should not be shimmed and should be replaced when the thickness is worn down to 3 8 9 5 mm A WARNING Failure to maintain proper slide pad clearance and thickness could cause damage to the boom resulting in sudden boom failure Service Every 1000 Hours or Yearly 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 the trans mission oil to 150 200 F 65 93 C Shut off the engine Access to filter is from under the access cover
111. 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 2000 lb load 20 feet high and can only get to within 15 feet of the load placement point Can it be done within the capacity of the machine PRINTED IN U S A Analysis See Typical Load Zone Chart Projecting up from the 15 foot reach mark on the hor izontal axis to intersect a line through the 20 foot height mark on the vertical axis shows that a load up to 2000 Ib can be placed in that zone During placement the operator should observe when the boom extension mark number 4 on the boom is visible and stop further extension The operator knows the maximum safe extension distance with the 2000 Ib load has been reached BOOM EXTENSION e5 MARKERS HEIGHT ABOVE GROUND o DISTANCE LOAD IS EXTENDED Typical Load Zone Chart A WARNING NEVER exceed the rated operating capacity of the Telescopic Handler as shown on the load zone charts HANDLING NON SUSPENDED LOADS Picking Up the Load Inspect the load before picking it up If it appears unstable DO NOT attempt to move it DO NOT attempt lifting double tiered loads or straddling side by side pallets with one on
112. local waste disposal regulations Fill Cap T 4 7 Dipstick Y Access Cover Element d Hydraulic Reservoir Sump Strainer Removal 2 Remove the access cover and wash the inlet screen with clean solvent Remove and wash the sump fil ter strainer from the bottom inside of the reservoir If the strainer has any damage holes etc it should be replaced 3 Flush out the bottom of the reservoir with clean hydraulic oil Re install all cleaned components and install the access cover on the reservoir with a new gasket Clean the filter breather cap 4 Fil the reservoir with fresh oil Follow specifica tions in the Lubrication chapter of this manual IMPORTANT Hyaraulic fluid and filters should be replaced any time contamination is present before the normally scheduled change A WARNING Escaping hydraulic oil under pressure can have sufficient force to penetrate the skin Before applying pressure to the hydraulic sys tem 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 imme diately or gangrene may result PRINTED IN U S A CHANGING RADIATOR COOLANT Drain old coolant and fill with recommended coolant Radiator Drain Cock A WARNING Remove the radiator cap only when the engine is cool or painf
113. 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 Explain that a copy of the product warranty is included on the inside back cover of this Operator s Manual Customer s Signature Date Delivered Pages 5 and 6 have been removed at perforation PRINTED IN U S A 50960083 AP0914 Chapter 4 The above Safety Alert Symbol means ATTENTION ALWAYS BE ALERT YOUR SAFETY IS INVOLVED It stresses an attitude of safety aware ness 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 A DANGER DANGER indicates an imminently haz ardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A 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 50960083 AP0914 SAFETY Gehl Company ALWAYS takes the operator s safety into consideration when design
114. ment When removing tires follow industry safety practices Deflate completely prior to removal After assembly of the tire on the rim use a safety cage or restraining device while inflating CHECKING WHEEL NUT TORQUE On new machines or anytime wheel has been removed re torque wheel nuts until 450 ft Ibs 610 Nm is maintained CHECKING INSTRUMENTS OPERA TION 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 frame angle indicator movement PRINTED IN U S A 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 vibra tions or noises Are any hose or fitting connections leaking Is the engine exhaust color normal CHECKING PERSONNEL WORK PLAT FORM PWP SYSTEM if used A WARNING If the PWP System fails to operate properly during any of the System checks DO NOT USE the machine until the cause has been cor rected Contact your dealer or Gehl Company for service information and parts Machine Position The following must be performed before beginning the PWP System checking procedures Machine on level surface Boom fully lowered Frame level Transmission in N Neutral P
115. mine the cause of the engine shutdown signal D Parking Brake When the machine is parked this switch should be pressed to actuate the parking brake mechanism in the front axle A 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 oper ator or bystanders Periodically check the parking brake opera tion to maintain adequate holding power Always be sure the parking brake switch is off when resuming machine operation PRINTED IN U S A Middle Row Switches Switches have graphic symbols to indicate function and effect The following descriptions start with the first switch on the left NOTE Some switches are optional and may not be on machine E Head Lights Work Lights Pressing the top of the switch will illuminate the lights mounted on the top of the operator s station and the red tail lights for use in forward travel operations Pressing 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 1 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 G Haza
