Gehl Dynalift DL Series User manual
Indicator and Operation Symbols
Read Operator’s
Manual
Fasten Seat Belt
Parking Brake Ignition Switch ON Safety
Fuel Low Head LightsVolume Half FullVolume Full
Engine Stop Hazard FlasherBattery
Heater BeaconClutch Disengaged
Hydraulic Oil
Filter
Clutch Engaged
Transmission
Temperature Fan Work Lights
Frame LevelCrab Steer
Lower LoadFront Wheel Steer
Raise Load4-Wheel Steer
Outrigger
(RH Shown) Engine Coolant
Temperature
Rear Wheels
Alignment Hourmeter
Air Conditioning Turn Signal
Outriggers Down Outriggers Up
Retract Load
Diesel Fuel
Engine Oil
Pressure
Volume Empty
Starting Aid
Injection
Tilt Rearward
Wiper/WasherLow Accumulator
Pressure
Extend LoadTilt Forward
Fuse Engine Air Filter
Engine StartHorn
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PRINTED IN U.S.A. 1913287/BP0808
Table of Contents
Chapter Description Page
International Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover
1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6,7
4SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5Indicators and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6Operation and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
7Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
8Service and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
9Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Standard Hardware Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Back Cover
IDENTIFICATION INFORMATION
Write your Gehl Dynalift®
®Telescopic Handler Model and Serial Numbers below.
Refer to these numbers when inquiring about parts or service from your Gehl dealer.
The model and serial numbers for this machine are on a decal located inside the operator’s station.
DL
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913287/BP0808 2PRINTED IN U.S.A.
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.
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 PWPSystem activated, and in full com-
pliance with the “Mandatory Work Platform Safety Rules” (see SAFETY chapter).
The use of this Telescopic Handler is subject to certain hazards that cannot be eliminated by mechanical means,
but only by the exercise of intelligence, care and common sense. It is therefore essential to have competent and
careful operators, who are not physically or mentally impaired, and who are thoroughly trained in the safe opera-
tion of the equipment and the handling of the loads.
Throughout this manual information is provided that is set in italic type and introduced by the word IMPORTANT
or NOTE. Be sure to read carefully and comply with the message or directive given. Following this information
will improve operating and maintenance efficiency, help to avoid breakdowns and damage, and extend the
machine’s life. A chart of standard hardware torques is located in the back of this manual.
A storage pocket in the back of the seat is provided for storing the Operator’s Manual. After using the manual,
please return it to the pocket and keep it with the unit at all times! If this machine is resold, GEHL Company 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 noti-
fied directly in case of an important product issue, such as a safety update program.
“Right” and “left” are determined from a position sitting on the seat and facing forward.
The wide GEHL dealership network stands ready to provide any assistance that may be required, including gen-
uine GEHL service parts. All parts should be obtained from or ordered through your GEHL dealer. Give complete
information about the part and include the model and serial number of the machine. Record the serial number in
the space provided on the previous page, as a handy record for quick reference.
GEHL Company reserves the right to make changes or improvements in the design or construction of any part
without incurring the obligation to install such changes on any unit previously delivered.
GEHL Company, in cooperation with the Society of Automotive
Engineers, has adopted this
Safety Alert Symbol
to identify potential safety hazards, which, if not properly avoided, could
result in injury. When you see this symbol in this manual or on the
machine itself, you are reminded to BE ALERT! Your personal safety is
involved!
Courtesy of Crane.Market
PRINTED IN U.S.A. 3913287/BP0808
Identification
(DL12-40 Shown)
Attachment
Tool
Tilt
Cylinder
Operator's
Seat ROPS/FOPS
Access Door
with Rear
Lights and
Backup Alarm
Storage
Compartment
Access Door
Dash Indicators
and Controls
Boom Angle
Indicator
Side Panel
and Controls
Dynattach®
Quick-Attach
Slave
Cylinder Engine
Exhaust
Pipe
Frame Leveling
Cylinder
Rear View
Mirror
Lift
Cylinder
Stabilizing
Cylinder
Power Train
Cover
Telescopic
Boom
Engine Air
Precleaner
Courtesy of Crane.Market
913287/BP0808 4PRINTED IN U.S.A.
