Gehl Dynalift 663, Operator'S Manual

Page 1: ...Form No 907879 OPERATOR S MANUAL 663 Dynalift Telescopic Boom Forklift Courtesy of CraneMarket com...

Page 2: ...ransmission 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 4...

Page 3: ...Index 58 Electrical Hydraulic Schematics 62 Standard Hardware Torque Data 66 Load Zone Charts 67 Warranty Inside Back Cover IDENTIFICATION INFORMATION Write your Gehl Dynalift Model and Serial Number...

Page 4: ...urn 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 positio...

Page 5: ...Dynattach System Tool Hookup Rear Boom Access Access Cover With Rear Lights and Backup Alarm Operator s Station Engine Access Covers Battery Fuel Access Tank Extend Cylinder Inside Boom Lift Cylinder...

Page 6: ...disc type Hydraulic booster master cylinder w electric reserve in event of engine failure Manual foot pedal actuation Parking brake Mechanical disc type Electrical System Type 12 volt negative ground...

Page 7: ...essure 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 H...

Page 8: ...INTENTIONALLY BLANK PAGE 907879 AP1198 6 PRINTED IN U S A Courtesy of CraneMarket com...

Page 9: ...isten 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...

Page 10: ...INTENTIONALLY BLANK To be removed as Dealer s file copy Form No 907879 AP1198 8 Printed In USA Courtesy of CraneMarket com...

Page 11: ...stem 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 uni...

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

Page 13: ...the machine ALWAYS wear appropriate personal protective equipment called for by the job and working con ditions Hard hats protective glasses protective shoes gloves reflector type vests respirators an...

Page 14: ...an odor less and deadly gas Internal combustion engines deplete the oxygen supply within enclosed spaces and may create a serious hazard unless the oxygen is replaced This includes the atmosphere with...

Page 15: ...arked to identify the attachment tool and the total capacity with attachment tool at maximum elevation with load laterally centered ALWAYS make sure all nameplates caution and instruction markings are...

Page 16: ...907879 AP1198 14 PRINTED IN U S A 43 44 45 46 47 15 15 43 47 45 44 46 SAFETY Courtesy of CraneMarket com...

Page 17: ...PRINTED IN U S A 15 907879 AP1198 41 34 29 7 29 34 41 SAFETY 7 Courtesy of CraneMarket com...

Page 18: ...907879 AP1198 16 PRINTED IN U S A 3 15 1 4 15 1 3 3 4 SAFETY Courtesy of CraneMarket com...

Page 19: ...PRINTED IN U S A 17 907879 AP1198 3 17 1 3 19 3 3 28 SAFETY 28 19 3 17 1 Courtesy of CraneMarket com...

Page 20: ...907879 AP1198 18 PRINTED IN U S A SAFETY Truss Boom Winch Boom Rotate Carriage 3 48 47 47 48 3 Courtesy of CraneMarket com...

Page 21: ...operating it This GEHL machine is designed and intended to be used ONLY with a mounted GEHL Company attachment tool or a GEHL Company approved accessory or referral attachment tool The GEHL Company c...

Page 22: ...ser vice brake pedal is depressed DASH AREA Start Keyswitch OFF When the key is vertical in the keyswitch power from the battery is disconnected to the control and instrument panel electrical circuit...

Page 23: ...n trol actions Steering The power steering motor is designed to give effortless steering with no shock reaction from the axle wheels to the steering wheel Turn the direct connect ed steering wheel to...

Page 24: ...m and attachment Graphic symbols on the side panel illustrate the control actions Frame Level Joystick This may be tilted slowly 10o to the left or right to level the frame and boom in rela tion to th...

Page 25: ...chment cable OTHER OPERATION INDICATORS The following indicators are for fluid level and opera tor rear vision safety Hydraulic Reservoir Oil Level Fill Cap The sight gauge on the side of the reservoi...

Page 26: ...it produces a loud warning sound whenever the machine is in reverse Side Mirror This is located on the front outside cor ner of the fuel tank It provides the operator with a rear view on the right sid...

Page 27: ...PRINTED IN U S A 25 907879 AP1198 THIS PAGE INTENTIONALLY BLANK Courtesy of CraneMarket com...