116. nes do not of course preclude the use of good judgment care and com mon sense that may be necessary for the particular jobsite conditions gt Itisessential that operators be physically and men tally fit and free of mind altering drugs and chem icals 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 gt 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 oper ating positions BEFORE starting the engine Before Operation Safety Reminders gt Perform a pre start walk around inspection before starting the engine at the beginning of each work shift Contact with a running engine or moving parts during the pre start inspection could cause death or serious injury Refer to the pre start walk around inspection checklist in the Operation and Adjustment chapter gt 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 gt Check brakes steering and hydraulic system prior to starting operation Operate all controls to ensure
117. ntacts the filter head then turn an addi tional 3 4 turn 10 Turn drain plug into filter and re connect the water sensor wire 11 To release the fuel priming pump grasp fuel priming pump knob A and push in while turning it counter clockwise Primary Fuel Filter Water Separator Priming Pump and Vent Screw 12 Operate the priming pump until fuel flows from the vent screw B on the top of the filter head 13 Return the priming pump to the locked position by pushing it fully in and turning it clockwise Then tighten the vent screw B Secondary Fuel Filter Replacement Secondary Fuel Filter 50960083 AP0914 1 Thoroughly clean fuel filter assembly and sur rounding area 2 Using a filter wrench remove the filter from the filter head 3 Inspect filter head for cleanliness Clean as required 4 Apply a small amount of fuel to the sealing gas ket of the replacement filter 5 Turn replacement filter onto filter head until the filter contacts the filter head then turn an addi tional 3 4 turn 6 Loosen vent screw A on the top of the filter head several turns 7 Turn the ignition key to the ON position until fuel flows from the vent screw 8 Tighten the vent screw A 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 o
118. oltage of sen sor measured by ECU is out of the target range low Water in Fuel Sensor Error Fuel filter water level sensor the maximum level is exceeded Oil Pressure Sensor Error Oil pressure is below the target range warning power reduction or shutdown threshold Oil Pressure Sensor Error Oil pressure sensor the voltage of sensor mea sured by ECU is out of target range high Oil Pressure Sensor Error Oil pressure sensor the voltage of sensor mea sured by ECU is out of target range low Charge air pressure measured by sensor is above the warning threshold or shutdown thresh old Charge air pressure sensor the measured volt age of sensor by ECU is out of the target range high Charge air pressure sensor the measured volt age of sensor by ECU is out of the target range low Charge air temperature downstream calculated by ECU is above the taget range the ECU acti vates a warning threshold or shutdown threshold Charge air temperature Sensor the voltage of sensor measured by ECU is out of target range high Charge air temperature Sensor the voltage of sensor measured by ECU is out of target range low Air filter differential pressure the pressure differ ence of the intake air between the filter inlet and outlet calculated by ECU is above the target range and the ECU activates a warning threshold Coolant temperature the coolant temperature calculated by ECU is above the target range the ECU activates a warn
119. ompartment 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 DO NOT attempt to jump start the machine if the battery is frozen because this may cause it to rupture or explode 1 Turn the key switches on both units to OFF Be sure that both units are in Neutral and touching 2 Connect one end of the red positive jumper cable to the positive battery terminal on the dis abled 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 black negative jumper cable to the jumper battery negative terminal 4 Make the final negative jumper cable connec tion to the disabled machine s engine block or frame ground NOT to the disabled machine negative battery post If making the connection to the engine keep the jumper cable clamp away from the battery fuel lines and moving parts NOTE Twist the j
