Gehl CT5-16, Operator'S Manual

Page 1: ...CT5 16 CT5 16 Turbo Telescopic Handlers Operator s Manual Form No 913225 Revision C August 2007 Courtesy of CraneMarket com...

Page 2: ...nual please return it to the storage area and keep it with the unit at all times If this machine is resold GEHL Company recommends that this manual be given to the new owner If this machine was purcha...

Page 3: ...r Instructions 23 C Enviroment 23 D Visibility 24 E Starting the Telescopic Handler 24 F Operating the Telescopic Handler 26 G Stopping the Telescopic Handler 26 H Driving the Telescopic Handler on a...

Page 4: ...arts 42 21 Heater Controls CT5 16 Turbo 42 21 Heater and Air Conditioner Controls CT5 16 Turbo 42 22 Cab Air Filters CT5 16 Turbo 43 23 Windshield Defroster CT5 16 Turbo 43 24 Heater Vents CT5 16 Turb...

Page 5: ...ice 64 E Every 1000 Hours of Service 68 F Every 2000 Hours of Service 71 G Periodic Maintenance 72 H Every Two Years 74 7 DECALS 75 General Information 75 New Decal Application 75 Decal Locations 76 8...

Page 6: ...lescopic Handler model and serial numbers below Refer to these numbers when inquiring about parts or service from your GEHL dealer The model and serial numbers for this machine are on a decal located...

Page 7: ...dification Serial No Manufacturer s No Year of Manuafacture C D B IDENTIFICATION OF THE TELESCOPIC HANDLER Because of our policy to promote a continual improve ment of our products our lines of telesc...

Page 8: ...FIG F Type Serial No Reference No OVERHEAD GUARD CT5 16 FIG G Type Serial No CAB CT5 16 TURBO FIG H Type Serial No BOOM FIG I Reference No Date of Manufacture SERIAL PLATE OF THE ATTACHMENT FIG J Mod...

Page 9: ...SO TR 14396 58 hp 43 kW 75 hp 55 kW Maximum torque 164 ft lbs 222 Nm at 1400 rpm 215 ft lbs 291 Nm at 1400 rpm Air cleaner Dry w safety element Dry w safety element COOLING CIRCUIT Type Water Fan Pull...

Page 10: ...ries Epicyclic BRAKE Service brake Foot pedal applied hydraulic brake on the front wheels Type Multi disc brake immersed in oil Parking brake Hand lever applied mechanical brake on the front wheels Ty...

Page 11: ...mes No load extending 4 5 seconds Rated load extending 4 6 seconds No load retracting 3 0 seconds Rated load retracting 2 4 seconds Rearward tilt time no load 2 7 seconds Forward tilt time no load 2 3...

Page 12: ...No load extending 4 5 seconds Rated load extending 4 6 seconds No load retracting 3 0 seconds Rated load retracting 2 4 seconds Rearward tilt time no load 2 7 seconds Forward tilt time no load 2 3 sec...

Page 13: ...40 mm D2 11 10 3605 mm E 17 9 5400 mm F 4 11 1500 mm F1 4 11 1500 mm G 11 290 mm G1 1 1 335 mm G2 1 305 mm I 3 905 mm J 2 10 865 mm K 3 5 1040 mm L 1 5 40 mm N 4 7 1390 mm O 5 125 mm P2 39 P3 31 R 10...

Page 14: ...40 mm D2 11 11 3626 mm E 17 9 5405 mm F 4 11 1500 mm F1 4 11 1500 mm G 12 305 mm G1 1 2 355 mm G2 1 1 325 mm I 3 905 mm J 2 10 865 mm K 3 4 1020 mm L 1 75 45 mm N 4 8 1410 mm O 5 125 mm P2 39 P3 31 R...

Page 15: ...n under pressure Listen for abnormal noises or vibrations if detected deter mine their cause and repair as necessary I acknowledge that pre delivery procedures were performed on this unit as outlined...

Page 16: ...913225 CP0807 14 PRINTED IN U S A INTENTIONALLY BLANK To be removed as Dealer s file copy Courtesy of CraneMarket com...

Page 17: ...when under pressure Listen for abnormal noises or vibrations if detected deter mine their cause and repair as necessary I acknowledge that pre delivery procedures were performed on this unit as outli...

Page 18: ...achinery and guards exposed moving parts for his her protection However some areas cannot be guarded in order to assure proper operation Further this Operator s Manual and decals on the machine warn o...

Page 19: ...stry and the construction ship yard and cargo handling industries excepting agricultural operations to ensure that forklift operators are competent as demonstrated by successful completion of a traini...

