Yard Machines | 663 | Operator`s manual | Yard Machines 663 Operator`s manual

Form No.
663
907879
Dynalift
®
Telescopic
Boom Forklift
OPERATOR’S MANUAL
Dynalift® Indicator & Operation Symbols
Read Operator’s
Manual
Park Brake On
Fasten Seat Belt
Battery Charge
Volume - Full
Volume
Half Full
Transmission
Temperature
Hydraulic
Oil Filter
Horn
Engine Start
Fuse
(Circuit Breaker)
Engine
Air Filter
Volume - Empty
Diesel Fuel
Starting Aid
Inject
Electrical
Preheat
Safety
Engine
Oil Pressure
Hazard Flasher
Fuel Low
Head Lights
Engine Oil
Pressure
Circulating
Fan
Work Lights
Wiper/Washer
Heater
Beacon
Air Conditioning
Turn Signal
Clutch Engaged
Clutch
Disengaged
Low Accumulator
Pressure
4-Wheel Steer
Raise Load
Tilt Rearward
Retract Load
Front Wheel
Steer
Lower Load
Tilt Forward
Extend Load
Rear Wheels
Alignment
Hourmeter
Crab Steer
Level Left
Level Right
Outrigger Down
(RH Shown)
Outrigger Up
(RH Shown)
Engine Coolant
Temperature
Table of Contents
Chapter
Description
Page
International Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover
1
2
3
4
5
6
7
8
9
10
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Check Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Indicators & Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Operation & Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Service & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
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 Numbers in the space provided below.
Refer to these numbers when inquiring about parts or service from your Gehl dealer.
663
The Model and Serial Numbers for this machine are on a decal located inside the Operator’s Station.
PRINTED IN U.S.A.
1
907879/AP1198
Chapter 1
INTRODUCTION
The information in this Operator’s Manual was written to give the owner/operator assistance in preparing, adjusting, maintaining and servicing of the Telescopic Boom Forklift. More importantly, this manual provides an operating plan for safe and proper use of the machine. Major points of safe operation are detailed in the SAFETY chapter of this manual.
The GEHL Company asks that you read and understand the contents of this manual
COMPLETELY and become familiar with your new machine, BEFORE attempting to operate it.
Throughout this manual, information is provided which is set in italic type and introduced by the word NOTE or
IMPORTANT. Be sure to read carefully and comply with the message or directive given. Following this information will improve your operating or maintenance efficiency, help you to avoid breakdowns or damage and
extend your machine’s life. A chart of standard hardware torques is located in the back of this manual.
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.
“Right” and “left” are determined from a position sitting on the seat and facing forward.
Our wide dealership network stands ready to provide you with any assistance you may require, including genuine
GEHL service parts. All parts should be obtained from or ordered through your GEHL dealer. Give complete
information about the part and include the model and serial numbers of your machine. Record the serial number
in the space provided on the previous page as a handy record for quick reference.
GEHL Company reserves the right to make changes or improvements in the design or construction of any part
without incurring the obligation to install such changes on any unit previously delivered.
The GEHL Company, in cooperation with the
Society of Automotive Engineers, has adopted this
Safety Alert Symbol
to pinpoint characteristics which, if NOT
properly followed, can create a safety hazard.
When you see this symbol in this manual or on the
machine itself, you are reminded to BE ALERT!
Your personal safety is involved!
907879/AP1198
2
PRINTED IN U.S.A.
Identification
Dash Indicators
& Controls
Side Panel
Controls
Seat
Telescoping
Boom
Rear Boom
Access
Tilt Cylinder
Dynattach®
System
(Tool Hookup)
Access Cover
With
Rear Lights
and
Backup
Alarm
Operator’s
Station
Extend Cylinder
(Inside Boom)
Lift Cylinder
Access
Covers
Rear
Boom
Access
Auxiliary
Quick
Couplers
(Not Shown)
Slave
Cylinder
Engine Access
Covers
PRINTED IN U.S.A.
Frame Sway
Cylinder
Battery
Access
Fuel
Tank
3
907879/AP1198
Chapter 2
SPECIFICATIONS
Lifting Performance
Maximum lift capacity:
6000 lbs (2727 kg)
Monitoring lights:
Engine oil pressure, alternator,
transmission oil temperature,
brake failure
Axles:
Differentials (2):
3.4 qts. (3.22 L) ea.
Hubs (4): 1.3 qts. (1.18 L) ea.
Maximum lift height:
27’-6” (11.43 m)
Monitoring alarms:
Park brake on
Transmission
Capacity at maximum lift height:
6000 lbs (2727 kg)
Visual indicators:
Boom angle, frame angle
Max. forward reach to load center:
23’-4” (7.0 m)
Steering System
Capacity at maximum forward reach :
1500 lbs (680 kg)
Maximum below grade reach:
24” (610 mm)
Frame Leveling:
10o left/10o right
General Dimensions
Based on standard machine equipped
with listed tires, 48” masonry carriage
and 48” pallet forks.
Recommended tire type:
13.00 x 24 10-ply
10.00 x 24 12-ply
13.00 x 24-ply steel guard
14.00 x 24 12-ply
15.00 x 19.5 12-ply (low profile)
13.00 x 24/10 PR, foam filled
13.00 x 24/12 PR, foam filled
13.00 x 24/12 PR, steel guard foam filled
14.00 x 24/12 PR, foam filled
15.00 x 19.5/12 PR, foam filled
Steer Valve: Fixed displacement rotary
Displacement/Rev: 17.9 cu. in. (293 cc)
System pressure: 2000 psi (138 bar)
Steer cylinders: 2 per axle
Steer mode valve:
3-position, 4-way solenoid with
dash-mounted switch actuation.
Steer modes: 2 wheel, 4 wheel, crab
Braking System
Service brakes: Oil immersed in-board
hydraulic wet 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,
Battery: 745 cold cranking amps
Circuit protection: Circuit breakers
Backup alarm: 107 dB(A)
Horn: 111 dB(A)
Overall length, less forks:
17’-4” (5.3 m)
Standard on all models:
Brake lights, neutral start switch.
Overall width:
8’ (2.4 m)
Alternator: 65 amp.
Overall height:
7’-8” (2.3 m)
Ground clearance: 16” (406 mm)
Wheel base: 9’-10” (3.0 m)
Outside turn radius: 13’-8” (4.2 m)
Machine weight:
20,300 lbs (9,156 kg)
Instrumentation
Gauges: Fuel level, hourmeter
and coolant temperature
907879/AP1198
Service Capacities
Cooling System:
4.3 gallons (16.3 L)
50/50 mixture
Anti-freeze protection -34oF (-31oC)
Pressure cap: 10 psi (69 pKa)
Fuel tank: 47 gallons (178 L)
Hydraulic tank & system:
47 gallons (178 L)
Hydraulic Cooler Flow:
19 gpm (72 L/m)
Transmission & cooler: 6 gal. (22.7 L)
4
Type: Clark Powershift T12000
Speeds: 3 fwd / 3 rev
Torque converter:
Single stage, dual phase
Travel Speeds:
1st gear: 3.6 mph (5.8 km/h)
2nd gear: 7.0 mph (11.3 km/h)
3rd gear: 18.6 mph (29.9 km/h)
Axles (front and rear)
Type: Dana
Drive/steer, open differential, double
reduction planetary, full-time four
wheel drive
Overall ratio: 22.58:1
Engine Options
Common to all options:
In-line 4 cycle, 4 cylinder, direct
injection diesel fuel system, in-line
fuel filter w/water trap, positive
pressure lubrication, liquid
pressurized cooling system,
18” (457 mm) blower fan,
dry single-element air cleaner,
spin-on oil filter.
Natural aspiration:
John Deere 4045D
276 cu. in. (4523 cc) displacement,
80 hp (60 kW) @ 2500 rpm
Oil capacity: 10 qts. (9.5 L),
Turbocharged aspiration:
John Deere 4045T
276 cu. in. (4523 cc) displacement,
115 hp (86 kW) @ 2500 rpm
Oil capacity: 10 qts. (9.5 L)
Perkins 4236
243 cu. in. (3982 cc) displacement,
86 hp (64 kW) @ 2500 rpm
Oil capacity: 8 qts. (7.6 L)
PRINTED IN U.S.A.
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.
Rated flow: 100 gpm (379 L/min)
Rated pressure: 100 psi (690 kPa)
By-pass pressure (full flow):
25 psi (172 kPa)
Hydraulic strainer:
In-tank suction, 100 micron media,
replaceable element.
Rated flow: 100 gpm (379 L/min)
By-pass pressure: 3 psi (21 kPa)
PRINTED IN U.S.A.
5
907879/AP1198
INTENTIONALLY BLANK PAGE
907879/AP1198
6
PRINTED IN U.S.A.
