RS6-34. Operator s Manual. Telescopic Handler

Transcription

1 RS6-34 Teescopic Hander Seria Number thru (with Tier 3 engine) Beginning with Seria Number (with Interim Tier 4 engine) Form No Revision C January 2012 Operator s Manua

2 Indicator and Operation Symbos Read Operator s Manua Fasten Seat Bet Parking Brake Brake Faiure Safety Aert Hazard Fasher Ignition Off Ignition ON Engine Start Engine Oi Pressure Engine Oi Engine Cooant Temperature Starting Aid Injection Voume Fu Voume Haf Fu Voume Empty Fue Diese Fue Transmission Oi Transmission Temperature Beacon Turn Signas Lights Work Lights Fan Cutch Disengaged Cutch Engaged Crab Steer 2-Whee Steer 4-Whee Steer Raise Load Lower Load Tit Rearward Tit Forward Retract Load Extend Load Brake Fuid Frame Leve Left Frame Leve Right Wiper/Washer Horn Hourmeter Hydrauic Oi Femae Auxiiary Hydrauic Couper Mae Auxiiary Hydrauic Couper Battery Transmission Temperature

3 Tabe of Contents Chapter Description Page Indicator and Operation Symbos Inside Front Cover 1 Introduction Specifications Check Lists , 7 4 SAFETY Indicators and Contros Operation and Adjustments Lubrication Service and Storage Deca Locations Maintenance Hydrauic Schematics Eectrica Schematics Load Zone Charts Standard Hardware Torque Data Index Warranty Inside Back Cover IDENTIFICATION INFORMATION Write your Geh Teescopic Hander seria number beow. Refer to the mode and seria number when inquiring about parts or service from your Geh deaer. MODEL NO. RS6-34 SERIAL NO. The mode and seria numbers for this machine are on a deca ocated inside the operator s station. PRINTED IN U.S.A /CP0112

4 Chapter 1 INTRODUCTION The information in this Operator s Manua was written to give the owner/operator assistance in preparing, adjusting, maintaining and servicing of the Teescopic Hander. More important, this manua provides an operating pan for safe and proper use of the machine. Major points of safe operation are detaied in the SAFETY chapter of this manua. GEHL Company asks that you read and understand the contents of this manua COMPLETELY and become famiiar with the machine before operating it. This Teescopic Hander is primariy intended for use as a materia hander. However, it may be equipped with an optiona system: the Personne Work Patform (PWP) System, which is intended for use when ifting personne. When there is no other practica option avaiabe, this machine, when equipped with the PWP System, is approved for use to ift personne, but ony with an approved work patform, with the PWP System activated, and in fu compiance with the Mandatory Work Patform Safety Rues (see SAFETY chapter). The use of this Teescopic Hander is subject to certain hazards that cannot be eiminated by mechanica means, but ony by the exercise of inteigence, care and common sense. It is therefore essentia to have competent and carefu operators, who are not physicay or mentay impaired, and who are thoroughy trained in the safe operation of the equipment and the handing of the oads. Throughout this manua information is provided that is set in itaic type and introduced by the word IMPORTANT or NOTE. Be sure to read carefuy and compy with the message or directive given. Foowing this information wi improve operating or maintenance efficiency, hep to avoid breakdowns and damage, and extend the machine s ife. A chart of standard hardware torques is ocated in the back of this manua. A storage pocket in the back of the seat is provided for storing the Operator s Manua. After using the manua, pease return it to the pocket and keep it with the unit at a times! If this machine is resod, Geh Company recommends that this manua be given to the new owner. If this machine was purchased used, or if the owner s address has changed, pease provide your Geh deaer or Geh Company Service Department with the owner s name and current address, aong with the machine mode and seria number. This wi aow the registered owner information to be updated, so that the owner can be notified directy in case of an important product issue, such as a safety update program. Right and eft are determined from a position sitting on the seat and facing forward. The wide Geh deaership network stands ready to provide any assistance required, incuding providing genuine Geh service parts. A parts shoud be obtained from or ordered through your Geh deaer. Give compete information about the part, and incude the mode and seria number of the machine. Record the seria number in the space provided on the previous page, as a handy record for quick reference. Geh Company reserves the right to make changes or improvements in the design or construction of any part without incurring the obigation to insta such changes on any unit previousy deivered. Geh Company, in cooperation with the Society of Automotive Engineers, has adopted this Safety Aert Symbo to identify potentia safety hazards, which, if not propery avoided, coud resut in injury. When you see this symbo in this manua or on the machine itsef, you are reminded to BE ALERT! Your persona safety is invoved! /CP PRINTED IN U.S.A.

5 Identification Boom Ange Indicator Teescopic Boom Dash Indicators and Contros Quick-attach System Save Cyinder Tit Cyinder Operator s Station Seat Lift Cyinder Extend Cyinder Rear Boom Access Cover Exhaust Pipe Auxiiary Hydrauics (not shown) Access Cover with Rear Lights and Backup Aarm Air Ceaner Fue Tank Hydrauic Reservoir Side View Mirror Frame Leveing Cyinder PRINTED IN U.S.A /CP0112

6 Lifting Performance Maximum ift capacity: 6000 bs. (2721 kg) Maximum ift height: 34-3 (10.44 m) Capacity at maximum ift height: 4000 bs. (1820 kg) Max. forward reach to oad center: 23-3 (7.09 m) Capacity at maximum forward reach: 900 bs. (408 kg) Maximum beow grade reach: 24 (610 mm) Frame eveing: 10 o eft/10 o right Genera Dimensions Based on standard machine equipped with isted tires, 48 masonry carriage and 48 paet forks. Recommended tire type: x py Infate to 60 psi (415 kpa) Overa ength, ess forks: 16-0 (4.88 m) Overa width: 7-10 (2.39 m) Overa height: 7-9 (2.36 m) Ground cearance: 14 (356 mm) Whee base: 9-2 (2.8 m) Outside turn radius: 12-6 (3.81 m) Machine weight: 15,100 bs. (6855 kg) Instrumentation Gauges: Fue eve, hourmeter and cooant temperature Monitoring ights: Engine oi pressure, aternator, transmission oi temperature, brake faiure Visua indicators: Boom ange, frame ange Chapter 2 SPECIFICATIONS Steering System Steer Vave: Fixed dispacement rotary Dispacement/Rev: 17.9 cu. in. (293 cc) System pressure: 2000 psi (138 bar) Steer cyinders: 1 per axe Steer mode vave: 3-position, 4-way soenoid with dash-mounted switch actuation Steer modes: 2-whee, 4-whee, crab Braking System Service brakes: Oi-immersed inboard hydrauic wet-disc type; separate front and rear systems; Manua foot peda actuation Parking brake: Spring-appied, hydrauicreease disc-type in front axe Actuation is eectric switch with engine running, automatic with engine off. Eectrica System Type: 12-vot, negative ground Battery: 950 cod cranking amps Circuit protection: Fuse pane Backup aarm: 107 db(a) Horn: 111 db(a) Standard features: Brake ights, rear backup ight, neutra start switch Aternator: 75-amp Service Capacities Cooing System: 4.3 gaons (16.3 L) 50/50 mixture Anti-freeze protection: -34 o F (-31 o C) Pressure cap: 16 psi (110 kpa) Fue tank: 29 gas. (110 L) Hydrauic reservoir and system: 35 gas. (133 L) Transmission and cooer: 24 qts. (22.7 L) Axes: Differentias: 9.6 qts. (9 L) ea. Hubs: 0.6 qts. (0.5 L) ea. Transmission Type: Cark Powershift T12000 Speeds: 3 fwd / 3 rev Torque converter: Singe-stage, dua-phase Trave Speeds: 1st gear: 3.6 mph (5.8 km/h) 2nd gear: 7.9 mph (12.7 km/h) 3rd gear: 20.2 mph (32.5 km/h) Axes (front and rear) Type: Dana Drive/steer, open differentia, doube reduction panetary, fu-time fourwhee drive Overa ratio: 15.4:1 Engine Options Features: Turbocharged In-ine 4-cyce, 4-cyinder, direct-injection diese fue system, in-ine fue fiter w/water trap, positive pressure ubrication, iquid pressurized cooing system, 20 (508 mm) bower fan, dry dua-eement air ceaner, spin-on oi fiter. Machines with s/n thru 21700: John Deere 4045T Tier cu. in. (4523 cc) dispacement 84 hp ( rpm Oi capacity: 15.5 qts. (14.7 L) Machines beginning with s/n 21701: John Deere 4045T Interim Tier cu. in. (4523 cc) dispacement 74 hp ( rpm Oi capacity: 15.5 qts. (14.7 L) Hydrauic System Type: Open-center Pump: Singe-section gear type Dispacement / revoution: 2.7 cu. in. (44.3 cc) 2500 RPM: 29 gpm (110 L/min) Main reief pressure: 3000 psi (207 bar) Steer reief pressure: 2000 psi (138 bar) Hydrauic fiter: In-tank return type, 10 micron media, repaceabe eement. Rated fow: 100 gpm (379 L/min) Rated pressure: 100 psi (690 kpa) By-pass pressure (fu fow): 25 psi (172 kpa) Hydrauic strainer: In-tank suction, 149 micron media, repaceabe eement. Rated fow: 50 gpm (189 L/min) By-pass pressure: 3 psi (21 kpa) /CP PRINTED IN U.S.A.

7 PRE-DELIVERY The foowing Checkist is an important reminder of the inspections that MUST be made before deivering the Teescopic Hander to the customer. Check off each item after the prescribed action is taken. Check that: q NO parts of machine have been damaged in shipment. Check for such things as dents and oose or missing parts; correct or repace components as required. q Battery is securey mounted and not cracked. Cabe connections are tight. Eectroyte at proper eve. q Cyinders, hoses and fittings are not damaged, eaking or oosey secured. q Oi, fue and air fiters are not damaged, eaking or oosey secured. q A grease fittings have been propery ubricated and no fittings are missing; see Lubrication chapter of this manua. q Whee nuts are torqued to 450 ft.-bs. (610 Nm). q Tires are infated to 60 psi (415 kpa) cod. q Hydrauic system reservoir, engine crankcase, engine cooant, transmission and axes are fied to the proper operating fuid eves. q A adjustments have been made to compy with the settings given in this manua and in the separate engine manua. q A guards, shieds and decas are in pace and securey attached. q Mode and seria numbers for this unit are recorded in space provided on this page and page 1. Start the machine and test-run the unit whie checking that proper operation is exhibited by a contros. Check that: q A indicators (amps, switches, etc.) function propery. q A hand and foot contros operate propery. q The PWP System operates propery (if equipped). Refer to Service and Storage chapter for the procedure to check the PWP System. q Boom, Quick-attach System with attachment too and frame eve contro a function propery. q No hydrauic system eaks when under pressure. q Listen for abnorma noises or vibrations; if detected, determine their cause and repair as necessary. Chapter 3 CHECKLISTS (Deaer s Fie Copy - Remove at Perforation) I acknowedge that the pre-deivery procedures were performed on this unit as outined above. Deaership s Name Deaer Representative s Name Date Checkist Fied Out Machine Mode # Machine Seria # Engine Seria # DELIVERY Check that: The foowing Checkist is a reminder of the important information that MUST be passed on to the customer at the time the unit is deivered. Check off each item as it is expained to the customer. q Review with the customer the contents of this manua and the AEM Safety Manua for the foowing: q The Index at the back, for quicky ocating topics; q The Safety, Indicators and Contros, and Operation and Adjustment chapters for information regarding safe use of the machine. q The Lubrication and Service and Storage chapters for information regarding proper maintenance of the machine. Expain that reguar ubrication and maintenance are required for continued safe operation and ong ife. q Give this Operator s Manua and the AEM Safety Manua to the customer and instruct them to be sure to read and competey understand their contents before operating the unit. q Remind the customer of U.S. OSHA reguation (), which specifies operator training requirements. q Expain that the customer must consut the engine manua (provided) for reated specifications, operating adjustments and maintenance instructions. q Competey fi out the Owner s Registration, incuding customer s signature, and return it to the Company. q Expain that a copy of the product warranty is incuded on the inside back cover of this Operator s Manua. Customer s Signature Date Deivered PRINTED IN U.S.A /CP0112

8 INTENTIONALLY BLANK (To be removed as Deaer s fie copy) /CP PRINTED IN U.S.A.

9 PRE-DELIVERY The foowing Checkist is an important reminder of the inspections that MUST be made before deivering the Teescopic Hander to the customer. Check off each item after the prescribed action is taken. Check that: q NO parts of machine have been damaged in shipment. Check for such things as dents and oose or missing parts; correct or repace components as required. q Battery is securey mounted and not cracked. Cabe connections are tight. Eectroyte at proper eve. q Cyinders, hoses and fittings are not damaged, eaking or oosey secured. q Oi, fue and air fiters are not damaged, eaking or oosey secured. q A grease fittings have been propery ubricated and no fittings are missing; see Lubrication chapter of this manua. q Whee nuts are torqued to 450 ft.-bs. (610 Nm). q Tires are infated to 60 psi (415 kpa) cod. q Hydrauic system reservoir, engine crankcase, engine cooant, transmission and axes are fied to the proper operating fuid eves. q A adjustments have been made to compy with the settings given in this manua and in the separate engine manua. q A guards, shieds and decas are in pace and securey attached. q Mode and seria numbers for this unit are recorded in space provided on this page and page 1. Start the machine and test-run the unit whie checking that proper operation is exhibited by a contros. Check that: q A indicators (amps, switches, etc.) function propery. q A hand and foot contros operate propery. q The PWP System operates propery (if equipped). Refer to Service and Storage chapter for the procedure to check the PWP System. q Boom, Quick-attach System with attachment too and frame eve contro a function propery. q No hydrauic system eaks when under pressure. q Listen for abnorma noises or vibrations; if detected, determine their cause and repair as necessary. Chapter 3 CHECKLISTS (Pages 5 and 6 have been removed at perforation) I acknowedge that the pre-deivery procedures were performed on this unit as outined above. Deaership s Name Deaer Representative s Name Date Checkist Fied Out Machine Mode # Machine Seria # Engine Seria # DELIVERY Check that: The foowing Checkist is a reminder of the important information that MUST be passed on to the customer at the time the unit is deivered. Check off each item as it is expained to the customer. q Review with the customer the contents of this manua and the AEM Safety Manua for the foowing: q The Index at the back, for quicky ocating topics; q The Safety, Indicators and Contros, and Operation and Adjustment chapters for information regarding safe use of the machine. q The Lubrication and Service and Storage chapters for information regarding proper maintenance of the machine. Expain that reguar ubrication and maintenance are required for continued safe operation and ong ife. q Give this Operator s Manua and the AEM Safety Manua to the customer and instruct them to be sure to read and competey understand their contents before operating the unit. q Remind the customer of U.S. OSHA reguation (), which specifies operator training requirements. q Expain that the customer must consut the engine manua (provided) for reated specifications, operating adjustments and maintenance instructions. q Competey fi out the Owner s Registration, incuding customer s signature, and return it to the Company. q Expain that a copy of the product warranty is incuded on the inside back cover of this Operator s Manua. Customer s Signature Date Deivered PRINTED IN U.S.A /CP0112

10 Chapter 4 SAFETY The above Safety Aert Symbo means ATTENTION! ALWAYS BE ALERT! YOUR SAFETY IS INVOLVED! It stresses an attitude of safety awareness and can be found throughout this Operator s Manua and on the machine itsef. Before operating this equipment, read and study the foowing safety information. In addition, be sure that everyone who operates or works with this equipment is famiiar with these safety precautions. DANGER DANGER indicates an imminenty hazardous situation, which, if not avoided, wi resut in death or serious injury. WARNING WARNING indicates a potentiay hazardous situation, which, if not avoided, coud resut in death or serious injury. CAUTION CAUTION indicates a potentiay hazardous situation, which, if not avoided, may resut in minor or moderate injury. It may aso aert to unsafe practices. Geh 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 shieded in order to assure proper operation. Further, this Operator s Manua, the Safety Manua and decas on the machine warn of additiona hazards and shoud be read and observed cosey. It is the responsibiity of the operator to read and understand the Operator s Manua and other information provided and use the correct operating procedures. Machines shoud be operated ony by quaified operators. REMEMBER! It is the owner s responsibiity for communicating information on the safe use and proper maintenance of this machine! This incudes providing understandabe interpretations of these instructions for operators who are not fuent in reading Engish. MANDATORY SAFETY SHUTDOWN PROCEDURE BEFORE ceaning, adjusting, ubricating or servicing the unit: 1. Stop machine on a eve surface. (Avoid parking on a sope, but if necessary, park across the sope and bock the tires.) 2. Fuy retract the boom and ower the attachment too to the ground. Ide engine for gradua cooing. 3. Pace contros in neutra and appy 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. Faiure to foow the above procedure coud ead to death or serious bodiy injury /CP PRINTED IN U.S.A.