Chapter 2
SPECIFICATIONS
Lifting Performance
Maximum lift capacity:
DL7-44: 7000 lbs. (3175 kg)
DL9-44: 9000 lbs. (4080 kg)
DL11-44: 11000 lbs. (4990 kg)
DL11-55: 11000 lbs. (4990 kg)
DL12-40: 12000 lbs. (5443 kg)
Maximum lift height:
DL7-44: 44’-4” (13.5 m)
DL9-44: 44’-4” (13.5 m)
DL11-44: 44’-4” (13.5 m)
DL11-55: 55’-5” (16.8 m)
DL11-55 (Low Boom):55’-1” (16.8 m)
DL12-40: 40’-4” (12.3 m)
Capacity at maximum lift height:
DL7-44: 6000 lbs. (2721 kg)
DL9-44: 7000 lbs. (3171 kg)
DL11-44: 8000 lbs. (3629 kg)
DL11-55 (Outriggers up):
5000 lbs. (2267 kg)
DL11-55 (Outriggers down):
5500 lbs. (2495 kg)
DL11-55 (Low Boom)
Outriggers up: 5000 lbs. (2267 kg)
DL11-55 (Low Boom)
Outriggers down: 5500 lbs. (2495 kg)
DL12-40: 10000 lbs. (4535 kg)
Forward reach at max. lift height:
DL7-44: 3’-4” (1016 mm)
DL9-44: 3’-4” (1016 mm)
DL11-44: 3’-4” (1016 mm)
DL11-55: 6’-7” (2007 mm)
DL11-55 (Low Boom):
5’-9” (1753 mm)
DL12-40: 2’-0” (610 mm)
Reach below grade:
DL7-44: 2’-0” (610 mm)
DL9-44: 2’-0” (610 mm)
DL11-44: 2’-0” (610 mm)
DL11-55: 2’-10” (864 mm)
DL11-55 (Low Boom):2’-2” (660 mm)
DL12-40: 1’-4” (406 mm)
Frame leveling:
10oleft/10oright
Loader Performance
Breakout force:
DL7-44: 11000 lbs. (48.9 kN)
DL9-44: 12500 lbs. (55.6 kN)
DL11-44: 14000 lbs. (62.2 kN)
DL12-40: 14000 lbs. (62.2 kN)
Maximum dump height:
DL7-44: 42’-11” (13.1 m)
DL9-44: 42’-11” (13.1 m)
DL11-44: 42’-11” (13.1 m)
DL12-40: 39’-0” (11.9 m)
Maximum reach at max. dump height:
DL7-44: 2’-3” (686 mm)
DL9-44: 2’-3” (686 mm)
DL11-44: 2’-3” (686 mm)
DL12-40: 1’-2” (356 mm)
Dump angle at maximum dump height:
DL7-44, DL9-44, DL11-44,
DL12-40: 24o
Maximum loadover height:
DL7-44: 44’-2” (13.5 m)
DL9-44: 44’-2” (13.5 m)
DL11-44: 44’-2” (13.5 m)
DL12-40: 40’-3” (12.3 m)
Dump height at 45odump angle:
DL7-44: 34’-0” (10.4 m)
DL9-44: 34’-0” (10.4 m)
DL11-44: 34’-0” (10.4 m)
DL12-40: 30’-9” (9.4 m)
Maximum reach at 45odump angle:
DL7-44: 14’-3” (4.3 m)
DL9-44: 14’-3” (4.3 m)
DL11-44: 14’-3” (4.3 m)
DL12-40: 11’-10” (3.6 m)
Rollback at ground level: 30o
Total bucket rotation: 132o
Parallel lift: Standard
General Dimensions
Based on standard machine equipped
with listed tires, 48” (1.2 m) masonry
carriage and 48” (1.2 m) pallet forks.
