Gehl Dynalift 552, Operator'S Manual

Page 1: ...Form No 908424 OPERATOR S MANUAL 552 553 Dynalift Telescopic Boom Forklift Courtesy of Crane Market...

Page 2: ...Transmission Hydraulic Starting Aid Engine Oil Circulating Work Lights Temperature Oil Filter Inject Pressure Fan Clutch Engaged Clutch Low Accumulator Wiper Washer Heater Beacon Disengaged Pressure...

Page 3: ...61 Index 64 Electrical Hydraulic Schematics 68 Standard Hardware Torque Data 72 Load Zone Charts 73 Warranty Inside Back Cover IDENTIFICATION INFORMATION Write your Gehl Dynalift Model and Serial Numb...

Page 4: ...it to the container 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 Right and left are determined from a position si...

Page 5: ...Cylinder Slave Cylinder Dash Indicators and Controls Seat Fuel Tank Rear Access Cover with Rear Lights and Reverse Alarm Rear Boom Access Cover Lift Cylinder Level Cylinder Hydraulic Tank Extend Cylin...

Page 6: ...Oil immersed in board hydraulic wet disc type Separate front and rear systems Manual foot pedal actuation Parking brake Mechanical disc type Electrical System Type 12 volt negative ground Battery 745...

Page 7: ...pressure 2000 psi 138 bar Hydraulic filter In tank return type 10 micron media replaceable element Rated flow 100 gpm 379 L min Rated pressure 100 psi 690 kPa By pass pressure full flow 25 psi 172 kPa...

Page 8: ...INTENTIONALLY BLANK PAGE 908424 AP500 6 PRINTED IN U S A Courtesy of Crane Market...

Page 9: ...ten for abnormal noises or vibrations if detected deter mine their cause and repair as necessary I acknowledge that pre delivery procedures were performed on this unit as outlined above Dealership s N...

Page 10: ...INTENTIONALLY BLANK To be removed as Dealer s file copy 908424 AP500 8 Printed In USA Courtesy of Crane Market...

Page 11: ...m leaks when under pressure Listen for abnormal noises or vibrations if detected deter mine their cause and repair as necessary I acknowledge that pre delivery procedures were performed on this unit a...

Page 12: ...he slope and block the wheels 2 Fully retract the boom and lower the attachment tool to the ground Idle engine for gradual cooling 3 Place controls in neutral and set parking brake 4 Shut off engine a...

Page 13: ...BOVE FAC TORS COULD CAUSE THE MACHINE TO TIP AND THROW YOU OUT OF THE OPERATOR S STATION WHICH MAY CAUSE SERIOUS BODILY INJURY OR DEATH PRINTED IN U S A 11 908424 AP500 WARNING U S OSHA regulations re...

Page 14: ...t until all personnel are clearly away from the machine ALWAYS use the recommended hand holds and steps with at least three points of support when get ting on and off the machine Keep steps and plat f...

Page 15: ...nd block the wheels DO NOT fill the fuel tank to capacity Allow room for expansion Maintain control of the fuel filler nozzle when filling the tank Use the correct fuel grade for the operating season...

Page 16: ...maximum capacity to be lifted and placed at specific outward and upward distances ALWAYS be aware of load weights prior to attempting lift and placement with this machine Safety Guards and Warning De...

Page 17: ...PRINTED IN U S A 15 908424 AP500 INTENTIONALLY BLANK Courtesy of Crane Market...

Page 18: ...908424 AP500 16 PRINTED IN U S A L65928 SAFETY L65948 L65929 L66042 093475 Courtesy of Crane Market...

Page 19: ...PRINTED IN U S A 17 908424 AP500 SAFETY L65925 L65440 L63690 L65925 L65925 Courtesy of Crane Market...

Page 20: ...908424 AP500 18 PRINTED IN U S A SAFETY L65924 L65927 L65933 L65928 072798 Courtesy of Crane Market...

Page 21: ...PRINTED IN U S A 19 9084241 AP500 SAFETY L65942 L65927 L65925 L65932 L65927 L65924 Courtesy of Crane Market...

