Gehl Dynalift 663 Operator's Manual
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Gehl Dynalift 663 Operator's Manual

Gehl Dynalift 663 Operator's Manual

Telescopic boom forklift
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Form No.
907879
663
Dynalift
®
Telescopic
Boom Forklift
OPERATOR'S MANUAL
Courtesy of CraneMarket.com

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Summary of Contents for Gehl Dynalift 663

  • Page 1 Form No. 907879 Dynalift ® Telescopic Boom Forklift OPERATOR’S MANUAL Courtesy of CraneMarket.com...
  • 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 Dash Indicators & Controls Side Panel Seat Controls Telescoping Boom Rear Boom Tilt Cylinder Access ® Dynattach System (Tool Hookup) Access Cover With Rear Lights Backup Alarm Operator’s Station Extend Cylinder (Inside Boom) Lift Cylinder Access Frame Sway Covers Cylinder Rear Boom...

  • Page 6: Specifications

    Chapter 2 SPECIFICATIONS Lifting Performance Monitoring lights: Axles: Differentials (2): Engine oil pressure, alternator, Maximum lift capacity: 3.4 qts. (3.22 L) ea. transmission oil temperature, 6000 lbs (2727 kg) brake failure Hubs (4): 1.3 qts. (1.18 L) ea. Maximum lift height: Monitoring alarms: Transmission 27’-6”...
  • 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 (193 bar) Steer relief pressure: 2000 psi (138 bar) Hydraulic filter: In-tank return type, 10 micron media, replaceable element.
  • Page 8 INTENTIONALLY BLANK PAGE 907879/AP1198 PRINTED IN U.S.A. Courtesy of CraneMarket.com...

  • 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) Form No. 907879/AP1198 Printed In USA Courtesy of CraneMarket.com...
  • 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 speed, the type of load being carried and placed, and the abrupt movement of any control lever. IF WARNING YOU ARE NOT CAREFUL WHILE OPERAT- ING THIS MACHINE, ANY OF THE ABOVE U.S. OSHA regulations require employers in FACTORS COULD CAUSE THE MACHINE general industry and the construction, ship- TO TIP AND THROW YOU OUT OF THE yard and cargo-handling industries (excepting...
  • Page 14 SAFETY and may create a serious hazard unless the oxygen Walk around the machine and warn all personnel is replaced. This includes the atmosphere within who may be servicing the machine or are in the the cab when provided. machine’s path prior to starting. DO NOT start until all personnel are away from the machine.
  • Page 15 It is intended To insure continued safe operation, replace dam- to offer protection to the operator from falling aged or worn-out parts with genuine GEHL service objects, but cannot protect against every possible parts, before using this equipment.
  • Page 16 SAFETY 907879/AP1198 PRINTED IN U.S.A. Courtesy of CraneMarket.com...
  • Page 17 SAFETY PRINTED IN U.S.A. 907879/AP1198 Courtesy of CraneMarket.com...
  • Page 18 SAFETY 907879/AP1198 PRINTED IN U.S.A. Courtesy of CraneMarket.com...
  • Page 19 SAFETY PRINTED IN U.S.A. 907879/AP1198 Courtesy of CraneMarket.com...
  • Page 20 SAFETY Winch Boom Truss Boom Rotate Carriage 907879/AP1198 PRINTED IN U.S.A. Courtesy of CraneMarket.com...