120. 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 down shifting 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 Turn the steering wheel to the right or left to turn the machine in that direction The power steering system 15 designed to provide low effort steering without shock reaction from the tires to the steering wheel FLOOR AND SEAT AREA Throttle Pedal This pedal operated by the right foot controls the engine speed to match power require ments Pushing down on the pedal increases engine speed letting up on the pedal decreases engine speed Service Brake Pedal Pressing 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 Pedal Brake Reservoir PRINTED IN U S A Brake Fluid Reservoir Located under the hinged cover on the cab floor directly in front of the seat Seat Positioning The seat is mounted on rails for for ward and rearward repositioning for comfort and to accommodate the operator s size A spring loaded latch handl
121. ovided on this page and page 1 Start the machine and test run the unit while checking that proper operation is exhibited by all controls Check that indicators lamps switches etc function properly hand and foot controls operate properly D DO 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 DC Listen for abnormal noises or vibrations if detected deter mine their cause and repair as necessary I acknowledge that the pre delivery procedures were per formed on this unit as outlined above Dealership s Name Dealer Representative s Name Date Checklist Filled Out Machine Model Machine Serial DELIVERY Engine Serial V Check that The following Checklist is a reminder of the important infor mation that MUST be passed on to the customer at the time the unit is delivered Check off each item as it is explained to the customer L Review with the customer the contents of this manual and the AEM Safety Manual for the following The Index at the back for quickly locating topics The Safety Indicators and Controls and Operation and Adjustment chapters for information regarding safe use of the machine The Lubrication and Service an
122. ow 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 Plug in fill and check position CHANGING FUEL FILTERS This telehandler is equipped with a primary fuel fil ter water separator A and a secondary fuel filter B PRINTED IN U S A 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 1 used A WARNING NEVER service the fuel system while smok ing while near an open flame or after the engine has been operated and is hot Primary Fuel Filter Water Separator Replacement Primary Fuel Filter Water Separator 1 Thoroughly clean fuel filter assembly and sur rounding area 2 Loosen vent screw D on the top of the filter head several turns 3 Disconnect water sensor wiring B from the A filter 4 Loosen drain plug C and drain fuel into a suit able container 5 When fuel has drained turn the drain plug out completely 6 Using a filter wrench remove the filter A from the filter head Inspect filter head for cleanliness Clean as required 50960083 AP0914 8 Apply a small amount of fuel to the sealing gas ket of the replacement filter 9 Turn replacement filter onto filter head until the filter co
123. perate the attachment tilt The blue buttons operate the auxiliary hydraulics The trigger switch increases the function speed of both the attachment tilt and aux iliary hydraulics To extend the boom move the joystick to the right to retract the boom move the joystick to the 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 han dle 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 The upper blue button will cause the reverse effect of the lower blue button 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 PRINTED IN U S A Speed Control Knobs The tri function joystick incor porates a manually adjusted speed control Speed adjustment 1s accomplished through the manual adjust ment of pilot pressure apply valves located next to the main valve at the rear of the machine Attachment Tilt Pilot Auxiliary Hydraulics Pressure Apply Valve Pilot Pressure
124. platform during rais ing and lowering Be sure that the personnel and equipment on the platform do not exceed the available space 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 Any harness body belt lanyard or deceleration device that has sustained permanent deformation or is otherwise damaged must be replaced Modifications to the platform that are detrimental to its safe use are prohibited PRINTED IN U S A A SAFETY A WARNING Use ONLY an approved work platform for ele vating personnel NEVER move the machine with the work plat form in a raised position or with personnel on board NEVER tilt the platform forward rearward or to the side with personnel aboard ALWAYS engage the PWP System and follow the Mandatory Work Platform Safety Rules when elevating personnel Remote Shutdown Switch Remote Shutdown Switch j with Coiled Wire Connector PRINTED IN U S A Work Platform Design Requirements Per ANSI 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 fork lift nor