Page 22: ...908424 AP500 20 PRINTED IN U S A SAFETY Truss Boom Rotate Carriage L65927 L66042 Courtesy of Crane Market...

Page 23: ...pany cannot be responsible for operator safety if the machine is used with an unapproved attach ment tool Chapter 5 INDICATORS AND CONTROLS PRINTED IN U S A 21 908424 AP500 DASH AREA Start Keyswitch P...

Page 24: ...cates whether the transmission oil is at the proper operating temperature During normal operation this lamp should be off indicating that the transmission oil system is at the proper temperature IMPOR...

Page 25: ...visibility for the operator through the windshield and the top of the opera tor s station Windshield Washer Used to apply cleansing agent while activating the windshield wipers Turn Signal This switc...

Page 26: ...n reverse IMPORTANT Care should be taken when downshifting or reversing as damage to the trans mission can occur if shifting is forced or attempt ed at too high a speed Allow engine RPM to slow before...

Page 27: ...E PANEL These controls and indicators are used to position the frame boom and attachment Graphic symbols on the side panel illustrate the control actions Frame Level Tilt Joystick The machine may be t...

Page 28: ...R OPERATION INDICATORS The following indicators are for fluid level and opera tor rear vision safety 908424 AP500 26 PRINTED IN U S A BOOM ANGLE INDICATOR WARNING Use extreme caution when raising or e...

Page 29: ...g toward the rear of the main hood section Backup Alarm Located inside the rear frame cover produces a loud warning sound whenever the machine is in reverse ATTACHMENT TOOLS Gehl offers a versatile ra...

Page 30: ...th the various operating con trols indicators and safety features STARTING THE ENGINE Before mounting the operator s compartment walk completely around the machine to be sure NO one is under on or clo...

Page 31: ...neutral Set the parking brake lever to ON 4 Turn the keyswitch key to the OFF position Remove the key 5 Unlatch the seat belt and grasp the hand holds while climbing out of the operator s compartment...

Page 32: ...Quick attach System To detach attachment tool proceed as follows 1 Raise the boom slightly and extend it 2 or 3 feet 0 6 0 9 m for better visibility Lower the boom until the attachment tool is approxi...

Page 33: ...ons Grade and Slope Precautions The Telescopic Forklift complies with industry stabili ty tests requirements and is stable when properly oper ated However improper operation faulty mainte nance or poo...

Page 34: ...unds with the trav el selector in reverse Care should be taken when down shifting or reversing as damage to the transmission can occur if shifting is forced or attempted while traveling When ramps MUS...

Page 35: ...conductor or gas line It is not necessary to make direct contact with a power line for power to ground through the structure of the machine Keep the boom at least 10 ft 3 m from all power lines Accid...

Page 36: ...e boom is visible and stops He knows the maximum safe distance of extension with this load has been reached LIFTING ATTACHMENT TOOL APPLICATIONS Picking Up the Load Inspect the load If it appears unst...

Page 37: ...he back of the Telescopic Forklift Activate hazard lights on the machine For highway operation obtain and install an amber flashing beacon NOTE ALWAYS follow ALL state and local reg ulations regarding...

Page 38: ...hed pair of ramps is requIred Use ramps as described in Steps 1 thru 4 and proceed as follows to unload the machine 8 If necessary adjust the machine so that the wheels are in line and centered with t...

Page 39: ...Kits Spanish _ _ _ _Additional Student Materials English 80 00 _ _ _ _Additional Student Materials Spanish _ _ _ _Additional Visual Aids English 48 00 _ _ _ _Additional Visual Aids Spanish Order Proc...

Page 40: ...908424 AP500 38 PRINTED IN U S A INTENTIONALLY BLANK May be removed at perforation as Fax or Mail order sheet Courtesy of Crane Market...

Page 41: ...e dirt from the fittings before greasing them to prevent contamination Replace any missing or damaged fittings To minimize dirt build up avoid excessive greasing Chapter 7 LUBRICATION CAUTION NEVER lu...

Page 42: ...20054 L98600 L94746 a L98978 552 L97489 L99184 PERKINS L120054 078850 078849 b L88976 JOHN DEERE L120054 L98600 L94746 a L98978 553 L97489 L99184 PERKINS L120054 078850 078849 b L88976 a 552 After S N...