Recommended tire type:
DL7: 13.00x24 G2 12-ply
Inflate to 70 psi (480 kPa)
DL9, DL11, and DL12: 14.00x24 G2
12-ply
Inflate to 70 psi (480 kPa)
Overall length, less forks:
DL7-44: 20’-7” (6.3 m)
DL9-44: 20’-7” (6.3 m)
DL11-44: 20’-7” (6.3 m)
DL11-55: 20’-10” (6.3 m)
DL11-55 (Low Boom): 21’-2” (6.5 m)
DL12-40: 19’-4” (5.9 m)
Overall width:
DL7: 8’-1” (2.5 m)
DL9, DL11, DL-12: 8’-3” (2.5 m)
Overall height:
DL7: 7’-10” (2.4 m)
DL9, DL11, DL12: 7’-11” (2.4 m)
Ground clearance: 16” (400 mm)
Wheel base: 10’-8” (3.3 m)
Outside turn radius: 12’-2” (3.7 m)
Machine weight:
DL7-44: 23250 lbs. (10546 kg)
DL9-44: 24650 lbs. (11181 kg)
DL11-44: 25400 lbs. (11521 kg)
DL11-55: 28460 lbs. (12909 kg)
DL11-55 (Low Boom):
28460 lbs. (12909 kg)
DL12-40: 25300 lbs. (11475 kg)
Instrumentation
Gauges: Fuel level, engine coolant tem-
perature, engine oil pressure, voltage
meter and hourmeter
Monitoring lights:
Oil pressure, coolant temperature,
alternator, low fuel, air filter
restriction, hydraulic filter
restriction, transmission temper-
ature, accumulator charge pressure
Monitoring alarms:
Low accumulator charge
Visual indicators:
Boom angle, boom extension,
frame angle
Steering System
Steer valve: Fixed displacement rotary
Displacement/Rev: 20 cu. in. (328 cc)
System pressure: 2500 psi (172 bar)
Steer cylinders: 1 per axle
Steer mode valve:
3-position, 4-way solenoid, dash-
mounted switch actuation.
Steer modes: 2-wheel, 4-wheel, crab
Outside turn radius: 12’-2” (3.7 m)
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PRINTED IN U.S.A. 5913287/BP0808
Braking System
Service brakes:
Oil-immersed disc-type,
hydraulic fluid type,
manual foot pedal actuation.
Parking brake:
Spring-applied, hydraulic-release
disc-type on front axle.
Actuation is electric switch with
engine running, automatic with
engine shutdown.
Electrical System
Type: 12-volt DC, negative ground
Alternator: 65A
Battery: 4DLT group,
900 cold-cranking amps
Circuit protection: Fuse panel
Backup alarm: 107 dB(A)
Horn: 111 dB(A)
Standard on all models:
Brake lights, neutral start switch,
master disconnect switch
Service Capacities
Cooling System:
20 qts. (18.9 L)
50/50 mixture
Anti-freeze protection: -34oF (-37oC)
Pressure cap: 16 psi (110 kPa)
Fuel tank: 30 gal. (114 L)
Hydraulic tank and
system: 45 gal. (170 L)
Transmission and cooler: 16 qts. (15 L)
Transfer case: 3 qts. (2.8 L)
Axles: 26.48M
Differentials: 14.8 qts. (14 L)
Hubs: 1.8 qts. (1.7 L)
Transmission
Type: Clark Powershift T16000
Speeds: 4 fwd / 2 rev
Torque converter:
Single-stage, dual-phase
Travel speeds, DL7:
1st gear: 3.2 mph (5.2 km/h)
2nd gear: 6.0 mph (9.7 km/h)
3rd gear: 12.1 mph (19.5 km/h)
4th gear: 22.0 mph (35.4 km/h)
Travel speeds, DL9, DL11, and DL12:
1st gear: 3.3 mph (5.4 km/h)
2nd gear: 6.3 mph (10.2 km/h)
3rd gear: 12.7 mph (20.4 km/h)
4th gear: 22.8 mph (36.7 km/h)
Axles (front and rear)
Type: Carraro
26.48M
Drive/steer, open differential, double
reduction planetary, full-time four
wheel drive
Overall ratio: 23.04:1
Drive Train
Transfer case: Durst with 1.063:1 ratio
and Lord vibration damper
Engine
Turbocharged aspiration:
John Deere 4045T
276 cu. in. (4.5 L) displacement,
115 hp (86 kW) @ 2500 rpm
Oil capacity: 15.5 qts. (14.7 L)
In-line 4-cylinder, 4-cycle,
direct injection diesel fuel system,
in-line fuel filter w/water trap,
positive pressure lubrication,
liquid pressurized cooling system,
dry dual-element air cleaner,
spin-on oil filter.