125. quipped with a WARNING and SHUT DOWN feature to warn of critical engine related fault errors These fault errors will be displayed in the multi function display If the cause of the error code is not corrected the engine power will be reduced automati cally or the engine will shut down PARKING BRAKE NOTE The parking brake mechanism within the front axle is not designed for and not intended to be used as the primary means of stopping move ment of the machine Hydraulic braking provided through the service brakes within the axles is the primary means for stopping movement The axle by 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 shut ting off the engine and to disengage the parking brake ONLY after the engine 1 running In an emergency however if it becomes necessary to stop movement activate the parking brake switch to PRINTED IN U S A CHANGING ATTACHMENT TOOLS The Telescopic Handler boom nose will accept Gehl Quick attach System attachment tools The Quick attach System has a quick release hookup and lock ing mechanism for mounting framing type or mason ry type attachment tools to the boom nose Attaching Procedure To pick up an attachment tool proceed as follows 1 Raise the boom slightly extend it two to three feet 600 to 900 mm for better visibility and tilt t
126. r In tank suction 149 micron media replaceable element Rated flow 50 gpm 189 L min By pass pressure 3 psi 21 kPa PRINTED IN U S A Chapter CHECKLISTS PRE DELIVERY The following Checklist is an important reminder of the inspections that MUST be made before delivering the Telescopic Handler to the customer Check off each item after the prescribed action 1s taken 4 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 Ibs 610 Nm Tires are inflated to 60 psi 415 kPa cold Hydraulic system reservoir engine crankcase engine coolant transmission and axles are filled to the proper operating fluid levels OOO D DO DO DO adjustments been made to comply with the set tings given in this manual and in the separate engine man ual guards shields and decals are in place and securely attached Model and serial numbers for this unit are recorded in space pr
127. rator 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 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 com pounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling battery Ciz HL Manitou Americas P O Box 179 West Bend WI 53095 0179 U S A www gehl com 50960083 AP0914 2014 Manitou Americas PRINTED IN U S A All Rights Reserved
128. rd 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 H Strobe Light When a stobe light is installed on the machine activating this switch will produce a strobe light on and off flashing for working in condi tions that may obscure view of the machine Bottom Row Switches Switches have graphic symbols to indicate function and effect The following descriptions start with the first switch on the left PRINTED IN U S A NOTE Some switches are optional and may not be on machine I1 and 12 Wiper Washer The windshield and top window of the operator s station are each equipped with wiper and washer mechanism Switch ates the wiper and washer on the windshield switch 12 operates the wiper and washer on the top window J Personnel Work Platform This is a red switch used to activate the Personnel Work Platform PWP System When activated an amber lamp in the switch will be on 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 K Blank Heater Controls Temperature Control Knob Fan Speed Knob 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 clockw
129. responsible to ensure users are instructed on sale use and maintenance a OSHA regulations require forktitt operators to be tained tested and judged to be competent Check machine belore operating Inspect and service machine per Operator s Manual AVOID INJURY OR DEATH LL Do not modity machina without manyiacturer s written approval For infomation and service parts contact dealer or manuiaciurer L65926 17 A WARNING CARRY LOAD LOW e Retract and lower boom before moving machine tay within stability limits ee Operator s Manual L65932 RUN OVER HAZARD No riders 50960083 AP0914 L70305 L65932 8724 RUN OVER HAZARD XG No riders e Keep hands away when engine is running Stop engine and allow it to cool before servicing 170306 165942 WARNING HOT SURFACE HAZARD Engine exhaust produces hot surfaces DO NOT TOUCH BN MES L65933 L65927 RUN OVER HAZARD PINCH POINT HAZARD DO NOT bypass starter solenoid Follow jump statting procedure in Operator s Manual e Keep clear when engine is running 50960083 AP0914 18 PRINTED IN U S A A SAFETY A L65927 NES PINCH POINT HAZARD e Keep clear when engine is running e Follow Procedure belore servicing 072798 WARNING i HOT LIQUID HAZARD 7 00 NOT remove hot radiator e Allow engine to cool betore servicin