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 valuable information and inspections which MUST be made
before delivering the Telescopic Forklift to the Customer.
Check off each item after prescribed action is taken.
Dealership’s Name
Check that:
Dealer Representative’s Name
‰ NO parts of machine have been damaged in shipment.
Date Checklist filled-out
Check for such things as dents and loose or missing parts;
correct or replace components as required.
Machine Model#
‰ Battery is securely mounted and not cracked. cable con-
Machine Serial #
nections are tight. electrolyte at proper level.
Engine Serial #
DELIVERY
‰ Cylinders, hoses and fittings are not damaged, leaking or
Check that:
loosely secured.
The following Checklist is an important reminder of valuable information that MUST be passed on to the Customer at
the time the unit is delivered. Check off each item as you
explain it to the Customer.
‰ Oil, fuel and air filters are not damaged leaking or loosely
secured.
‰ All grease fittings have been properly lubricated and no fittings are missing; see LUBRICATION chapter of this
manual.
‰ Review with the Customer the contents of the EMI Safety
Manual and this manual for the following:
‰ Hydraulic system reservoir, engine crankcase, engine
‰ The INDEX at the back, for quickly locating topics;
coolant, transmission and axles are filled to the proper
operating fluid levels.
‰ The SAFETY; INDICATORS/CONTROLS; and OPERA-
‰ All adjustments have been made to comply with the set-
TION/ADJUSTMENTS chapters for information regarding safe use of the machine.
tings given in this manual and in the separate engine manual.
‰ The LUBRICATION, SERVICE/STORAGE chapters for
‰ All guards, shields and decals are in place and securely
information regarding proper maintenance of the machine.
Explain that regular lubrication and maintenance are
required for continued safe operation and long life.
attached. All tires have proper operating pressure.
‰ Model and Serial Number for this unit is recorded in space
‰ Give this Operator’s Manual and the EMI Safety Manual to
provided on this page and page 1.
the Customer and instruct them to be sure to read and completely understand its contents BEFORE operating the
unit.
Start the machine and test-run the unit while
checking that proper operation is exhibited by all
controls.
‰ Explain that the Customer MUST consult the Engine
Manual (provided) for related specifications, operating
adjustments and maintenance instructions.
Check that:
‰ All indicators (lamps, switches, etc.) function properly.
‰ Completely fill out the Owner’s Registration, including
Customer’s signature and, return it to the company.
‰ All hand and foot controls operate properly.
‰ Boom, Dynattach System with attachment tool and frame
level control all function properly.
Customer’s Signature
‰ No hydraulic system leaks when under pressure.
Date Delivered
‰ Listen for abnormal noises or vibrations; if detected, determine their cause and repair as necessary.
PRINTED IN U.S.A.
(Dealer’s File Copy - Remove at Perforation)
7
907879/AP1198
INTENTIONALLY BLANK
(To be removed as Dealer’s file copy)
Form No. 907879/AP1198
8
Printed In USA
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 valuable information and inspections which MUST be made
before delivering the Telescopic Forklift to the Customer.
Check off each item after prescribed action is taken.
Dealership’s Name
Check that:
Dealer Representative’s Name
‰ NO parts of machine have been damaged in shipment.
Date Checklist filled-out
Check for such things as dents and loose or missing parts;
correct or replace components as required.
Machine Model#
‰ Battery is securely mounted and not cracked. cable con-
Machine Serial #
nections are tight. electrolyte at proper level.
Engine Serial #
DELIVERY
‰ Cylinders, hoses and fittings are not damaged, leaking or
Check that:
loosely secured.
The following Checklist is an important reminder of valuable information that MUST be passed on to the Customer at
the time the unit is delivered. Check off each item as you
explain it to the Customer.
‰ Oil, fuel and air filters are not damaged leaking or loosely
secured.
‰ All grease fittings have been properly lubricated and no fittings are missing; see LUBRICATION Chapter of this
manual.
‰ Review with the Customer the contents of the EMI Safety
Manual and this manual for the following:
‰ Hydraulic system reservoir, engine crankcase, engine
‰ The Index at the back, for quickly locating topics;
coolant, transmission and axles are filled to the proper
operating fluid levels.
‰ The SAFETY; INDICATORS/CONTROLS; and OPERA-
‰ All adjustments have been made to comply with the set-
TION/ADJUSTMENTS chapters for information regarding safe use of the machine.
tings given in this manual and in the separate engine manual.
‰ The LUBRICATION, SERVICE/STORAGE chapters for
‰ All guards, shields and decals are in place and securely
information regarding proper maintenance of the machine.
Explain that regular lubrication and maintenance are
required for continued safe operation and long life.
attached. All tires have proper operating pressure.
‰ Model and Serial Number for this unit is recorded in space
‰ Give this Operator’s Manual and the EMI Safety Manual to
provided on this page and page 1.
the Customer and instruct them to be sure to read and completely understand its contents BEFORE operating the
unit.
Start the machine and test-run the unit while
checking that proper operation is exhibited by all
controls.
‰ Explain that the Customer MUST consult the Engine
Manual (provided) for related specifications, operating
adjustments and maintenance instructions.
Check that:
‰ All indicators (lamps, switches, etc.) function properly.
‰ Completely fill out the Owner’s Registration, including
Customer’s signature and, return it to the company.
‰ All hand and foot controls operate properly.
‰ Boom, Dynattach System with attachment tool and frame
level control all function properly.
Customer’s Signature
‰ No hydraulic system leaks when under pressure.
Date Delivered
‰ Listen for abnormal noises or vibrations; if detected, determine their cause and repair as necessary.
PRINTED IN U.S.A.
(Pages 7 & 8 - have been removed at perforation)
9
907879/AP1198
Chapter 4
SAFETY
The above Safety Alert Symbol means ATTENTION!
ALWAYS BE ALERT! YOUR SAFETY IS
INVOLVED! It stresses an attitude of “Heads Up for
Safety” and can be found throughout this Operator’s
Manual and the machine itself.
CAUTION
“CAUTION” indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury. Also alerts to unsafe
practices.
Before you operate this equipment, read and
study the following safety information. In
addition, be sure that every individual who
operates or works with this equipment,
whether family member or employee, is familiar with these safety precautions.
REMEMBER: It is the owner’s responsibility for
communicating information on the safe use and proper
maintenance of this machine. This includes providing
understandable interpretation of these instructions for
operators who are not fluent in reading English.
The Gehl Company ALWAYS takes the operator’s
safety into consideration when designing its machinery
and guards exposed moving parts for his/her protection. However, some areas cannot be guarded or
shielded in order to assure proper operation. Further,
this Operator’s Manual, the EMI Safety Manual, and
decals on the machine warn of additional hazards and
should be read and observed closely.
It is the responsibility of the operator to read and
understand the Operator’s Manual and other information provided and use the correct operating procedure.
Machines should be operated only by qualified operators.
MANDATORY SAFETY SHUTDOWN
PROCEDURE
BEFORE cleaning, adjusting, lubricating or servicing the unit:
DANGER
1. Bring machine to full stop on level surface
(AVOID parking on a slope or hillside, but if necessary, park across the slope and block the wheels).
“DANGER” indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
2. Fully retract boom and lower attachment tool to
ground.
3. Place controls in neutral and set park brake.
WARNING
4. Idle engine for gradual cooling. Shut off engine
and remove key.
“WARNING” indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
907879/AP1198
ONLY when you have taken these precautions can
you be sure it is safe to proceed. Failure to follow
the above procedure could lead to death or serious
injury.
10
PRINTED IN U.S.A.
SAFETY
speed, the type of load being carried and placed,
and the abrupt movement of any control lever. IF
YOU ARE NOT CAREFUL WHILE OPERATING THIS MACHINE, ANY OF THE ABOVE
FACTORS COULD CAUSE THE MACHINE
TO TIP AND THROW YOU OUT OF THE
OPERATOR’S STATION, WHICH MAY
RESULT IN SERIOUS INJURY OR DEATH!
WARNING
U.S. OSHA regulations require employers in
general industry and the construction, shipyard and cargo-handling industries (excepting
agricultural operations) to ensure that forklift
operators are competent, as demonstrated by
successful completion of a training course.
Â
The training course must consist of a combination of formal instruction and practical
training, including both forklift-related and
workplace-related topics, and evaluation of
the operator’s performance in the workplace.
Â
All operator training and evaluation is to be
conducted by persons who have the knowledge, training and experience to train and
evaluate operators.
Â
ALWAYS wear appropriate personal protective
equipment called for by the job and working conditions. Hard hats, protective glasses, protective
shoes, gloves, reflector type vests, respirators and
ear protection are examples of types of equipment
that may be required. DO NOT wear loose or
baggy clothing, long hair, jewelry or loose personal items while operating or servicing the machine.