Hydraulic System
Type: Open-center
Pump: Dual-section gear type
Displacement / revolution:
Front: 1.77 cu. in. (29 cc)
Rear: 2.19 cu. in. (36 cc)
Flow @ 2500 RPM:
Front: 19 gpm (72 L/min)
Rear: 24 gpm (90 L/min)
Main relief pressure: 3000 psi (207 bar)
Aux. relief pressure: 2500 psi (172 bar)
Main control valve:
Parallel, 3-spool sectional,
remote hydraulic actuation
Frame level control valve:
Solenoid type w/ remote switch
actuation
Auxiliary control valve:
Parallel, 1-spool sectional,
remote hydraulic actuation with
joystick switch
Hydraulic filter:
Remote return type, 15-micron
media, replaceable element.
Rated flow: 70 gpm (265 L/min)
Rated pressure: 800 psi (55 bar)
By-pass pressure (full flow):
45 psi (310 kPa)
Hydraulic strainer:
In-tank suction, 149-micron media,
replaceable element.
Rated flow: 50 gpm (189 L/min)
By-pass pressure: 3 psi (20 kPa)
Operator’s Station
Rollover Protective Structure (ROPS)
ISO 3471-1994
Falling Object Protective Structure
(FOPS)
Meets ANSI/ITSDF B56.6-2005,
Sec 8.16
ISO 3449-2005
Seatbelt:
Meets SAE J386
Courtesy of Crane.Market
913287/BP0808 6PRINTED IN U.S.A.
(Pages 7 & 8 - have been removed at perforation)
Chapter 3
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 is taken.
Check that:
NO parts of machine have been damaged in shipment.
Check for such things as dents and loose or missing parts;
correct or replace components as required.
Battery is securely mounted and not cracked. Cable con-
nections are tight. Electrolyte at proper level.
Cylinders, hoses and fittings are not damaged, leaking or
loosely secured.
Oil, fuel and air filters are not damaged, leaking or loosely
secured.
All grease fittings have been properly lubricated and no fit-
tings are missing; see Lubrication chapter of this manual.
Wheel nuts are torqued to 450 ft.-lbs. (610 Nm).
Tires are inflated to 70 psi (480 kPa) cold.
Hydraulic system reservoir, engine crankcase, engine
coolant, transfer case, transmission and axles are filled to
the proper operating fluid levels.
All adjustments have been made to comply with the set-
tings in this manual and in the separate engine manual.
All guards, shields and decals are in place and securely
attached.
Model and serial number for this unit is recorded in space
provided on this page and page 1.
Check that:
All indicators (lamps, switches, etc.) function properly.
All hand and foot controls operate properly.
The PWP System operates properly (if equipped). Refer to
Service and Storage chapter for the procedure to check the
PWP System.
Boom, Dynattach®or Dynacarrier®with attachment tool
and frame level control all function properly.
No hydraulic system leaks when under pressure.
Listen for abnormal noises or vibrations; if detected, deter-
mine their cause and repair as necessary.
I acknowledge that 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 No. Machine Serial No. Engine Serial No.
DELIVERY
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.
Review with the customer the contents of this manual and
the AEM Safety Manual and for the following:
The Index at the back, for quickly locating topics;
The Safety, Indicators and Controls, and Operation and
Adjustments chapters for information regarding safe use of
the machine.