11 SAFETY WARNING U.S. OSHA reguations require empoyers in genera industry and the construction, shipyard and cargo-handing industries (excepting agricutura operations) to ensure that forkift operators are competent, as demonstrated by successfu competion of a training course. The training course must consist of a combination of forma instruction and practica training, incuding both forkift-reated and workpace-reated topics, and evauation of the operator s performance in the workpace. A operator training and evauation is to be conducted by persons who have the knowedge, training and experience to train and evauate operators. WARNING U.S. OSHA reguations effective November 8, 2010 (29 CFR Part 1926, Subpart CC - Cranes and Derricks in Construction) incude requirements for empoyers that use powered industria trucks ("forkifts") configured to hoist (by means of a winch or hook) and move suspended oads horizontay. In particuar, this reguation appies to any rough-terrain forkift (e.g., "teescopic hander") equipped with a jib or truss boom with a hook (with or without a winch), or a hook assemby attached to the forks. [Note: This reguation is in addition to the OSHA reguation that requires specific forkift operator training: ().] When a forkift / teescopic hander is configured and used for hoisting, the empoyer must ensure that: 1. Forkift, ift equipment and rigging have been inspected (each shift, month and year) and are in good, safe condition and propery instaed. 2. An operator's manua and appicabe oad charts are on the forkift. 3. Work zone ground conditions can support the equipment and oad. 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 manufacturer's instructions. 5. Operator and crew members have been trained in the safe use and operation of the equipment, incuding how to avoid eectrocution. 6. During use, no part of the equipment, oad ine or oad wi be within the minimum cearance distance specified by OSHA [10 feet (3.0 m), and more for ines rated over 50 kv] of any energized power ine, and any tagines used are non-conductive. 7. In addition, for ift equipment with a rated capacity greater than 2000 bs. (907 kg), the empoyer must ensure that: a.) An accessibe fire extinguisher is on the forkift; b.) Monthy and annua inspections are performed and documented, and records retained (three months for monthy, one year for annua); c.) Before November 10, 2014, operators must have had the additiona training and quaification / certification required by OSHA reguations and Note: Refer to the fu text of the OSHA crane reguation (29 CFR Part 1926, Subpart CC) for a detaied description of the reguatory requirements. PRINTED IN U.S.A /CP0112

12 SAFETY WARNING ALWAYS maintain a safe distance from eectric power ines and avoid contact with any eectricay charged conductor or gas ine. It is not necessary to make direct contact with a power ine for power to ground through the structure of the machine. Keep the boom and oad at east 10 ft. (3 m) from a power ines. Accidenta contact or rupture can resut in eectrocution or an exposion. Contact the Ca Before You Dig referra system number at in the U.S., or in the U.S. and Canada, to ocate any underground utiity ines BEFORE starting to dig. Additiona Safety Reminders Ü User/operator safety practices, as indicated by industry standards, are incuded in this Operator s Manua and intended to promote safe operation of the machine. These guideines do not, of course, precude the use of good judgment, care and common sense that may be necessary for the particuar jobsite conditions. Ü It is essentia that operators be physicay and mentay fit and free of mind-atering drugs and chemicas, and thoroughy trained in the safe operation of the machine. Such training shoud be presented competey to a new operators and not condensed for those caiming previous experience. Information on operator training is avaiabe from severa sources, incuding the manufacturer. Ü Some iustrations used in this manua may show doors, guards and shieds open or removed for iustration purposes ONLY. BE SURE that a doors, guards and shieds are in their proper operating positions BEFORE starting the engine. Before Operation Safety Reminders Ü Check brakes, steering, and hydrauic system prior to starting operation. Operate a contros to ensure proper operation. Observe a gauges and indicators for proper operation. If any mafunctions are found, correct the cause prior to using the machine. Ü ALWAYS wear appropriate persona protective equipment for the job and working conditions. Hard hats, gogges, protective shoes, goves, refector-type vests, respirators and ear protection are exampes of types of equipment that may be required. DO NOT wear oose fitting cothing, ong hair, jewery or oose persona items whie operating or servicing the machine. Ü ALWAYS check the job site for terrain hazards, obstructions and peope. Remove a objects that do not beong in or on the machine and its equipment. Ü Wak around the machine and warn a personne who may be servicing the machine or who are in the machine path prior to starting. DO NOT start unti a personne are ceary away from the machine. Ü Geh teescopic handers are designed and intended to be used ony with Geh attachments and approved attachments. To avoid possibe persona injury, equipment damage and performance probems, use attachments that are approved for use on and within the operating capacity of the machine. Contact your deaer or Geh Company for information on attachment approva and compatibiity with specific machine modes. Geh cannot be responsibe if the machine is used with a nonapproved attachment. Operation Safety Reminders Ü Any or a of the foowing eements may affect the stabiity of the machine: terrain, engine speed, type of oad being carried and paced, improper tire infation, weight of the attachment too, and abrupt movement of any contro ever. 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! /CP PRINTED IN U.S.A.

13 SAFETY Ü ALWAYS wear the seat bet provided to prevent being thrown from the machine. If you are in an overturn: - DO NOT jump! - Hod on tight and stay with the machine! - Lean away from the fa! Ü ALWAYS keep hands, feet and arms inside of the operator s station when operating the machine! Ü DO NOT depend on the backup aarm to cear bystanders out of the path of the machine. ALWAYS ook in the direction of trave. Look to the rear before backing. Ü ALWAYS use the recommended handhods and steps with at east three points of support when getting on and off the machine. Keep steps and patform cean. Face the machine when cimbing up and down. Ü DO NOT raise or drop a oaded fork or bucket suddeny. Abrupt movements under oad can cause serious instabiity. Ü Study the oad chart carefuy. It shows maximum capacity to be ifted and paced at specific outward and upward distances. ALWAYS be aware of oad weights prior to attempting ift and pacement with this machine. Ü DO NOT exceed the machine s rated operating capacity for the type of attachment too being used. Ü DO NOT aow minors or any unquaified personne to operate or be near the machine uness propery supervised. Ü DO NOT start the engine or operate any contros uness propery seated in the operator s seat! Ü DO NOT run the engine in an encosed area without providing proper ventiation for the exhaust. Exhaust gases contain carbon monoxide, an odoress and deady gas. Interna combustion engines depete the oxygen suppy within encosed spaces and may create a serious hazard uness the oxygen is repaced. This incudes the atmosphere within the cab when equipped. Ü DO NOT eave the operator s station with the boom and attachment too raised. ALWAYS ower the boom and attachment too to the ground, shut off the engine and engage the park brake before eaving the operator s station. Ü DO NOT drive too cose to an excavation or ditch. BE SURE that the surrounding ground has adequate strength to support the weight of the machine and the oad it is carrying. Ü DO NOT turn quicky whie traveing on a sope or operate the machine beyond the grade and sope imits noted in the Operation and Adjustments chapter of the Operator s Manua. Ü NEVER aow any riders on this machine. This is stricty a singe-seat, NO-passenger machine. Ü NEVER use as a ift for personne uness the machine is equipped with the Personne Work Patform (PWP) System. Ü When road trave is required, know and use the signaing devices on the machine. Provide an escort and Sow-Moving Vehice (SMV) embem when required. Ü If necessary to park on a sope, park across the sope and bock the tires. Servicing Safety Reminders Ü ALWAYS be aware of and avoid pinch point areas on the machine, such as whees-to-frame, cyinders-to-frame, boom-attachment-too-to-frame. Ü NEVER attempt to by-pass the keyswitch to start the engine. ONLY use the jump-starting procedure detaied in the Service and Storage chapter. Ü NEVER use your hands to search for hydrauic fuid eaks. Instead use a piece of paper or cardboard. Escaping fuid under pressure can be invisibe and can penetrate the skin, causing serious injury. If any fuid is injected into your skin, see a doctor at once. Injected fuid MUST be surgicay removed by a doctor famiiar with this type of injury or gangrene may resut. PRINTED IN U.S.A /CP0112

14 SAFETY Ü ALWAYS wear safety gasses with side shieds when striking meta against meta. In addition, it is recommended that a softer (chip-resistant) materia be used to cushion the bow. Faiure to heed coud ead to serious injury to the eyes or other parts of the body. Ü DO NOT refi the fue tank when the engine is hot. Aow engine to coo down before refiing to prevent hot engine parts from igniting the fue if it shoud spi or spash. Ü DO NOT smoke whie fiing the fue tank, whie working on the fue or hydrauic systems, or whie working around the battery. Ü DO NOT fi the fue tank competey. Aow room for expansion. Maintain contro of the fue fier nozze when fiing the tank. Use the correct fue grade for the operating season. Ü NEVER use fue for ceaning purposes. Ü DO NOT remove the radiator cap after the engine has reached operating temperature or if it is overheated. At operating temperatures, the engine cooant wi be extremey hot and under pressure. ALWAYS wait for the engine to coo before attempting to reieve pressure and remove the radiator cap. Faiure to heed this warning coud resut in severe burns. Ü DO NOT oosen or disconnect any hydrauic ines, hoses or fittings without first reieving hydrauic circuit pressure. Aso, be carefu not to touch any hydrauic components that have been in recent operation, because they can be extremey hot and can burn you! Ü Avoid ubrication or mechanica adjustments with the machine in motion or the engine operating. If the engine must be running to make certain adjustments, pace the transmission in neutra, appy the parking brake, pace the equipment in a safe position, securey bock the tires and use extreme caution. Ü To ensure continued safe operation, repace damaged or worn-out parts with genuine Geh service parts before using this equipment. Modifications, Namepates, Markings and Capacities Ü Modifications and additions that affect capacity or safe operation sha not be performed without the manufacturer s prior written approva. Where such authorization is granted, any appicabe markings are to be changed accordingy. Ü A attachment toos MUST be marked to identify the attachment too and the tota capacity with the attachment too at maximum eevation with the oad ateray centered. Ü ALWAYS be sure a namepates, warnings and instruction markings are in pace and egibe. Loca government reguations may require specific decas, which then become the responsibiity of the owner or user to provide. Safety Guards and Warning Devices Ü This machine is fitted with a Ro-Over Protective Structure (ROPS) and Faing Object Protective Structure (FOPS) in accordance with industry standards. It is intended to offer protection to the operator from faing objects, and in case of an overturn, but it cannot protect against every possibe hazard. Therefore it shoud not be considered a substitute for good judgment and safe practices in operating the machine. If the ROPS / FOPS structure is damaged, it must be repaced to restore the protection it provides. Ü This machine is equipped with a horn and backup aarm. The user must determine if operating conditions require the machine to be equipped with additiona devices (mirrors, rotating beacon, etc.) and be responsibe for providing and maintaining such devices. Personne Work Patform (PWP) System The Mandatory Work Patform Safety Rues must be adhered to at a times whie eevating personne. These rues are based on ANSI/ITSDF Standard B , Safety Standard for Rough Terrain Forkift Trucks. (A copy of this and reated standards can be obtained from the Industria Truck Standards Deveopment Foundation, 1750 K Street NW, Suite /CP PRINTED IN U.S.A.

15 SAFETY 460, Washington DC 20009; or downoaded from: The rues appy to the owner, operator and the personne in the work patform. WARNING The machine must not be used to ift or carry personne, or be fitted with any form of personne work patform uness fitted with the optiona PWP System. If fitted with the PWP System, the Mandatory Work Patform Safety Rues must be foowed at a times whie ifting personne. MANDATORY WORK PLATFORM SAFETY RULES 1. The work patform must compy with ANSI/ITSDF B , Sec. 8.24, Patforms for Eevating Personne. (See page 14, Work Patform Design Requirements. ) 2. The patform must be securey attached to the carriage or forks, and the carriage securey 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 automaticay when the PWP System is switched on.) 5. Personne on the patform must be provided protection from any moving parts on the forkift that may present a hazard. 6. If overhead hazards exist for patform personne, overhead protection must be provided. 7. Be sure that the ifting mechanism is operating smoothy throughout its entire range, both empty and oaded, and that any ift-imiting devices and atches are functiona. 8. Be sure that the frame is eve, to ensure a vertica ift. 9. Be sure the patform is horizonta before ifting. 10. Be sure that the forkift has a firm footing. 11. Be sure that any required restraining means (raiings, chains, harnesses, etc.) are in pace and propery used. 12. Before ifting personne, shift the transmission into Neutra, appy the parking brake, and activate the "PWP System" mode switch. 13. Before ifting personne, the area shoud be marked to warn others of work by eevated personne. 14. Be sure the path of patform trave is cear of hazards, such as scaffods, eectrica wires and overhead obstructions. 15. The operator must keep hands and feet cear of contros that are not in use. 16. Personne must be ifted and owered smoothy and cautiousy, and ony at their request. 17. The patform must be owered fuy before moving the forkift. Do not drive the forkift with personne on the patform. 18. Eevated personne must aways be aerted before raising or owering the patform. 19. A trained operator must be in position to operate the forkift and boom contros at a times. 20. The combined weight of the patform, personne and oad must not exceed one-third of the materia-handing capacity of the forkift. 21. Patform personne must maintain firm footing on the patform foor. A harness is to be worn and a anyard attached to the patform or boom when working from an eevated work patform, in accordance with OSHA reguations. Use of raiings, panks, adders, etc. on patform for the purpose of achieving additiona reach or height is prohibited. 22. Workers on the patform must keep a parts of their bodies inside the work patform during raising and owering. 23. Be sure that the personne and equipment on the patform do not exceed the avaiabe space. PRINTED IN U.S.A /CP0112

16 SAFETY 24. The patform must be fuy owered for personne to enter and exit. Personne must not cimb on any part of the forkift in attempting to enter and exit. 25. Any harness, body bet, anyard, or deceeration device that has sustained permanent deformation or is otherwise damaged must be repaced. 26. Modifications to the patform that are detrimenta to its safe use are prohibited. Eectrica Connection PWP Remote Shutdown Switch WARNING Use ONLY an approved work patform for eevating personne. NEVER move the machine with the work patform in a raised position or with personne on board. NEVER tit the patform forward, rearward, or to the side with personne aboard. ALWAYS engage the PWP System and foow the Mandatory Work Patform Safety Rues when eevating personne. Work Patform System Switch Remote Shutdown Switch with Coied Wire Connector Work Patform Design Requirements (Per ANSI/ITSDF B , Sec. 8.24) 1. A patform foor having a sip-resistant surface ocated not more than 8 inches (200 mm) above the norma oad-supporting surface of the forks. 2. Foor dimensions, which sha not exceed two times the oad center distance of 24 inches (610 mm) isted on the forkift namepate, measured parae to the ongitudina center pane of the forkift, nor have a width greater than the overa width of the forkift [measured across the oad-bearing tires] pus 10 inches (250 mm) on either side. Minimum space for each person on the patform sha not be ess than 18 inches (450 mm) in either direction. 3. A 4 inch (100 mm) minimum height toe pate, which may be omitted at the access opening. 4. An overhead protective device, when requested by the user. 5. Protection for personne in their norma working position on the patform from moving parts of the forkift that may present a hazard. 6. Information prominenty indicated on the patform: a. maximum work oad incuding personne and equipment, and b. weight of empty patform /CP PRINTED IN U.S.A.

