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Gehl Dynalift 552 Operator's Manual

Telescopic boom forklift
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Table of Contents

Form No.
908424
552/553
®
Dynalift
Telescopic
Boom Forklift
OPERATOR'S MANUAL
Courtesy of Crane.Market

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Summary of Contents for Gehl Dynalift 552

  • Page 1 Form No. 908424 552/553 ® Dynalift Telescopic Boom Forklift OPERATOR’S MANUAL Courtesy of Crane.Market...
  • Page 2 Dynalift Indicator & Operation Symbols ® Read Operator’s Park Brake On Horn Engine Start Electrical Safety Manual Preheat Fasten Seat Belt Battery Charge Fuse Engine Engine Hazard Flasher (Circuit Breaker) Air Filter Oil Pressure Volume - Full Volume Volume - Empty Diesel Fuel Fuel Low Head Lights...

  • Page 3: Table Of Contents

    Write your Gehl Dynalift Model and Serial Numbers in the space provided below. Refer to these numbers when inquiring about parts or service from your Gehl dealer. The Model and Serial Numbers for this machine are on a decal located inside the Operator’s Station.

  • Page 4: Introduction

    A plastic container is provided on the unit for storing the Operator’s Manual. After using the manual, please return 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.
  • Page 5 Identification (553 Shown) Dash Indicators and Controls Boom Angle Telescopic Boom Indicator ® Dynattach System Slave Cylinder Seat Tilt Cylinder Operator’s Station Lift Cylinder Extend Cylinder Rear Boom Access Cover Auxilluary Hydraulics (not shown) Exhaust Pipe Level Cylinder Rear Access Cover with Rear Lights and Reverse Alarm Mirror...

  • Page 6: Specifications

    Chapter 2 SPECIFICATIONS Lifting Performance Instrumentation Fuel tank: 29 gals. (110 L) Hydraulic tank & Maximum lift capacity: Gauges: Fuel level, hourmeter system: 35 gals. (133 L) 552: 5500 lbs (2495 kg) and coolant temperature Transmission & cooler: 24 qts. (22.7 L) 553: 6000 lbs (2721 kg) Axles:...
  • Page 7 Hydraulic System Type: Open center Pump: Single section gear type Displacement / revolution: 2.7 cu. in. (44.3 cc) Flow @ 2500 RPM: 29 gpm (110 L/min) Main relief pressure: 2800 psi (194 bar) Steer relief pressure: 2000 psi (138 bar) Hydraulic filter: In-tank return type, 10 micron media, replaceable element.
  • Page 8 INTENTIONALLY BLANK PAGE 908424/AP500 PRINTED IN U.S.A. Courtesy of Crane.Market...

  • Page 9: Checklists

    Chapter 3 CHECKLISTS PRE-DELIVERY I acknowledge that pre-delivery procedures were performed on this unit as outlined above. The following Checklist is an important reminder of valu- able information and inspections which MUST be made before delivering the Telescopic Forklift to the Customer. Check off each item after prescribed action is taken.
  • Page 10 INTENTIONALLY BLANK (To be removed as Dealer’s file copy) 908424/AP500 Printed In USA Courtesy of Crane.Market...
  • Page 11 Chapter 3 CHECKLISTS PRE-DELIVERY I acknowledge that pre-delivery procedures were performed on this unit as outlined above. The following Checklist is an important reminder of valu- able information and inspections which MUST be made before delivering the Telescopic Forklift to the Customer. Check off each item after prescribed action is taken.