  • Page 21: Indicators & Controls

    Telescopic Forklift BEFORE operating it. special operating procedures. Know how to stop the machine operation BEFORE operating it. This GEHL machine is designed and intended to be used ONLY with WARNING a mounted GEHL Company attachment tool or...
  • Page 22 DASH AREA Brake Failure Lamp: The front and rear brakes are on independent brake line systems. If during normal oper- ation with the brake pedal depressed, a loss of pressure Start Keyswitch OFF: When the key is vertical in the occurs in either system, the brake failure lamp comes keyswitch, power from the battery is disconnected to the control and instrument panel electrical circuits.
  • Page 23 In the “OFF” position, the clutch mechanism of the Steering: The power steering motor is designed to give transmission remains engaged when applying brakes. effortless steering with no shock reaction from the axle In the “ON” position, the clutch mechanism is disen- wheels to the steering wheel.
  • Page 24 Travel Direction Selector: This lever is used to RIGHT SIDE PANEL change travel direction (forward or reverse). The selec- These controls and indicators are used to position the tor MUST be in N (Neutral) position before the engine frame, boom, and attachment. Graphic symbols on the will start.
  • Page 25 SAFETY SHUTDOWN PROCEDURE (Safety chapter, p.10). DO NOT attempt repairs. Call Depress the left side of the rocker switch to retract the your GEHL dealer immediately for assistance. load or forks horizontally. Releasing the rocker switch The truss boom and winch attachment tools...
  • Page 26 ATTACHMENT TOOLS Gehl offers a versatile range of attachment tools to meet various lifting and material handling applications with this machine. Contact your area Gehl dealer for specifications and ordering information.
  • Page 27 THIS PAGE INTENTIONALLY BLANK PRINTED IN U.S.A. 907879/AP1198 Courtesy of CraneMarket.com...

  • Page 28: Operation & Adjustments

    20 F (-7 C) or lower. See your Gehl dealer for recommended heater. 907879/AP1198 PRINTED IN U.S.A. Courtesy of CraneMarket.com...
  • Page 29 The Telescopic Forklift boom nose will accept climbing out of the operator’s compartment. ® Dynattach system Gehl attachment tools. The Dynattach system has a quick-release hookup and locking mechanism for mounting framing, masonry, or CAUTION material handling type attachment tools to the boom nose.
  • Page 30 12” (0.3 m) Modifications, alterations to, or use of attach- off the ground. ment tools NOT authorized by GEHL Co. in 2. Roll the carrier backward as far as it will go. Once writing can void warranty and cause machine...
  • Page 31 GENERAL MACHINE OPERATION Operate the travel controls gradually and smoothly when starting, stopping, turning and reversing the directions. Take time to check the Telescopic Forklift to make sure all systems are in good operating condition. Perform Grade and Slope Precautions the following steps before starting the machine for the first time each day.
  • Page 32 When ramps MUST be utilized in transporting loads WARNING with the machine, the following shall be minimum widths for safe travel: DO NOT attempt to correct the frame level Compacted dirt, gravel, etc. 12 ft. (3.6 m) condition with the boom raised or extended. Woodboard, concrete, etc.
  • Page 33 Load Capacity and Reach WARNING This machine has a flip-chart in the operator’s station which provides, at a glance, the capacity limits at var- Excessive speed can be hazardous. ALWAYS ious positions of attachment tool extension and eleva- exercise caution and good judgement while tion.
  • Page 34 BOOM EXTENSION MARKERS REFERENCE DISTANCE LOAD IS EXTENDED Typical Load Zone Chart Carrying The Load WARNING If the load obstructs your view get someone to direct you. Maintain ground speed consistent with ground Operating conditions can reduce the safe lift conditions and that permit stopping in a safe manner.
  • Page 35 Remove or tape over the slow moving vehicle (SMV) NOT attempt to bring down the boom or make emblem if it will be visible to traffic. repairs. Call your GEHL dealer immediately. Tie-down hooks are provided for inserting chains As lift height increases, depth perception through to secure the machine while transporting.
  • Page 36 STRONG DETERRENT TO THEFT OF CON- 3. Incline of ramps MUST be less than 15 degrees; STRUCTION EQUIPMENT! GEHL has recorded all ramp length MUST be at least 16 feet (4.8 m) long. part numbers and serial numbers. Users should take as many of the following actions as possible to discour- 4.