17 SAFETY 7. Means so that the patform can ony be centered ateray on the forkift, and retained against the vertica face of the forks, carriage or ifting mechanism. 8. A means to securey attach the patform to the ifting mechanism, and to prevent the patform from inadvertenty pivoting. 9. Restraining means such as a guardrai or a means for securing personne such as a body harness and anyard. A guardrai or simiar structure sha have a nomina height to the patform foor of 42 inches (1066 mm) around its upper periphery and incude a midrai. It may be hinged, removabe, or of chains, and used to provide an access opening, if proper positioning is easiy accompished and a secure condition is discernabe. Such restraining means sha be capabe of withstanding a concentrated horizonta force of 200 bs. (890 N) appied at the point of east resistance without permanent deformation. A body harness and anyard is to have an attachment point provided overhead for freedom of movement, and its ength is to imit freefa to 5 feet (1500 mm) measured from the point of attachment to the operator. The compete system sha be capabe of withstanding three consecutive drop tests to simuate a 250-pound (113 kg) person faing 6 feet (1800 mm) without aowing the test weight to fa free to the ground. A deceeration device may be incuded. NOTE: Fa protection shoud compy with appicabe U.S. OSHA reguations: (c)(2)(v) (for Genera Industry) or (b)(2)(v) (for Construction). 10. Lanyards, when provided, sha be arranged so as not to cause a tripping hazard. 11. Body harnesses, when provided, shoud have a width of at east 1.75 inches (44 mm). 12. Structura safety factor-a oad-supporting structura eements of the work patform sha have a structura safety factor of not ess than 2-to-1 based on the minimum yied strength of the materias used. PRINTED IN U.S.A /CP0112

18 SAFETY L70306 L70307 L65926 L70307 L L L65932 L /CP PRINTED IN U.S.A.

19 SAFETY L70305 L65942 L65942 L65932 L65927 L70305 L70305 L65927 L65933 L65933 L65932 L65927 PRINTED IN U.S.A /CP0112

20 SAFETY L65928 L /CP PRINTED IN U.S.A.

21 SAFETY L65927 L65927 L66613 RED L66613 L65928 L65927 L65928 PRINTED IN U.S.A /CP0112

22 SAFETY PWP Safety Decas L71700 L71700 L71554 L L71554 L71555 L /CP PRINTED IN U.S.A.

23 Chapter 5 INDICATORS AND CONTROLS CAUTION Become famiiar with and know how to use ALL safety devices and contros on the Teescopic Hander BEFORE operating it. Know how to stop the machine operation BEFORE operating it. This Geh machine is designed and intended to be used ONLY with a Geh Company attachment too, or a Geh Company approved accessory or referra attachment too. Geh Company cannot be responsibe for product safety if the machine is used with a non-approved accessory or attachment too. GUARDS AND SHIELDS Whenever possibe and without affecting machine operation, guards and shieds are used to protect potentiay hazardous areas. In many paces, decas are aso provided to warn of potentia hazards and to dispay specia operating procedures. WARNING Read and thoroughy understand a safety decas on the Teescopic Hander BEFORE operating it. DO NOT operate the machine uness a factory-instaed guards and shieds are propery secured in pace. Boom Ange Indicator Boom Contro Joystick Auxiiary Hydrauics Contro Frame Ange Indicator Frame Leve and Attachment Joystick Speed and Trave Direction Lever Instrument and Switch Pane Two Joystick Contros Steering Whee Load Zone Charts Tri-Function Joystick Frame Leve Contro Brake Peda Brake Fuid Reservoir Key Switch, Start and Horn Button Throtte Peda Operator s Compartment and Indicators/Contros Locations Tri-Function Joystick Contro PRINTED IN U.S.A /CP0112

24 DASH PANEL AREA A1 A2 B C Ignition Switch, Start and Horn Button Instrument and Switch Pane A1 - Key Switch OFF: When the key is vertica in the keyswitch, power is disconnected from the battery to the contro and instrument pane eectrica circuits. This is the ony position in which the key can be inserted and removed. A2 - Key Switch ON: When the key is turned one position cockwise from the vertica (OFF) position, power from the battery is suppied to the engine and a contro and instrument pane eectrica circuits. A B NOTE: If the engine requires repeated attempts to start, the key MUST be returned to the OFF position between starting attempts to prevent battery run down. B - Start Button: With key switch in the ON position, press the start button to activate the starter. Reease it as soon as the engine starts. C - Horn Button: With the key switch ON, press the horn button to activate warning sound. Load Zone Charts: A series of fip charts show ift height and reach imits reative to the oad weight being handed with various attachment toos. D Instrument Pane A - Fue Leve Gauge: The upper eft gauge in the instrument pane, it indicates the amount of fue in the fue tank. B - Cooant Temperature Gauge: The upper right gauge in the instrument pane, it indicates the temperature of the engine cooant. Under norma conditions, this gauge shoud indicate approximatey 185 F (85 C). C C - Hourmeter: Located to the right of the amp custer gauge, it indicates the tota operating time of the machine and shoud be used for keeping the maintenance og. D - Lamp Custer Gauge: The ower eft gauge in the instrument pane, it contains four indicator amps. The functions of these amps are shown on the next page: /CP PRINTED IN U.S.A.

25 Aternator Lamp: Located in the upper eft section of the amp custer gauge, this amp indicates the condition of the eectrica charging system. During norma operation, this amp shoud be off. If the charge rate is too high or too ow, this amp wi come on. IMPORTANT: If this amp comes on during norma operation, a probem may exist in the transmission oi system. Stop the machine immediatey and investigate the cause of the probem! Engine Oi Pressure Lamp: Located in the upper right section of the amp custer gauge, this amp indicates whether the engine ubricating oi pressure is sufficient. During norma operation, with the engine running, this amp shoud be off. During starting and when the engine is not running, this amp wi be on. IMPORTANT: If this amp comes on during norma operation with the engine running, stop the engine immediatey! After aowing the oi to drain down for a few minutes, check the engine oi eve. Maintain oi eve at the FULL mark on the dipstick. Brake Faiure Lamp: Located in the ower eft section of the amp custer gauge, this amp indicates the condition of the service brake system. The front and rear brakes are on independent systems. If a oss of pressure occurs in either system during norma operation with the brake peda depressed, this amp wi come on. Faiure in one of the brake systems does not affect the operation of the other system. However, the MANDA- TORY SAFETY SHUTDOWN PROCEDURE (p. 8) shoud be foowed and any necessary repairs made immediatey. During norma operation this amp shoud remain off. Transmission Oi Temperature Lamp: Located in the ower right section of the amp custer gauge, this amp indicates whether or not the transmission oi is at the proper temperature. During norma operation this amp shoud be off, indicating that the transmission oi system is at the proper temperature. Switch Pane Top Row Switches Switches have graphic symbos to indicate function and effect. The foowing descriptions start with the first switch on the eft. A B C A - Steering Mode: This 3-position switch is used to seect among the three steering modes. The upper position engages the 4-whee-steer mode. This mode provides a-whee steering, used for making tighter turns, usuay on a jobsite. The center position engages the 2- whee-steer mode. This mode provides front-whee steering ony, used for higher speed trave. The ower position engages the crab-steer mode. This mode is used when a sma amount of side shift is needed for picking or pacing a oad. PRINTED IN U.S.A /CP0112

26 NOTE: The rear whees are not sef-centering. Make sure a whees are in a straight-ahead position before changing the steering mode. Any of the steering modes can be used in forward and reverse trave. The operator shoud earn to anticipate changes in machine movement if the steering mode must be changed. B - Cutch Cutout: When activated, this switch aows faster engine acceeration and more power to the hydrauic system, without power to the drive axes, whie the service brake peda is pressed. In the OFF position, the cutch mechanism of the transmission remains engaged when the brakes are appied. In the ON position, the cutch mechanism is disengaged when the brakes are appied. Norma brake force wi hod the machine in position whie acceerating the engine to power hydrauic contro functions during oad pacement. C - Parking Brake: When the machine is parked, this switch shoud be pressed to actuate the parking brake mechanism in the front axe. WARNING UNATTENDED MACHINE HAZARD Activate parking brake switch and ower attachment too to ground before eaving machine. An unattended machine can move or ro and cause death or serious injury to operator or bystanders. Periodicay check the parking brake operation to maintain adequate hoding power. Aways be sure the parking brake switch is off when resuming machine operation. Midde Row Switches Switches have graphic symbos to indicate function and effect. The foowing descriptions start with the first switch on the eft. A B C D NOTE: Some switches are optiona and may not be on machine. A - Head Lights/Work Lights: Pressing the top of the switch wi iuminate the ights mounted on the top of the operator s station and the red tai ights, for use in forward trave operations. Pressing the bottom of the switch wi iuminate the ights at the end of the boom in addition to the ights on the operator s station, for additiona ighting in working operations. B - Turn Signa: This switch is used to indicate the direction of a turn with the tai ights. Press the right arrow for a right turn; press the eft arrow for a eft turn. Return the switch to the center position after the turn is competed. C - Hazard: This switch can be activated to make the tai ights fash on and off in case the machine is staed or temporariy stopped in a traffic area on the road or jobsite. D - Personne Work Patform: This is a red switch used to activate the Personne Work Patform (PWP) System. When activated, an amber amp in the switch wi be on. NOTE: This amp wi fash on and off, indicating that the system is not yet fuy functiona, unti the brakes are hed on for three or more seconds. Bottom Row Switches Switches have graphic symbos to indicate function and effect. The foowing descriptions start with the first switch on the eft. A1 A2 NOTE: Some switches are optiona and may not be on machine. A1 and A2 - Wiper/Washer: The windshied and top window of the operator s station are each equipped with a wiper and washer mechanism. Switch A1 operates the wiper and washer on the windshied; switch A2 operates the wiper and washer on the top window. B C /CP PRINTED IN U.S.A.

27 B - Cod Starting: This switch activates the injection of ether starting fuid, used for engine starting in cod weather. C - Strobe Light: When a stobe ight is instaed on the machine, activating this switch wi produce a strobe ight on and off fashing, for working in conditions that may obscure view of the machine. Heater Contros Temperature Contro: This is the upper knob ocated to the eft of the steering whee. This knob is used to adjust the temperature output of the heater. Turning the knob cockwise wi increase the temperature output of the cab heater. Fan Speed: This knob is ocated beow the temperature contro knob. Rotating the knob cockwise wi increase the fan speed for increased air circuation. Temperature Contro Knob Fan Speed Knob Trave Lever Located on the eft side of the steering whee coumn, this ever is used to change trave direction (forward or reverse) and speed. NOTE: Backup aarm automaticay sounds with trave ever in R (Reverse). Position F (Forward) Position N (Neutra) Position R (Reverse) Speed Range: Twisting the ever end cockwise or counter-cockwise wi change the transmission speed between ow, medium and trave ranges. Position 3 (Trave Range) Position 2 (Medium Range) Position 1 (Low Range) IMPORTANT: Care shoud be taken when downshifting or changing direction, because damage to the transmission can occur if shifting is forced or attempted at too high a speed. Aow engine speed to sow before any downshift or directiona change is attempted. Steering Turn the steering whee to the right or eft to turn the machine in that direction.the power steering system is designed to provide ow-effort steering without shock reaction from the tires to the steering whee. FLOOR AND SEAT AREA Throtte Peda: This peda, operated by the right foot, contros the engine speed to match power requirements. Pushing down on the peda increases engine speed; etting up on the peda decreases engine speed. Throtte Peda Brake Fuid Reservoirs Trave Direction: The ever MUST be in N (Neutra) position before the starter wi engage to start the engine. Brake Peda PRINTED IN U.S.A /CP0112

28 Service Brake Peda: Pressing this peda activates inboard hydrauic wet-disc-type brakes on a four whees. Separate front and rear brake systems aow bringing the machine to a safe stop if either system oses pressure. Brake Fuid Reservoirs: Located under the hinged cover on the cab foor directy in front of the seat. Seat Positioning: The seat is mounted on rais for forward and rearward repositioning, for comfort and to accommodate the operator s size. A spring-oaded atch hande under the front of the seat actuates the adjustment mechanism. Side Adjustment Lever Suspension Seat Option: This option is avaiabe for additiona operator comfort. It is adjustabe for a soft or firm ride. Side Adjustment Lever Ride Adjustment Knob Seat Bet: This machine has a retractabe seat bet. Grasp the bet on the eft side of the seat, pu the bet over your ap, and insert the bet into the bucke on the right side of the seat unti you hear it ock in pace. Seat Bet RIGHT SIDE PANEL These contros and indicators are used to position the frame, boom and attachment. Graphic symbos on the side pane indicate the contro actions and effect. WARNING Use extreme caution when raising or extending the boom. The Teescopic Hander MUST be eve. Loaded or empty, the machine can tip over if it is not eve. ALWAYS pace the transmission in neutra, appy the parking brake and keep the service brakes fuy appied before raising or extending the boom. NEVER exceed the specified ift and reach capacities of the machine, or serious machine damage and persona injury may resut. Refer to the oad charts at the operator s station or this manua. If a boom circuit hose fais with the boom up, with or without a oad, shut down the machine foowing the MANDATORY SAFETY SHUT- DOWN PROCEDURE. DO NOT attempt repairs. Instead, ca your Geh deaer for assistance. The truss boom and winch attachment toos shoud ONLY be used to ift and pace oads when the machine is in a stationary position. Transporting suspended oads must ALWAYS be done sowy and cautiousy, with the boom and oad as ow as possibe. Use tagines to restrict oads from swinging, to avoid overturn. NEVER use winch for ifting or moving personne. NEVER exceed the maximum rated capacity of the winch (3000 bs./1360 kg) or exceed the oad chart rating for winch appications. DO NOT tit the truss boom back more than 45 o from horizonta. DO NOT attempt to use the optiona rotating carriage as a oad eveing function. ALWAYS eve the frame prior to raising a oad. Faiure to heed coud resut in death or serious injury /CP PRINTED IN U.S.A.

29 This machine is equipped with one of two types of boom and attachment joystick contro configurations, either a two-joystick configuration, or a singe tri-function joystick. Two-Joystick Configuration Frame Leve and Attachment Joystick Boom Contro Joystick the eft. To raise the boom, move the joystick hande rearward; to ower the boom, move the joystick hande forward. Auxiiary Hydrauics Contro: This two-position ever is for attachment toos that require additiona hydrauics. Tri-Function Joystick Configuration Boom, Attachment and Auxiiary Hydrauic Joystick Frame Leve Contro Auxiiary Hydrauics Contro Two-Joystick Configuration Frame Leve/Attachment Tit Joystick: The machine may be tited sowy as much as 10 to the eft or right to eve the frame and boom in reation to the ground. Move the joystick hande to the eft to tit to the eft; move the joystick hande to the right to tit to the right. WARNING DO NOT eve the frame with the boom raised or extended. Leve the frame ONLY whie stopped, with the boom fuy retracted and the attachment raised just enough to cear the ground. To tit the attachment too up, move the joystick hande rearward. To tit the attachment too down, move the joystick hande forward. After the operator tits the attachment too to a desired ange, that ange wi be maintained as the boom is raised and owered, extended and retracted, unti a new ange is set. Boom Contro Joystick: This machine has a hydrauic-type boom with teescopic sections. The sections extend by means of a hydrauic cyinder and chain system inside the boom, sequenced for uniform extension of each section. To extend the boom, move the joystick hande to the right; to retract the boom, move the joystick hande to Singe Tri-Function Joystick Configuration Tri-Function Joystick: This joystick hande is equipped with two yeow buttons and two bue buttons on the upper rear of the hande, and a trigger switch on the front of the hande. The yeow buttons operate the attachment tit. The bue buttons operate the auxiiary hydrauics. The trigger switch increases the function speed of both the attachment tit and auxiiary hydrauics. To extend the boom, move the joystick to the right; to retract the boom, move the joystick to the eft. To raise the boom, move the joystick rearward; to ower the boom, move the joystick forward. To tit the attachment too up, depress and hod the ower yeow button on the eft side of the joystick hande; to tit the attachment too down, depress and hod the upper yeow button on the eft side of the joystick hande. To operate the auxiiary attachment hydrauics, depress and hod either the upper or ower bue button on the right side of the joystick hande. The upper bue button wi cause the reverse effect of the ower bue button. Depressing and hoding the trigger on the front side of the joystick hande wi increase the speed of the attachment tit and auxiiary hydrauic functions. NOTE: The joystick hande does not need to be moved to operate the tit or auxiiary hydrauic functions. PRINTED IN U.S.A /CP0112

30 Speed Contro Knobs: The tri-function joystick incorporates a manuay adjusted speed contro. Speed adjustment is accompished through the manua adjustment of piot-pressure appy vaves ocated next to the main vave at the rear of the machine. NOTE: There is a ocking knob ocated forward of the adjusting knob, which must be oosened before the adjusting knob can be turned. After adjustment has been made, tighten the ocking knob to maintain the seected speed. Attachment Tit Piot- Pressure Appy Vave Locking Knobs Auxiiary Hydrauics Piot-Pressure Appy Vave Piot-Pressure Appy Vave Frame Leve Contro: This contro is ocated to the rear of the tri-function joystick. The machine may be tited sowy as much as 10 to the eft or right to eve the frame and boom in reation to the ground. WARNING DO NOT eve the frame with the boom raised or extended. Leve the frame ONLY whie stopped, with the boom fuy retracted and the attachment raised just enough to cear the ground. FUNCTION INDICATORS Frame Ange Indicator: Located in front of the operator on the ROPS upper cross tube, the position of the ba indicates when the frame is eve reative to a soping ground surface. Frame Ange Indicator Boom Ange Indicator: Mounted on the eft side of the outer boom, the movement of a ba indicates the ange of boom eevation reative to the ground. Speed Contro Knobs L71378 Deca If the machine is equipped with auxiiary hydrauics, there wi be two piot-pressure appy vaves, each having two speed-contro knobs. The top piot vave contros the auxiiary hydrauics, and the ower piot vave contros the attachment tit function. On the attachment tit piot vave, the eft knob contros the attachment tit-back speed, and the right knob contros the attachment tit-forward speed. On the auxiiary hydrauic piot vave, the function of the knobs wi depend on the type of attachment requiring auxiiary hydrauics. Turning a knob cockwise wi increase the speed of its associated function. Turning a knob counter-cockwise wi decrease the speed of its associated function. Boom Ange Indicator SERVICE AND SAFETY FEATURES Cooant Leve: The radiator cap is ocated under the opening toward the rear of the main hood section. Radiator Cap /CP PRINTED IN U.S.A.