Page 20: ...e and warn all personnel who may be servicing the machine or who are in the machine s path prior to starting DO NOT start until all personnel are clearly away from the machine The operator must immedi...

Page 21: ...r card board Escaping fluid under pressure can be invis ible and can penetrate the skin causing serious injury If any fluid is injected into your skin see a doctor at once Injected fluid MUST be surgi...

Page 22: ...and legible Local govern ment regulations may require specific equipment which is the responsibility of the owner to provide Replace any warning decals that are no longer leg ible Safety Guards and W...

Page 23: ...PRINTED IN U S A 21 913225 CP0807 SAFETY DECAL LOCATIONS 093475 L65928 L65932 L70307 100359 L70306 101506 L65927 L65928 L65927 L65924 L65933 Courtesy of CraneMarket com...

Page 24: ...913225 CP0807 22 PRINTED IN U S A 101506 L70306 L70307 093475 100359 L65928 L65932 L65924 L65927 L65933 Courtesy of CraneMarket com...

Page 25: ...to leave the cab without first locking the control in neutral C ENVIRONMENT Comply with all work site safety rules If the telescopic handler must be used in a dark area or at night make sure it is eq...

Page 26: ...ansmission If it s necessary to tow the telescopic handler in an emergency the trans mission must be placed in neutral see chapter 6 MAINTENANCE TOWING THE TELESCOPIC HANDLER Check for closing and loc...

Page 27: ...tery 6 After the machine is started and running smoothly have the second person remove the jumper cables negative jumper cable first from the jumper vehicle battery and then from the disabled machine...

Page 28: ...on Always remember that hydrostatic steering is very sensitive to movement of the steering wheel so turn it gently and smoothly Never leave the engine running when the telescop ic handler is unattend...

Page 29: ...necessary contact your dealer If equipped make sure the rotating beacon is in place Switch it on and verify its operation Check for good working order and cleanliness of lights indicators and windshie...

Page 30: ...dler is valid for a load in which the longitudinal position of the load center is 24 610 mm forward of the base of the forks fig L1 For different load centers con tact your dealer For irregular loads...

Page 31: ...rriage 1 forward and move the tele scopic handler slowly forward 2 to insert the forks under the load fig N4 block the load if necessary Continue to move the telescopic handler forward 2 tilting the c...

Page 32: ...ure its sta bility If possible lower the load without moving the tele scopic handler Lift the boom 1 to release the load retract 2 and lower the boom 3 to bring the load into the transport position fi...

Page 33: ...NOT exceed the Telescopic Handler capacity for handling suspended loads Only lift the load vertically NEVER drag it horizontally Use tag lines to restrain load swing whenever possible GUIDELINES FOR...

Page 34: ...3225 CP0807 32 PRINTED IN U S A 1 19 19 5 24 25 23 23 6 16 20 26 7 24 11 25 8 3 17 21 21 2 1 22 18 9 10 24 15 14 11 12 13 29 28 27 33 Chapter 5 INSTRUMENTS AND CONTROLS 19 19 Courtesy of CraneMarket c...

Page 35: ...CE BRAKE PEDAL AND TRANSMISSION CUT OFF 16 FORWARD REVERSE LEVER 17 PARKING BRAKE LEVER 18 STEERING MODE SELECTOR 19 HYDRAULIC CONTROLS 20 LOAD CHARTS 21 HEATER CONTROLS HEATER AND AIR CONDITIONER CON...

Page 36: ...can be adjusted as follows WEIGHT ADJUSTMENT FIG A It is recommended that the weight be adjusted when the operator is not sitting in the seat Refer to graduation 1 of the seat Turn handle 2 according...

Page 37: ...t pull the lever and position the back rest to find the desired position LONGITUDINAL ADJUSTMENT FIG H Adjust the locking lever until you reach the position required This then locks and the seat will...

Page 38: ...l dropping of the level con sult your dealer G RED PARKING BRAKE LAMP This lamp comes on when the parking brake is applied H RED ALTERNATOR CHARGE LAMP If the lamps F H I J K and the buzzer come on wh...

Page 39: ...this switch only to do so the switch E1 located on the rear windshield wiper motor must be switched to the ON position I F OPTION G FRONT WORKING LIGHTS option for CT5 16 Pressing the bottom of this s...

Page 40: ...EL Lift up the fuse and relay access panel 11 12 FUSES AND RELAYS A chart on the inside of the access panel displays the use of the components described below K0 OPTION K1 OPTION K2 Transmission cut o...