  • Page 37: 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 and conforms to ISO VG46. Capacity: NEVER service this machine when any part of 47 gallons (178 Liters) the machine is in motion.
  • Page 38 John Deere Engine fitting locations. Wipe dirt from the fittings before greasing them to prevent contamination. Replace any Oil Filter Element Gehl P/N L99420 missing or damaged fittings. To minimize dirt build- Fuel Filter Element Gehl P/N L98978 up, avoid excessive greasing.
  • Page 39 Boom Transmission Chassis Front View Axle Rotate Carriage 13,14 Other Side -- NOT SHOWN -- Operator Station Floor Item (12) Location Reference for Grease Fittings PRINTED IN U.S.A. 907879/AP1098 Courtesy of CraneMarket.com...

  • Page 40: 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 servicing the Telescopic Forklift,...
  • Page 41 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 42 Block the wheels. Remove the ignition key. Remove WARNING only guards or covers that provide needed access. Wipe away excess grease and oil. DO NOT smoke or allow any open flames in NEVER weld on attachment tools, boom support area while checking servicing...
  • Page 43 in storing fuel supplies and the operating condi- CHECK HYDRAULIC OIL LEVEL tions in which the machine is used. The machine must be on level ground and make sure Small amounts of water can be drained from the fuel the boom is lowered and completely retracted. The filter.
  • Page 44 CHECK INSTRUMENTS OPERATION WARNING Allow the engine to warm up for about five minutes before beginning operation. Indicator lamps should be NEVER attempt to service tires if the bead lock OFF and gauges should register normal readings. Tilt ring appears loose. Clear the area and call for the frame from side to side with the level control and professional tire repair help.
  • Page 45 PLANETARY Dust Cup & Clamp Ring Inlet Cap Horizontal Check Side Opposite Drive Shaft Mount DIFFERENTIAL Mount Band Element Check & Fill Air Cleaner Assembly Axle Oil Plugs Location 1. Loosen the clamp ring and remove the dust cup. CHECK AXLE OIL LEVELS Remove the baffle.
  • Page 46 NOTE: CHANGE ENGINE OIL & FILTER For proper replacement procedures refer to the engine manual for your machine. Change the engine oil and filter using the following After fuel filter replacement, bleed the air out of the procedure: fuel system following the procedures in the engine 1.
  • Page 47 Jump Starting WARNING If the battery becomes discharged or does not have enough power to start the engine, use jumper cables The ONLY safe method for jump-starting a and the following procedure to jump-start the engine. disharged battery is for TWO PEOPLE to per- form the following procedure.
  • Page 48 6. Proceed to start the machine. If it does not start 12.375” (314.3 mm), the chain should be discarded. immediately, start the jumper vehicle engine to avoid DO NOT repair sections of a chain. Replace the com- excessive drain on the booster battery. plete chain.
  • Page 49 2. Open the radiator drain cock. Remove the water Service Every 1000 Hours jacket drain plug from the engine block. When all coolant is drained, flush the system with clean fresh water. Allow the flush to drain completely. NOTE: Perform all other service requirements up to this point, as well as the following: 3.
  • Page 50 Remove the top cover of the housing. Remove the ele- 2. Re-position the hub so the arrow points down. Fill ment and discard. Insert the new element onto the with fresh oil as specified in the LUBRICATION chap- housing and Replace the cover. ter.
  • Page 51 STORAGE Element If the Telescopic Forklift will not be operated for a Fill Cap Dipstick long period of time, prepare and store it using the pro- cedures as follows. Before Storage Access Cover Perform the following prior to placing the machine in storage: Gasket Wash off the entire machine.
  • Page 52 After Storage After removing the machine from storage and BEFORE operating it, perform the following: 1. Change engine oil and filter to remove condensa- tion or other residues. 2. Wipe off grease from cylinder rods. 3. Lubricate ALL grease fittings. 4.