31 Engine Oi Leve: The dipstick is ocated on the right side of the engine. Engine Oi Dipstick Transmission Oi Leve: The dipstick is ocated under the access cover on the front hood section. Hydrauic Reservoir Oi Leve and Fi Cap: The dipstick on the fi cap of the reservoir indicates the eve of the hydrauic oi in the reservoir. Hydrauic Pressure Test Ports: A gauge can be attached to these ports to check main vave, joystick and steering pressures. Side-View Mirror: Located on the front outside corner of the fue tank, this mirror provides the operator with a view toward the rear of the machine. Battery Compartment: The battery is ocated under the access cover on the front hood section. Hydrauic Test Ports Battery Compartment Side-View Mirror Transmission Dipstick Hydrauic Fi Cap/Dipstick Air Fiter Restriction Indicator: Located in the rubber connector at the rear of the air ceaner, it indicates when the air ceaner needs service. If the cear portion of the indicator is red, the air ceaner shoud be checked for a cogged fiter eement. Air Fiter Restriction Indicator Backup Aarm: Located inside the rear frame cover, this aarm produces a oud warning sound when the machine is in reverse. Fuse and Reay Access Compartment: This compartment is ocated under the oad chart pane. Remove the four screws to gain access to the fuses and reays. Backup Aarm Fuse and Reay Access PRINTED IN U.S.A /CP0112

32 Fuses and Reays Functions: Refer to the iustration and foowing description for the fuse and reay functions. A E D C ATTACHMENT TOOLS Geh Company offers a range of attachment toos to meet various ifting and materia-handing appications. Contact your Geh deaer for specifications and ordering information. ACCESSORIES Geh aso offers a range of specia accessories for this machine. Contact your Geh deaer for specifications and ordering information. B F NOTE: A accessories are fied-instaed uness otherwise noted. Information and parts for instaing accessories are provided by your Geh Teescopic Hander deaer or Geh Company. FUSES: AMP fuse: Ignition Switch, Horn, Brake Lights, and Backup Aarm AMP fuse: Transmission, Park Brake, PWP, Steer Seect, and Injector Pump AMP fuse: Lights, Ether, and Cutch Cutout AMP fuse: Heater and Gauges AMP fuse: Top Wiper Motor AMP fuse: Front Wiper Motor. RELAYS: A. 20 AMP change-over reay: Ignition. B. 20 AMP change-over reay: Park Brake. C. 20 AMP reay: Front Wiper. D. 20 AMP reay: Bub Check. E. 20 AMP reay: Lights. F. 20 AMP reay: Top Wiper /CP PRINTED IN U.S.A.

33 Chapter 6 OPERATION AND ADJUSTMENTS GENERAL INFORMATION ENGINE BREAK-IN CAUTION BEFORE starting the engine and operating the Teescopic Hander, review and compy with ALL safety recommendations in the SAFETY chapter of this manua. Know how to STOP the machine before starting it. Aso, BE SURE to fasten and propery adjust the seatbet. A new engine does not require extensive break-in. However, for the first 100 hours of operation: Aow the engine to ide for a few minutes after every cod start, DO NOT ide the engine for ong periods of time, DO NOT operate the engine at maximum power for ong periods of time, and check the oi eve frequenty, and repenish as necessary with the oi specified in the engine manua. John Deere engines use a break-in oi for the first 100 hours of operation. After the first 100 hours of operation, change the oi and repace the oi fiter. Consut the Lubrication chapter or the engine manua for the type of oi to use in the engine. Refer to the Service and Storage chapter for the proper service intervas. PRE-START INSPECTION It is the operator s responsibiity to inspect the machine before the start of each workday. Every pre-start inspection must incude more than checking the fue and oi eves. It is a good practice to personay inspect any machine you are assigned to use, even if it has aready been checked and put into service by other personne. The most efficient method of checking a machine is by conducting a Wak-Around Inspection. Before mounting the operator s compartment, wak competey around the machine to be sure no one is under, on, or cose to it. Let others in the area know you are going to start up. Wait unti everyone is cear of the machine before starting it.. BEFORE STARTING ENGINE Before starting the engine and running the machine, refer to the Indicators and Contros chapter and become famiiar with the various operating contros, indicators and safety features. STARTING THE ENGINE WARNING ALWAYS fasten your seat bet BEFORE starting the engine. Leave the parking brake appied unti the engine is running and you are ready to operate the machine. The foowing procedure is recommended for starting the engine: 1. Grasp the handhods and step up into the operator s compartment. 2. Adjust the seat and fasten the seatbet. 3. Check that a contros are in their neutra positions, except the parking brake switch, which shoud be in the ON position. 4. Turn the key switch to the ON position and press the start button. If the button is reeased before the engine starts, turn the key switch to the OFF position and aow the starter to stop before attempting to start again. IMPORTANT: Crank the starter unti the engine starts. If the engine fais to start within 30 seconds, return the key to the OFF position, wait two minutes, and try to start the engine. Cranking the engine for onger than 30 seconds wi resut in premature faiure of the starter. 5. After the engine starts, aow a sufficient warm-up time before operating the contros. 6. Check that indicators are in their norma operating conditions. PRINTED IN U.S.A /CP0112

34 7. Verify that there are no fue, oi or engine cooant eaks, and no abnorma noises or vibrations. COLD STARTING PROCEDURES The engine is equipped with a bock heater. This bock heater or other starting aid is required for starting in temperatures beow 32 F (0 C). See your Geh deaer for additiona starting aids. For proper use of starting aids, check the instructions in the engine manua. If the battery becomes discharged and has insufficient power to start the engine, jumper cabes can be used for starting assistance. Refer to the jump starting instructions in the Service and Storage chapter of this manua for safe jump starting procedures. STOPPING The foowing procedure is the recommended sequence for stopping the machine: 1. Bring the machine to a stop on a eve surface. Avoid parking on a sope, but if necessary park across the sope and bock the whees. 2. Fuy retract the boom and ower the attachment to the ground. Ide the engine for gradua cooing. 3. Pace contros in neutra. Appy the parking brake. 4. Turn the ignition switch key to the OFF position. Remove the key. 5. Unfasten the seatbet, and grasp the handhods whie cimbing out of the operator s compartment. FIRST TIME OPERATION Make sure the engine is warm, and then go through the foowing procedures: CAUTION Be sure the area being used for test-running is cear of spectators and obstructions. Initiay, operate the machine with an empty attachment too. Pace the trave ever in Forward or Reverse and seect a speed range. Switch off the parking brake and move ahead sowy, whie testing the steering and brakes. Stop and operate a boom, attachment too functions and frame eveing contros, checking for smooth response. Appy the service brakes, stop the machine and move the trave ever to the opposite direction (forward or reverse). Shifting to the next higher gear may be done at any engine speed whie the machine is in motion. DO NOT overspeed the engine when down-shifting. Aow the machine to sow down before shifting to the next ower gear. PARKING BRAKE NOTE: The parking brake mechanism within the front axe is not designed for, and not intended to be used as, the primary means of stopping movement of the machine. Hydrauic braking provided through the service brakes within the axes is the primary means for stopping movement. The axeby-axe spit brake system is the secondary means of stopping movement. The proper sequence for correct machine operation is to aways engage the parking brake switch before shutting off the engine; and to disengage the parking brake ONLY after the engine is running. In an emergency however, if it becomes necessary to stop movement, activate the parking brake switch to ON. CHANGING ATTACHMENT TOOLS The Teescopic Hander boom nose wi accept Geh Quick-attach System attachment toos. The Quickattach System has a quick-reease hookup and ocking mechanism for mounting framing-type or masonry-type attachment toos to the boom nose. Attaching To pick up an attachment too, proceed as foows: 1. Raise the boom sighty, extend it two to three feet (600 to 900 mm) for better visibiity, and tit the too carrier forward. 2. Aign the too carrier squarey with the back of the attachment too. 3. Sowy extend the too carrier and ower the hooks under the attachment too hookup bar. 4. Tit the too carrier back so that the ock pate engages the attachment too. This secures the attachment too to the Quick-attach System. 5. For an attachment too with auxiiary hydrauics, connect the hoses to the quick-disconnect connectors on the boom nose /CP PRINTED IN U.S.A.

35 Attachment Too Quick-attach System Tited Forward for Hookup NOTE: One side of the ock pate has a bright red deca to indicate the unocked position. 5. If the attachment too has auxiiary hydrauics, disconnect the hoses from the quick-disconnects on the boom nose. 6. Start the engine and ro the Quick-attach System forward. Sowy back the machine unti the attachment too is free from the boom nose. Attachment Too Shown Locked to Quick-attach System Quick-attach System Attaching Detai Detaching To detach the attachment too, proceed as foows: 1. Raise the boom sighty and extend it two to three feet (600 to 900 mm) for better visibiity. Lower the boom unti the attachment too is approximatey 12 (0.3 m) off the ground. 2. Tit the carrier rearward as far as it wi go. Once the carrier is tited back a the way, perform the Mandatory Safety Shutdown Procedure (Safety chapter, page 8). 3. With the engine off, eave the operator s station and manuay raise the ock spring and fip the ock pate up and outward at east 180 so it is in position to re-ock onto the next attachment too. 4. Tit the Quick-attach System forward to aow the attachment too to ro out, then ower the boom so that the hook ears cear the hookup bar on the attachment too. Attachment Too Shown Unocked for Reease from Quick-attach System Quick-attach System Detaching Detai SELF-LEVELING WARNING Modifications, aterations to, or use of attachment toos not authorized by Geh (or the manufacturer) in writing can void warranty and cause machine damage and/or serious persona injury or death. The machine is equipped with a hydrauic sef-eveing feature. This feature is designed to keep the attachment too eve whie the boom is being raised. PRINTED IN U.S.A /CP0112

36 GENERAL MACHINE OPERATION WARNING Exhaust fumes can ki. Ensure proper ventiation when starting indoors or in encosed areas. Use proper hand-hods, NOT the steering whee or contro evers as handhods when mounting and dismounting. NEVER operate the machine with safety guards or covers removed. Over-infated tires can expode and cause injury or death. Tire repairs MUST be made ony by authorized personne using proper toos and equipment. Check the Teescopic Hander to be sure a systems are in good operating condition. Perform the foowing steps before starting the machine the first time each day: 1. Check the engine oi, cooant, transmission oi and hydrauic oi eves. 2. Make sure weeky ubrication has been done. 3. Visuay inspect for eaks, broken or mafunctioning parts. Make sure a caps, covers and safety shieds are in pace. 4. Check tires for cuts, buges, nais, correct pressure, oose whee nuts, etc. 5. Inspect the work area. Be sure you know where you wi make oad pickups, pacements, ifts, and turns. Look over the terrain of the jobsite for hoes, obstaces, sippery surfaces, and soft or deep mud. 6. Check cearances of ramps, doorways and passageways. Check overhead cearances if you wi trave and pace oads near power or teephone ines. 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 immediatey to the user s designated authority. The machine shoud NOT be operated unti it has been restored to a safe operating condition. Grade and Sope Precautions The Teescopic Hander compies with industry stabiity test requirements and is stabe when propery operated. However, improper operation, fauty maintenance, and poor housekeeping can contribute to a condition of instabiity. The amount of forward and rearward tit to be used is governed by the appication. Athough use of maximum rearward tit is aowabe under certain conditions, such as traveing with the oad fuy owered, the stabiity of the machine, as determined by the industry standard tests, does not encompass consideration for excessive tit at high eevations, or the handing of offcenter oads. Ony hande oads within the capacity imits of the machine, and which are stabe and safey arranged. When attachments are used, extra care shoud be taken in securing, manipuating, positioning and transporting the oad. Grade Limits NOTE: Grade imits are based on ANSI/ITSDF standard B The teescopic hander meets or exceeds the safety standard (ANSI/ITSDF B56.6) stabiity imits for rough terrain forkifts. The stabiity tipping imits cover specific, controed test conditions, which are extremes, and which are not intended to be achieved during norma worksite operations. The foowing specifications are provided ony as information to the operator, and must not be used as a guideine for operating the teescopic hander. For safe operation, aways foow the instructions and warnings provided in this manua. 1. DO NOT pace or retrieve oads on an up or down sope or grade that exceeds 7% or DO NOT trave up or down a grade or sope that exceeds 22% or 12 whie oaded. 3. DO NOT pace or retrieve oads on a side hi with a sope or grade that exceeds 12% or 7. Regardess of the terrain or position of the whees, the FRAME MUST BE LEVEL, as indicated by the frame ange indicator on the ROPS/FOPS crossmember. Operate the trave contros graduay and smoothy when starting, stopping, turning and reversing direction /CP PRINTED IN U.S.A.

37 4. DO NOT trave across a side hi that exceeds 18% or 10 grade. Regardess of the terrain or position of the whees, the FRAME MUST BE LEVEL, as indicated by the frame ange indicator on the ROPS/FOPS crossmember. The attachment too MUST be maintained at the carry position with the boom fuy retracted, and attachment too at minimum ground cearance. When ascending or descending grades in excess of 5% or 3, the machine shoud be driven with the oad upgrade. An unoaded machine shoud be operated on a forward grades with the oad handing attachment too downgrade, tited back if appicabe, and raised ony as far as necessary to cear the road surface. Safety Hand Signas Continued On grades, ramps and incines, use extreme caution and avoid turning if possibe. Normay trave straight up and down the sope. WARNING DO NOT eve the frame with the boom raised or extended. Ony eve the frame whie stopped, and with the boom fuy retracted, and the attachment too raised just enough to cear the ground. Traffic Fow Patterns Know and understand the traffic fow patterns of your jobsite. Know a Teescopic Hander hand signas for safety. Utiize signa persons and be sure you can see the signa person and acknowedge the signas given. Safety Hand Signas When ramps must be used in transporting oads with the machine, the foowing sha be the minimum widths for safe trave: Compacted dirt, grave, etc. 12 ft. (3.6 m) Woodboard, concrete, etc. 10 ft. (3.0 m) Permanent aises, roadways, passageways, foors and ramps shoud be marked or defined in some fashion. Permanent or temporary protrusion of oads, equipment, materia and construction faciities into the usua operating area shoud be guarded, ceary and distinctivey marked, or ceary visibe. Maintain a safe distance from the edge of ramps, patforms and other simiar working surfaces. PRINTED IN U.S.A /CP0112

38 Controed ighting of adequate intensity shoud be provided in operating areas. Where operating conditions dictate, the operator/user is responsibe for having the machine equipped with ights. Provisions shoud be made to prevent trucks, semitraiers and rairoad cars from being moved during oading and unoading. Whee stops, parking brakes, or other positive hoding means shoud be used to prevent movement during oading and unoading. DO NOT move rairoad cars and traiers with the Teescopic Hander. DO NOT use the boom and attachment for everage to push the machine out of mud. IMPORTANT: DO NOT ower boom at high engine speed when attachment too is at maximum rearward tit. Damage to save cyinders may resut. GENERAL LOAD HANDLING NEVER operate contros except from the operator s seat. NEVER jerk or use fast movements. Avoid sudden stops, starts and changes in direction. Operation of the hydrauic system depends on engine speed and the distance the contros are moved. When operating these contros it is important to deveop a technique caed feathering. Feathering the contro means starting the desired motion by moving the contro a sma distance away from neutra. Then, after movement has started, the contro can be eased to fu trave. Use the same feathering technique to sow and stop the motion. WARNING Excessive speed can be hazardous. ALWAYS exercise caution and good judgement whie operating the machine. ALWAYS maintain a safe distance from eectric power ines and avoid contact with any eectricay charged conductor and gas ine. It is not necessary to make direct contact with a power ine for power to ground through the structure of the machine. Keep the boom and oad at east 10 ft. (3 m) from a power ines. Accidenta contact with a power ine or rupture of a gas ine can resut in eectrocution or an exposion. Contact the Ca Before You Dig referra system number at in the U.S., or in the U.S. and Canada, to ocate any underground utiity ines BEFORE starting to dig. Keep a body parts inside the operator s station whie operating the machine. BE SURE of cearance for the attachment too when turning, working around buidings, etc. Turning corners too fast can tip the machine, or cause a oad to side off the attachment. Sudden sowing or stopping of the machine may cause the oad to fa off the attachment too. Be certain you can contro both speed and direction before moving. Aways pace the machine in neutra and set the parking brake before raising or extending the boom. NEVER drive the machine up to someone standing in front of the oad. NEVER eave the operator s station without first owering the attachment too to the ground. Then set the parking brake, pace contros in neutra, shut off engine and remove the key. AVOID parking the machine on a sope, but if necessary, park across the sope and bock the tires. Load Capacity and Reach The machine has fip-charts in the operator s station that provide, at a gance, the oad capacity imits at various positions of attachment too extension and eevation. A set of the oad zone charts is reproduced at the end of this manua for reference. A typica oad zone chart is shown on the next page. The scae on the eft indicates height in feet above the ground eve. The scae on the bottom shows the distance in feet from the front of the machine. The arc ines noted by the numbers 1 through 5 correspond with the position extension markers on the operator side of the intermediate boom section. The foowing exampe iustrates proper use of the oad zone charts for the Teescopic Hander: /CP PRINTED IN U.S.A.