Page 41: ...indicator light 15A F28 15A MAX Main beam 15A Main beam lamp 15A F29 25A MAX Hazard warning lights power supply 15A Roof light 15A F30 25A MAX Light switch power supply horn and indicators 25A F31 20...

Page 42: ...hift into neutral and follow the sequence 17 PARKING BRAKE LEVER To prevent inadvertant release the lever has a safety lock To apply the parking brake pull the lever rearward position A To release the...

Page 43: ...ith Pick N Place Controls LIFTING A LOAD Pull lever A rearward to raise the boom Push lever A forward to lower the boom TELESCOPING THE BOOM Move lever A to the left to retract the boom Move lever A t...

Page 44: ...ssor circuit to turn into gas under the effect of the heat given off by the engine because the compressor is likely to be damaged by liquid refrigerant In winter To ensure proper operation and complet...

Page 45: ...g way A Control with signal light on B At the selected temperature C At the selected temperature 1 2 or 3 22 CAB AIR FILTERS CT5 16 TURBO See chapter 6 MAINTENANCE D EVERY 500 HOURS SERVICE 23 WINDSHI...

Page 46: ...rear stoplight left tail light E G F H A C B D C Right tail light right rear stoplight D Right rear indicator 32 BACKUP ALARM The backup alarm sounds automatically when the Forward Reverse lever is in...

Page 47: ...er hitch ring Apply the parking brake and turn off the engine Remove the clip 1 lift the tow pin 2 and insert or remove the trailer hitch ring B TRAILER ELECTRIC CONNECTOR This 7 pin connector enables...

Page 48: ...FOR MAINTENANCE OPERATIONS YOU BEN EFIT THROUGH ITS DEALER NETWORK WHICH PROVIDES USERS WITH expert know how and competence guarantee of high quality work original equipment replacement components hel...

Page 49: ...NATOR BELT Part number 216851 CYCLONIC PRE FILTER Part number 216855 Clean 10 H HYDRAULICS HYDRAULIC RETURN OIL FILTER CARTRIDGE 15 Part number 216853 Change 500 H FILTER CAP FOR HYDRAULIC OIL TANK Pa...

Page 50: ...thium Based Grease GREASING THE BOOM No 2 Lithium Based Grease HYDRAULIC SYSTEM HYDRAULIC OIL RESERVOIR 27 gallons 102 5 liters Hydraulic ISO VG46 Mobil DTE 15 M or equal BRAKE SYSTEM BRAKE CIRCUIT AT...

Page 51: ...ricants Do not fill the fuel tank when the engine is run ning Only fill the fuel tank in areas specified for this purpose Do not fill the fuel tank to the maximum level Do not smoke or approach the te...

Page 52: ...ndler with clean clear water and wipe them dry Touch up the paint if necessary Shut down the telescopic handler see chapter 4 OPERATING AND SAFETY INSTRUCTIONS STOPPING THE TELESCOPIC HANDLER Make sur...

Page 53: ...install and adjust the tension in the drive belts see chapter 6 MAINTENANCE C EVERY 250 HOURS SERVICE Turn the engine using the starter to allow the oil pressure to rise Reconnect the engine fuel cut...

Page 54: ...o obtain an angle as low as possible to load the telescopic handler Load the telescopic handler parallel to the trailer Stop the telescopic handler see chapter 2 OPERATING AND SAFETY INSTRUCTIONS OPER...

Page 55: ...elescopic handler on the trailer with chains and binders at the front of the telescopic handler at the tie down points 1 fig 3 3 and at the back at the tow pin 2 fig 3 4 Tighten the chains and binders...

Page 56: ...arger C Bleed the fuel system TRANSMISSION Transmission universal joint G G C Transmission controls C Hydrostatic transmission circuit pressures C Governing start of the hydrostatic transmission C Wor...

Page 57: ...ls reducers pivots G G C Transfer box oil level C Front axle differential oil level C Front wheels reducers oil level C Transfer box oil V V Front axle differential oil V V Front wheels reducers oil V...

Page 58: ...e condensation due to atmospheric humidity Open the right side cover Remove cap 1 fig A3 Fill the fuel tank with clean fuel see chapter 6 MAINTENANCE LUBRICANTS AND FUEL filtered through a strainer or...

Page 59: ...s of the telescoping sections fig A6 A4 1 2 A6 WARNING Check that the air hose is correctly connected to the tire valve before inflating Keep every one away during inflation Follow the recommended tir...

Page 60: ...Do not clean the safety car tridge located inside the filter cartridge Instead replace it if it is dirty or damaged Telescope the boom several times in order to spread the grease evenly Remove any ex...