130. restrain the load from swinging or rotating Carrying Suspended Load PRINTED IN U S A 1 Rigging between the load and attachment should be as short as possible to reduce boom height 2 Do not raise the load more than 12 inches 305 mm above the ground or raise the boom more than 45 degrees 3 telehandler movements should be performed slowly and cautiously to prevent load swing Avoid abrupt movement Do not exceed walking speed 4 Use a signal person anytime the load restricts the operators view or assistance is required The sig nal person should remain in contact verbally or visually with the operator at all times until the load is placed Ground Level Suspended Load Placement 1 sure the area under the load and around the telehandler is clear of equipment and personnel 2 Lower the load to the ground till load is stationary and the rigging is loose from the load Have sig nal person disconnect the rigging from the load 3 Raise boom enough to clear the rigging from the load before backing the telehandler away from the load Elevated Suspended Load Placement 1 Bring the telehandler as close as possible to the landing point 2 Level the telehandler BEFORE raising the load Use extreme caution for high placement Be sure personnel are clear of the load landing area 3 Set the parking brake shift the transmission into neutral hold the service brake pedal fully applied and slowly raise t
131. ror Missing CAN message of EGR throttle valve Timeout Error of CAN Transmit Frame ComEGRTVActr Missing CAN Bus message Timeout Error Missing message of EGR throttle valve Timeout error of CAN Receive Frame ComRxEGRTVActr Missing CAN Bus message 01 2 524109 PRINTED IN U S A 83 50960083 AP0914 INTENTIONALLY BLANK 50960083 AP0914 84 PRINTED IN U S A Hydraulic Schematic for Two Joystick Controls without PWP LEFT RIGHT E REAR FRONT cm FRONT CYLINDER BRAKE En BRAKE Discs 7 21565 FRONT R STEER CYL INDER VALVE uL PRESSURE c SWITCH STEERING CONTROL UNIT LS PUMP ET L 1 mm 2400 PSI AIV Er EE tH s Fiti FLOW DIVIDER I JOYSTICK RELIEF amp SAHR APPLY SP PB lt gt i RA GUAGE SUCT ON PORT STRAINER PRINTED IN U S A 85 50960083 AP0914 Ex 3000 PSI Lf EXTEND CYLINDER x SLAVE CYLINDER Ey 3000 PSI LIFT Jr BEL PIT AUXIL ARY CONTROLLER AUXIL ARY COUPLERS MALE FEMALE _ _ Di GN Iz Im D i d ato RETURN FILTER Hydraulic Schematic for Two Joystick Controls with PWP LEVEL CYLINDER 3700 PSI H R REAR STEER CYLINDER L B STEER 159 ese FRONT S
132. rotective Structure ROPS and Falling Object Protective Structure FOPS in accordance with industry stan dards It is intended to offer protection to the oper ator from falling objects and in case of an over turn but it cannot protect against every possible hazard Therefore it should not be considered a substitute for good judgment and safe practices in operating the machine If the ROPS FOPS struc ture is damaged it must be replaced to restore the protection it provides gt This machine is equipped with a horn and backup alarm The user must determine if operating condi tions 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 System WARNING The machine must not be used to lift or carry personnel or be fitted with any form of per sonnel 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 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
133. s replacing 1621 7 7 Parking Brake Switch 1 241 Oil Sump Strainer replacing 164 Park Brake Pressure Setting 1 64 Pressure Checking 164 MN nem f m ree Paint refinishing 2 2225 24 4 1 1 68 Hydraulic Pump servicing 150 25 Pump Delivery Rates See Chapter 2 Hydraulic Valves servicing 50 Em BEN Personnel Work Platform Safety Decals 20 Personnel Work Platform Safety Rules 114 EAS am Identification Reference 1 3 Personnel Work Platform 5 n Indicators _ 23 Work Platform PWP System 13 Indicator Symbols Inside Front Cove 2 Personnel Work Platform Checking Procedure 1 551 Introduction 1 21 Pre Start Walk Around Inspection FEE J Pre Start Walk Around Inspection Illustration 3 f Joystick Pressure Setting 164 Pre start WalkAround ii t35 PRINTED IN U S A 95 50960083 AP0914 Quick attach System Attach Detach Mechanism 1 37 Radiator Checking coolant
134. se Front Wiper Motor RELAYS A 40 AMP change over relay Ignition B 40 AMP change over relay Ignition C 20 AMP relay Front Wiper D 20 AMP relay Park Brake 20 AMP relay Lights 20AMP relay Top Wiper PRINTED IN U S A ATTACHMENT TOOLS Gehl Company offers a range of attachment tools to meet various lifting and material handling applica tions Contact your Gehl dealer for specifications and ordering information ACCESSORIES Gehl also 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 are provided by your Gehl Telescopic Handler dealer or Gehl Company 50960083 AP0914 INTENTIONALLY BLANK 50960083 AP0914 32 PRINTED IN U S A Chapter 6 OPERATION AND ADJUSTMENTS GENERAL INFORMATION A 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 ENGINE BREAK IN A new engine does not require extensive break in However for the first 100 hours of operation e Allow the engine to idle for a few minutes after every cold start e DO NOT idle the engine for long periods
135. ssi bility of overfilling the hydraulic system Locate the filler cap next to the side view mirror on the right side of the machine Remove the filler cap and check the level on the dipstick Oil levels anywhere between the upper mark and lower mark on the dip stick 1s considered full If the oil is below the lower mark on the dipstick fill with the required type of oil to bring the level to within the FULL area 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 LEVEL Flip up the cover on the cab floor in front of the seat The transparent reservoir on the brake valve has maxi mum and minimum fill marks on the right side Visually verify that the fluid level is between these marks If low remove the reservoir cap and fill to the proper level with the correct fluid See the Lubrication chapter for the type of fluid to use CHECKING TIRE PRESSURES To ensure proper operating stability and extend tire life proper and equal tire pressure should be main tained in all four tires Check tire pressures cold Inflate as necessary per the chart below 15 00 x 19 5 12 PR 60 psi 415 kPa NOTE f the tires have been filled with water or calcium chloride for ballast a calcium chloride tire pressure gauge MUST be used to check the tire pressure