  • Page 12: Safety

    English. The Gehl Company ALWAYS takes the operator’s It is the responsibility of the operator to read and safety into consideration when designing its machinery understand the Operator’s Manual and other informa-...
  • Page 13 SAFETY ADDITIONAL SAFETY REMINDERS WARNING User/operator safety practices, as established by industry standards, are included in this Operator’s U.S. OSHA regulations require employers in Manual and intended to promote safe operation of general industry and the construction, ship- the machine. These guidelines do not, of course, yard and cargo-handling industries (excepting preclude the use of good judgment, care and com- agricultural operations) to ensure that forklift...
  • Page 14 SAFETY ALWAYS wear the seat belt provided to prevent ALWAYS use the recommended hand holds and being throwned from the machine. If you are in an steps with at least three points of support when get- overturn: ting on and off the machine. Keep steps and plat- - DO NOT jump! form clean.
  • Page 15 NO passenger machine! If necessary to park on a grade, park across the To insure continued safe operation, replace dam- slope and block the wheels. aged or worn-out parts with genuine GEHL service parts, BEFORE using this equipment. PRINTED IN U.S.A. 908424/AP500...
  • Page 16 SAFETY When road travel is required, know and use the Safety Guards and Warning Devices signaling devices on the machine. Provide an escort and Slow Moving Vehicle (SMV) emblem This machine is fitted with an overhead guard in when required. accordance with industry standards.
  • Page 17 INTENTIONALLY BLANK PRINTED IN U.S.A. 908424/AP500 Courtesy of Crane.Market...
  • Page 18 SAFETY 093475 L65929 L65948 L65928 L66042 908424/AP500 PRINTED IN U.S.A. Courtesy of Crane.Market...
  • Page 19 SAFETY L65925 L65440 L63690 L65925 L65925 PRINTED IN U.S.A. 908424/AP500 Courtesy of Crane.Market...
  • Page 20 SAFETY 072798 L65924 L65927 L65928 L65933 908424/AP500 PRINTED IN U.S.A. Courtesy of Crane.Market...
  • Page 21 SAFETY L65942 L65924 L65927 L65932 L65925 L65927 PRINTED IN U.S.A. 9084241/AP500 Courtesy of Crane.Market...
  • Page 22 SAFETY Rotate Carriage L65927 L66042 Truss Boom 908424/AP500 PRINTED IN U.S.A. Courtesy of Crane.Market...

  • Page 23: Indicators & Controls

    Know how to stop the machine operation BEFORE operating it. This GEHL machine is designed and intended to be used ONLY with BRAKE a GEHL Company attachment tool, or a GEHL FAILURE Company approved accessory or referral attachment tool. The GEHL Company cannot...
  • Page 24 Circuit Breaker: The 15 amp breaker protects dash IMPORTANT: If this lamp comes ON during and engine electrical circuits. If it is not in the normal operation with the engine running, STOP depressed position, the gauges and indicators on the the engine immediately.
  • Page 25 Switch Panel Windshield Washer: Used to apply cleansing agent while activating the windshield wipers. Turn Signal: This switch is used to indi- SWITCH cate the direction of a turn. Depress the PANEL arrow which indicates the direction of your turn. Hazard: This switch can be activated to make the tail lights flash off and on if the machine is stalled or temporarily...
  • Page 26 Steer Select: Use “2-wheel mode” for higher speed Travel Direction Selector: Changes the direction of travel. Use “4-wheel mode” for making tighter turns, travel between forward and reverse. The usually on jobsite. Use “crab mode” when a small selector MUST be in N (NEUTRAL) amount of side shift is needed for picking or placing position before the engine will start.
  • Page 27 Brake Fluid Reservoirs: Lift hinged cover located on STEERING WHEEL ADJUSTMENT (later models) the cab floor. RIGHT SIDE 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 and ATTACHMENT TILT JOYSTICK...
  • Page 28 The inner boom nose section has an attachment carry- SAFETY SHUTDOWN PROCEDURE. DO NOT ing device feature called Dynattach system. This pro- attempt repairs. Call your GEHL dealer imme- ® vides the operator with a convenient means of utilizing diately for assistance.
  • Page 29 HYDRAULIC RESERVOIR BACKUP ALARM ATTACHMENT TOOLS Gehl offers a versatile range of attachment tools to Transmission Oil Level: The dipstick is located under meet various lifting and material handling applications the access cover on the front hood section. for this machine. Contact your area Gehl dealer for specifications and ordering information.