Page 61: ...de fig B3 2 This is the only effective way of cleaning the core B3 1 B3 2 1 B4 BOOM GREASE To be performed weekly even if the telescopic handler has been operated for less than 50 hours during the wee...

Page 62: ...d Loosen screw 1 fig B6 1 and remove the access panel for the brake fluid reservoir and windshield washer tank 2 fig B6 1 The level is correct when it is at the MAX level on the reservoir If necessary...

Page 63: ...distilled water that has been stored in a glass container Clean and dry caps 1 fig B10 and replace and tighten Check the terminal connections and lightly coat them with petroleum jelly to prevent corr...

Page 64: ...COMPRESSOR BELTS TENSION CHECK ADJUST Open the engine cover Unscrew the fastening screws 1 fig C2 1 Remove the protective guard 2 fig C2 1 Check the belts for signs of wear and cracks and change if ne...

Page 65: ...If necessary add oil see chapter 6 MAINTE NANCE D11 TRANSFER BOX OIL by the same filler port Replace and tighten the level plug 1 fig C3 2 25 to 36 ft lb 34 to 49 Nm tightening torque C4 PARKING BRAKE...

Page 66: ...CK Park the telescopic handler on level ground with the engine stopped Remove level plug 1 fig C6 The oil should be flush with the edge of the hole If necessary add oil see chapter 6 MAINTE NANCE LUBR...

Page 67: ...nkcase Start the engine and let it run for a few minutes Check for possible leaks at the drain plug and the oil filter D1 3 D1 4 3 4 D1 5 5 7 Stop the engine wait a few minutes and check that the leve...

Page 68: ...alling check the condition of the new cartridge see chapter 6 MAINTENANCE FIL TER CARTRIDGES AND BELTS Install the cartridge onto the filter axis and push it in pressing the edges and not the middle R...

Page 69: ...With the engine running at mid speed tilt the car riage forward While it is tilting turn off the engine Movement should slow down as the engine speed falls and stop when the engine stops WARNING Keep...

Page 70: ...Nm Fill with oil see chapter 6 MAINTENANCE LUBRICANTS AND FUEL by filler port 3 fig D9 2 The level is correct when the oil is flush with the edge of the level hole 3 fig D9 2 Check for any possible le...

Page 71: ...two changes of the air filter cartridge E3 HYDRAULIC OIL DRAIN Park the telescopic handler on level ground with the engine stopped and telescopic boom retracted and low ered as far as possible E1 1 E1...

Page 72: ...Check for any possible leaks at the drain plug Replace filler cap 2 fig E3 2 with a new filler cap see chapter 6 MAINTENANCE FILTER CARTRIDGES AND BELTS Close the right side cover FILTERING OF THE HYD...

Page 73: ...e if necessary Rinse the cooling system with clean water Use a cleaning agent if necessary REFILL Retighten drain plug 3 fig F1 2 15 ft lb 20 Nm torque and drain plug 4 fig F1 3 30 ft lb 40 Nm torque...

Page 74: ...nd then stops or runs irregularly check for pos sible leaks in the low pressure circuit If in doubt contact your dealer G2 WHEELS CHANGE For this operation use a hydraulic jack and a safety support St...

Page 75: ...he transport position and facing to a white wall on flat level ground fig G6 Check the tire pressures see chapter 1 SPECI FICATIONS SPECIFICATIONS Place the shift lever in neutral and apply the park i...

Page 76: ...HE REFRIGERANT TO REPLACE THE FILTER DRIER H4 RELOADING REFRIGERANT AND CHECKING THE THERMOSTATIC CONTROL AND PRESSURE SWITCHES NOTE When opening the evaporator unit remember to replace the cover seal...

Page 77: ...ew decals surfaces must be free from dirt dust grease and other foreign material To apply a solid formed decal remove the smaller portion of the decal backing paper and apply this part of the exposed...

Page 78: ...nt 1 12 215822 Belt Guard 1 13 218842 Hydraulic Oil 1 14 216392 Diesel Fuel 1 15 103585 Loadchart Rotating Carriage 1 103584 Loadchart Standard Carriage 1 103587 Loadchart Bucket Grapple 1 25 yd 1 103...

Page 79: ...927 Decal Pinch Point Warning 2 05a 103202 Decal Turbo 1 06 218845 Decal Hydraulic Couplers 1 07 183962 Decal Gehl 6 00 x 25 47 1 08 217684 Decal Boom Angle 1 09 183963 Decal Gehl 3 75 x 15 92 1 10 21...

Page 80: ...913225 CP0807 78 PRINTED IN U S A INTENTIONALLY BLANK Courtesy of CraneMarket com...