39 Exampe: The operator, using a standard carriage attachment too, wants to raise a 2000 b. oad 20 feet high, and can ony get to within 15 feet of the oad pacement point. Can it be done within the capacity of the machine? Anaysis: See Typica Load Zone Chart beow. Projecting up from the 15-foot reach mark on the horizonta axis to intersect a ine through the 20-foot height mark on the vertica axis shows that a oad up to 2000 b. can be paced in that zone. During pacement, the operator shoud observe when the boom extension mark number 4 on the boom is visibe and stop further extension. The operator knows the maximum safe extension distance with the 2000 b. oad has been reached. WARNING NEVER exceed the rated operating capacity of the Teescopic Hander as shown on the oad zone charts. LIFTING ATTACHMENT TOOL APPLI- CATIONS Picking Up the Load Inspect the oad before picking it up. If it appears unstabe, DO NOT attempt to move it. DO NOT attempt ifting doube-tiered oads, or stradding sideby-side paets with one on each fork. NEVER add extra unauthorized counterweights to the machine. WARNING Operating conditions such as sopes or soft ground can reduce the machine s safe operating capacity. Exceeding the capacity when raising or extending the boom wi cause the machine to tip forward. Approach the oad sowy and squarey with the machine straight and eve. Adjust the space between forks, if necessary. Engage the oad equay on the forks unti the oad touches the carriage backrest. Tit the forks back to position the oad for trave. HEIGHT ABOVE GROUND BOOM EXTENSION MARKERS Carrying the Load If the oad 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 trave with the boom above the carry position (attachment too shoud be at minimum ground cearance). Boom shoud be fuy retracted. Use ower gear when traveing down an incine. NEVER coast with the transmission in neutra. Trave up and down grades sowy. DO NOT operate the machine on a sope or grade that exceeds 22% or 12 o. DISTANCE LOAD IS EXTENDED Typica Load Zone Chart Load Eevation and Pacement For ground eve oad pacement, be sure the area under the oad and around the machine is cear of equipment and personne. Lower the oad to the ground, tit the forks to the horizonta position, and then carefuy back away to disengage the forks from the oad. PRINTED IN U.S.A /CP0112

40 For eevated or overhead pacement, bring the machine as cose as possibe to the anding point, and then: 1. Leve the machine BEFORE raising the oad. Use extreme caution for high pacement. Be sure personne are cear of the area where the oad or the machine coud fa or tip. 2. Set the parking brake, hod the service brake peda fuy appied and sowy raise the oad, maintaining a sight rearward tit to crade the oad. 3. As the oad approaches the desired height, feather the boom contro at minimum speed unti the oad is sighty higher than the anding point. 4. Continuing the feathering technique, ower the oad into pace. 5. Free the forks from the oad by aternatey retracting and raising the boom. If this process is not possibe, very sowy and carefuy reverse the teescopic hander to free the forks from the oad. 6. Lower the forks to trave height. Instaing a Personne Work Patform (PWP) WARNING The machine must not be used to ift or carry personne or be fitted with any form of personne work patform uness fitted with the optiona PWP System. If fitted with the PWP System, the Mandatory Work Patform Safety Rues (p. 13) must be foowed at a times whie ifting personne. 1. Center the forks on the carriage, spaced apart to match the distance required to engage the PWP. 2. After the forks are fuy engaged in the PWP, secure the PWP to the forks. This can be accompished by means of a retaining pin behind the hee of the forks, as shown. 3. Secure the forks from pivoting upward in case the PWP is owered onto an obstruction. This can be accompished by using the chain suppied with the PWP to secure the ower portion of the PWP to the bottom of the carriage, as shown beow. Chain WARNING The PWP must meet ANSI/ITSDF B , Section (See page 14 in the Safety chapter for PWP design requirements.) If the PWP being used does not offer means to secure the PWP to the forks and to secure the forks from pivoting, as shown in steps 2 and 3, then an aternate method must be used. 4. Connect the coied 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 beow. Eectrica Connection PWP Remote Shutdown Switch Remote Shutdown Switch with Coied Wire Connector 5. Secure the anyard from the body harness to the PWP or the boom. Each person in the PWP shoud have a body harness with a anyard attached to the PWP. Retaining Pin /CP PRINTED IN U.S.A.

41 Eevating Personne The Teescopic Hander is primariy intended for use as a materia hander. It shoud ony be used to eevate personne if it is equipped with the (optiona) PWP System when there is no other practica option. If this machine is to be used to eevate personne, then use ony an approved work patform, ift personne ony with the PWP System activated, and foow the Mandatory Work Patform Safety Rues (p. 13 Safety chapter). If the Teescopic Hander is equipped with a PWP System and is to be used for eevating personne, the system must be activated, by using the "PWP System" mode switch, which is ocated in the instrument and switch pane. To activate the system, press the top of the PWP rocker switch, appy and hod the service brakes on for three or more seconds. The system is activated when the amp in the PWP rocker switch is on continuousy. WARNING ALWAYS check the PWP System for proper operation prior to use. (See page 50 for PWP System checking procedure.) When the PWP System is active: transmission is de-cutched into Neutra, parking brake is appied, auxiiary hydrauic and carriage tit and swing functions are disabed, machine incination sensor is activated, with the resut that the Teescopic Hander must be eve ateray (side-to-side) and ongitudinay (front-toback) to within the factory pre-set imits before the boom contro joystick wi function, and remote shutdown switch is activated, meaning that the switch must be connected and in the on position for the boom contro joystick to function. Pressing the shutdown switch wi disengage the boom contro joystick, and stop a patform movement. The remote shutdown switch box is suppied with a coied eectrica cabe that must be connected to the outet on the front of the innermost boom section near the carriage. The switch must be accessibe by the patform personne at a times when the patform is to be moved. To de-activate the PWP System, appy and hod the service brakes on for three or more seconds, and press the bottom of the PWP System rocker switch. The system is de-activated when the amp in the PWP System rocker switch is off. NOTE: If the amp in the PWP system rocker switch is fashing, appy the service brakes unti the amp goes off. WARNING In an emergency, if the patform worker has activated the remote shut-off switch and then is not abe to re-activate the switch, such as if the worker fainted, then the Teescopic Hander operator is permitted to turn off the PWP System to regain contro of the boom functions, in order to ower the work patform and come to the aid of the worker. But, understand this is ony permitted in case of an emergency. Otherwise, the PWP System must be used at a times when there are workers on the patform. This is the ony exception! WARNING The machine becomes ess stabe as the oad is raised higher. NEVER use frame eveing to position an eevated oad. Aways ower the oad to the ground and reposition the machine. If a hydrauic boom circuit hose shoud break with the boom up, shut down the machine. DO NOT attempt to bring down the boom or make repairs. Ca your Geh deaer immediatey. As ift height increases, depth perception decreases. High eevation pacement may require a signa person to guide the operator. DO NOT ram the ift cyinders to the end of the stroke. The resuting jot coud spi the oad. A jib or truss boom shoud ONLY be used to ift and pace oads when the machine is stationary and the frame is eve. Transporting suspended oads must ALWAYS be done sowy and cautiousy, with the boom and oad as ow as possibe. Use tagines to restrict oads from swinging, to avoid overturn. PRINTED IN U.S.A /CP0112

42 SUSPENDED LOADS The handing of suspended oads by means of a truss boom or other simiar device can introduce dynamic forces affecting the stabiity of the machine that are not considered in the stabiity criteria of industry test standards. Grades and sudden starts, stops and turns can cause the oad to swing and create a hazard. Guideines for Free Rigging / Suspended Loads 1. DO NOT exceed the rated capacity of the teescopic hander as equipped for handing suspended oads. The weight of the rigging must be incuded as part of the oad. 2. During transport, the ength of the rigging between the attachment and oad shoud be as short as possibe to reduce booms height and movement. DO NOT raise the oad more than 12 inches (305 mm) above the ground, or raise the boom more than 45 degrees. 3. Ony ift the oad verticay NEVER drag it horizontay. 4. Use mutipe pickup points on the oad when possibe. Use tagines to restrain the oad from swinging and rotating. 5. Start, trave, turn and stop SLOWLY to prevent the oad from swinging. DO NOT exceed waking speed. 6. Inspect rigging before use. Rigging must be in good condition and in the U.S. compy with OSHA reguation , Sings, or , Rigging equipment for materia handing. 7. Rigging equipment attached to the forks must be secured such that it cannot move either sideways or fore and aft. The oad center must not exceed 24 inches (610 mm). 8. DO NOT ift the oad with anyone on the oad, rigging or ift equipment, and NEVER ift the oad over personne. 9. Beware of the wind, which can cause suspended oads to swing, even with tagines. 10. DO NOT attempt to use frame-eveing to compensate for oad swing. ROAD TRAVEL For short distance highway trave, attach a Sow- Moving Vehice (SMV) embem (purchased ocay) to the rear of the Teescopic Hander. For highway operation, obtain and insta an amber fashing beacon. NOTE: ALWAYS foow ALL state and oca reguations regarding the operation of equipment on or across pubic highways. Whenever there is an appreciabe distance between jobsites, or if driving on pubic highway is prohibited, transport the machine using a vehice of appropriate size and capacity. TRANSPORTING BETWEEN JOB- SITES ALWAYS abide by the foowing recommended procedures and guideines when using ramps to oad the machine onto (and unoad it from) a truck or traier. Faiure to heed can resut in damage to equipment and serious persona injury or death! Tie-down eyes are provided for inserting chains through to secure the machine during transporting. Front Tie-Down Rear Tie-Down Loading Machine Using Ramps NOTE: A matched pair of ramps is required. Ramp Pacement 1. The ramps MUST be of sufficient strength to support the machine. The use of strong stee ramps is recommended, as we as center supporting bocks /CP PRINTED IN U.S.A.

43 2. The ramps MUST be firmy attached to the truck or traier bed with NO step between the bed and the ramps. 3. The incine of the ramps MUST be ess than 15 degrees. For a four-foot high truck bed, ramp ength must be at east 16 feet (4.9 m) ong. 4. Ramp width MUST be at east 1-1/2 times the tire width. 5. Bock the front and rear of the tires on the truck or traier. Engage the parking brake. 6. Position the machine with the boom facing toward the front of the truck or traier so that it is straight in ine with the ramps. 7. Sowy (at the owest engine speed possibe) and carefuy drive the machine up the ramps. 8. Secure the machine to the bed of the truck or traier with tie-down chains/cabes. Unoading Machine Using Ramps NOTE: A matched pair of ramps is required. Repeat steps 1 through 5 and proceed as foows to unoad the machine: THEFT DETERRENTS Geh Company has recorded a major component part numbers and seria numbers. Users shoud take as many of the foowing actions as possibe to discourage theft, to aid in the recovery of the machine in the event it is stoen, and to reduce vandaism: 1. Remove keys from unattended machines. 2. Attach, secure, and ock a anti-vandaism and anti-theft devices on the machine. 3. Lock doors of cabs when not in use. 4. Inspect the gates and fences of the equipment storage yard. If possibe, keep machines in we-ighted areas. Ask the oca aw enforcement agency to make frequent checks around the storage and work sites, especiay at night, during weekends, and on hoidays. 5. Report any theft to your deaer and insurance company. Provide the mode and seria numbers. Request your deaer to forward this information to Geh Company. 6. Remove the tie-down chains/cabes. 7. If necessary, adjust the machine so that the whees are in ine and centered with the ramps. 8. Sowy (at the owest engine speed possibe) and carefuy drive the machine down the ramps. WARNING NEVER adjust trave direction (even sighty) whie traveing on the ramps. Instead, back down off the ramps, and then reaign 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 traier bed using chain and binders or stee cabes, to prevent any movement whie transporting. PRINTED IN U.S.A /CP0112

44 INTENTIONALLY BLANK /CP PRINTED IN U.S.A.

45 Chapter 7 LUBRICATION GENERAL INFORMATION NOTE: The Maintenance chapter (Chapter 10) in this manua has provisions for recording the dates and hourmeter readings after ubrication or other service has been performed; use those spaces to keep a og for maintaining a current service interva record. Proper routine ubrication is an important factor in preventing excessive part wear and eary faiure. LUBRICANTS WARNING NEVER ubricate 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 ubricating or servicing this equipment. The chart on this page ists the ocations, temperature ranges and recommended types of ubricants to be used when servicing the machine. Refer to the separate engine manua for additiona information regarding recommended engine ubricants, quantities and grades required. NOTE: Refer to Operator Services topic in the Service and Storage chapter of this manua for detaied information regarding periodic checking and repenishing of ubricants. A Grease Fittings Use No. 2 ithium-based grease Brake System Use Muti-ATF Dexron III or equivaent Hydrauic System Reservoir Use Mobi DTE 15M, or an equivaent that contains anti-rust, anti-foam and anti-oxidation additives and conforms to ISO VG46/VG32. Capacity: 35 gaons (133 iters) Engine Crankcase Oi Ambient Temperature Grade* -22 F F (-30 C - 40 C) SAE 5W F F (-40 C - 50 C) SAE 0W F F (-25 C - 40 C) SAE 10W F F (-25 C - 50 C) SAE 10W-40 5 F F (-15 C - 50 C) SAE 15W-40 *API Service Cassification: CJ-4/C-4 PLUS/CI-4 *API Service Cassification for first 100 hours on new or rebuit John Deere engines: CE, CD, or CC Capacity: 15.5 quarts (14.7 iters) Diese Fue 84 hp Tier 3 Engine: Use ony ow sufur (LSD) or utra ow sufer (ULSD) diese fue. Sufur content of 1000 PPM or beow specified to EN590 or ASTM D975 is strongy recommended. 74 hp IT4 Engine: Use ony utra ow sufer (ULSD) diese fue with a maximum of 15 PPM sufer content specified to EN590 or ASTM D975. Axe Gear Oi MobiFuid 424 (recommended) API GL4/GL5 80W with Wet Brake Additive (Geh Wet Brake Additive part number L71456) Differentia capacity: 9.6 quarts (9.0 iters) Panetary capacity: 0.6 quarts each (0.5 iters) Transmission Oi Use Muti-ATF Dexron III or equivaent Capacity: 24 quarts (23 iters) PRINTED IN U.S.A /CP0112

46 REPLACEMENT FILTER CHART AIR FUEL ENGINE HYDRAULIC TRANS. ENGINE TYPE FILTER FILTER OIL FILTER STRAINER OIL JOHN DEERE Primary L97489 L49327 L99184 Safety GREASING Refer to the iustrations and istings for fitting ocations. Wipe dirt from the fittings before greasing them to prevent contamination. Repace any missing or damaged fittings. To minimize dirt buid-up, avoid excessive greasing. BASIC MACHINE GREASE FITTINGS LOCATIONS Every 50 Hours (or weeky) Refer to the iustration on the facing page for ocations. CHASSIS AREA 1 Brake foot peda inkage Whee spinde pins (per axe) Axe-to-frame pivot pins (per axe) Drive shaft, sip joint (per shaft) Drive shaft, u-joint (per shaft) Leve cyinder pivot pins Base end, ift cyinder pivot pins Base end, save cyinder pivot pins BOOM AREA 9 Boom-to-frame-upright pivot pins Rod end, save cyinder pivot pins Rod end, ift cyinder pins Extend cyinder pivot pins Chain sheave pins Quickattach-to-boom-nose pivot pins Tit cyinder pivot pins Rotate cyinder pivot pins Rotate carriage wear pads Rotate pivot bearing Boom side pads - as required, front and rear FRONT SIDE /CP PRINTED IN U.S.A.

47 UNDER COVER Grease Fittings Locations PRINTED IN U.S.A /CP0112

48 Chapter 8 SERVICE AND STORAGE GENERAL INFORMATION NOTE: A service routines, with the exception of those described under the Deaer Services topic, are owner-operator responsibiities. A operator services described under the subtopics are aso referred to on a deca ocated on the inside right side pane of the operator s station. Refer to the Lubrication chapter of this manua for ubrication information. NOTE: This Service and Storage chapter detais procedures to foow for making routine maintenance checks, adjustments and repacements. The majority of the procedures are aso referred to in the Maintenance chapter of this manua. For engine-reated adjustments and servicing procedures, refer to the engine manua provided. PRECAUTIONS WARNING BEFORE performing any service on the Teescopic Hander, uness expressy instructed to the contrary, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (p. 8, Safety chapter). After service has been performed, BE SURE to restore a guards, shieds and covers to their origina positions BEFORE resuming machine operation. DO NOT perform any maintenance or repair without the owner s prior authorization. Aow ony trained personne to service the machine. Warranty repairs can ony be done by a Geh deaer. Deaers know what portions of the machine are covered under the terms of the Geh Warranty and what portions are covered by other vendor warranties. When a probem occurs, do not overook simpe causes such as an empty fue tank. Check for eaks and broken connections. Make note of any specific symptoms, noises, etc. and contact your oca Geh deaer. IMPORTANT: Aways dispose of waste ubricating ois, anti-freeze and hydrauic fuids according to oca reguations or take them to a recycing center for disposa. DO NOT pour them onto the ground or into a drain. DEALER SERVICES The foowing areas of interna components service repacement and operating adjustments shoud ony be performed by (or under the direction of) an authorized Geh Teescopic Hander deaer. IMPORTANT: DO NOT service or repair major components, uness authorized to do so by your Geh deaer. Any unauthorized repair wi void the warranty. POWERTRAIN COMPONENTS The engine and transmission are couped directy to each other. A service routines reated to the interna components are precise and critica to proper powertrain operation. The axe differentia and panetary ends are aso sophisticated assembies that require specia know-how and toos for servicing. IMPORTANT: If any powertrain components are suspected of fauty operation, contact your Geh deaer for assistance. HYDRAULIC SYSTEM COMPONENTS Vaves, pumps, motors and cyinders are sophisticated assembies, which require specia know-how and toos for servicing. A cyinders are appropriatey designed with particuar strokes, diameters, checks and hose connection provisions unique to the machine appication requirements. A hydrauic schematic (ocated at the back of this manua) can be used as a guide for service reference, as required /CP PRINTED IN U.S.A.