The Lubrication 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.
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. OSHA regulation 1910.178
(l), which specifies operator training requirements.
Explain that the customer MUST consult the engine manu-
al (provided) for related specifications, operating adjust-
ments and maintenance instructions.
Completely fill out the Owner’s Registration, including
customer’s signature, and return it to the Company.
Explain that a copy of the warranty is included on the
inside back cover of this Operator’s Manual.
Customer’s Signature
Date Delivered
Start the machine and test-run the unit while
checking that proper operation is exhibited by all
controls.
Courtesy of Crane.Market
PRINTED IN U.S.A. 7913287/BP0808
(Dealer’s File Copy - Remove at Perforation)
Chapter 3
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 is taken.
Check that:
NO parts of machine have been damaged in shipment.
Check for such things as dents and loose or missing parts;
correct or replace components as required.
Battery is securely mounted and not cracked. Cable con-
nections are tight. Electrolyte at proper level.
Cylinders, hoses and fittings are not damaged, leaking or
loosely secured.
Oil, fuel and air filters are not damaged, leaking or loosely
secured.
All grease fittings have been properly lubricated and no fit-
tings are missing; see Lubrication chapter of this manual.
Wheel nuts are torqued to 450 ft.-lbs. (610 Nm).
Tires are inflated to 70 psi (480 kPa) cold.
Hydraulic system reservoir, engine crankcase, engine
coolant, transfer case, transmission and axles are filled to
the proper operating fluid levels.
All adjustments have been made to comply with the set-
tings in this manual and in the separate engine manual.
All guards, shields and decals are in place and securely
attached.
Model and serial number for this unit is recorded in space
provided on this page and page 1.
Check that:
All indicators (lamps, switches, etc.) function properly.
All hand and foot controls operate properly.
The PWP System operates properly (if equipped). Refer to
Service and Storage chapter for the procedure to check the
PWP System.
Boom, Dynattach®or Dynacarrier®with attachment tool
and frame level control all function properly.
No hydraulic system leaks when under pressure.
Listen for abnormal noises or vibrations; if detected, deter-
mine their cause and repair as necessary.
I acknowledge that 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 No. Machine Serial No. Engine Serial No.
DELIVERY
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.
Review with the customer the contents of this manual and
the AEM Safety Manual and for the following:
The Index at the back, for quickly locating topics;
The Safety, Indicators and Controls, and Operation and
Adjustments chapters for information regarding safe use of
the machine.
The Lubrication 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.
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. OSHA regulation 1910.178
(l), which specifies operator training requirements.
Explain that the customer MUST consult the engine manu-
al (provided) for related specifications, operating adjust-
ments and maintenance instructions.
Completely fill out the Owner’s Registration, including
customer’s signature, and return it to the Company.
Explain that a copy of the warranty is included on the
inside back cover of this Operator’s Manual.
Customer’s Signature
Date Delivered
Start the machine and test-run the unit while
checking that proper operation is exhibited by all
controls.
Courtesy of Crane.Market
PRINTED IN U.S.A. 9913287/BP0808
Chapter 4
SAFETY
Gehl Company ALWAYS takes the operator’s safety
into consideration when designing its machinery, and
guards exposed moving parts for his/her protection.
However, some areas cannot be guarded or shielded in
order to assure proper operation. Further, this
Operator’s Manual, the Safety Manual (also available
in Spanish) and decals on the machine warn of addi-
tional hazards and should be read and observed close-
ly.
It is the responsibility of the operator to read and
understand the Operator’s Manual and other informa-
tion provided, and use 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 interpretation 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 attachment
tool to the ground. Idle engine for gradual cool-
ing.
3. Place controls in neutral and apply the parking
brake.
4. Shut off the engine and remove the key.
ONLY when you have taken these precautions can
you be sure it is safe to proceed. Failure to follow
the above procedure could lead to death or serious
bodily injury.
The above Safety Alert Symbol means ATTENTION!