Page 81: ...ions Consult your dealer WARNING Only attachments approved by the manufac turer are to be used on GEHL telescopic han dlers see chapter 7 ATTACHMENTS TECH NICAL SPECIFICATIONS OF ATTACHMENTS The manuf...

Page 82: ...ING AN ATTACHMENT Proceed in the reverse order of paragraph INSTALLING AN ATTACHMENT Be sure to place the attachment flat on the ground and in a closed position B HYDRAULIC ATTACHMENT WITH MANUAL LOCK...

Page 83: ...with the boom lowered in front of and in line with the attachment Tilt the carriage forward fig B Bring the carriage under the mounting tube of the attachment slightly lift the boom and tilt the car r...

Page 84: ...mes Connect the quick connectors as needed for the attachment s hydraulic movements IMPORTANT Make sure that the quick connec tors are clean and protect the connections that are not used with the caps...

Page 85: ...the valve to position B fig D with the hydraulic circuit for attachment locking closed HYDRAULIC RELEASING Place the valve in position A fig D with the hydraulic circuit for attachment locking open Pr...

Page 86: ...aulic control valve joystick to release the attachment Stop the engine but keep the ignition on Relieve the pressure from the attachment hydraulic circuit by pressing buttons 1 and 2 fig E on the hydr...

Page 87: ...or more times Connect the quick connectors as needed for the attachment s hydraulic movements IMPORTANT Make sure that the quick connec tors are clean and protect the connections that are not used wi...

Page 88: ...GE MASONRY STOCK NUMBER 820271 Nominal load capacity 7 000 lbs 3175 kg Width 48 Weight 687 lbs 312 kg FORK SETS STOCK NUMBER 804401 Section 5 x 1 3 4 x 48 Weight 325 lbs 147 kg Rated Capacity 7 500 lb...

Page 89: ...SHIFT CARRIAGE WITH LOAD BACKREST REFERENCE 820194 Nominal load capacity 10 000 lbs 4536 kg Side shift 2 x 4 Width 48 Weight 225 lbs 102 kg ITA HOOK TYPE FORK SETS REFERENCE 820195 Section 5 x 1 3 4 x...

Page 90: ...GE REFERENCE 820330 LIGHT MATERIAL BUCKET REFERENCE 820254 Nominal load capacity 1 5 cu yd Width 73 Weight 1014 lbs 460 kg BOLT ON CUTTING EDGE REFERENCE 820255 GENERAL PURPOSE BUCKET WITH BOLT ON CUT...

Page 91: ...und bales Weight 490 lbs 222 kg BALE GRAB REFERENCE 820154 for three square bales Weight 1 098 lbs 498 kg OTHER UNIVERSAL SKID STEER ADAPTER REFERENCE 820295 with manual engagement includes 1 2 flat f...

Page 92: ...07 90 PRINTED IN U S A LOAD ZONE CHARTS Rotating Carriage Load Chart 103585 1 25 Cu Yd Bucket Load Chart 103587 1 00 Cu Yd Bucket Load Chart 103586 Standard Carriage Load Chart 103584 Courtesy of Cran...

Page 93: ...5 110 80 1 2 20 40 40 90 65 120 90 9 16 12 55 55 110 80 150 110 9 16 18 60 60 120 90 170 130 5 8 11 75 75 150 110 220 170 5 8 18 85 85 180 130 240 180 3 4 10 130 130 260 200 380 280 3 4 16 150 150 300...

Page 94: ...ng Lamp 36 Electrolyte Level 61 Jump Starting 25 Service 67 Brake Fluid Check Level 60 Recommended Type 48 Boom Function Controls 41 Grease 59 Wear Pads 57 C Cab Ventilation Filter Clean 61 Change 64...

Page 95: ...Load Handling 28 Starting 24 Stopping 26 Travel 27 Operator Manual storing 18 Operator Maintenance 18 Operator s Station Heater Air Conditioner Controls 42 P Park Brake Lever 40 Pressures Boom and At...

Page 96: ...copic Handler 51 Transfer Box Oil Change 68 Check 63 Recommended Grade 48 Transmission Description 7 W Warranty Inside Rear Cover Wheel Alignment Indicator Lamp 40 Switch 40 Windshield Wiper Switch 37...

Page 97: ...E TO APPLY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW GEHL WARRANTY DOES NOT INCLUDE 1 Transportation to selling dea...

Page 98: ...r the service department of Gehl Company before starting or continuing operation GEHL Company 143 Water Street P O Box 179 West Bend WI 53095 0179 U S A www gehl com 913225 CP0807 2007 Gehl Company PR...