Â
ALWAYS be aware of pinch point areas on the
machine such as wheels-to-frame, cylinders-toframe, boom and attachment tool-to-frame, etc.
Â
ALWAYS maintain safe clearance from electrical
power lines and avoid contact with any electrically charged conductor. Contact can result in electrocution. Contact proper local authorities for utility
line location BEFORE starting a job.
Â
ALWAYS check the job site for terrain hazards,
obstructions and people. Remove all objects which
do not belong in or on the machine and its equipment.
ADDITIONAL SAFETY REMINDERS
Â
Â
Â
User/operator safety practices, as established by
industry standards, are included in this Operator’s
Manual and intended to promote safe operation of
the machine. These guidelines do not, of course,
preclude the use of good judgment, care and common sense as may be indicated by the particular
jobsite work conditions. It is essential that operators be physically and mentally free of mind altering drugs and chemicals.
Some illustrations used in this manual may show
doors, guards and shields open or removed for
illustration purposes only. BE SURE that all doors,
guards and shields are in their proper operating
positions BEFORE starting the engine to operate
the machine.
ALWAYS wear the seat belt to prevent being
thrown from the machine. If you are in an overturn:
- DO NOT jump!
- Hold on tight and stay with the machine!
- Lean away from the fall!
ALWAYS keep hands, feet and arms inside of the
operator’s station when operating the machine!
Any or all of the following elements can affect the
stability of the machine: The terrain, the engine
PRINTED IN U.S.A.
11
907879/AP1198
SAFETY
Â
Â
Â
Â
and may create a serious hazard unless the oxygen
is replaced. This includes the atmosphere within
the cab when provided.
Walk around the machine and warn all personnel
who may be servicing the machine or are in the
machine’s path prior to starting. DO NOT start
until all personnel are away from the machine.
ALWAYS use the recommended hand holds and
steps with at least three points of support when getting on and off the machine. Keep steps and platform clean. Face the access system when climbing
up and down.
NEVER attempt to by-pass the keyswitch to start
the engine. ONLY use the jump-starting procedure
detailed in the SERVICE & STORAGE chapter.
DO NOT bypass the machine’s neutral-start system. The neutral-start system must be repaired if it
malfunctions.
NEVER use your hands to search for hydraulic
fluid leaks. Use a piece of paper or cardboard.
Escaping fluid under pressure can be invisible 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 surgically removed
by a doctor familiar with this type of injury or gangrene may result.
Â
DO NOT exceed the machine’s rated operating
capacity for the type of attachment tool being used.
Â
DO NOT allow minors or unqualified personnel to
operate or be near the machine unless properly
supervised; this is strictly a single seat, NO passenger machine!
Â
DO NOT start the engine or operate any controls
unless properly seated in the operator’s seat!
Â
DO NOT run the engine in an enclosed area without providing proper ventilation for the exhaust.
Exhaust gases contain carbon monoxide, an odorless and deadly gas. Internal combustion engines
deplete the oxygen supply within enclosed spaces
907879/AP1198
12
Â
DO NOT leave the operator’s station with the
boom and attachment tool raised. ALWAYS lower
the boom and attachment tool to the ground, shut
off the engine and engage the parking brake
BEFORE leaving the operator’s station.
Â
DO NOT refill the fuel tank when the engine is
hot. Allow engine to cool down BEFORE refilling
to prevent hot engine from igniting the fuel if it
should spill or splash.
Â
DO NOT smoke while filling the fuel tank, while
working on the fuel or hydraulic systems, or while
working around the battery.
Â
DO NOT drive too close to an excavation or ditch.
BE SURE that the surrounding ground has adequate strength to support the weight of the machine
and the load it is carrying.
Â
DO NOT turn quickly while traveling on a slope or
operate the machine beyond the grade and slope
limits noted in the OPERATION & ADJUSTMENT chapter of the Operator’s Manual.
Â
If necessary to park on a grade, park across the
slope and block the wheels.
Â
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.
Â
NEVER use fuel for cleaning purposes.
Â
DO NOT remove the radiator cap after the engine
has reached operating temperature or if it is overheated. At operating temperatures, the engine
coolant will be extremely HOT and under pressure.
ALWAYS wait for the engine to cool down before
PRINTED IN U.S.A.
SAFETY
attempting to relieve pressure and remove the radiator cap. Failure to heed this warning could result
in severe burns.
Â
Â
Â
DO NOT attempt to loosen or disconnect any
hydraulic lines, hoses or fittings without first
relieving hydraulic circuit pressure. Also, be careful not to touch any hydraulic components that
have been in recent operation because they can be
extremely hot and can burn you!
Avoid lubrication or mechanical adjustments with
the machine in motion or the engine operating. If
the engine must be in operation to make certain
adjustments, place the transmission in neutral,
apply the parking brake, place the equipment in a
safe position, securely block the wheels and use
extreme caution.
To insure continued safe operation, replace damaged or worn-out parts with genuine GEHL service
parts, before using this equipment.
Â
When road travel is required, know and use the
signaling devices required on the machine. Provide
an escort when required.
All attachment tools MUST be marked to identify
the attachment tool and the total capacity with
attachment tool at maximum elevation with load
laterally centered.
Â
ALWAYS make sure all nameplates, caution and
instruction markings are in place and legible.
Local government regulations may require local
decals, which then become the responsibility of the
local owner to provide.
Â
Study the load chart carefully. It shows 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.
Protective Guards and Warning
Devices
NEVER allow any riders on this machine or use as
a lift for personnel.
Â
Â
Â
This machine is fitted with an overhead guard in
accordance with industry standards. It is intended
to offer protection to the operator from falling
objects, but cannot protect against every possible
impact. Therefore, it should not be considered a
substitute for good judgment and care in operating
the machine.
Â
This machine is equipped with a horn and backup
alarm. The user shall determine if operating conditions require the machine to be equipped with
additional devices (mirrors, rotating beacon, etc.)
and be responsible for providing and maintaining
such devices.
Â
DO NOT modify the ROPS in any manner.
Unauthorized modifications such as welding,
drilling, cutting or adding components can weaken
the structure and reduce its protective ability. If a
ROPS is subjected to roll-over or other damage it
must be replaced. DO NOT attempt to repair a
ROPS.
Modifications, Nameplates, Markings
and Capacities
Â
Modifications and additions that affect capacity or
safe operation shall NOT be performed without the
manufacturer’s prior written approval. Where such
authorization is granted, tags or decals shall be
changed accordingly.
PRINTED IN U.S.A.
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Form No. 907879/AP1198
SAFETY
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Truss
Boom
Winch
Boom
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Carriage
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907879/AP1198
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Chapter 5
INDICATORS AND CONTROLS
GUARDS AND SHIELDS
CAUTION
Whenever possible and without affecting machine
operation, guards and shields are used to protect potentially hazardous areas. In many places, decals are also
provided to warn of potential dangers and to display
special operating procedures.
Become familiar with and know how to use
ALL safety devices and controls on the
Telescopic Forklift BEFORE operating it.
Know how to stop the machine operation
BEFORE 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
cannot be responsible for operator safety if
the machine is used with an unapproved
accessory or attachment tool.
WARNING
Read and thoroughly understand ALL safety
decals on the Telescopic Forklift BEFORE
operating it. DO NOT operate the machine
unless ALL factory installed guards and
shields are properly secured in place.
Test Ports
OUTER
BOOM
Steer Mode
Travel
Steering
Wheel
Horn
Start
Park Brake
Speed Range
Engine Oil
Boom
Angle
Switch
Panel
Coolant
Load Zone
Charts
Fuel
Alternator
Brake
Throttle
Brake Failure
Boom
Control
Joystick
Hourmeter
Transmission
Oil
UPPER LEFT
OPERATOR
STATION
Brake Reservoir
(Under Seat)
Frame Level
Indicator
Attachment
Joystick
Frame
Level
Joystick
OPERATOR STATION
Operator Compartment & Boom Indicators/Controls Location
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907879/AP1198
DASH AREA
Brake Failure Lamp: The front and rear brakes are on
independent brake line systems. If during normal operation with the brake pedal depressed, a loss of pressure
occurs in either system, the brake failure lamp comes
on.
Start Keyswitch OFF: When the key is vertical in the
keyswitch, power from the battery is disconnected to
the control and instrument panel electrical circuits.
Also, this is the only position in which the key can be
inserted or removed.
Failure in one line of the system does not affect the
operation of the other system line. However, the
MANDATORY SAFETY SHUTDOWN PROCEDURE (p.10) should be followed and required repairs
made immediately.