Page 28: ...seat belt 3 Check that all controls are in their neutral posi tions except the parking brake lever which should be in the ON position 4 Turn the keyswitch to ON position and depress the start button I...

Page 29: ...or reverse Shifting to the next higher gear may be done at any engine RPM while the machine is in motion DO NOT overspeed the engine when down shifting Allow the machine to slow down before shifting...

Page 30: ...chment tool has auxiliary hydraulics dis connect the hoses from the quick disconnects on the boom nose 5 Start the engine 6 Tilt the Dynattach system forward to allow the attachment tool to roll out t...

Page 31: ...e of maxi mum rearward tilt is allowable under certain condi tions such as traveling with the load fully lowered the stability of the machine as determined by the industry standard tests does not enco...

Page 32: ...s or changes in direction Operation of the hydraulic system depends on engine speed and the distance the controls are moved When operating these controls it is important to develop a technique called...

Page 33: ...controls in neutral shut off engine and remove the key AVOID parking the machine on a slope or hill side but if necessary park across the slope and block the wheels Load Capacity and Reach This machin...

Page 34: ...in ground speed consistent with ground conditions and that permit stopping in a safe manner Typical Load Zone Chart HEIGHT ABOVE GROUND BOOM EXTENSION MARKERS REFERENCE DISTANCE LOAD IS EXTENDED WARNI...

Page 35: ...chased locally to the 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...

Page 36: ...ary adjust the machine so that the wheels are in line and centered with the ramps 9 Slowly at the lowest engine speed possible and carefully drive the machine down the ramps THEFT DETERRENTS THE CERTA...

Page 37: ...manu al has provisions for recording the dates and hourmeter readings after lubrication or other ser vice has been performed use those spaces to keep a log for maintaining a current service inter val...

Page 38: ...e pivot bearing 1 11 Boom slide pads as required front and rear CHASSIS AREA 12 Brake foot pedal linkage 1 13 Wheel spindle pins 4 per axle 14 Tie rod ends 2 per axle 15 Axle to frame pivot pins 1 per...

Page 39: ...gs PRINTED IN U S A 37 907879 AP1098 16 16 16 Chassis 4 18 3 11 19 15 7 Transmission 2 1 5 11 5 Boom 10 Other Side 9 8 7 6 Rotate Carriage NOT SHOWN Operator Station Floor Item 12 Front View Axle 15 1...

Page 40: ...em 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 aut...

Page 41: ...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 42: ...low water and fuel to drain into a container 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...

Page 43: ...over filling the hydraulic system and also reduce potential injury due to hot fluid Remove the front cover from the front hood section Loosen the filler cap to release pressure Remove the filler cap a...

Page 44: ...mpletely prior to removal Following assem bly of the tire on the rim use a safety cage or restrain ing device while inflating CHECK WHEEL NUT TORQUE On NEW machines re torque until 450 ft lbs 610 Nm i...

Page 45: ...e Telescopic Forklift should be on a level surface for this procedure See illustration Remove the check fill plug located on opposite side of the drive shaft U joint If low fill until oil overflows th...

Page 46: ...alves built in Use only genuine OEM engine replacement filters 3 Apply a thin coat of clean oil to the new oil filter gasket and spin tighten Refill the crankcase with new oil Follow specifications in...

Page 47: ...ell ventilated area NEVER lay a metal object on top of a battery as a short circuit can result Battery acid is harmful on contact with skin or fabrics If acid spills follow these first aid tips 1 IMME...

Page 48: ...ne to avoid excessive drain on the booster battery 7 After the machine is started and running smoothly have the second person remove the jumper cables negative jumper cable first from the jumper vehi...

Page 49: ...the transmission oil Shut down the engine Access to filter and drain plug is from underneath the machine Proceed as follows 1 Remove the drain plug and drain out old oil Replace the drain plug IMPORT...

Page 50: ...for possible holes Re tighten any loose clamps and make sure the mani fold outlet gasket is not leaking NOTE Perform all other service requirements up to this point as well as the following CHECK HYDR...

Page 51: ...arge and then shut it off IMPORTANT If it is desired to operate the hydraulic cylinders at this time BE SURE to wipe the protective grease and any adhering dirt from the cylinder rods prior to startin...