49 WARNING Tit, ift, extend and eveing cyinders have counterbaance vaves. These vaves keep hydrauic fuid from entering and exiting the cyinders whie not being used, and are under extremey high pressure. Before removing any of these vaves, it is REQUIRED to ca the your Geh Service Department. Faiure to do so may resut in serious injury or death. Interna service on any of these components shoud ony be performed by (or under the direction of) an authorized Geh Teescopic Hander deaer. ELECTRICAL COMPONENTS An eectrica system schematic is provided, which incudes instrumentation, eectrica components and switch connections. It is ocated at the back of this manua and can be used as a guide for service reference, as required. OPERATOR SERVICES Some of the operator-reated services wi require access to components ocated inside the superstructure, under shieds, hoods and covers. The chart on this page notes the components accessed in each particuar area. ACCESS TO COMPONENTS CHART Component Operator s Frame Front Mid-Rear Station Cover Hood Axe (underside) Engine Transmission (center area) Drive Shafts (underside) Main Contro Vave (rear) Muffer (underside) Air Ceaner (top fue tank) Battery Radiator Brake Vave (underside) Trave Contros (dash area) Boom Contros (right side) Hydrauic Test Ports Hourmeter (dash) Switches/Indicators (dash) Hydrauic Pump Hydrauic Fiter (Reservoir) Misc. Hydrauic Vaves Heater (ower front) PRINTED IN U.S.A /CP0112

50 WARNING DO NOT smoke or aow any open fames in the area whie checking or servicing hydrauic, battery or fue systems; a contain highy fammabe iquids or exposive gases, which can cause an exposion or fire if ignited. Wear a face shied when disassembing spring-oaded components or working with battery acid. Wear a hemet or gogges with specia enses when weding or cutting with a torch. When working beneath a raised machine, aways use bocks, jack-stands or other rigid and stabe supports. Wear appropriate protective cothing, goves, and shoes. Keep feet, cothing, hands and hair away from moving parts. Aways wear safety gasses or gogges for eye protection from eectric arcs from shorts, fuids under pressure, and fying debris or oose materia when the engine is running or toos are used for grinding or pounding. NEVER wed on bucket, forks, boom, support frame or ROPS/FOPS without the consent of the manufacturer. These components may be made with metas that require specia weding techniques, or with designs that do not aow wed repairs. NEVER cut or wed on fue ines or tanks. If repair weding is ever required, BE SURE to attach the ground (-) cabe from the weder as cose as possibe to the area to be repaired. Aso, remove positive (+) battery termina connection before weding. Choose a cean, eve work area. Be sure there is sufficient room, cearances, and adequate ventiation. Cean the waking and working surfaces. Remove oi, grease and water to eiminate sippery areas. Use sand or oi absorbing compound, as necessary, whie servicing the Teescopic Hander. guards or covers that provide needed access. Wipe away excess grease and oi. Excessivey worn or damaged parts can fai and cause injury or death. Repace any cracked or damaged parts. Use ony genuine Geh parts for service. Use care not to damage machined and poished surfaces. Cean or repace a pates and decas that are damaged or painted over and cannot be read. WARNING NEVER eave 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 eft over, etc. Insta a guards and covers. Service Every 10 Hours or Daiy CHECKING FUEL TANK LEVEL The fue eve is shown by the fue eve gauge on the instrument pane. After operation each day, the fue tank shoud be fied to prevent water from condensing in the tank. To fi, remove the fier cap and add fue. See the Lubrication chapter for the diese fue requirements. CHECKING FUEL FILTER NOTE: The fue fiter wi require occasiona repacement to maintain a cean and adequate fue fow for maximum engine horsepower. The frequency of fiter repacement wi be determined by the ceaniness of avaiabe fue, the care used in storing fue suppies, and the operating conditions in which the machine is used. B Before starting inspection and repair, move the machine onto a eve surface, shut down engine, and reease a hydrauic pressure. Aways bock the boom securey, or ower it to fu ground contact. Pace a contros in neutra. Bock the tires. Remove the ignition key. Remove ony C A /CP PRINTED IN U.S.A.

51 Check the fue fiter (C) for water and debris. IMPORTANT: Drain water into a suitabe container and dispose of propery. 1. Loosen two or three turns drain pug (A) at bottom of fue fiter. 2. Loosen air beed pug (B) two fu turns on fue fiter mounting and drain water from bottom unti fue starts to drain out. 3. When fue starts to drain out, tighten drain pug securey. After draining water from the fue fiter, the fiter must be primed by beeding a air from the fue system. Refer to the fue beeding procedure on page 53. A drain pug is aso provided in the bottom of the fue tank for removing condensation and other foreign materias. Open the pug and aow water and fue to drain into a container unti ony cear fue is fowing from the tank. CHECKING ENGINE OIL LEVEL With the machine on eve ground, and the engine stopped for ten minutes or more, remove the engine oi dipstick. Wipe it cean, re-insert it and remove to obtain a reading. If the oi eve is beow the crosshatch pattern on the dipstick, fi with the required amount of oi to bring the eve to within the crosshatch pattern. Oi eves anywhere within the crosshatch are considered fu. See the Lubrication chapter for the type of oi to use. CHECKING RADIATOR COOLANT LEVEL WARNING DO NOT remove the radiator cap when the engine is running hot or overheated. Cooant is extremey hot and under pressure and it can burn your skin. Aow sufficient time for the radiator to coo BEFORE reieving the pressure and removing the radiator cap. With the machine on eve ground, remove the radiator cap. If the cooant eve is beow the fier neck, add a ow-siicate ethyene gyco based cooant mixed with quaity water and suppementa cooant additives (SCAs) suitabe for heavy-duty diese engines. See your engine manua for additiona information. Repace the radiator cap securey. NOTE: If the engine is operated with a oose radiator cap, the pressure bypass wi not work and the engine wi run hot. CHECKING TRANSMISSION OIL LEVEL The machine must be on eve ground. With the engine and transmission at operating temperature, parking brake on, transmission in neutra and engine speed at ow ide, remove the access cover to the transmission and hydrauic pump. Remove the dipstick and check the oi eve. Add the required amount of oi to bring the eve to the FULL mark. See the Lubrication chapter for the type of oi to use. CHECKING HYDRAULIC OIL LEVEL The machine must be on eve ground with boom owered and competey retracted. The fuid MUST be coo when checking the reservoir eve, to reduce the possibiity of overfiing the hydrauic system. Locate the fier cap next to the side-view mirror on the right side of the machine. Remove the fier cap and check the eve on the dipstick. Oi eves anywhere between the mark on the dipstick and the bottom of the dipstick is considered fu. If the oi does not register on the dipstick, fi with the required type of oi to bring the eve to within the FULL area. See the Lubrication chapter for the type of oi to use. IMPORTANT: Be carefu when removing the reservoir fier cap so that no dirt or other foreign matter enters the hydrauic system. DO NOT OVERFILL. CHECKING BRAKE RESERVOIR LEV- ELS Fip up the cover on the cab foor in front of the seat. Remove both reservoir covers to check the fuid eves. If ow, fi to the proper eve with the correct fuid. See the Lubrication chapter for the type of fuid to use. CHECKING TIRE PRESSURES To ensure proper operating stabiity and extend tire ife, proper and equa tire pressure shoud be maintained in a four tires. Check tire pressures cod. Infate as necessary per the chart beow: x PR: 60 psi (415 kpa) PRINTED IN U.S.A /CP0112

52 NOTE: If the tires have been fied with water or cacium choride for baast, a cacium choride tire pressure gauge MUST be used to check the tire pressure. To ensure proper oad carrying capabiity, origina equipment tires compy with the specifications pubished in the Tire and Rim Association Yearbook. Repacement tires MUST meet the same specifications. When repacing tires, be sure a tires are of the same type, quaity and oad rating, and the same size as the origina equipment. When removing tires, foow industry safety practices. Defate competey prior to remova. After assemby of the tire on the rim, use a safety cage or restraining device whie infating. WARNING Infating or servicing tires can be dangerous. Whenever possibe, trained personne shoud service and mount tires. To avoid possibe death or serious injury, foow these safety precautions: 1. BE SURE the rim is cean and free of rust. 2. Lubricate both the tire beads and rim fanges with a soap soution. DO NOT use oi or grease. 3. DO NOT pace fingers on the tire bead or rim during infation. Use a cip-on tire chuck with a remote hose and gauge, which aows standing cear of the tire whie infating it. 4. NEVER infate beyond 35 psi (240 kpa) to seat the beads. If the beads have not seated by the time the pressure reaches 35 psi (240 kpa), defate the assemby, reposition the tire on the rim, reubricate both parts and re-infate. Infation pressure beyond 35 psi (240 kpa) with unseated beads may break the bead or rim with exposive force sufficient to cause death or serious injury. 5. After seating the beads, adjust the infation pressure to the recommended operating pressure isted. 6. DO NOT wed, braze, or otherwise attempt to repair and use a damaged rim. CHECKING WHEEL NUT TORQUE On new machines, or anytime a whee has been removed, re-torque whee nuts unti 450 ft.-bs. (610 Nm) is maintained. CHECKING INSTRUMENTS OPERA- TION Aow the engine to warm up for about five minutes before beginning operation. Indicator amps shoud be off and gauges shoud register norma readings. Tit the frame from side to side with the frame eveing contro and note the frame ange indicator movement. CHECKING GENERAL MACHINE OPERATION AND CONDITION Are any decas missing or damaged? Are a guards, shieds and covers in pace? Do a contros function smoothy and propery? Are there any abnorma vibrations or noises? Are any hose or fitting connections eaking? Is the engine exhaust coor norma? WARNING Manufacturers of push-pu contro cabes advise taking the foowing operation and maintenance precautions: Do not adjust the contro cabe with the engine running. A gradua or sudden increase in the no-oad friction (cabe disconnected at both ends) of a contro cabe is an indication of an impending or present performance probem. The contro cabe shoud be repaced. A gradua or sudden decrease in the useabe trave is a indication of an pending or present performance probem. The contro cabe shoud be repaced. Contro cabes that have moisture inside of them or have frozen shoud be repaced. Do not appy heat to dry or thaw contro cabes. Contro cabes are ubricated for the ife of the contro cabe. Do not remove the seas or ubricate contro cabes /CP PRINTED IN U.S.A.

53 Contro cabes are designed to be nonrepairabe. Do not attempt to repair contro cabes. Faiure to heed coud resut in death or serious injury. CHECKING PERSONNEL WORK PLAT- FORM (PWP) SYSTEM (if used) WARNING If the PWP System fais to operate propery during any of the System checks, DO NOT USE the machine unti the cause has been corrected. Contact your deaer (or Geh Company) for service information and parts. Machine Position The foowing must be performed before beginning the PWP System checking procedures: 1. Machine on eve surface, 2. Boom fuy owered, 3. Frame eve, 4. Transmission in N (Neutra), 5. Parking brake switch OFF, 6. PWP System switch OFF, 7. Remote switch pugged in and ENGAGED. Activation Tests To test the PWP System activation ogic: 1. Start the engine and press the PWP rocker switch to ON. The PWP System amp in the switch shoud be fashing. 2. Appy the service brakes. The PWP switch amp shoud be iuminated continuousy after three seconds, indicating that the PWP System has been activated. The parking brake shoud engage, as indicated by the amp in the parking brake switch iuminating. The carriage tit and auxiiary functions shoud now be disabed. The joystick contro shoud continue to function normay for boom raise/ower and extend/retract. Lockout Tests To test the transmission and joystick contro ockout ogic: 1. Shift transmission into F (Forward) and increase the engine speed sighty. The transmission shoud remain de-cutched, aowing the engine to increase speed easiy. Return the transmission seector to N (Neutra) after the check. 2. Have an assistant move the remote shutdown switch to Dis-engaged. The joystick contro shoud now be disabed, so that boom raise/ower and extend/retract wi no onger function. Have the assistant move the remote shutdown switch to Engaged after the check. 3. Tit the frame to the right sighty more than two degrees. The joystick contro shoud now be disabed so that boom raise/ower and extend/retract no onger function. Repeat the procedure with the frame tited to the eft. Return the frame to a eve position after the checks. De-activation Tests To test the PWP System de-activation ogic: 1. Turn the key switch to OFF and wait for the engine to stop. Then turn the key switch back to ON. The PWP switch amp and the parking brake switch amp shoud both be iuminated. 2. Turn the key switch to OFF and then turn the PWP rocker switch to OFF. Turn the key switch back to ON. The PWP switch amp shoud be fashing and the parking brake switch amp shoud be on continuousy. PRINTED IN U.S.A /CP0112

54 3. Start the engine and appy the service brakes. The PWP switch amp and the parking brake switch amp shoud go off after approximatey three seconds of brake peda appication. If PWP System fais to perform propery, troubeshoot using the chart on page 61. Contact your deaer for service information and parts. Remove the oi check pug. See iustration beow. Oi shoud fow from the hoe. If ow, remove the oi fi pug and add oi unti it fows from the check hoe. Repace the pug, wait 10 to 15 minutes and repeat the fi procedure. Continue this process unti the differentia is fu. See the Lubrication chapter for the proper oi specification. Repace the check and fi pugs. Fi Pug Check Pug Service Every 50 Hours or Weeky LUBRICATE GREASE POINTS Refer to the Lubrication chapter of this manua for grease fitting ocations and other reated detais. Drain Pug 100 Hours (New Machine Ony) The foowing initia oi and fiter changes shoud be performed at 100 hours on a new machine. Thereafter these changes shoud be performed at the reguar maintenance intervas. Refer to the maintenance schedues for the necessary procedures. Engine Oi and Fiter Transmission Oi and Fiter Hydrauic Return Fiter Eement (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 repaced. Thereafter the boom chains shoud be inspected for wear and proper tension at the reguar service interva of 250 hours. Refer to the boom chain torquing procedure in the 250 hour service interva. Panetary Hubs NOTE: The panetary hubs can be checked without jacking up the machine. The panetary hubs have one pug each used for fiing and draining. See iustration beow. For checking the eve and fiing, position the whee unti the oi eve arrow is horizonta. Remove the pug. If oi does not run out, add oi unti it overfows. Check the remaining hubs the same way. Refer to the oi specifications found in the Lubrication chapter of this manua. Pug in fi and check position. Service Every 250 Hours or Quartery NOTE: Perform a other service requirements up to this point, as we as the foowing: CHECKING AXLE OIL LEVELS Differentias NOTE: The Teescopic Hander shoud be on a eve surface for this procedure. CHANGING FUEL FILTER The frequency of fiter repacement wi be determined by the ceaniness of avaiabe fue, the care used in storing fue suppies and the operating conditions in which the machine is used. WARNING NEVER service the fue system whie smoking, whie near an open fame, or after the engine has been operated and is hot /CP PRINTED IN U.S.A.