Start Keyswitch ON: When the key is turned one
position clockwise from the vertical (OFF) position,
power from the battery is supplied to all control and
instrument panel electrical circuits.
During normal operation the lamp should remain off.
NOTE: If the engine requires repeated attempts
Engine Oil Pressure Lamp: Indicates whether sufficient engine lubricating oil pressure is present or not.
During normal operation, with the engine running, this
lamp should be off. During starting and when the
engine is not running, this lamp will be on.
to start, the key MUST be returned to the OFF
position between starting attempts to prevent battery run down.
Start Pushbutton: With keyswitch in ON position,
depress the button to activate the starter. Release it as
soon as the engine starts.
IMPORTANT: If this lamp comes on during normal operation with the engine running, stop the
engine immediately. After allowing the oil to drain
down for a few minutes, check the engine oil
level. Maintain oil level at the FULL mark on the
dipstick
Circuit Breaker: The left 15 amp breaker protects
dash and engine electrical circuits. If it is not in the
depressed position, the gauges and indicators on the
dash will not work and the engine will shut off.. The
right 15 amp breaker protects the reserve brake system.
Hourmeter: Indicates the operating time of the
machine and should be used for keeping up the maintenance log.
Horn Push Button: With the keyswitch ON, depress
the horn button to activate warning sound.
Coolant Temperature Gauge: Indicates the temperature of the engine coolant. Under normal conditions,
this gauge should indicate approximately 185oF
(85oC)
Park Brake ON: A buzzer located behind the dash
sounds as long as the park brake lever is engaged, and
the transmission is in forward or reverse.
Transmission Oil Temperature: This lamp indicates
whether the transmission oil is at the proper temperature or not. During normal operation this lamp should
be off indicating that the transmission oil system is at
the proper temperature.
Fuel Level Gauge: Indicates
remaining in the fuel tank.
the amount of fuel
Hydraulic Pressure Test Ports: A test gauge can be
inserted to check main or steering system pressures.
IMPORTANT: If this lamp comes on during normal operation, a problem may exist in the transmission oil system. Stop the machine immediately and investigate the cause of the problem!
Boom Load Capacity: A series of flip charts show lift
height and reach limits relative to the load weight
being handled with various attachment tools.
Alternator Lamp: Indicates the condition of the electrical charging system. During normal operation, this
lamp should be off. If the charge rate is too high or too
low, this lamp will come on.
Switch Panel
907879/AP1198
Clutch Cutout Function: When activated, it allows
greater engine acceleration and power to the hydraulics
system without power to the drive axles while the service brake pedal is depressed.
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In the “OFF” position, the clutch mechanism of the
transmission remains engaged when applying brakes.
In the “ON” position, the clutch mechanism is disengaged while applying the brakes.
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 connected steering wheel to the right or left to turn the machine
in the direction of wheel turn action.
Normal brake force will hold the machine in position
while accelerating the engine to power hydraulic control functions during load placement.
Steer Selector: Use “2-wheel mode” for higher speed
travel. Use “4-wheel mode” for making tighter turns,
usually on jobsite. Use “crab mode” when a small
amount of side shift is needed for picking or placing
loads. Any mode can be used in forward or reverse
travel.
NOTE: The switch panel also includes control
switches for the following accessories used with
the cab enclosure option:
NOTE: The rear wheels are not self-centering.
Heater: Provides circulating heated air throughout the
cab interior.
Make sure all wheels are in a straight ahead position before changing the selector mode.
Heater/AC: This switch turns on or off either heating
or cooling selection for the operator’s station interior.
Units without air conditioning have only the heater
mode switch.
Any of the steering position modes can be used in forward or reverse travel. The operator should learn to
anticipate changes in machine movement if the steering selector mode must be changed.
Head Lights/Work Lights: Work lights may be added
to the operator station and boom to provide illumination for forward travel and work operations.
Park Brake: Functions as both a parking brake and
emergency brake. The park brake handle is linked by a
cable to a brake assembly on the transmission output
shaft.
Windshield Wiper: Helps maintain proper visibility
for the operator through the windshield area.
To adjust the tension, turn the knob on the top of the
brake lever until a pull effort on the hand lever is 20
lbs. (89 N) is achieved.
Windshield Washer: Used to apply cleansing agent
while activating the windsheld wiper motor.
Turn Signal: Used with the light package to indicate
direction of turns.
WARNING
Hazard: This switch can be activated to make the tail
lights flash off and on if the machine is stalled or temporarily stopped in a traffic area on the road or jobsite.
Unattended machine hazard.
Set park brake and lower attachment tool to
ground before leaving machine. An unattended machine can move or roll and cause death
or serious injury to operator or bystanders.
Cold Start: Activates injection of ether agent for faster
engine start in cold weather.
Periodically check the park brake tension and
adjust, if required, to maintain adequate holding power. Always be sure the park brake lever
is off when resuming machine operation.
Engine Preheat (Perkings Engine only): Warms
intake air to the engine manifold.
Travel Controls
These controls are used to maneuver the machine
around the jobsite or for road travel. Decals on the dash
area provide graphic representation of the various control actions.
PRINTED IN U.S.A.
The park brake may be used as an emergency stopping
system on relatively level terrain should the service
brakes fail. When properly adjusted and maintained it
meets ANSI test requirements providing 35% of service brake performance at 20 lb (89 N) hand lever
effort.
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907879/AP1198
RIGHT SIDE PANEL
Travel Direction Selector: This lever is used to
change travel direction (forward or reverse). The selector MUST be in N (Neutral) position before the engine
will start.
These controls and indicators are used to position the
frame, boom, and attachment. Graphic symbols on the
side panel illustrate the control actions.
Position “F” (FORWARD)
Position “N” (NEUTRAL)
Position “R” (REVERSE)
Frame Level Joystick: This may be tilted slowly 10o
to the left or right to level the frame and boom in relation to the ground. Position the lever to the left to tilt to
the left. Position the lever to the right to tilt to the right.
NOTE: Backup alarm automatically sounds with
travel lever in reverse.
Bubble Indicator: Located in front of the operator on
the ROPS upper cross tube, movement of the bubble
shows when the frame is at level position relative to
slopping ground surface.
IMPORTANT: Care should be taken when
downshifting or reversing as damage to the transmission can occur if shifting is forced or attempted at too high a speed. Allow engine RPM to slow
before any downshift or directional change is
attempted.
WARNING
DO NOT attempt to correct the frame level
condition with the boom raised or extended.
Only level the machine while at complete stop
with the boom fully retracted and the attachment raised just enough to clear the ground.
Speed Range Selector: Twist this lever counter clockwise or clockwise to change the transmission speed
between low and travel range.
Position “3” TRAVEL RANGE
Position “2” MEDIUM RANGE
Position “1” LOW RANGE
The boom inner section nose has an attachment carrying device feature called Dynattach® system. This provides the operator with a convenient means of utilizing
optional attachment tools. Refer to the OPERATION
& ADJUSTMENTS chapter for changing attachment
tools procedure.
FLOOR & SEAT AREA
Throttle Pedal: This is right-foot operated and controls the engine RPM to match increased power
requirements. Pushing down on the pedal increases the
RPM. Letting up on the pedal decreases RPM.
Once the operator tilts the attachment tool to a desired
angle, that angle will be maintained as the boom is
raised or lowered, extended or retracted, until a new
angle is desired.
Service Brake Pedal: Depressing this pedal hydraulically activates the internal braking mechanism of the
front and rear axles to all four wheels.
To tilt the attachment tool, move the joystick back to
tilt up. To tilt the attachment tool down, move the joystick forward.
Brake Fluid Reservoir: The reservoir is located under
the hinged seat mounting section. With rear bolts
removed, this section may be tilted forward to check
fluid level.
Boom Lift/Extend Joystick: This machine has a
hydraulic type boom with telescopic sections. The sections extend by means of a hydraulic cylinder and
chain system inside the boom, sequenced for uniform
extension of each section.
Seat Positioning: The seat is mounted on rails for forward or backward repositioning to accommodate operator’s size and comfort. A spring-loaded latch handle
under the front of the seat activates the adjustment
mechanism.
907879/AP1198
To EXTEND the boom, move the joystick RIGHT. To
RETRACT the boom, move the joystick LEFT. To
RAISE the boom, move the joystick REARWARD. To
LOWER the boom, move the joystick FORWARD.
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Boom Angle Indicator: Mounted on the left side of
the outer boom. Movement of a bubble shows the
angle of boom elevation relative to the frame ground
surface.
AutoTroll Option: When provided, a rocker switch
on the top of the lift/extend joystick handle performs
this function. The AutoTroll option automatically lowers the boom as it extends to provide true horizontal
movement of the attachment tool forks. On retraction,
the boom is automatically raised to maintain true horizontal fork movement.