ALWAYS BE ALERT! YOUR SAFETY IS
INVOLVED! It stresses an attitude of 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.
DANGER
“DANGER” indicates an imminently haz-
ardous situation, which, if not avoided, will
result in death or serious injury.
WARNING
“WARNING” indicates a potentially hazardous
situation, which, if not avoided, could result in
death or serious injury.
CAUTION
“CAUTION” indicates a potentially hazardous
situation, which, if not avoided, may result in
minor or moderate injury. It may also alert to
unsafe practices.
Courtesy of Crane.Market
913287/BP0808 10 PRINTED IN U.S.A.
SAFETY
WARNING
U.S. OSHA regulations 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.
Additional Safety Reminders
ÂUser/operator safety practices, as established by
industry standards, are included in this Operator’s
Manual and intended to promote safe operation of
the machine. These guidelines do not, of course,
preclude the use of good judgment, care and com-
mon sense that may be necessary for the particular
jobsite conditions.
ÂIt is essential that operators be physically and men-
tally fit, free of mind-altering drugs and chemicals,
and thoroughly trained in the safe operation of the
machine. Such training should be presented com-
pletely to all new operators and not condensed for
those claiming previous experience. Information
on operator training is available from several
sources, including the manufacturer.
ÂSome 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
ÂCheck brakes, steering, and hydraulic system prior
to starting operation. Operate all controls to ensure
proper operation. Observe all gauges and indica-
tors for proper operation. If any malfunctions are
found, correct the cause prior to using the machine.
ÂALWAYS wear appropriate personal protective
equipment for the job and working conditions.
Hard hats, goggles, protective shoes, gloves,
reflector-type vests, respirators and ear protection
are 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.
ÂALWAYS 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.
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.
Courtesy of Crane.Market
PRINTED IN U.S.A. 11 913287/BP0808
ÂWalk around the machine and warn all personnel
who may be servicing the machine or who are in
the machine’s path prior to starting. DO NOT start
until all personnel are clearly away from the
machine.
Operation Safety Reminders
ÂAny or all 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 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 BODILY
INJURY OR DEATH!
ÂALWAYS 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!
ÂALWAYS keep hands, feet and arms inside of the
operator’s station when operating the machine!
ÂDO 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
the rear before backing.
ÂALWAYS 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.
ÂDO NOT raise or drop a loaded fork or bucket sud-
denly. Abrupt movements under load can cause
serious instability.
ÂStudy the load charts carefully. They show maxi-
mum capacity to be lifted and placed at specific
outward and upward distances.ALWAYS be aware
of load weights prior to attempting lift and place-
ment.
ÂDO NOT exceed the machine’s rated operating
capacity for the type of attachment tool being used.
ÂDO NOT allow minors or any unqualified person-
nel to operate or be near the machine unless prop-
erly supervised.
ÂDO NOT start the engine or operate any controls
unless properly seated in the operator’s seat!
ÂDO 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 provided.
ÂDO 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.
ÂDO NOT drive too close to an excavation or ditch.
BE SURE that the surrounding ground has ade-
quate strength to support the weight of the machine
and the load it is carrying.
ÂDO 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 this Operator’s Manual.
ÂNEVER allow riders on this machine. This is
strictly a single-seat, NO passenger machine!
ÂNEVER use as a lift for personnel unless the
machine is equipped with the Personnel Work
Platform (PWP) Safety System.
ÂWhen road travel is required, know and use the
signaling devices on the machine. Provide an
escort and Slow-Moving Vehicle (SMV) emblem
when required.
ÂIf necessary to park on a grade, park across the
slope and block the tires.
SAFETY
Courtesy of Crane.Market
913287/BP0808 12 PRINTED IN U.S.A.
Servicing Safety Reminders
ÂALWAYS be aware of and avoid pinch point areas
on the machine, such as wheels-to-frame, cylin-
ders-to-frame, and boom-attachment-tool-to-
frame.
ÂNEVER attempt to by-pass the keyswitch to start
the engine. ONLY use the jump-starting procedure
detailed in the Service and Storage chapter.