Page 43: ...PRINTED IN U S A 41 908424 AP500 2 4 6 3 1 5 6 11 4 10 14 9 UNDER COVER 12 8 13 4 13 15 16 16 20 14 20 Courtesy of Crane Market...

Page 44: ...m onto the ground or into a drain DEALER SERVICES The following areas of internal components service replacement and operating adjustments should only be attempted by or under the direction of an auth...

Page 45: ...electrical components and switch connections It is located at the end of this man ual and can be used as a guide for service reference as required OPERATOR SERVICES Some of the operator related servi...

Page 46: ...iner until only clear fuel is flowing from the tank CHECK FUEL FILTER NOTE The fuel filter will require occasional replacement to maintain a clean and adequate fuel flow for maximum engine horsepower...

Page 47: ...om the front hood section Loosen the filler cap to release pressure Remove the filler cap and check the level on the dipstick If the oil level is down or below the ADD mark fill with the required amou...

Page 48: ...and clear of the tire while inflating it 4 NEVER inflate beyond 35 PSI 240 kPa to seat the beads If the beads have not seated by the time the pressure reaches 35 PSI 240 kPa deflate the assembly repos...

Page 49: ...air side of the old element indicates a leakage problem Be sure to remove the cause before installing a new element 4 Inspect the new element for possible damage Placing a bright light inside the elem...

Page 50: ...l Injection Pump Timing Whenever injection pump timing or other pump ser vice is indicated by abnormal engine operation contact your nearest engine dealer CHANGE ENGINE OIL AND FILTER Change the engin...

Page 51: ...sparks away from the battery area Make sure battery is charged in a well ventilated area NEVER lay a metal object on top of a battery as a short circuit can result Battery acid is harmful on contact...

Page 52: ...If it does not start immediately start the jumper vehicle engine to avoid excessive drain on the booster battery 6 After the machine is started and running smoothly have the second person remove the...

Page 53: ...on the pad tracking areas of the boom sections An exception would be if a boom section has been replaced Visually check for loose pad bolts The bolts are torqued to 30 ft lb 40 Nm If the bolts are re...

Page 54: ...anetary Hubs The hubs have one plug each used for draining and fill ing see illustration 1 Position the wheel until the arrow points to the left Remove the drain fill plug and allow the oil to drain o...

Page 55: ...test port and the boom extended retract the boom fully The gauge should read 2800 PSI 193 bar Joystick Relief Pressure on Later Units Plug a 1000 PSI 69 bar gauge in the joystick test port Start the e...

Page 56: ...PRINTED IN U S A During Storage 1 About once each month connect the battery and check all fluid levels to make sure they are at the prop er level before starting the engine 2 Start the engine and all...

Page 57: ...s part of the exposed adhesive backing to the clean surface while maintaining proper position and alignment Slowly peel off the other portion of the backing paper while applying hand pressure to smoot...

Page 58: ...3 L66581 05 WARNING PINCH POINT L65927 L65927 06 WARNING NO RIDERS 122288 122288 07 WARNING JUMP START L65933 L65933 08 GEHL 6 38 L65932 L65932 09 BRAKE FLUID LEVEL L63474 L63474 10 OPERATOR MANUAL IN...

Page 59: ...L65927 L65927 05 GEHL 6 38 122288 122288 06 DYNATTACH 1 1 2 L66569 L66569 07 WARNING HOT SURFACE L65942 L65942 08 WARNING NO RIDERS L65932 L65932 09 GEHL 2 L66584 L66584 10 DYNATTACH UNLOCK RED STRIP...

Page 60: ...67721 02 NO 4 EXTENSION MARKER L67722 02 NO 5 EXTENSION MARKER L67723 03 GREASE DAILY L65920 L65920 04 DYANTTACH DIAGRAM L65937 L65937 05 WARNING PINCH POINT L65927 L65927 06 WARNING CARRY LOAD LOW L6...

Page 61: ...63692 05 IGNITION HORN w Pushbutton Start L68513 L68513 06 MADE IN USA 094951 094951 07 WARNING PARK BRAKE L65925 L65925 08 WARNING OPERATOR L63690 L63690 09 WARNING CARRY LOAD LOW 093475 093475 10 LO...