WARNING
AutoTroll option performs equally well below or
above grade for easy insertion or retraction of the forks
from the load. To operate this function, first raise the
load to the desired position by normal movement of the
joystick.
Use extreme caution when raising or extending the boom. The Telescopic Handler MUST
be level. Loaded or empty, this machine can
tip if not level.
ALWAYS place the transmission in neutral, set
the park brake lever and keep the service
brake pedal fully depressed before raising or
extending the boom.
To move the load or forks horizontally, depress the
right side of the rocker switch. This activates the
microprocessor, pump pressure and extend solenoid.
Fork movement will continue at factory pre-set speed
of three seconds per foot as long as the extend side of
the rocker switch is depressed.
NEVER exceed the specified lifting or extending capacities of this machine. Serious
machine damage or personal injury may
result. Refer to the load charts in the operator’s station or this manual.
CAUTION
If a boom circuit hose should break with the
boom up, with or without a load, shut the
machine down following the MANDATORY
SAFETY SHUTDOWN PROCEDURE (Safety
chapter, p.10). DO NOT attempt repairs. Call
your GEHL dealer immediately for assistance.
DO NOT depress rocker switch during manual
operation.
Depress the left side of the rocker switch to retract the
load or forks horizontally. Releasing the rocker switch
allows the operator to use the machine in normal operation.
The truss boom and winch attachment tools
should ONLY be used to lift and place loads
when the machine is stationary. DO NOT use
truss boom to transport loads around the jobsite This can cause the load to swing, resulting in either the load dropping or machine
tipover.
Attachment Joystick: Moving the joystick forward
tilts the attachment down. Moving it rearward tilts the
attachment up. Moving the joystick left positions the
rotating carriage up to 10o to the left. Moving it to the
right positions the rotating carriage up to 10o to the
right. The function of this attachment is to place or
pickup loads from sloped surfaces. The same left/right
joystick action lowers and raises the winch attachment
cable.
NEVER use winch for lifting or moving of personnel. NEVER exceed the maximum rated
capacity of the winch (3000 lbs/1360 kg) or
exceed the load chart rating for winch applications.
DO NOT tilt the truss boom back more than
45o from horizontal. DO NOT attempt to use
the rotating carriage as a load leveling function. Always level the frame prior to handling a
load.
OTHER OPERATION INDICATORS
Failure to heed could result in death or serious injury.
Hydraulic Reservoir Oil Level & Fill Cap: The sight
gauge on the side of the reservoir indicates the level of
the hydraulic oil. The fill cap is accessible by removing the front cover of the front hood section.
PRINTED IN U.S.A.
The following indicators are for fluid level and operator rear vision/safety.
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907879/AP1198
Battery Compartment: The battery compartment is
just below the tool box section at the rear of the fuel
reservoir. Remove the bottom panel of the tool box to
check the electrolyte level.
Transmission Oil Level: This dipstick is located
below the rear cover on the front section of the main
hood.
Engine Oil Level: The dipstick is located on the
left(John Deere engine) or right (Perkins engine) side
of the mid-section of the main hood.
Coolant Level: The coolant can be checked and added
through the radiator cap located under the top rear
opening on the main hood.
Backup Alarm: Located inside the rear frame cover, it
produces a loud warning sound whenever the machine
is in reverse.
Side Mirror: This is located on the front outside corner of the fuel tank. It provides the operator with a rear
view on the right side and rear area behind the
machine.
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.
ACCESSORIES
Gehl offers a versatile range of special accessories for
this machine. Contact your area Gehl dealer for specifications and ordering information.
NOTE: All accessories are field-installed unless
otherwise noted. Information and parts for field
installing of all of the accessories will be provided
by the factory or Gehl Telescopic Forklift dealers.
907879/AP1198
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907879/AP1198
Chapter 6
OPERATION & ADJUSTMENTS
GENERAL INFORMATION
WARNING
CAUTION
ALWAYS fasten your seat belt BEFORE starting the engine. Leave the parking brake
“engaged” until the engine is running and you
are ready to operate the machine.
BEFORE starting the engine and operating the
Telescopic Forklift, review and comply with
ALL safety recommendations set forth in the
SAFETY chapter of this manual. Know how to
STOP the machine before starting it. Also, BE
SURE to fasten and properly adjust the seat
belt.
The following procedure is recommended for starting
the engine:
1. Carefully step up and grasp the hand holds to step
into the operator’s compartment.
ENGINE BREAK-IN
2. Adjust the seat and fasten the seat belt.
Your new engine does not require extensive “breakin”. However, for the first 100 hours of operation, keep
the following in mind. Allow the engine to idle for a
few minutes after every cold start. DO NOT idle the
engine for long periods of time. DO NOT operate the
engine at maximum power for long periods of time.
Check the oil level frequently and replenish, as necessary.
3. Check that all controls are in their “neutral” positions, except the parking brake lever which should be
in the “ON” position.
4. Turn the keyswitch to “ON” position and depress
the start button. If the button is released before the
engine starts, turn the keyswitch to “OFF” position,
allowing the starter to stop before attempting to start
again.
A special “break-in” oil is NOT used. The oil in the
engine crankcase is the same specified for regular oil
changes. Change the oil and replace the oil filter at the
intervals specified in the Service chapter. DO NOT add
special additives or special “break-in” components to
the crankcase.
IMPORTANT: Crank the starter until the engine
is started. If the engine fails to start within 15 seconds, return the key to the “OFF” position, wait 2
minutes, and try to restart the engine. Cranking
the engine for longer than 30 seconds will result
in premature failure of the starter.
BEFORE STARTING ENGINE
Before starting the engine and running the machine,
refer to the INDICATORS & CONTROLS chapter and
familiarize yourself with the various operating controls, indicators and safety features.
6. After the engine starts, allow a sufficient warm-up
time before attempting to operate the controls.
7. Check that indicators are in normal condition.
STARTING THE ENGINE
8. Check that there are no fuel, oil or engine coolant
leaks, and no abnormal noises or vibrations.
Before mounting the operator’s compartment, walk
completely around the machine to make sure NO one
is under, on, or close to it. Let others near the area
know you are going to start up and wait until everyone
is clear of the machine.
907879/AP1198
COLD STARTING PROCEDURES
A block heater or lower radiator hose heater is recommended for starting in temperatures of 20oF (-7oC) or
lower. See your Gehl dealer for recommended heater.
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Select the travel direction and the speed range mode.
Release the parking brake lever and move slowly,
while testing the steering and brakes. Stop and operate
all boom, attachment tool functions and frame level
controls checking for smooth response.
If prevailing temperature is 40oF (4oC) or below, it
may be necessary to use a cold weather starting aid to
start the diesel engine. For proper use of starting aids,
check instructions in the engine manual.
WARNING
Apply the service brakes, stop the machine and move
the travel selector to the opposite direction (forward or
reverse).
For Perkins engine with electric pre-heat, DO
NOT use ether starting aid.
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 to the next lower
gear.
If the battery becomes discharged and fails to have sufficient power to start the engine, jumper cables can be
used to obtain starting assistance. Refer to the jump
starting instructions in the Service chapter of this manual for safe jump-start procedure.
PARK BRAKE
STOPPING
NOTE: The park brake mechanism is NOT
designed for, NOR intended to be used as, the
primary means of stopping forward or reverse
movement of the machine. Hydraulic braking provided through the service brakes within the axles
is the primary means for stopping movement. The
axle-by-axle split brake system is the secondary
means of stopping movement.
The following procedure is the recommended
sequence for stopping the machine:
1. Bring the machine to full parking stop on a level
surface. AVOID parking on a slope if possible, but if
necessary, park across the slope and block the wheels.
2. Retract the boom all the way and lower the attachment to the ground.
The proper sequence for correct machine operation is
to always engage the park brake lever before shutting
off the engine; to disengage the brake ONLY after the
engine is running. In an EMERGENCY, when it
becomes necessary to STOP the movement, pull out
the park brake lever.
3. Place controls in neutral. Set the parking brake
lever to “ON”.
4. Idle the engine for gradual cooling. Turn the
keyswitch key to the “OFF” position to shut the engine
off. Remove the key.
CHANGING ATTACHMENT TOOLS
5. Unlatch the seat belt. Grasp the hand holds while
climbing out of the operator’s compartment.
The Telescopic Forklift boom nose will accept
Dynattach® system Gehl attachment tools. The
Dynattach system has a quick-release hookup and
locking mechanism for mounting framing, masonry, or
material handling type attachment tools to the boom
nose.
CAUTION
Be sure the area being used for test-running is
clear of spectators and obstructions. For initial operation, operate the machine with an
empty attachment tool.