ÂNEVER 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.
ÂALWAYS wear safety glasses with side shields
when striking metal against metal. In addition, it is
also recommended that a softer (chip-resistant)
material be used to cushion the blow. Failure to
heed could lead to serious injury to the eyes or
other parts of the body.
ÂDO NOT refill the fuel tank when the engine is
hot. Allow engine to cool down BEFORE refilling
to prevent the hot engine from igniting the fuel if it
should spill or splash.
ÂDO NOT smoke while filling the fuel tank, while
working on the fuel or hydraulic systems, or while
working around the battery.
ÂDO NOT fill the fuel tank completely.Allow room
for expansion. Maintain control of the fuel filler
nozzle when filling the tank. Use the correct fuel
grade for the operating season.
ÂNEVER use fuel for cleaning purposes.
ÂDO 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 down before
attempting to relieve pressure and remove the radi-
ator cap. Failure to heed this warning could result
in severe burns.
ÂDO NOT loosen or disconnect any hydraulic lines,
hoses or fittings without first relieving hydraulic
circuit pressure. Also, be careful not to touch any
hydraulic components that have been in recent
operation, because they can be extremely hot and
can burn you!
ÂAvoid lubrication or mechanical adjustments with
the machine in motion or the engine operating. If
the engine must be in operation to make certain
adjustments, place the transmission in neutral,
apply the park brake, place the equipment in a safe
position, securely block the tires and use extreme
caution.
ÂTo 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
ÂModifications 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.
ÂAll attachment tools MUST be marked to identify
the attachment tool and the total capacity with
attachment tool at maximum elevation with the
load laterally centered.
ÂALWAYS be sure all nameplates, caution 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.
SAFETY
Courtesy of Crane.Market
PRINTED IN U.S.A. 13 913287/BP0808
SAFETY
Safety Guards and Warning Devices
ÂThis machine is fitted with a Roll-Over Protective
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.
ÂThis machine is equipped with a horn and backup
alarm. The user must determine if operating condi-
tions require that the machine be equipped with
additional devices (mirrors, rotating beacon, etc.)
and be responsible for providing and maintaining
such devices.
Personnel Work Platform (PWP) System
The Mandatory Work Platform Safety Rules must be
followed to at all times while lifting personnel. These
rules are based on ANSI/ITSDF Standard B56.6-2005,
“Safety Standard for Rough Terrain Forklift Trucks.”
(A copy of this and related standards can be obtained
from the Industrial Truck Standards Development
Foundation, 1750 K Street NW, Suite 460, Washington
DC 20009; or downloaded from: www.itsdf.org.) The
rules apply to the owner, operator and personnel in the
work platform.
MANDATORY WORK PLATFORM
SAFETY RULES
1. The work platform must comply with
ANSI/ITSDF Standard B56.6-2005, Sec. 8.24,
“Platforms for Elevating Personnel.” (See page
15, “Work Platform Design Requirements.”)
2. The platform must be securely attached to the car-
riage or forks, and the carriage securely attached
to the boom.
3. The carriage and forks must be secured to prevent
them from pivoting upward.
4. If the machine is equipped with a rotating or
swinging carriage, the rotation or swing must be
deactivated. (This occurs automatically when the
“PWP System” is switched on.)
5. Personnel on the platform must be provided pro-
tection from any moving parts on the forklift that
may present a hazard.
6. If overhead hazards exist for platform personnel,
overhead protection must be provided.
7. Be sure that the lifting mechanism is operating
smoothly throughout its entire range, both empty
and loaded, and that any lift-limiting devices and
latches are functional.
8. Be sure that the frame is level, to ensure a vertical
lift.
9. Be sure the platform is horizontal before lifting.
10. Be sure that the forklift has a firm footing.
11. Be sure that any required restraining means (rail-
ings, chains, harnesses, etc.) are in place and
properly used.
12. Before lifting personnel, shift the transmission
into Neutral, apply the parking brake, and activate
the “PWP System” switch.