  • Page 30: Operation & Adjustments

    Chapter 6 OPERATION & ADJUSTMENTS GENERAL INFORMATION BEFORE STARTING ENGINE Before starting the engine and running the machine, CAUTION refer to the INDICATORS & CONTROLS chapter and familiarize yourself with the various operating con- BEFORE starting the engine and operating the trols, indicators and safety features.
  • Page 31 F (-7° C) or Place the travel lever in a speed range and in forward lower. See your Gehl dealer for recommended heater. or reverse direction. Release the parking brake lever and move slowly, while testing the steering and brakes.
  • Page 32 Detaching - Using Dynattach Quick- ® attach System The Telescopic Forklift boom nose will accept Dynattach quick-attach system Gehl attachment tools. ® To detach attachment tool, proceed as follows: The Dynattach ® quick-attach system has a quick- release hookup and locking mechanism for mounting 1.
  • Page 33 Modifications, alterations to, or use of attach- 6. Check clearances of ramps, doorways and passage ment tools not authorized by GEHL Company ways. Check overhead clearances if you will travel and can void the warranty and cause machine place loads near power or telephone lines.
  • Page 34 2. DO NOT travel up or down a grade or slope that exceeds 22% or 12 grade while loaded. 3. DO NOT place or retrieve loads on a side hill with a slope or grade that exceeds 12% or 7 grade.
  • Page 35 IMPORTANT: Turning corners too fast can tip the machine, DO NOT lower boom at high or cause a load to tip off the attachment. engine RPM when attachment tool is at maximum Sudden slowing or stopping of the machine rearward tllt. Damage to slave cylinders may may cause the load to drop off the attachment result.
  • Page 36 BOOM EXTENSION MARKERS REFERENCE DISTANCE LOAD IS EXTENDED Typical Load Zone Chart weight of any attachment tool as part of the picking During placement, the operator observes when the arc load capacity of the machine. reference number “3” on the boom is visible and stops. He knows the maximum safe distance of extension with this load has been reached.
  • Page 37 Use lower gear when traveling down an NOT attempt to bring down the boom or make incline. NEVER coast with the transmission in repairs. Call your GEHL dealer immediately. neutral. Travel up and down grades slowly. As lift height increases, depth perception DO NOT operate the machine on a slope or decreases.
  • Page 38 THEFT DETERRENTS 2. The ramps MUST be firmly attached to the truck GEHL has recorded all part numbers and serial num- or trailer bed with NO step between the bed and the bers. Users should take as many of the following ramps.
  • Page 39 Order Form Safety Training for Operators of Rough Terrain Forklifts PRICE OPERATOR TRAINING KIT (P/N 908405) Includes: Instructor’s Guide, Agenda, Objectives and Goals Sheet, Instructor’s English: $160.00 ea. * Resource Guide, Evaluation Test, Evaluation Log Book, Student Material Spanish: * ®...
  • Page 40 INTENTIONALLY BLANK (May be removed at perforation as Fax or Mail order sheet) 908424/AP500 PRINTED IN U.S.A. Courtesy of Crane.Market...

  • Page 41: Lubrication

    Chapter 7 LUBRICATION GENERAL INFORMATION Hydraulic System Reservoir Use a Mobil DTE 15M, or equivalent CAUTION which contains anti-rust, anti-foam and anti- oxidation additives & conforms to ISO VG46. Capacity: NEVER lubricate or service this unit when any 35 Gallons (133 liters) part of the machine is in motion.
  • Page 42 REPLACEMENT FILTER CHART FUEL ENGINE HYDRAULIC TRANSMISSION MODEL FILTER FILTER JOHN DEERE L120054 L98600 L94746 (a) L98978 L97489 L99184 PERKINS L120054 078850 078849 (b) L88976 JOHN DEERE L120054 L98600 L94746 (a) L98978 L97489 L99184 PERKINS L120054 078850 078849 (b) L88976 (a) 552 After S/N 1010, 553 After S/N 3176 including S/N 3173 (b) 552 After S/N 1006, 553 After S/N 3077 BASIC MACHINE...
  • Page 43 UNDER COVER PRINTED IN U.S.A. 908424/AP500 Courtesy of Crane.Market...