Page 62: ...FILTER CHART L68084 L68084 08 DANGER PANEL IN PLACE L65948 L65948 09 DANGER POWER LINES L65929 L65929 10 BRAKE FLUID LEVEL L63474 L63474 11 OPERATOR MANUAL INSIDE L65922 L65922 12 WARNING PINCH POINT...

Page 63: ...irst 100 Every 250 Hours Hours Hours Hours or Daily or Weekly Check Fuel Tank Level z Check Fuel Filter Drain Water If Required z Check Engine Oil z Check Radiator Coolant Level z Check Transmission O...

Page 64: ...Transmission Oil and Filter z Change Radiator Coolant z Change Hydraulic Return Filter Element z Change Axle Differential Planetary Oil z Check Exhaust System z Check Hydraulic System Relief Pressures...

Page 65: ...PRINTED IN U S A 63 908424 AP500 Date Hours Service Procedure MAINTENANCE LOG Courtesy of Crane Market...

Page 66: ...Reach 33 Load Carry Elevation Placement 34 Checklists delivery pre delivery 7 Controls Dash 21 Right Side Panel 25 Floor Seat 25 Other Miscellaneous 26 Cylinders Servicing 42 D Dealer Services 42 Dec...

Page 67: ...Check 53 Maintenance Recording 62 Scheduled Intervals 61 Mandatory SAFETY Shutdown Procedure 10 O Oils See Lubrication Operation Load Handling 33 Starting 28 Stopping 29 Symbols Inside Front Cover Tr...

Page 68: ...rns 32 Transmission Description See Chapter 2 Temperature Lamp 22 Transmission Oil Changing 51 Check level 45 Recommended Trades 39 Transporting Loading 36 Unloading 36 Travel Speed See Controls W War...

Page 69: ...Notes PRINTED IN U S A 67 908424 AP500 Courtesy of Crane Market...

Page 70: ...552 553 Electrical Schematic J D Engine 908424 AP500 68 PRINTED IN U S A Courtesy of Crane Market...

Page 71: ...552 553 Electrical Schematic Perkins Engine PRINTED IN U S A 69 908424 AP500 Courtesy of Crane Market...

Page 72: ...552 553 Hydraulic Schematic 908424 AP500 70 PRINTED IN U S A A Courtesy of Crane Market...

Page 73: ...552 553 Hydraulic Schematic PRINTED IN U S A 71 908424 AP500 A Courtesy of Crane Market...

Page 74: ...120 90 9 16 12 55 55 110 80 150 110 9 16 18 60 60 120 90 170 130 5 8 11 75 75 150 110 220 170 5 8 18 85 85 180 130 240 180 3 4 10 130 130 260 200 380 280 3 4 16 150 150 300 220 420 320 7 8 9 125 125...

Page 75: ...Load Zone Charts PRINTED IN U S A 73 908424 AP500 552 L63661 Standard Carriage 552 L63437 Rotating Carriage 552 L63926 1 Cu Yd Bucket 552 L63454 8 Ft Truss Boom Courtesy of Crane Market...

Page 76: ...Load Zone Charts 553 L68671 Standard Carriage 553 L68672 Rotating Carriage 553 L68674 Cu Yd Bucket 553 L68673 8 Ft Truss Boom 908424 AP500 74 PRINTED IN U S A Courtesy of Crane Market...

Page 77: ...553 L68675 Winch Boom Load Zone Charts PRINTED IN U S A 75 908424 AP500 Courtesy of Crane Market...

Page 78: ...908424 AP500 76 PRINTED IN U S A Intentionally Blank Courtesy of Crane Market...

Page 79: ...elling dealer s business location GEHL WARRANTY DOES NOT INCLUDE 1 Transportation to selling dealer s business location or at the option of the Original Retail Purchaser the cost of a service call 2 U...

Page 80: ...YOUR DEALER OR THE SERVICE DEPART MENT OF GEHL COMPANY BEFORE STARTING OR CONTINUING OPERATION California Proposition 65 Warnings Diesel engine exhaust and some of its constituents are known to the St...