13. Before lifting personnel, the area should be
marked to warn others of work by elevated per-
sonnel.
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.
Courtesy of Crane.Market
913287/BP0808 14 PRINTED IN U.S.A.
SAFETY
14. Be sure the path of platform travel is clear of haz-
ards, such as scaffolds, electrical wires and over-
head obstructions.
15. The operator must keep hands and feet clear of
controls that are not in use.
16. Personnel must be lifted and lowered smoothly
and cautiously, and only at their request.
17. The platform must be lowered fully before mov-
ing the forklift. Do not drive the forklift with per-
sonnel on the platform.
18. Elevated personnel must always be alerted before
raising or lowering the platform.
19. A trained operator must be in position to operate
the forklift and boom controls at all times.
20. The combined weight of the platform, personnel
and load must not exceed one-third of the materi-
al handling capacity of the forklift.
21. Platform personnel must maintain firm footing on
the platform floor, unless secured by harness and
lanyard. A harness is to be worn and a lanyard
attached to the platform or boom when working
from an elevated work platform, in accordance
with OSHA regulations. Use of railings, planks,
ladders, etc. on platform for the purpose of
achieving additional reach or height is prohibited.
22. Workers on the platform must keep all parts of
their bodies inside the work platform during rais-
ing and lowering.
23. Be sure that the personnel and equipment on the
platform do not exceed the available space.
24. The platform must be fully lowered for personnel
to enter and exit. Personnel must not climb on
any part of the forklift in attempting to enter and
exit.
25. Any harness, body belt, lanyard, or deceleration
device that has sustained permanent deformation
or is otherwise damaged must be replaced.
26. Modifications to the platform that are detrimental
to its safe use are prohibited.
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 lifting personnel.
Work Platform System Switch
PWP
Remote
Shutdown
Switch
Electrical
Connection
Remote Shutdown Switch With Coiled Wire
Connector on 40’ and 44’ Models
Courtesy of Crane.Market
PRINTED IN U.S.A. 15 913287/BP0808
SAFETY
Wireless Remote Battery Replacement
1. Remove the four screws from the cover of the
wireless remote.
2. Open the cover to gain access to the batteries.
3. Remove the batteries from their holders.
4. Install the replacement batteries in the holder tak-
ing care to position the battery terminals as shown
in the diagram at the bottom of the battery holder.
5. Replace the cover and install the screws to secure
the cover in place.
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
truck, nor 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 plat-
form shall not be less than 18 inches (450 mm) in
either direction.
3. A 4 inch (100 mm) minimum height toe plate,
which may be omitted at the access opening.
4. An overhead protective device, when requested
by the user.
5. Protection for personnel in their normal working
position on the platform from moving parts of the
forklift that may present a hazard.
6. Information prominently indicated on the 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
mechanism.
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.Aguardrail or similar structure shall have
a nominal height to the platform floor of 42 inch-
es (1066 mm) around its upper periphery and
include a midrail. It may be hinged, removable, or
of chains, and used to provide an access opening
if proper positioning is easily accomplished and a
secure condition is discernable. Such restraining
means shall be capable of withstanding a concen-
trated horizontal force of 200 lbs. (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
freedom 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.
Wireless Remote Shutdown Switch
on 55’ Models
PWP
Remote
Shutdown
Switch
Courtesy of Crane.Market
913287/BP0808 16 PRINTED IN U.S.A.
SAFETY
NOTE: Fall protection should comply with applic-
able U.S. OSHAregulations: 1910.67 (c)(2)(v) (for
General Industry) or 1926.453 (b)(2)(v) (for
Construction).
10. Lanyards, when provided, shall be arranged so as
not to cause a tripping hazard.
11. Body harnesses, when provided, should have a
width of at least 1.75 inches (44 mm).
12. Structural safety factor - All load supporting
structural elements of the work platform shall
have a structural safety factor of not less than 2-
to-1 based on the minimum yield strength of the
materials used.
Courtesy of Crane.Market
This manual suits for next models
4
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