55 B A D 2. Operate the fue suppy pump primer ever (E) unti fue fows out of the beed vent screw. 3. Tighten beed vent screw securey. Continue operating the primer unti pumping action is not fet. 4. Start engine and check for eaks. If the engine wi not start, repeat steps 1-4. WARNING C 1. Thoroughy cean fue fiter assemby and surrounding areas. 2. Loosen drain pug (C) and drain fue into a suitabe container. 3. Firmy grasp retaining ring (A) and rotate it cockwise 1/4 turn. Remove ring with the fiter eement (B). NOTE: Lifting up on retaining ring (A) as it is rotated heps to get it past raised ocators. 4. Inspect fiter mounting base for ceaniness. Cean as required. NOTE: Raised ocators on the fue fiter canister must be indexed propery with sots in mounting base for correct instaation. 5. Insta new fiter eement onto mounting base. Be sure eement is propery indexed and firmy seated on base. It may be necessary to rotate fiter for correct aignment. 6. Insta retaining ring onto mounting base making certain dust sea is in pace on fiter base. Hand tighten ring countercockwise (about 1/3 turn) unti it snaps into the detent. DO NOT overtighten retaining ring. After fue fiter repacement, beed the air out of the fue system by foowing the fue beeding procedure. Fue Beeding Procedure When the fue fiter is removed and repaced, or the engine runs out of fue, air must be bed from the system. Refer to the foowing procedure for proper beeding procedures. 1. Loosen the air beed vent screw (D) two fu turns by hand on the fiter base. E Escaping diese fue under pressure can have sufficient force to penetrate the skin. Before appying pressure to the fue system, BE SURE a connections are tight and ines and hoses are not damaged. Use a piece of wood or cardboard to search for suspected eaks. If injured by escaping fue, see a doctor famiiar with this type of injury at once or gangrene may resut. Diese Fue Injectors Whenever fauty or pugged injectors are indicated, see your authorized engine deaer. Diese Injection Pump Timing Whenever injection pump timing, or other injection pump service is indicated, such as by abnorma engine operation, contact your authorized engine deaer. NOTE: Ony an authorized engine deaer can perform warranty service on the engine. CHANGING ENGINE OIL AND FILTER Change the engine oi and fiter using the foowing procedure: 1. With the engine warm, remove the crankcase drain pug. IMPORTANT: DO NOT discharge oi onto ground. Catch and dispose of per oca waste disposa reguations. 2. The engine oi fiter shoud be changed at every oi change interva. Using a suitabe fiter wrench, remove and discard the fiter. IMPORTANT: Fitration of ois is critica to proper ubrication. Aways change fiter with every oi change. Use ony genuine OEM engine repacement fiters. PRINTED IN U.S.A /CP0112

56 3. Appy a thin coat of cean engine oi to the new oi fiter at the inner (A) and outer (B) seas and to the fiter threads. 4. Wipe both seaing surfaces of the fiter header (C, D) with a cean rag. Ensure keys in the dust sea (E) are propery instaed in the sots in the housing. Repace dust sea if damaged. 5. Insta and tighten oi fiter by hand unti firmy against dust sea (E). DO NOT appy an extra 3/4 to 1-1/4 turn after gasket contact is made, as is done with standard fiters. 6. Cean and re-insta the drain pug. 7. Re-fi the crankcase with new oi. Foow specifications in the Lubrication chapter for type and viscosity of new oi. 8. After new oi has been added, run the engine at ide speed unti the oi pressure amp is off. Check for eaks at the fiter and drain pug. CHECKING THE BATTERY The battery furnished in the machine is a 12-vot, wetce battery. The top of the battery must aways be kept cean. Cean the battery with a brush dipped in an akaine soution (ammonia or baking soda and water). After the foaming has stopped, fush the top of the battery with cean water. If the terminas and cabe connection camps are corroded or have a buidup, disconnect the cabes and cean the terminas and camps with the same akaine soution. NOTE: The battery in the machine is warranted by the suppier. See the punch tag on the top of the battery for warranty information. Jump Starting WARNING Exposive gas is produced whie a battery is in use or being charged. Keep fames and sparks away from the battery. Make sure battery is charged in a we-ventiated area. NEVER ay a meta object on top of a battery, because a short circuit can resut. Battery acid is harmfu on contact with skin or fabrics. If acid spis, foow these first aid tips: 1. IMMEDIATELY remove any cothing on which acid spied. 2. If acid contacted the skin, rinse the affected area with running water for 10 to 15 minutes. 3. If acid comes in contact with the eyes, food the eyes with running water for 10 to 15 minutes. See a doctor at once. NEVER use any medication or eye drops uness prescribed by the doctor. 4. To neutraize acid spied on the foor, use one of the foowing mixtures: a. 1 pound (0.5 kg) of baking soda in 4 quarts (4 iters) of water. b. 1 pint (0.4 iters) of househod ammonia in 4 quarts (4 iters) of water. Whenever battery is removed from the unit, BE SURE to disconnect the negative (-) battery termina connection first. If the battery becomes discharged or does not have enough power to start the engine, use jumper cabes and the foowing procedure to jump-start the engine. IMPORTANT: BE SURE that the jumper battery is aso a 12-vot D. C. battery, and the vehice used for jump starting has a negative-ground eectrica system /CP PRINTED IN U.S.A.

57 WARNING The ONLY safe method for jump-starting a discharged battery is for TWO PEOPLE to perform the foowing procedure. The second person is needed for removing the jumper cabes, so that the operator does not have to eave the operator s compartment whie the engine is running. NEVER connect the jumper cabes directy to the starter soenoid of either engine. DO NOT start the engine from any position other than the operator s seat, and then ONLY after making sure a contros are in neutra. Cosey foow the jump-start procedures, in the order isted, to avoid persona injury. In addition, wear safety gasses to protect your eyes, and avoid eaning over the batteries whie jump-starting. DO NOT attempt to jump-start the machine if the battery is frozen, because this may cause it to rupture or expode. 1. Turn the key switches on both units to OFF. Be sure that both units are in Neutra and NOT touching. 2. Connect one end of the (red) positive (+) jumper cabe to the positive (+) battery termina on the disabed machine first. DO NOT aow the positive (+) jumper cabe camps to touch any meta other than the positive (+) battery terminas. Connect the other end of the positive (+) jumper cabe to the jumper battery positive (+) termina. 3. Connect one end of the (back) negative (-) jumper cabe to the jumper battery negative (-) termina. 4. Make the fina negative (-) jumper cabe connection to the disabed machine s engine bock or frame (ground) NOT to the disabed machine negative battery post. If making the connection to the engine, keep the jumper cabe camp away from the battery, fue ines, and moving parts. NOTE: Twist the jumper cabe camps on the battery terminas to ensure a good eectrica connection. 5. Start the engine. If it does not start immediatey, start the jumper vehices engine to avoid excessive drain on the booster battery. 6. After the machine has started and is running smoothy, have the second person remove the jumper cabes (negative (-) jumper cabe first) from the jumper vehice battery, and then from the disabed machine, whie being carefu not to short the two cabes together. Aow sufficient time for the aternator to buid up a charge in the battery before operating the machine or shutting off the engine. NOTE: If the battery frequenty becomes discharged, have the battery checked for possibe dead ces, or troubeshoot the eectrica system for possibe short circuits or damaged wire insuation. CHECKING AND TORQUING BOOM LEAF CHAINS Inspect the eaf chains for wear and proper tension. Two of the chains are on the top front of the boom. A third chain is accessibe from inside the rear of the boom (see boom iustration). Torque the two chains on the front of the three-section boom to 25 ft.-bs. (34 Nm). Lubricate with 80W-90 oi. IMPORTANT: On new machines or when chains have been repaced, it is necessary to retorque the front doube chain assemby after one hundred (100) hours of operation. Faiure to do so may aow the chains to become sack, which can resut in a chain jumping off a sheave. If this occurs, it coud resut in severe damage to the boom assemby. Outer Section One Rear Boom Chain Intermediate Section Inner Section Chain Hookup Detai Two Front Boom Chains Inspect the eaf chains for wear. Run the boom out sowy to inspect. Conditions to ook for incude: cracked or broken pates, protruding or turned pins, and excessive wear. With a stee tape, measure 16 inks of the strand that fexes over the sheaves. If the section PRINTED IN U.S.A /CP0112

58 measures 10.3 (262 mm) or more, the chain shoud be repaced. DO NOT repair sections of a chain. Repace the compete chain. Chain anchors and sheaves aso require inspection, for worn or broken fingers and worn fanges. After any chain has been repaced, operate under oaded conditions and re-check the torque. Adjust the chains per the foowing procedure: Extend the boom to its maximum ength, then retract the boom sowy unti the chain sack aows the chain to rest on the top of the boom. Torque the two chains on the front of the boom to 25 ft.-bs. (34 Nm). Lubricate with 80W-90 oi. CHECKING BOOM SLIDE PAD WEAR AND CLEARANCE Rear Inner Shim Pad of the boom for even distribution of cearance. Re-appy Loctite 271 (red) thread ock or equivaent to the bots and re-torque to 30 ft.-bs. (40 Nm). Bottom side pads shoud not be shimmed and shoud be repaced when the thickness is worn down to 3/8 (9.5 mm). WARNING Faiure to maintain proper side pad cearance and thickness coud cause damage to the boom, resuting in sudden boom faiure. Service Every 1000 Hours or Yeary NOTE: Perform a other service requirements up to this point as we as the foowing: CHANGING TRANSMISSION OIL AND FILTER Front Outer Side Pad Detai The boom is equipped with specia nyon ow-friction side pads between the teescopic sections (see iustration). These are pre-greased and initiay worn-in at the factory. Normay greasing is not required, except for maintaining a ight fim of grease on the pad tracking areas of the boom sections. An exception is if a boom section has been repaced. Visuay check for oose pad bots. The bots are torqued to 30 ft.-bs. (40 Nm). If the bots are retorqued at any time, Loctite thread ock must be reappied to the bots. If the boom starts to chatter under oad, grease the side pads and wipe off the excess grease. Maintain a cearance of 1/16 between the top or side side pads and the boom. Shims can be added to achieve the proper cearance. Loosen the bots and insert shims unti proper cearance is obtained. NOTE: When inserting shims in the side side pads, be sure to pace equa shims on both sides Operate the machine ong enough to warm the transmission oi to F (65-93 C). Shut off the engine. Access to fiter is from under the access cover on the front hood section. Access to the drain pug is from underneath the machine. Proceed as foows: 1. Remove the drain pug and drain oi. Repace the drain pug. Transmission Drain Pug IMPORTANT: DO NOT discharge oi onto ground. Catch and dispose of per oca waste disposa reguations. 2. Remove and discard the oi fiter. Wipe the seaing surface on the transmission with a cean coth. Appy a thin coat of cean oi to the new oi fiter gasket. Hand tighten. 3. Refi the transmission with new oi as shown in the Lubrication chapter of this manua /CP PRINTED IN U.S.A.

59 Transmission Fiter IMPORTANT: DO NOT OVERFILL! f the oi eve is too high, oi foaming, excessivey high oi temperature and oi eakage at the seas coud resut. 4. Start and run the machine ong enough for the oi to circuate and warm sighty. Recheck the eve with the dipstick. CHANGING HYDRAULIC RETURN FIL- TER ELEMENT WARNING Lower the boom to the ground when servicing the hydrauic system. The hydrauic return fiter eement is a cartridge-type accessibe from a housing on top of the hydrauic reservoir. Initia repacement is after the first 100 hours. See iustration. Remove the top cover of the housing. Remove the eement and discard. Insert the new eement into the housing and repace the cover. Housing Top Fiter Eement Fiter Housing Reservoir Fiter Remova CHANGING AIR FILTER ELEMENTS IMPORTANT: Faiure to foow proper fiter servicing instructions coud resut in catastrophic engine damage. The air ceaner assemby consists of an outer (primary) fiter eement and an inner (secondary) fiter eement. An air fiter restriction indicator for monitoring the condition of the eements is ocated in the rubber ebow at the rear of the air ceaner. If the air fiter becomes restricted, this indicator turns red to warn the operator that the air ceaner requires service. Push the reset button ocated at the end of the indicator after repacing the eement NOTE: Before repacing the fiter eement(s), push the reset button on the indicator. Start the engine and run at fu throtte. If the indicator does not turn red, do not repace the eement(s). Eement Cover Dust Ejector Mounting Band Outer Fiter Eement Inet Cap Air Ceaner Assemby Inner Safety Eement Restriction Indicator The outer eement shoud be repaced when the restriction indicator turns red. The inner eement shoud be repaced every third time the outer eement is repaced, uness the outer eement is damaged or the inner eement is visiby dirty. Aong with a daiy check of the restriction indicator, check that the air ceaner intake hose and camps, and the mounting bracket hardware are propery secure. Unatch the three atches on the air ceaner and remove the end cap. Cean out any dirt in the end cap. Primary Eement 1. Carefuy pu the primary (outer) eement out of the housing. Never remove the secondary (inner) eement uness it is to be repaced. 2. Cean out any dirt in the housing. Leave the secondary eement instaed during this step to prevent debris from entering the engine intake manifod. 3. Use a troube ight inside the new primary eement to inspect for bad spots, pinhoes and ruptures. Repace the primary eement if any damage is found. The primary eement must be repaced if it PRINTED IN U.S.A /CP0112

60 is oi- or soot-aden. NOTE: Ceaning the primary eement is not recommended. Secondary Eement NOTE: Repace the secondary eement ony if it is visiby dirty or if the primary eement has been repaced three times. Before removing the secondary eement from the housing, cean out any dirt in the housing. Leave the secondary eement instaed during this step to prevent debris from entering the engine intake manifod. Remove the secondary eement. Reinstaation IMPORTANT: NEVER use an eement that is damaged. Severe engine wear and eventua faiure can resut if dirt gets through a hoe in the eement. 1. Check inside the housing for any damage that may interfere with the eements. 2. Be sure that the eement seaing surfaces are cean. 3. Insert the eement(s), making sure that they are seated propery. 4. Secure the end cap to the housing with the three atches. 5. Check the hose connections and make sure they are a camped and tightened propery. 6. Reset the restriction indicator by pressing the reset button. CHANGING AXLE DIFFERENTIAL AND PLANETARY OIL Differentia 1. Remove the three drain pugs and drain the oi. Repace the drain pugs (see iustration). Fi Pug Check Pug IMPORTANT: DO NOT discharge oi onto ground. Catch and dispose of per oca waste disposa reguations. 2. Remove the check and fi pugs. Fi the differentia with oi as specified in the Lubrication chapter. When the oi fows out the check hoe, repace the pug. Wait 10 to 15 minutes and repeat this process unti the axe is fu. Repeat this procedure with the other axe. Axe Panetary Hubs The axe hubs have one pug each used for draining and fiing (see iustration). Pug in drain position. 1. Position the whee unti the oi eve arrow points down. Remove the drain/fi pug and aow the oi to drain out. Repace the pug. IMPORTANT: DO NOT discharge oi onto ground. Catch and dispose of per oca waste disposa reguations. 2. Re-position the hub so the oi eve arrow is horizonta. Fi with fresh oi as specified in the Lubrication chapter. When the oi runs out, insta the drain/fi pug. Repeat this procedure on the three remaining hubs. CHECKING ALTERNATOR AND FAN BELT CONDITION Refer to the engine manua for proper fan bet tension adjustment and repacement procedures. If the bet is worn or cut, it shoud be repaced. Order repacement bets from your Geh deaer. CHECKING EXHAUST SYSTEM Examine the muffer and tai pipe for possibe hoes. Re-tighten any oose camps and make sure the manifod outet gasket is not eaking. Drain Pug /CP PRINTED IN U.S.A.

61 Service Every 2000 Hours or Two Years NOTE: Perform a other service requirements up to this point, as we as the foowing: CHECKING HYDRAULIC SYSTEM RELIEF PRESSURES Pressure settings for reief vaves are pre-set at the factory. Three test ports are provided under the front hood access cover. IMPORTANT: DO NOT discharge oi onto ground. Catch and dispose of per oca waste disposa reguations. Eement Fi Cap Dipstick Access Cover Gasket Test ports under access cover Before conducting any pressure checks, check the engine speed. Engine speed must be 800 RPM at ide and 2500 to 2550 RPM at high ide. Steering Reief Pressure Pug a 3000 psi (207 bar) oi- or iquid-fied gauge into the test port abeed SP. Turn the steering fu to the right or eft. The gauge shoud read 2000 psi (138 bar). Joystick and Parking Brake Reease Pressure Pug a 1000 psi (70 bar) gauge into the port abeed JP. With the engine running, the gauge shoud read 350 psi (24 bar). Main Reief Pressure Pug a 3000 psi (207 bar) oi-or iquid-fied gauge into the test port abeed MP. Fuy retract the boom over the reief vave. The gauge shoud read 3000 psi (207 bar). CHANGING HYDRAULIC RESERVOIR OIL AND STRAINER Cean a dirt and debris from around the top of the reservoir, especiay around the access cover. Refer to iustration and use the foowing procedure: 1. Remove the drain pug and drain oi. Wash or bow off any partices coected on the magnetic drain pug. TOP OF RESERVOIR Hydrauic Reservoir Sump Strainer Remova 2. Remove the access cover and wash the inet screen with cean sovent. Remove and wash the sump fiter strainer from the bottom inside of the reservoir. If the strainer has any damage, hoes, etc., it shoud be repaced. 3. Fush out the bottom of the reservoir with cean hydrauic oi. Re-insta a ceaned components and insta the access cover on the reservoir with a new gasket. Cean the fiter/breather cap. 4. Fi the reservoir with fresh oi. Foow specifications in the Lubrication chapter of this manua. IMPORTANT: Hydrauic fuid and fiters shoud be repaced any time contamination is present before the normay schedued change. WARNING Escaping hydrauic oi under pressure can have sufficient force to penetrate the skin. Before appying pressure to the hydrauic system, be sure a connections are tight and ines and hoses are not damaged. Use a piece of wood or cardboard to search for suspected eaks. If injured by escaping hydrauic oi, see a doctor famiiar with this type of injury immediatey or gangrene may resut. PRINTED IN U.S.A /CP0112

62 CHANGING RADIATOR COOLANT Drain od cooant, fush the entire cooing system, test thermostats and fi with recommended cooant. WARNING Remove the radiator cap ony when the engine is coo, or painfu burns coud resut. IMPORTANT: DO NOT discharge cooant onto ground. Catch and dispose of per oca waste disposa reguations. Refer to the John Deere engine manua for detaied cooant repacement instructions. IMPORTANT: Fi the cooing system with a owsiicate ethyene gyco based cooant mixed with quaity water and suppementa cooant additives (SCAs) suitabe for heavy-duty diese engines. See the engine manua for additiona information. NOTE: Check the engine temperature gauge every minute or two after cooant has been changed. Air pockets can form and it may be necessary to refi the cooing system after a short period of use, as the air wi naturay beed out of the system. STORING THE MACHINE If the Teescopic Hander wi not be operated for a period of three months or more, prepare and store it using the foowing procedure: NOTE: If the storage area is outdoors or in a harsh environment, the storage procedure shoud be foowed if the Teescopic Hander is to be stored for one month. 5. Disconnect the battery cabe camps and cover the battery, or remove the battery from the machine and store it separatey. 6. If the ambient temperature (at any time during the storage period) is expected to drop beow freezing, make sure the engine cooant is either competey drained from the radiator and engine bock or that the concentration of anti-freeze is adequate to keep the cooant from freezing. Refer to the engine manua for anti-freeze recommendations and quantities. During Storage 1. About once each month, connect the battery, check a fuid eves to make sure they are at the proper eve, and start the engine. IMPORTANT: If it is desired to operate the hydrauic cyinders at this time, BE SURE to wipe the protective grease (and any adhering dirt) from the cyinder rods prior to starting the engine. After operating, if the machine is to be returned to storage recoat the cyinder rods with grease. 2. Aow the engine to run unti it warms up. Then move the machine a short distance to hep reubricate the interna parts. Run the engine unti the battery is recharged, and then shut it off. After Storage After removing the machine from storage and BEFORE operating it, perform the foowing: 1. Change engine oi and fiter to remove any condensation and residues. 2. Wipe off grease from cyinder rods. 3. Lubricate ALL grease fittings. 4. Foow the start-up and warm-up procedures outined in the Operation and Adjustments chapter of this manua. Before Storage Perform the foowing prior to pacing the machine in storage: 1. Wash the entire machine. 2. Lubricate a grease fittings as described in the Lubrication chapter of this manua. 3. Change engine oi as outined in the Service and Storage chapter of this manua. 4. Appy grease to a exposed hydrauic cyinder rod areas /CP PRINTED IN U.S.A.