Attaching
To pickup the attachment tool proceed as follows:
1. Raise the boom slightly and extend it 2 to 3 feet
( 0.6 to 0.9 m) for better visibility and tilt the
Dynattach system forward.
INITIAL OPERATION
Make sure the engine is warm and then go through the
following procedures.
PRINTED IN U.S.A.
2. Align the Dynattach system squarely with the back
of the attachment tool.
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907879/AP1198
Hookup Ear
Hookup Bar
Attachment
Tool Unlocked
Manually For
Release
Dynattach System
Tilted Forward
For Hookup
Attachment
Tool
Dynattach
System Released
from
Attachment
Tool
Attachment
Tool Locked
To Dynattach
System
Dynattach System Attaching Detail
Dynattach System Detaching Detail
3. Slowly extend the Dynattach system and lower the
hooks under the attachment tool hookup bar.
connect the hoses from the quick-disconnects on the
boom nose.
4. Tilt the Dynattach system back so that the lock
plate engages the attachment tool. This secures the
attachment tool to the Dynattach system.
5. Start the engine.
5. For attachment tool with auxiliary hydraulics, connect hoses to the quick-connect connectors on the
boom nose.
6. Tilt the Dynattach system forward to allow the
attachment tool to roll out, then lower the boom so the
hook ears clear the hookup bar on the attachment tool.
Back the machine until the attachment tool is free of
the Dynattach system.
Detaching
NOTE: One side of the lock plate has a bright
red decal to indicate the unlocked position.
To detach attachment tool, proceed as follows:
1. Raise the boom slightly and extend it 2 to 3 feet
(0.6 m to 0.9 m) for better visibility. Lower the boom
until the attachment tool is approximately 12” (0.3 m)
off the ground.
WARNING
Modifications, alterations to, or use of attachment tools NOT authorized by GEHL Co. in
writing can void warranty and cause machine
damage and/or serious personal injury or
death.
2. Roll the carrier backward as far as it will go. Once
the carrier is rolled all the way back, perform the
MANDATORY SAFETY SHUTDOWN PROCEDURE (Safety chapter, p.10)
3. With the engine off, leave the operator’s station.
Manually raise the lock spring and flip the Lock Plate
up and outward at least 180o so it is in position to relock on the next attachment tool.
SELF-LEVELING
The machine is provided with a hydraulic self-leveling
feature. This feature is designed to keep the attachment
tool level while the boom is being raised.
4. If the attachment tool has auxiliary hydraulics, dis-
907879/AP1198
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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
the following steps before starting the machine for the
first time each day.
Grade and Slope Precautions
The Telescopic Forklift complies with industry stability test requirements and is stable when properly operated. However, improper operation, faulty maintenance, or poor housekeeping may contribute to a condition of instability and defeat the purpose of the standard.
1. Check the engine oil and coolant, transmission oil
and hydraulic oil levels.
2. Make sure weekly lubrication has been done.
3. Visually inspect for leaks, broken or malfunctioning parts. Make sure all caps, covers and safety shields
are in place.
The amount of forward and rearward tilt to be used is
governed by the application. Although use of maximum rearward tilt is allowable under certain conditions such as traveling with the load fully lowered, the
stability of the machine as determined by the industry
standard tests, does not encompass consideration for
excessive tilt at high elevations, or the handling of offcenter loads.
4. Check tires for cuts, bulges, nails, correct pressure,
loose wheel nuts, etc.
5. Inspect the work area. Make sure you know where
you will make load pickups, lifts, and turns. Look over
the terrain of the jobsite for holes, obstacles, slippery
surfaces, soft or deep mud.
Handle only loads within the capacity limits of the
machine, and which are stable or safely arranged.
When attachments are used, extra care shall be taken in
securing, manipulating, positioning and transporting
the load.
6. Check clearances of ramps, doorways and passage
ways. Check overhead clearances if you will travel and
place loads near power or telephone lines.
Grade Limits
WARNING
NOTE: Grade limits are based on ANSI standard
Exhaust fumes can kill. Insure proper ventilation when starting indoors or in enclosed
areas.
B56.6-1987.
1. DO NOT place or retrieve loads on an up or down
slope or grade that exceeds 6% (3.4o) grade.
Use proper grab handles, NOT the steering
wheel or control levers as hand holds when
mounting or dismounting.
2. DO NOT travel up or down a grade or slope that
exceeds 22% (12o) grade while loaded.
NEVER operate the machine with safety
guards or covers removed.
3. DO NOT place or retrieve loads on a side hill with
a slope or grade that exceeds 10% (6o) grade.
Regardless of terrain or position of wheels, the
FRAME MUST BE LEVEL as indicated by the level
indicator on the ROPS cross member.
Over-inflated tires can explode and cause
injury or death. Tire repairs MUST be made
only by authorized personnel using proper
tools and equipment.
4. DO NOT travel across a side hill that exceeds 18%
(10o) grade. Regardless of the terrain or position of the
wheels, the FRAME MUST BE LEVEL as indicated
by the level indicator on the ROPS cross member. The
attachment tool MUST be maintained at the “carry”
position with the boom fully retracted, and attachment
tool at minimum ground clearance.
If the machine is found to be in need of repair or in any
way unsafe, or contributes to an unsafe condition, the
matter shall be reported immediately to the user’s designated authority. The machine shall NOT be operated
until it has been restored to a safe operating condition.
When ascending or descending grades in excess of 5%
(3o) the machine shall be driven with the load upgrade.
PRINTED IN U.S.A.
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907879/AP1198
When ramps MUST be utilized in transporting loads
with the machine, the following shall be minimum
widths for safe travel:
WARNING
DO NOT attempt to correct the frame level
condition with the boom raised or extended.
Only level the machine while at a complete
stop with the boom fully retracted and the
attachment tool raised just enough to clear the
ground.
Compacted dirt, gravel, etc.
Woodboard, concrete, etc.
12 ft. (3.6 m)
10 ft. (3.0 m)
Permanent aisles, roadways or passageways, floors and
ramps shall be defined in some fashion or marked.
Permanent or temporary protrusion of loads, equipment, material and construction facilities into the usual
operating area shall be guarded, clearly and distinctively marked, or clearly visible.
Unloaded machine should be operated on all forward
grades with the load handling attachment tool downgrade, tilted back if applicable, and raised only as far
as necessary to clear the road surface.
Maintain a safe distance from the edge of ramps, platforms or other similar working surfaces.
Avoid turning if possible and use extreme caution on
grades, ramps or inclines. Normally travel straight up
and down.
Controlled lighting of adequate intensity should be
provided in operating areas. Where operating conditions indicate, the operator/user shall be responsible for
having the machine equipped with lights.
Traffic Flow Patterns
Provision shall be made to prevent trucks, semi-trailers
and railroad cars from being moved during loading and
unloading.
Know and understand the traffic flow patterns of your
jobsite and also know all Telescopic Forklift hand signals for safety. Utilize signalmen and make sure you
can see the signalmen and acknowledge the signals
given.
Wheel stops, hand brakes, or other recognized positive
means shall be used to prevent movement during loading and unloading.
The backup alarm automatically sounds with the travel 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.
DO NOT move railroad cars or trailers with the
machine.
DO NOT use the boom and attachment for leverage to
push the machine out of mud.
IMPORTANT: DO NOT lower boom at high
Stop
Raise Load
engine RPM when attachment tool is at maximum
rearward tilt. Damage to slave cylinders may
result.
Lower Load
GENERAL LOAD HANDLING
NEVER attempt to work controls except from the
operator’s seat. NEVER jerk or use fast movements.
Avoid sudden stops, starts or changes in direction.
Tilt Forks Right
Tilt Forks Left
Tilt Forks Up
Tilt Forks Down
Load Back
Load Forward
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 “feathering”. Feathering the control
means you start the desired motion by moving the control away from neutral a small amount. After movement has started, the control can be eased to full power.
Use the same technique to stop the motion.
Safety Hand Signals
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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 various positions of attachment tool extension and elevation. A set of current load zone charts is reproduced at
the end of this manual for reference.
Excessive speed can be hazardous. ALWAYS
exercise caution and good judgement while
operating the machine.
Twice daily, increase the engine speed (fast
idle) and extend and retract the frame level
cylinder to the stroke limit. This removes any
trapped air in the circuit, which could cause
the machine to lean to one side or the other.
A typical load chart is reproduced on the next page.
The scale on the left indicates height in feet above the
ground level. The scale on the bottom shows the distance in feet out from the front of the machine. The
arch lines noted by the numbers “1 through 5” correspond with the position extension markers on the operator side of the intermediate boom section.
The machine shall not be used to lift or carry
personnel, or be fitted with any form of personnel work platform.
The following example illustrates proper use of the
load charts for the Telescopic Forklift:
ALWAYS maintain a safe distance from electric power lines and avoid contact with any
electrically charged 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.