  • Page 44: Service & Storage

    Check for leaks and broken connections. Make note of any specific problem symp- WARNING toms, noises, etc. and contact your local Gehl Dealer. IMPORTANT: Always dispose of waste lubri- BEFORE performing any service on the...
  • Page 45 He will know what portions of the machine are covered WARNING under the terms of the GEHL warranty and what por- tions are covered by other vendor warranties. Tilt, lift, extend and leveling cylinders have ELECTRICAL COMPONENTS counterbalance valves. These valves keep...
  • Page 46 only guards or covers that provide needed access. Wipe WARNING away excess grease and oil. NEVER weld on attachment tools, boom support DO NOT smoke or allow any open flames in frame or overhead guards without the consent of the area while checking...
  • Page 47 Small amounts of water can be drained from the fuel By doing this, you will reduce the possibility of over- filter. The drain plug should be removed weekly to filling the hydraulic system, and also reduce potential drain off water accumulation until clear fuel is flowing injury due to hot fluid.
  • Page 48 shields and covers in place? Do all controls function WARNING smoothly and properly? Are there any abnormal vibra- tions or noises? Are any hose or fitting connections leaking? Is the engine exhaust color normal (light grey Inflating or servicing tires can be dangerous. or colorless)? Whenever possible, trained personnel should service and mount tires.
  • Page 49 3. Wipe the entire inside of the main body and inlet 100 Hours (New Machine Only) cap screen. A streak of dust on the clean air side of the old element The following initial oil and filter changes should be indicates a leakage problem.
  • Page 50 See the LUBRICATION chapter of this manual for the NOTE: Only an authorized engine dealer can proper oil specification. Replace the oil level check/fill perform WARRANTY Service on the engine. plug. Diesel Fuel Injectors Planetary Hubs Whenever faulty or plugged injectors are indicated, see NOTE: The planetary hubs can be checked with- your nearest authorized engine dealer.
  • Page 51 4. After new oil has been added, run the engine at idle 4. To neutralize acid spilled on the floor, use speed until the oil pressure light is OFF. Check for one of the following mixtures: leaks at the filter and drain plug. Re-tighten only as a.
  • Page 52 itive jumper cable to the jumper battery positive (+) the distance measures 10.31” (262 mm), the chain terminal. should be discarded. DO NOT repair sections of a chain. Replace the complete chain. 3. Connect one end of the negative (-) jumper cable to the jumper battery negative (-) terminal.
  • Page 53 maintaining a light film of grease on the pad tracking IMPORTANT: DO NOT OVERFILL! lf the oil areas of the boom sections. An exception would be if a level is too high, oil foaming, excessively high oil boom section has been replaced. temperature and oil leakage at the seal could result.
  • Page 54 CHANGE HYDRAULIC RETURN FRONT AXLE SHOWN FILTER ELEMENT WARNING When servicing the hydraulic system, lower the boom to the ground. This element is a cartridge type accessible from a hous- FILL ing on top of the hydraulic reservoir. Initial replace- DRAIN CHECK ment is after the first 100 hours.
  • Page 55 the strainer has any damage, holes, etc. it should be Service Every 2000 Hours replaced. 3. Flush out the bottom of the tank with clean NOTE: Perform all other service requIrements hydraulic oil. Re-install all cleaned components and up to this point, as well as the following. put the top back on the reservoir with a new gasket.
  • Page 56 During Storage STORAGE If the Telescopic Forklift will not be operated for a 1. About once each month, connect the battery and long period of time, prepare and store it using the pro- check all fluid levels to make sure they are at the prop- er level before starting the engine.

  • Page 57: Decal Locations

    Chapter 9 DECAL LOCATIONS NEW DECAL APPLICATION GENERAL INFORMATION Before applying the new decals, surfaces must be free from dirt, dust, grease and other foreign material. To CAUTION apply a solid-formed decal, remove the smaller portion of the decal backing paper and apply this part of the ALWAYS follow the safety precautions on exposed adhesive backing to the clean surface while decals.
  • Page 58 DECAL LOCATIONS - LEFT SIDE OF MACHINE REF. DESCRIPTION DANGER - ROTATING FAN L99863 L98864 GEHL 4.5” L66565 L66565 DYNALIFT L66568 L66568 L66585 L66581 WARNING - PINCH POINT L65927 L65927 WARNING - NO RIDERS 122288 122288 WARNING - JUMP START...
  • Page 59 DESCRIPTION DANGER - ROTATING FAN L65924 L65924 DYNALIFT L66568 L66568 L66585 L66581 WARNING - PINCH POINT L65927 L65927 GEHL 6.38” 122288 122288 DYNATTACH 1-1/2” L66569 L66569 WARNING - HOT SURFACE L65942 L65942 WARNING - NO RIDERS L65932 L65932 GEHL 2”...
  • Page 60 DECAL LOCATIONS REF. DESCRIPTION HALF ZONE EXTENSION MARKER L62583 L62583 (3 ea.) (5 ea.) NO. “0” EXTENSION MARKER L67718 NO. “1” EXTENSION MARKER L67719 L67719 NO. “2” EXTENSION MARKER L67720 L67720 NO. “3” EXTENSION MARKER L67721 NO. “4” EXTENSION MARKER L67722 NO.
  • Page 61 DECAL LOCATIONS - DETAILS IN OPERATOR STATION REF. DESCRIPTION GEHL 2.0” DIA. L65224 L65224 WARNING - SEAT BELT L65440 L65440 STEER SELECTOR L63618 L63618 F-N-R CONTROL L68295 L68295 IGNITION/HORN (w/o Pushbutton Start) L68052 L68052 IGNITION/HORN (Perkins Engine only) L63692 L63692...
  • Page 62 DECAL LOCATIONS - DETAILS IN OPERATOR STATION REF. DESCRIPTION DANGER - PERSONNEL L65928 L65928 WARNING - TRUSS BOOM L66042 L66042 WARNING - MACHINE LEVEL L65930 L65930 MAINTENANCE CHART L63542 L63542 TILT/LEVEL CONTROL L63632 L63632 BOOM CONTROL L63631 L63631 FILTER CHART L68084 L68084 DANGER - PANEL IN PLACE...