  • Page 53: 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 read and follow the safety precau- exposed adhesive backing to the clean surface while tions on decals.
  • Page 54 DETAILS “A-C” SHOWN ON PAGE 54 DECAL LOCATIONS - LEFT SIDE OF MACHINE (EXCEPT DETAILS “A-C”) REF. DESCRIPTION DANGER - ROTATING FAN (1 ea.) L659244 GEHL 4.5” (1 ea.) L65565 WARNING - PINCH POINT (3 ea.) L65927 WARNING - JUMP START (1 ea.) L65933 DYNALIFT, 2.0”...
  • Page 55 DANGER - ROTATING FAN (1 ea.) L65924 WARNING - PINCH POINT (3 ea.) L65927 DYNATTACH - 1-1/8” (1 ea.) L66569 GEHL, 8.0” (1 ea.) L66567 663 (1 ea.) L66578 HYDRAULIC OIL FILL (1 ea.) 072794 COOLANT UNDER PRESSURE (1 ea.) 072798 ANTI-FREEZE (2 ea.)
  • Page 56 WARNING - OPERATOR (1 ea.) L63690 STEER SELECT (1 ea.) L64814 F-N-4 SHIFT (1 ea.) L68295 GEHL, 2.0” DIA. (1 ea.) L66584 HYDRAULIC PRESSURE SETTINGS (1 ea.) L64643 WARNING - PARK BRAKE (1 ea.) L65925 LOAD ZONES FLIP CHART SET (1 ea.) L66603 ATTACHMENT CONTROL (1 ea.)

  • Page 57: 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 58 MAINTENANCE INTERVAL CHART (CONT.) SERVICE PROCEDURE Every Every Every 1000 2000 Hours Hours Hours Change Transmission Oil and Filter Change Air Filter Element Check Alternator & Fan Belt Tension Check Boom Slide Pads Wear & Clearance Change Radiator Coolant Change Hydraulic Return Filter Element Change Axle Differential &...
  • Page 59 MAINTENANCE LOG Date Hours Service Procedure PRINTED IN U.S.A. 907879/AP1198 Courtesy of CraneMarket.com...

  • Page 60: Index

    Index Floor & Seat .......22 Other Miscellaneous ......23 Access To Components Chart .
  • Page 61 Grade & Slope Precautions ..... .29 Operator’s Station Grade Limits ....... . .29 Environment Controls .
  • Page 62 Traffic Flow Patterns ......30 Transmission Description - See Chapter 2 Temperature Lamp ......20 Transmission Oil Changing .
  • Page 63 Notes PRINTED IN U.S.A. 907879/AP1198 Courtesy of CraneMarket.com...

  • Page 64: Electrical & Hydraulic Schematics

    663 Electrical Schematic (J.D. Engine) 907879/AP1198 PRINTED IN U.S.A. Courtesy of CraneMarket.com...
  • Page 65 663 Electrical Schematic (Perkins Engine) PRINTED IN U.S.A. 907879/AP1198 Courtesy of CraneMarket.com...
  • Page 66 663 Hydraulic Schematic 907879/AP1198 PRINTED IN U.S.A. Courtesy of CraneMarket.com...
  • Page 67 663 Hydraulic Schematic PRINTED IN U.S.A. 907879/AP1198 Courtesy of CraneMarket.com...

  • Page 68: 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 69: Load Zone Charts

    Load Zone Charts Standard Carriage 1 Cu. Yd. Bucket Rotating Carriage 12 Ft. Truss Boom PRINTED IN U.S.A. 907879/AP1198 Courtesy of CraneMarket.com...
  • Page 70 Load Zone Charts Winch Boom 907879/AP1198 PRINTED IN U.S.A. Courtesy of CraneMarket.com...

  • Page 71: Warranty

    GEHL CONSTRUCTION DIVISION of the GEHL COMPANY, hereinafter referred to as GEHL, warrants new GEHL 663 Dynalift Telescopic Forklifts to the Original Retail Purchaser to be free from defects in material and work- manship for a period of twelve (12) months from the Warranty Start Date.
  • Page 72 Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. GEHL Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 © Form 907879/AP1198 1998 Gehl Company...

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