Accidental contact or rupture can result in
electrocution or an explosion. Contact the
“Digger’s Hotline” or proper local authorities
for utility line locations BEFORE starting to
dig!
Example:
The operator, using a standard carriage attachment tool
without outriggers, MUST raise a 3000 lb load 20 feet
high and can only get to within 15 feet of the load
placement point. Can it be done within the capacity of
the machine?
Analysis: See “Typical Load Zone Chart” p. 32.
Projecting up from the 15 foot mark on the horizontal
axis to intersect a line through the 20 foot mark on the
vertical axis shows the load can be safely placed in the
3000 lb Zone.
Keep all body parts inside the operator’s station while operating the machine. BE SURE of
clearance of the attachment tool when turning,
working around buildings, etc.
During placement, the operator observes when the
extension reference number ”3” on the boom is visible.
He knows the maximum safe distance of extension
with this load has been reached.
Turning corners too fast can tip the machine
and cause a load to lean excessively and tip
off the attachment. Sudden slowing or stopping of the machine may cause the load to
drop off the attachment tool.
WARNING
Be certain you can control both speed and
direction before moving. Always place the
machine in neutral and set the park brake
before raising or extending the boom. NEVER
drive the machine up to someone standing in
front of the load.
NEVER exceed the rated operating capacity of
the Telescopic Forklift as shown on the capacity decal.
LIFTING ATTACHMENT TOOL
APPLICATIONS
NEVER leave the operator’s station without
first lowering the attachment tool to the
ground. Set the park brake, place 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.
PRINTED IN U.S.A.
Picking Up The Load
Inspect the load. If it appears unstable, DO NOT
attempt to move it. DO NOT attempt lifting doubletiered loads, or straddling side-by-side pallets one on
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907879/AP1198
HEIGHT ABOVE GROUND
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
conditions and that permit stopping in a safe manner.
Operating conditions can reduce the safe lift
of near capacity or capacity loads. Exceeding
capacity when lifting or extending the boom
will cause the machine to tip forward.
WARNING
each fork. NEVER add extra unauthorized counterweights to this machine. Consider the additional
weight of any attachment tool as part of the picking
load capacity of the machine.
NEVER travel with the boom above the carry
position (attachment tool should be at minimum ground clearance). Boom should be fully
retracted.
Approach the load squarely and slowly with the
machine straight and level. Adjust the space between
forks, if necessary. Engage the load equally on forks
until the load touches the carriage backrest. Tilt the
forks back to position the load for travel.
907879/AP1198
Use lower gear when traveling down an
incline. NEVER coast with the transmission in
neutral. Travel up and down grades slowly.
DO NOT operate the machine on a slope or
grade that exceeds 22% (12o).
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Load Elevation And Placement
SUSPENDED LOADS
For ground level placement, make sure the area under
the load and around the machine is clear of equipment
and personnel. Lower the load to the ground, tilt the
forks to the horizontal position, then back away carefully to disengage forks from the load. For elevated or
overhead placement, bring the machine as close as possible to the landing point.
DO NOT exceed the Telescopic Forklift capacity as
equipped for handling suspended loads. Only lift the
load vertically and NEVER drag it horizontally. Use
guy lines to restrain load swing, whenever possible.
The handling of suspended loads by means of the truss
boom or other similar device can introduce dynamic
forces affecting the stability of the machine that are not
considered in the stability criteria of industry test standards. Grades and sudden starts, stops and turns can
cause the load to swing and create a hazard.
Level the machine BEFORE raising the load. Use
extreme caution for high placement. Make sure personnel are clear of the area where the load or the
machine could tip or fall.
ROAD TRAVEL
Set the park brake, hold the service brake pedal in fully
depressed position and slowly raise the load maintaining a slight back tilt to cradle the load. As the load
approaches the desired height, feather the boom control at minimum speed until the load is slightly higher
than the landing point.
For short distance highway travel, attach a SMV (slow
moving vehicle) emblem (purchased locally) to the
back of the Telescopic Forklift. Activate hazard lights
on the machine. For highway operation, obtain and
install an amber flashing beacon.
Continue the feathering technique and lower the load
in place, until the Forks are free. Level the Forks and
retract clear of the load. Lower the Forks to travel
height, before moving the machine.
NOTE: ALWAYS follow ALL state and local regulations regarding the operation of equipment on
or across public highways! Also, whenever any
appreciable distance exists between jobsites or if
operation on public highway is probhibited, be
sure to transport the machine using a vehicle of
appropriate size and weight.
WARNING
NEVER use frame leveling to position an elevated load. Always lower the load to the
ground and reposition the machine.
TRANSPORTING BETWEEN
JOBSITES
If a hydraulic boom circuit hose should break
with the boom up, shut down the machine. DO
NOT attempt to bring down the boom or make
repairs. Call your GEHL dealer immediately.
When transporting the Telescopic Forklift, know the
overall height to allow clearance of obstructions.
Remove or tape over the slow moving vehicle (SMV)
emblem if it will be visible to traffic.
As lift height increases, depth perception
decreases. High elevation placement may
require a signal man to guide the operator.
The machine becomes less stable as load is
raised higher.
Tie-down hooks are provided for inserting chains
through to secure the machine while transporting.
DO NOT ram the lift cylinders to the end of the
stroke. The resulting jolt could spill the load.
ALWAYS abide by the following recommended
procedures and guidelines when attempting
to use ramps to load the machine onto (or
unload it from) a truck or trailer. Failure to
heed can result in damage to equipment and
serious personal injury or death!
WARNING
The truss boom attachment tools should
ONLY be used to lift and place loads when the
machine is stationary. DO NOT use truss
boom to transport loads around the jobsite.
This can cause the load to swing, resulting in
either load dropping or machine tipover.
PRINTED IN U.S.A.
33
907879/AP1198
with the ramps. Tie down slots are provided on the
front and rear sides of the frame structure.
7. Block the front and rear of the tires on the truck or
trailer. Engage the parking brake.
In Transit
If in transit for a few days: (a) Disconnect the battery.
(b) Clean all bright surfaces and coat with heavy, very
high flash point grease to prevent rusting.
Unloading Machine Using Ramps
Ramp Placement
NOTE: A matched pair of ramps is requIred.
Loading Machine Using Ramps
Use ramps as described in Steps 1 thru 4 and proceed
as follows to unload the machine:
NOTE: A matched pair of ramps is required.
8. If necessary, adjust the machine so that the wheels
are in line and centered with the ramps.
1. See illustration above. The ramps MUST be of sufficient strength to support the machine. Whenever possible, the use of strong steel ramps is recommended as
well as some type of center supporting block.
9. Slowly (at the lowest engine speed possible) and
carefully drive the machine down the ramps
THEFT DETERRENTS
2. The ramps MUST be firmly attached to the truck
or trailer bed with NO step between the bed and the
ramps.
THE CERTAINTY OF APPREHENSION IS A
STRONG DETERRENT TO THEFT OF CONSTRUCTION EQUIPMENT! GEHL has recorded all
part numbers and serial numbers. Users should take as
many of the following actions as possible to discourage theft, to aid in the recovery in the event that the
machine is stolen, or to reduce vandalism:
3. Incline of ramps MUST be less than 15 degrees;
ramp length MUST be at least 16 feet (4.8 m) long.
4. Ramp width MUST be at least 1-1/2 times the tire
width.
5. Slowly (at the lowest engine speed possible) and
carefully drive the machine up the ramps.
1. Remove keys from unattended machines.
2. Attach, secure, and lock all anti-vandalism and
anti-theft devices on the machine.
WARNING
3. Lock doors of cabs when not in use.
NEVER attempt to adjust travel direction (even
slightly) while traveling on the ramps. Instead,
back down off of the ramps and then realign
the machine with the ramps.
4. Inspect the gates and fences of the vehicle storage
yard. If possible, keep machines in well lighted areas.
Ask the law enforcement agency having jurisdiction to
make frequent checks around the storage or work sites,
especially at night, during weekends, or on holidays.
NEVER transport the machine with the boom
raised or extended. BE SURE to secure the
machine (including boom) to the truck or trailer bed using chain and binders of steel cables
to prevent any movement while transporting.
5. Report the theft to the dealer and insurance company. Provide the model, and all serial numbers.
6. Request that your dealer forward this information
to GEHL Company.
6. Remove the attachment tool from the boom.
Position the machine (with the boom facing toward the
front of the truck or trailer) so that it is straight in line
907879/AP1198
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Chapter 7
LUBRICATION
GENERAL INFORMATION
Hydraulic System/Reservoir
Use a Mobil DTE 15M, or equivalent
which contains anti-rust, anti-foam and antioxidation additives and conforms to ISO VG46.