136. st keep all parts of their bodies inside platiorm during raising and lowering PRINTED IN U S A Chapter 5 INDICATORS AND CONTROLS A 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 product safety if the machine is used with a non approved accessory or attachment tool Boom Angle s Indicator v Frame Angle Indicator Instrument and Switch Panel Speed and Travel Direction Lever Steering Wheel Brake Pedal Ignition Switch Throttle Pedal Frame Level and Attachment Joystick GUARDS AND SHIELDS Whenever possible and without affecting machine operation guards and shields are used to protect poten tially hazardous areas In many places decals are also provided to warn of potential hazards and to display special operating procedures A 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 Boom Control Joystick Auxiliary Hydraulics Control Two Joystick Controls Fram
137. t 1 ECU Error Internal Hardware Monitoring the ECU detects a deviation of the target range of the power supply voltage of sensor output 2 Engine Shut off Error Operator ignors the engine shut off request within an allowed period 13 13 2 0 50960083 AP0914 80 PRINTED IN U S A P 523350 523352 523354 523470 Injector Short Circuit Error Injector Short Circuit Error Injector Error Pressure Relief Valve PRV Error Pressure Relief Valve PRV Error Pressure Relief Valve PRV Error 523470 Pressure Relief Valve PRV Error Pressure Relief Valve PRV Error T50 Start Switch Error B 523612 Software Error 523612 Software Error PRINTED IN U S A Sensor Supply Voltage Monitor 3 Error 81 Description CAN Bus 1 the ECU is not allowed to send mes sages because the status BusOff is detected Override Switch the ECU receives a permanent signal plausibility error Rail Pressure Relief Valve reached maximum allowed opening count Rail Pressure Relief Valve reached maximum allowed opening time Injector Cylinder Bank 1 short circuit Injector Cylinder Bank 2 short circuit ECU detects an error of its injector high current output injector powerstage output defect PRV will be forced to open performed by pres sure increase PRV is open will be forced to open the forced open failed performed by pressure shock Rail pressure is out of the exp
138. t and keep it with the unit at all times If this machine is resold Gehl Company rec ommends that this manual be given to the new owner If this machine was purchased used or if the owner s address 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 required including providing genuine Gehl service parts All parts should be obtained from or ordered through your Gehl dealer Give complete infor mation 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 with out incurring the obligation to install such changes on any unit previously delivered 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
139. t in catastrophic engine damage 50960083 AP0914 Secondary Filter Element 4 Restriction Sensor Primary Filter Element Evacuator Air Cleaner Assembly The air cleaner assembly consists of an primary filter element and an secondary filter element An air filter restriction sensor for monitoring the condition of the elements is located in the front of the air cleaner hous ing If the air filter becomes restricted this sensor will display an air filter restriction message in the multi function display panel NOTE The air filter restriction message will clear when the filter element s are replaced The primary element should be replaced whenever the air filter restriction message displays The secondary element should be replaced every third time the prima ry element 15 replaced unless the primary element is damaged or the secondary element is visibly dirty Along with a daily check of the multi function display panel for air filter restrictions check that the air clean er intake hose and clamps and the mounting hardware are properly secure Unlatch the three latches on the air cleaner and remove the end cap Clean out any dirt in the end cap Primary Element 1 Carefully pull the primary element out of the hous ing Never remove the secondary element unless it Is to be replaced 2 Clean out any dirt in the housing Leave the sec ondary element installed during this step to prevent debris from enterin