  • Page 63: Maintenance

    Chapter 10 MAINTENANCE This Maintenance Chart was developed to match the Service chapter of this manual. Detailed information on each Service Procedure may be found in the Service chapter. A Maintenance Log follows the Interval Chart for record- ing the maintenance procedures performed. Recording the 10 Hour (or Daily) service intervals would be imprac- tical and is therefore not recommended.
  • Page 64 MAINTENANCE INTERVAL CHART (CONT.) SERVICE PROCEDURE Every Every Every 1000 2000 Hours Hours Hours Change Air Filter Element Check Alternator & Fan Belt Tension Check Boom Slide Pads Wear & Clearance Change Transmission Oil and Filter Change Radiator Coolant Change Hydraulic Return Filter Element Change Axle Differential &...
  • Page 65 MAINTENANCE LOG Date Hours Service Procedure PRINTED IN U.S.A. 908424/AP500 Courtesy of Crane.Market...

  • Page 66: Index

    Index Controls, Dash ........21 Access To Components Chart ....43 Right Side Panel .
  • Page 67 Grease Fittings Oils - See Lubrication Locations ....... . .40 Operation Types Of Grease .
  • Page 68 Tables Lubricants ....... . .39 Paint Notice .......55 Replacement Filters .
  • Page 69 Notes PRINTED IN U.S.A. 908424/AP500 Courtesy of Crane.Market...

  • Page 70: Electrical & Hydraulic Schematics

    552/553 Electrical Schematic (J.D. Engine) 908424/AP500 PRINTED IN U.S.A. Courtesy of Crane.Market...
  • Page 71 552/553 Electrical Schematic (Perkins Engine) PRINTED IN U.S.A. 908424/AP500 Courtesy of Crane.Market...
  • Page 72 552/553 Hydraulic Schematic 908424/AP500 PRINTED IN U.S.A. Courtesy of Crane.Market...
  • Page 73 552/553 Hydraulic Schematic PRINTED IN U.S.A. 908424/AP500 Courtesy of Crane.Market...

  • Page 74: Standard Hardware Torque Data

    Torque Specifications Use these torque values when tightening GEHL hardware (excluding: Locknuts and Self-tapping, Thread-forming and Metal Screws) unless otherwise specified. Grade 5 Grade 8 Grade 2 Unified National Thread Lubed Lubed Lubed 8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18...

  • Page 75: Load Zone Charts

    Load Zone Charts L63661 - Standard Carriage L63926 - 1 Cu. Yd. Bucket L63437 - Rotating Carriage L63454 - 8 Ft. Truss Boom PRINTED IN U.S.A. 908424/AP500 Courtesy of Crane.Market...
  • Page 76 Load Zone Charts L68671 - Standard Carriage L68674 - Cu. Yd. Bucket L68672 - Rotating Carriage L68673 - 8 Ft. Truss Boom 908424/AP500 PRINTED IN U.S.A. Courtesy of Crane.Market...
  • Page 77 Load Zone Charts L68675 - Winch Boom PRINTED IN U.S.A. 908424/AP500 Courtesy of Crane.Market...
  • Page 78 Intentionally Blank 908424/AP500 PRINTED IN U.S.A. Courtesy of Crane.Market...

  • Page 79: Warranty

    No agent, employee or representative of GEHL has any authority to bind GEHL to any warranty except as specif- ically set forth herein. Any of these limitations excluded by local law shall be deemed deleted from this warranty;...
  • Page 80 Battery posts, terminals and related accessories contain lead and lead com- pounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling battery. GEHL Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 U.S.A. 908424/AP500 ©...

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Dynalift 553

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