63 PWP SYSTEM TROUBLESHOOTING Probem PWP System switch amp fashes when switch is pressed ON. Parking brake does not engage when the PWP System switch is pressed ON. Carriage tit and auxiiary functions continue operating when the PWP System switch is pressed ON. Transmission does not remain de-cutched when shifted into Forward or Reverse when the PWP switch is ON. Boom contro functions do not operate. PWP System switch amp fashes when switch is turned OFF. Parking brake switch amp stays ON when PWP System switch is OFF. Possibe Cause PWP System is not activated. Machine is not eve. PWP System remote shutdown switch is disengaged. PWP System remote shutdown switch is not pugged into the connector at the end of the boom. PWP System ange sensor is unpugged or fauty. PWP System is not de-activated. Remedy With PWP System switch ON, appy service brakes for three seconds unti PWP switch amp is it continuousy. Leve the machine. Engage the PWP System remote shutdown switch. Pug in and engage the PWP System remote shutdown switch. Contact your Geh deaer for assistance. With engine running, appy service brakes for three seconds unti PWP switch amp goes off. PRINTED IN U.S.A /CP0112

64 Chapter 9 DECAL LOCATIONS GENERAL INFORMATION CAUTION ALWAYS read and foow the safety precautions and information shown on decas. If any decas are damaged or unreadabe, or if the unit is repainted, the decas must be repaced. If repainting, BE SURE that a decas that appy to your machine are affixed in their proper ocations Deca ocation information is provided to assist in the proper seection and appication of new decas, in the event the origina decas become damaged or the machine is repainted. For correct repacement of decas, compare the ocation photographs to the machine before starting to refinish the unit. Check off each required deca using the iustration reference number to find the part number, description and quantity in the ist. Refer to the appropriate iustration for repacement ocations. If there is a deca on a part that is being repaced, be sure that the deca is appied to the repacement part. NOTE: Refer to the Safety chapter of this manua for specific information provided on the various safety decas. NEW DECAL APPLICATION Before appying the new decas, surfaces must be free from dirt, dust, grease and other foreign materia. To appy a soid-formed deca, remove the smaer portion of the deca backing paper and appy this part of the exposed adhesive backing to the cean surface whie maintaining proper position and aignment. Sowy pee off the other portion of the backing paper whie appying hand pressure to smooth out deca surface. To appy a die-cut deca, first remove the backing paper. Then, propery orient and position the deca onto the cean mounting surface. After the deca is firmy appied and smoothy pressed down, pee off the top covering paper. PAINT FINISH Use this ist to order paint for refinishing: (1-qt. Cans) Yeow (12-oz. Spray Cans) Yeow (1-qt. Cans) Gun-Meta Gray (12-oz. Spray Cans) Gun-Meta Gray Deca Kits RS6-34 Teescopic Hander without PWP RS6-34 Teescopic Hander with PWP NOTE: Decas may be purchased in kits or individuay /CP PRINTED IN U.S.A.

65 DECAL LOCATIONS - FRAME AND BOOM REF. DESCRIPTION PART NO. NO. 01 DANGER - HANDS OUT L WARNING - PINCH POINT L WARNING - JUMP START L GEHL, QUICK-ATTACH DIAGRAM L GEHL, ANTI-FREEZE HALF ZONE MARKER (5 ea.) L NO. 0 EXTENSION MARKER (1 ea.) L67718 NO. 1 EXTENSION MARKER (1 ea.) L67719 NO. 2 EXTENSION MARKER (1 ea.) L67720 NO. 3 EXTENSION MARKER (1 ea.) L67721 NO. 4 EXTENSION MARKER (1 ea.) L67722 NO. 5 EXTENSION MARKER (1 ea.) L COOLANT UNDER PRESSURE WARNING - NO RIDERS L BRAKE FLUID L OPERATOR MANUAL WARNING DANGER - PERSONNEL INJURY (units without PWP) L CARRY LOAD LOW L LUBE CHART RS6-34 LH GEHL, PRINTED IN U.S.A /CP0112

66 DECAL LOCATIONS - FRAME AND BOOM REI. DESCRIPTION PART NO. NO. 01 DANGER - HANDS OUT L WARNING - PINCH POINT L GEHL, HYDRAULIC OIL FILL WARNING - NO RIDERS L Geh DANGER - PERSONNEL INJURY (units without PWP) L QUICK-ATTACH UNLOCKED L DIESEL FUEL RS6-34, RH HOT SURFACE L /CP PRINTED IN U.S.A.

67 Tri-Function Joystick Contro Two Joystick Contro 9 10 DECAL LOCATIONS - OPERATOR STATION REI. DESCRIPTION PART NO. NO. 01 WARNING - TILT HAZARD/GENERAL OPERATOR L WARNING - CARRY LOAD LOW L F-N-R SHIFT L MADE IN USA WARNING - PARK BRAKE/SEAT BELT STANDARD CARRIAGE LOAD CHART ROTATING CARRIAGE LOAD CHART BUCKET LOAD CHART TRUSS BOOM LOAD CHART WINCH LOAD CHART PWP LOAD CHART ATTACHMENT TILT/FRAME LEVEL L BOOM CONTROL L AUXILIARY HYDRAULIC CONTROL (Optiona) IGNITION/START/HORN DANGER - HIGH VOLT./MOVING PARTS L JOYSTICK CONTROL FRAME LEVEL L63311 PRINTED IN U.S.A /CP0112

68 DECAL LOCATIONS - PWP EQUIPPED UNITS REI. DESCRIPTION PART NO. NO. 01 WARNING - PERSONNEL LIFT L WARNING - WORK PLATFORM RULES L PERSONNEL LIFT SAFETY RULES L PWP LOAD CHART PWP SWITCH PWP SYSTEM /CP PRINTED IN U.S.A.

69 Chapter 10 MAINTENANCE This Maintenance Interva Chart was deveoped to match the Service and Storage chapter of this manua. Detaied information on each Service Procedure is in the Service and Storage chapter. A Maintenance Log foows the Maintenance Interva Chart for recording the maintenance procedures performed. Recording the 10-Hour (or Daiy) service procedures is impractica and is therefore not recommended. IMPORTANT: Under severe operating conditions, more frequent service than the recommended intervas may be required. Users must decide if the severity of their operation requires more frequent service than norma. MAINTENANCE INTERVAL CHART SERVICE PROCEDURE Every 10 Every 50 First 100 Every 250 Hours Hours Hours Hours (or (or Daiy) (or Weeky) Quartery) Check Fue Tank Leve Check Fue Fiter (Drain Water If Required) Check Engine Oi Leve Check Radiator Cooant Leve Check Transmission Oi Leve Check Hydrauic Oi Leve Check Brake Reservoir Leve Check Tire Pressures Check Whee Nut Torque 1,2 Check Instruments Operation Check Genera Machine Operation and Condition Check Personne Work Patform Safety System Lubricate Grease Points Change Engine Oi and Fiter 2 Change Transmission Oi and Fiter 2 Change Hydrauic Oi Fiter 2 Check Axe Oi Leves Change Fue Fiter Change Engine Oi and Fiter Check Battery Check and Torque Boom Leaf Chains On new machines, or when a whee has been removed, unti 450 ft.-bs. (610 Nm) is maintained. 2 - New machines ony. 3 - On new machines or when a chain has been repaced. Chains shoud be torqued to 25 ft.-bs. (34 Nm). PRINTED IN U.S.A /CP0112

70 MAINTENANCE INTERVAL CHART (CONT.) SERVICE PROCEDURE Every 250 Every 1000 Every 2000 Hours (or Hours (or Hours (or Quartery) Yeary) Two Years) Check Boom Side Pads Wear and Cearance Change Transmission Oi and Fiter Change Hydrauic Return Fiter Eement Change Air Fiter Eement Change Axe Differentia and Panetary Oi Check Aternator and Fan Bet Condition Check Exhaust System Check Hydrauic System Reief Pressures Change Hydrauic Reservoir Oi and Strainer Change Radiator Cooant MAINTENANCE LOG Date Hours Service Procedure /CP PRINTED IN U.S.A.

71 MAINTENANCE LOG Date Hours Service Procedure PRINTED IN U.S.A /CP0112

72 MAINTENANCE LOG Date Hours Service Procedure /CP PRINTED IN U.S.A.

73 Hydrauic Schematic for Two-Joystick Contros without PWP PRINTED IN U.S.A /CP0112

74 Hydrauic Schematic for Two-Joystick Contros with PWP /CP PRINTED IN U.S.A.

75 Hydrauic Schematic for Tri-Function Joystick without PWP PRINTED IN U.S.A /CP0112

76 Hydrauic Schematic for Tri-Function Joystick with PWP /CP PRINTED IN U.S.A.

77 Eectrica Schematic for Two-Joystick Contros PRINTED IN U.S.A /CP0112

78 Eectrica Schematic for Tri-Function Joystick /CP PRINTED IN U.S.A.

79 Load Zone Charts Deca Standard Carriage Deca Cu.-Yd. Bucket Deca Rotating Carriage Deca Ft. Truss Boom PRINTED IN U.S.A /CP0112

80 Load Zone Charts Deca Winch Boom Deca PWP /CP PRINTED IN U.S.A.

81 Torque Specifications Use these torque vaues when tightening hardware (excuding: ocknuts and sef-tapping, thread-forming and meta screws) uness otherwise specified. Unified Nationa Thread Grade 2 Grade 5 Grade 8 Dry Lubed Dry Lubed Dry Lubed * 14* 30* 22* 41* 31* * 15* 31* 23* 43* 32* * 21* 43* 32* 60* 45* * 23* 49* 36* 68* 51* 1/ * 50* 9 75* / * 56* 10 86* / / / / / / / / / / / / / / / / Metric Course Thread Grade 8.8 Grade 10.9 Grade 12.9 Dry Lubed Dry Lubed Dry Lubed M * 24M * M M M M * A torque vaues are in b-ft. except those marked with an *, which are in b-in. For metric torque vaue (Nm), mutipy b-ft vaue x 1.355, or b-in vaue x PRINTED IN U.S.A /CP0112

82 Index A Access to Components Chart Accessories Adjustments Side Pads Cearance Whee Lug Nuts Torque Air Fiter Changing Eements Aternator Bet Service Indicator Lamp Anti-freeze - See Radiator Attachment Toos Changing Operating Methods - See Chapter 6 Axes Description - See Chapter 2 Greasing See aso Service Axe Oi Changing Checking Leves Recommended Grades B Backup Aarm Battery Charging Lamp Jump Starting Service Boom Trave Function Contros Function Indicators Service C Capacities - See Chapter 2 Carriage Lifting Appications Load Capacity and Reach Load Carrying Load Eevation and Pacement Checkists, deivery and pre-deivery ,7 Contros Dash Right Side Pane Foor and Seat Cyinders Servicing D Deaer Services Deca Locations Decas, appying new Dimensions - See Chapter 2 E Eectrica Components Characteristics - See Chapter 2 Contros and Indicators - See Chapter 4 Servicing Engine Cod Weather Start Procedures Description - See Chapter 2 Oi Pressure Lamp Starting Temperature Gauge Engine Oi Changing Checking Leve Recommended Grades Engine Oi Fiter, repacing Exhaust System, checking F Fan Bet - See Aternator Bet Frame Ange Indicator Frame Leve Contro and Indicator Fue - See Separate Engine Manua Fue Fiter Checking and Draining Repacing Fue Beeding Procedure Fue Gauge Fuse Access Fuse Functions /CP PRINTED IN U.S.A.

83 G Grease Fittings Locations Types of Grease Guards Grade and Sope Precautions Grade Limits H Hand Signas Hourmeter Hydrauic Components, servicing Hydrauic Oi Changing Checking eve Recommended Type Hydrauic Maintenance Oi Fiters, repacing Oi Sump Strainer, repacing Pressure, Checking Hydrauic Pump, servicing Hydrauic Vaves, servicing I Identification Reference Indicators Indicator Symbos Inside Front Cover Introduction J Joystick Pressure Setting L Light Switch Load Zone Charts ,77 Lubrication See aso Service Intervas Locations Lubricants M Main Reief Pressure Check Maintenance Recording Schedued Intervas Mandatory Safety Shutdown Procedure Mandatory Work Patform Safety Rues O Ois - See Lubrication Operation Load Handing Starting Stopping Symbos Inside Front Cover Trave Operator s Manua, storing Operator Services Operator s Station Heater Contros P Parking Brake Switch Park Brake Pressure Setting Paint, refinishing Pump, Deivery Rates - See Chapter 2 Personne Work Patform Safety Decas Personne Work Patform Safety Rues Personne Work Patform Switch Personne Work Patform (PWP) System Personne Work Patform Checking Procedure Q Quick-attach System Attach/Detach Mechanism R Radiator Checking cooant Changing cooant Fushing and Refiing Reay Access Reay Functions Road Trave S SAFETY Decas Schematics Eectrica Hydrauic Seat, operator s Service and Safety Features PRINTED IN U.S.A /CP0112

84 Service Intervas Daiy Weeky hours hours hours hours Shieds Side-View Mirror Specifications Steering - See Contros Steering Reief Pressure Check Storage Suspended Loads Guideines For Free Rigging / Suspended Loads T Tabes Lubricants Paint Notice Repacement Fiters Theft Deterrents Tire Pressures Torque Specifications Traffic Fow Patterns Transmission Description - See Chapter 2 Temperature Lamp Transmission Oi Changing Checking Leve Recommended Grades Transporting Loading Unoading Trave Speed - See Contros Troubeshooting, PWP W Warranty Inside Rear Cover Water Trap - See Fue Fiter Windshied Wiper Switch Work Patform Design Requirements /CP PRINTED IN U.S.A.

85 GEHL COMPANY WARRANTY GEHL COMPANY, hereinafter referred to as Geh, warrants new Geh equipment to the Origina Retai Purchaser to be free from defects in materia and workmanship for a period of tweve (12) months from the Warranty Start Date. GEHL WARRANTY SERVICE INCLUDES: Genuine Geh parts and abor costs required to repair or repace equipment at the seing deaer's business ocation. GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT. ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL BE DEEMED DELETED FROM THIS WARRANTY; ALL OTHER TERMS WILL CONTINUE TO APPLY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW. GEHL WARRANTY DOES NOT INCLUDE: 1. Transportation to seing deaer's business ocation or, at the option of the Origina Retai Purchaser, the cost of a service ca. 2. Used equipment. 3. Components covered by their own non-geh warranties, such as tires, batteries, trade accessories and engines. 4. Norma maintenance service and expendabe, high-wear items. 5. Repairs or adjustments caused by: improper use; faiure to foow recommended maintenance procedures; use of unauthorized attachments; accident or other casuaty. 6. Liabiity for incidenta or consequentia damages of any type, incuding, but not imited to ost profits or expenses of acquiring repacement equipment. No agent, empoyee or representative of Geh has any authority to bind Geh to any warranty except as specificay set forth herein. PRINTED IN U.S.A /CP0112

86 THIS OPERATOR S MANUAL IS PROVIDED FOR OPERATOR USE DO NOT REMOVE FROM THIS MACHINE Do not start, operate or work on this machine unti you have carefuy read and thoroughy understand the contents of the operator s manua. Faiure to foow safety, operating and maintenance instructions coud resut in serious injury to the operator or bystanders, poor operation, and costy breakdowns. If you have any questions on proper operation, adjustment or maintenance of this machine, contact your deaer or the service department of Geh Company before starting or continuing operation. Caifornia Proposition 65 Warnings Diese engine exhaust and some of its constituents are known to the State of Caifornia to cause cancer and birth defects or other reproductive harm. Battery posts, terminas and reated accessories contain ead and ead compounds, chemicas known to the State of Caifornia to cause cancer and birth defects or other reproductive harm. Wash hands after handing battery. Manitou Americas P.O. Box 179, West Bend, WI U.S.A /BP Manitou Americas PRINTED IN U.S.A. A Rights Reserved.