140. tailed description of the regulatory requirements 50960083 AP0914 A SAFETY A 2 DO NOT exceed the rated capacity of the tele scopic handler as equipped for handling suspend ed loads The weight of the rigging must be included as part of the load 2 During transport the length of the rigging between the attachment and load should be as short as possible to reduce booms height and movement DO NOT raise the load more than 12 inches 305 mm above the ground or raise the boom more than 45 degrees 2 Only lift the load vertically NEVER drag it hor izontally 2 Use multiple pickup points on the load when pos sible Use taglines to restrain the load from swinging and rotating 2 Start travel turn and stop SLOWLY to prevent the load from swinging DO NOT exceed walking speed 2 Inspect rigging before use Rigging must be in good condition and in the U S comply with OSHA regulation 1910 184 Slings or 1926 251 Rigging equipment for material han dling 2 Rigging equipment attached to the forks must be secured such that it cannot move either sideways or fore and aft The load center must not exceed 24 inches 610 mm 2 DO NOT lift the load with anyone on the load rigging or lift equipment and NEVER lift the load over personnel gt Beware of the wind which can cause suspended loads to swing even with taglines 2 DO NOT attempt to use frame leveling to com pensate for load swing Servicin
141. th Internal service on any of these components should only be performed by or under the direction of an authorized Gehl Telescopic Handler dealer ELECTRICAL COMPONENTS An electrical system schematic is provided which includes instrumentation electrical components and switch connections It 1 located at the back of this manual and can be used as a guide for service refer ence 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 ACCESS TO COMPONENTS CHART Component Axle underside Engine Transmission center area Operator s Station Front Mid Rear Cover Hood Frame Drive Shafts underside Main Control Valve rear Muffler underside Air Cleaner between boom supports Battery Radiator Brake Valve underside Travel Controls dash area Boom Controls right side Hydraulic Test Ports Hourmeter dash Switches Indicators dash Hydraulic Pump Hydraulic Filter Reservoir Misc Hydraulic Valves Heater lower front PRINTED IN U S A 50960083 AP0914 A WARNING DO NOT smoke or allow any open flames in the area while checking servicing hydraulic battery or fuel systems all contain highly flammable liquids or explosive gases which can cause an
142. the maintenance schedules for the necessary procedures Engine Oil and Filter Transmission Oil and Filter Hydraulic Return Filter Element 250 Hours 1000 Hours 1000 Hours Torque the boom chains after the first 100 hours of operation on new machines or anytime a chain has been replaced Thereafter the boom chains should be inspected for wear and proper tension at the regular service interval of 250 hours Refer to the boom chain torquing procedure in the 250 hour service interval Service Every 250 Hours or Quarterly NOTE Perform all other service requirements up to this point as well as the following CHECKING AXLE OIL LEVELS Differentials NOTE The Telescopic Handler should be on a level surface for this procedure Remove the oil check plug See illustration below 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 differen tial is full See the Lubrication chapter for the proper oil specification Replace the check and fill plugs PRINTED IN U S A Check Plug Fill Plug Drain Plug Planetary Hubs NOTE 7he planetary hubs can be checked with out jacking up the machine The planetary hubs have one plug each used for filling and draining See illustration below For checking the level and filling position the wheel until the oil level arr
143. ting season Static electricity can produce dangerous sparks at the fuel filling nozzle Do not wear polyester or polyester blend clothing while fueling Before fueling touch the metal surface of the machine away from the fuel fill to dissipate any built up static electricity Do not re enter the machine but stay near the fuel filling point during refueling to minimize the build up of static electricity Do not use cell phones while fueling Make sure the stat ic line is connected from the machine to the fuel truck before fueling begins Ultra Low Sulfur Diesel ULSD poses a greater static ignition hazard than earlier diesel formula tions Avoid death or serious injury from fire or explosion consult with your fuel or fuel system supplier to ensure the entire fuel delivery system is in compliance with fueling standards for prop er grounding and bonding practices PRINTED IN U S A A SAFETY A gt NEVER use fuel for cleaning purposes gt DO NOT remove the radiator cap after the engine has reached operating temperature or if it is over heated 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 radi ator cap Failure to heed this warning could result in severe burns 2 DO NOT loosen or disconnect any hydraulic lines hoses or fittings without first relieving hydraulic circuit pressure Also be carefu