Page 52: ...residues 2 Wipe off grease from cylinder rods 3 Lubricate ALL grease fittings 4 Review and refamiliarize yourself with all safety precautions as outlined in the SAFETY chapter of this manual 5 Follow...

Page 53: ...his 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 smo...

Page 54: ...11 GEHL 8 0 1 ea L66567 12 HALF ZONE MARKER 5 ea L62583 13 NO 0 EXTENSION MARKER 1 ea L67718 13 NO 1 EXTENSION MARKER 1 ea L67719 13 NO 2 EXTENSION MARKER 1 ea L67720 13 NO 3 EXTENSION MARKER 1 ea L67...

Page 55: ...ea 072794 17 COOLANT UNDER PRESSURE 1 ea 072798 18 ANTI FREEZE 2 ea 056859 19 WARNING NO RIDERS 1ea L65932 20 HYDRAULIC OIL LEVEL 1 ea L65921 21 FILTER CHART Under Lid 1 ea L68083 22 LUBE CHART Under...

Page 56: ...ea L64810 39 MADE IN USA 1 ea 094951 40 IGNITION START HORN 1 ea L68052 41 WARNING SEAT BELT 1 ea L65440 42 OPERATOR MANUAL INSIDE 1 ea L65922 43 WARNING CARRY LOAD LOW 1 ea 093475 44 WARNING MACHINE...

Page 57: ...10 MAINTENANCE SERVICE PROCEDURE Every 10 Every 50 Every 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...

Page 58: ...om Slide Pads Wear Clearance z Change Radiator Coolant z Change Hydraulic Return Filter Element z Change Axle Differential Planetary Oil z Check Exhaust System z Check Hydraulic System Pressures z Che...

Page 59: ...PRINTED IN U S A 57 907879 AP1198 Date Hours Service Procedure MAINTENANCE LOG Courtesy of CraneMarket com...

Page 60: ...n Placement 31 Checklists delivery pre delivery 7 Controls Dash 20 Right Side Panel 22 Floor Seat 22 Other Miscellaneous 23 Cylinders Servicing 38 D Dealer Services 38 Decal Locations 52 Decals applyi...

Page 61: ...brication Operation Load Handling 30 Starting 26 Stopping 27 Symbols Inside Front Cover Operator Manual storing 2 Operator Services 39 Operator s Station Environment Controls 21 P Park Brake Lever 21...

Page 62: ...0 Transmission Oil Changing 47 Check level 41 Recommended Grades 35 Transporting Loading 33 Unloading 33 Travel Speed See Controls W Warranty Inside Rear Cover Water Trap See Fuel Filter Windshield Wi...

Page 63: ...Notes PRINTED IN U S A 61 907879 AP1198 Courtesy of CraneMarket com...

Page 64: ...663 Electrical Schematic J D Engine 907879 AP1198 62 PRINTED IN U S A Courtesy of CraneMarket com...

Page 65: ...663 Electrical Schematic Perkins Engine PRINTED IN U S A 63 907879 AP1198 Courtesy of CraneMarket com...

Page 66: ...663 Hydraulic Schematic 907879 AP1198 64 PRINTED IN U S A A Courtesy of CraneMarket com...

Page 67: ...663 Hydraulic Schematic PRINTED IN U S A 65 907879 AP1198 A Courtesy of CraneMarket com...

Page 68: ...20 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 43...

Page 69: ...Load Zone Charts PRINTED IN U S A 67 907879 AP1198 663 Standard Carriage 663 Rotating Carriage 663 1 Cu Yd Bucket 663 12 Ft Truss Boom Courtesy of CraneMarket com...

Page 70: ...Load Zone Charts 663 Winch Boom 907879 AP1198 68 PRINTED IN U S A Courtesy of CraneMarket com...

Page 71: ...g 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 Used e...

Page 72: ...TLY BREAKDOWN IF YOU HAVE ANY QUESTIONS ON PROPER OPERATION ADJUSTMENT OR MAIN TENANCE OF THIS MACHINE CONTACT YOUR DEALER OR THE SERVICE DEPART MENT OF GEHL COMPANY BEFORE STARTING OR CONTINUING OPER...