144. topping 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 3 Idle the engine for at least 2 minutes for gradual cooling 4 Place controls in neutral Apply the parking brake Turn the ignition switch key to the OFF position Remove the key 6 Unfasten the seatbelt and grasp the handholds while climbing out of the operator s compartment FIRST TIME OPERATION Make sure the engine is warm and then go through the following procedures PRINTED IN U S A A CAUTION Be sure the area used for test running is clear of spectators and obstructions Initially oper ate the machine with an empty attachment tool Place the travel lever in Forward or Reverse and select a speed range Switch off the parking brake 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 travel lever to the opposite direction forward or reverse Shifting to the next higher gear may be done at any engine speed 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 The engine is e
145. tor Services topic in the Service and Storage chapter of this manual for detailed information regarding periodic checking and replenishing of lubricants Transmission Oil Temp Range 25 F 75 F 32 C 24 C Use Dexron II or equivalent Factory filled with CHS Cenex Auto Gold D M Temp Range 0 F 100 F 18 C 38 C Use Allison C 4 30W or equivalent Capacity 24 quarts 23 liters Brake System Use Multi ATF Dexron or equivalent 0 PRINTED IN U S A Hydraulic System Reservoir Use an oil that contains anti rust anti foam anti oxidation additives and conforms to ISO VG46 VG32 Factory filled with CHS Cenex Indol Alternative oil Mobil DTE 15M or equivalent Capacity 35 gallons 133 liters Engine Crankcase Oil 5 Grade SAE 5W 30 SAE 5W 40 SAE 10W 30 Ambient Temperature 22 F 86 F 309 30 C 22 F 104 F 30 C 40 C 4 F 86 F 209 30 C 4 F 104 20 C 40 C SAE 10W 40 5 F 104 F 15 C 40 C SAE 15W 40 IMPORTANT Refer to the Engine Operator s Manual for specific oil recommendations and additional information API Service Classification CJ 4 Capacity 9 5 quarts 8 9 liters Diesel Fuel Use only ultra low sulfer ULSD diesel fuel with a maximum of 15 PPM sulfer content specified to EN590 or ASTM D975 Engine Coolant IMPORTANT Use an ethylene glycol based Extended Life Coolant and qual
146. ul burns could result 1 Loosen the radiator cap to its stop to release any pressure in the radiator Remove the cap when all pressure is bled off 2 Place a collection container with a 5 gallon capac ity under the right end of the radiator IMPORTANT DO NOT discharge coolant onto ground Catch and dispose of per local waste dis posal regulations 3 Attach a hose to the radiator drain cock and route it to the collection container placed below the radi ator Open the radiator drain cock to drain the radiator When coolant is completely drained Close the radiator drain cock 6 Slowly add coolant to the radiator until the sight glass is filled with coolant Radiator Cap gt Coolant Level Sight Gauge PRINTED IN U S A IMPORTANT Fill the cooling system with a low silicate ethylene glycol based coolant mixed with quality water and supplemental coolant additives SCAs suitable for heavy duty diesel engines See the engine manual for additional information 7 Inspect the radiator cap seal before installing it Replace it if it appears to be damaged 8 Start the engine and run it until the engine reaches operating temperature Check the coolant level through the sight glass If the coolant is low allow the engine to cool before removing the radiator cap to add coolant NOTE Check the engine temperature gauge every minute or two after coolant has been changed Air pockets can form and
147. umper cable clamps on the bat tery terminals to ensure a good electrical connec tion 5 Start the engine If it does not start immediately start the jumper vehicles engine to avoid excessive drain on the booster battery 50960083 AP0914 6 After the machine has started and is 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 being careful 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 f the battery frequently becomes dis charged have the battery checked for possible dead cells or troubleshoot the electrical system for possible short circuits or damaged wire insula tion 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 boom illustration Torque the two chains on the front of the three section boom to 25 ft lbs 34 Nm Lubricate with 80W 90 oil IMPORTANT On new machines or when chains have been replaced it is necessary to retorque the front double chain assembly after one hun dred 100 hours of operation Failure to do so may allow the chains to become slack which can result in a chain jumping off
148. unt of forward and rearward tilt to be used is governed by the application Although use of maxi mum rearward tilt is allowable under certain condi tions 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 off center loads Only handle 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 ANSI TSDF standard B56 6 2005 The telescopic handler meets or exceeds the safety standard ANSI 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 oper ating the telescopic handler For safe operation always follow the instructions and warnings provided in this manual A 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 1 DO NOT place or retr

RS6-34 Operator`s Manual

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