Capacity:
47 gallons (178 Liters)
CAUTION
NEVER service this machine when any part of
the machine is in motion. ALWAYS BE SURE
to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 10) BEFORE servicing this equipment.
All Grease Fittings
Use No. 2 Lithium-based Grease
Engine Crankcase Oil
NOTE: The “Maintenance” chapter in this manu-
Ambient Temperature
Below 32oF (0oC)
32-77oF (0-25oC)
al has provisions for recording the dates and
hourmeter readings after lubrication or other service has been performed; use those spaces to
keep a log for maintaining a current service interval record. Proper routine lubrication is an important factor in preventing excessive part wear and
early failure.
Above
77oF
(25oC)
Grade
SAE 10 or 10W30
SAE 20 or 10W30
SAE 30 or 10W30
*Service Classification: API - CD/CE/CF-4
Capacity:
Refer to Engine Specifications, Chapter 2
LUBRICANTS
Axle Gear Oil
The chart on this page lists the locations, temperature
ranges and types of recommended lubricants to be used
when servicing this machine. Also refer to the separate
engine manual for additional information regarding
recommended engine lubricants, quantities required
and grades.
Use API-GL-5 80W90
Differential Capacity:
3.4 quarts (3.22 Liters)
Planetary Capacity (each side):
1.3 quarts (1.2 Liters)
Transmission/Cooler Oil
NOTE: Refer to Operator Services topic in the
“Service & Storage” chapter of this manual for
detailed information regarding periodic checking
and replenishing of lubricants.
Use Sunco Multi-ATF or Equivalent
Capacity:
24 quarts (23.0 Liters)
Brake System
DOT-3 Brake Fluid
PRINTED IN U.S.A.
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907879/AP1198
GREASING
Replacement Filters Chart
Refer to the illustration and listing on the next page for
fitting locations. Wipe dirt from the fittings before
greasing them to prevent contamination. Replace any
missing or damaged fittings. To minimize dirt buildup, avoid excessive greasing.
John Deere Engine
Oil Filter Element
Fuel Filter Element
Gehl P/N L99420
Gehl P/N L98978
Perkins Engine
Oil Filter Element
Fuel Filter
BASIC MACHINE
GREASE FITTING LOCATIONS
Gehl P/N L97489
Gehl P/N L88976
Every 50 Hours (or weekly)
Transmission
Oil Filter Element
Refer to the illustration on the facing page for locations.
Gehl P/N L99184
--- BOOM AREA ---
IMPORTANT: Do NOT use a substitute replacement because high pressure may rupture filter.
1. Boom to frame upright pivot pins (2)
2. Rod end slave cylinder pivot pins (2)
Hydraulic System Filters
In-Tank Filter Element
Reservoir Sump Strainer
3. Rod end lift cylinder pins (2)
Gehl P/N L97489
Gehl P/N L62831
4. Extend cylinder pivot pins (2)
5. Chain sheaves pins, (2)
Air Cleaner
Dry Element
6. Dynattach to boom nose pivot pins (2)
Gehl P/N L120037
7. Tilt cylinder pivot pins (2)
8. Rotate cylinder pivot pins (2)
9. Rotate carriage wear pads (3)
10. Rotate 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 axle)
16. Drive shafts (3 per each)
17. Leveling cylinder pivot pins (2)
18. Base end lift cylinder pivot pins (2)
19. Base end slave cylinder pivot pins (2)
907879/AP1198
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PRINTED IN U.S.A.
2
1
5
11
5
Boom
4
18
3
11
19
15
7
Transmission
16
16
16
7
6
Chassis
Front View
Axle
15
17
Rotate
Carriage
13,14
10
Other
Side
9
8
-- NOT SHOWN -Operator Station Floor
Item (12)
Location Reference for Grease Fittings
PRINTED IN U.S.A.
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907879/AP1098
Chapter 8
SERVICE & STORAGE
When a problem occurs, don’t overlook simple causes
such as an empty fuel tank. Check for leaks and broken
connections. Make note of any specific problem symptoms, noises, etc. and contact your local Gehl Dealer.
GENERAL INFORMATION
WARNING
IMPORTANT: Always dispose of waste lubri-
BEFORE servicing the Telescopic Forklift,
unless expressly instructed to the contrary,
exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (Safety chapter, p.10).
After service has been performed, BE SURE to
restore all guards, shields and covers to their
original positions BEFORE resuming machine
operation.
cating oils, anti-freeze and hydraulic fluids
according to local regulations or take them to a
recycling center for disposal. DO NOT pour them
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 authorized
GEHL Telescopic Forklift Dealer.
NOTE: All Service routines, with the exception of
IMPORTANT: DO NOT attempt to service or
those described under the “Dealer Services” topic
are owner-operator responsibilities. All Operator
Services described under the hourly subtopics
are also referred to on a decal which is located on
the inside right side panel of the operator’s station. Refer to the Lubrication chapter of this manual for lubrication information.
repair major components, unless authorized to do
so by your Gehl Dealer. Any unauthorized repair
will void the warranty.
POWER TRAIN COMPONENTS
The engine and transmission are coupled directly to
each other. All service routines, related to the internal
components are precise and critical to proper power
train operation. The axle differential and planetary
ends are also sophisticated assemblies which require
special know-how and tools for servicing.
NOTE: This “Service” chapter describes procedures to follow for making routine maintenance
checks, adjustments and replacements. The
majority of the procedures are also referred to in
the “Maintenance” chapter of this manual. For
engine related adjustments and servicing procedures, be sure to refer to the engine manual provided.
NOTE: If any power train components are suspected of faulty operation, contact your Gehl
Dealer for further assistance.
PRECAUTIONS
HYDRAULIC SYSTEM COMPONENTS
DO NOT perform any maintenance or repair without
the owner’s prior authorization. Allow only trained
personnel to service the machine.
Valves, pumps, motors and cylinders are also sophisticated assemblies which require special know-how and
tools for servicing. All cylinders are appropriately
designed with particular strokes, diameters, checks and
hose connection provisions unique to the machine
application requirements. A schematic (located at the
end of this manual) can be used as a guide for service
reference, as required.
WARRANTY repairs can only be done by a GEHL
Dealer. He will know what portions of the machine are
covered under the terms of the GEHL Warranty and
what portions are covered by other vendor OEM warranties.
907879/AP1198
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He will know what portions of the machine are covered
under the terms of the GEHL warranty and what portions are covered by other vendor warranties.
WARNING
Tilt, lift, extend and leveling cylinders have
counterbalance valves. These valves keep
hydraulic fluid from entering or exiting the
cylinders while not being used, and are under
extremely high pressure. For your safety,
before removing any of these valves, you
must call Gehl Service. Failure to do so may
result in serious injury or death.
ELECTRICAL COMPONENTS
Internal service on any of these components should
only be attempted by (or under the direction of) an
authorized GEHL Telescopic Forklift dealer. WARRANTY repairs can only be done by a GEHL dealer.
Some of the operator related services will require
access to components located inside the superstructure
under shields, hoods and covers. The reference chart
on this page notes components accessed in each particular area.
An electrical system schematic is provided which
includes instrumentation, electrical components and
switch connections. It is located at the end of this manual and can be used as a guide for service reference, as
required.
OPERATOR SERVICES
ACCESS TO COMPONENTS REFERENCE CHART
Component
Operator
Station
Frame
Front
Cover
z
Axle (underside)
z
Engine
z
Transmission (mid area)
Drive Shafts (underside)
z
Main Control Valve (rear)
z
Muffler (underside)
z
Air Cleaner (top front hood)
z
Battery
z
z
Radiator
Brake Valve (underside)
z
Travel Controls (dash area)
z
Boom Controls (right side)
z
Hydraulic Test Ports (dash)
z
Hourmeter (dash)
z
Switches/Indicators (dash)
z
Hydraulic Pump
z
Hydraulic Filter (Reservoir)
z
Misc. Hydraulic Valves
z
Air Conditioner (rear)
z
Heater (lower front)
z
PRINTED IN U.S.A.
Mid-Rear
Hood
39
907879/AP1198
Block the wheels. Remove the ignition key. Remove
only guards or covers that provide needed access. Wipe
away excess grease and oil.
WARNING
DO NOT smoke or allow any open flames in
the area while checking or servicing
hydraulic, battery or fuel systems; all contain
highly flammable liquids or explosive gases
which can cause an explosion or fire if ignited.
NEVER weld on attachment tools, boom support
frame or overhead guards without the consent of the
manufacturer. Special metals may be used which
require special welding techniques or have a design
which should not have welded repairs. NEVER cut or
weld on fuel lines or tank.
Wear a face shield when you disassemble
spring loaded components or work with battery acid. Wear a helmet or goggles with special lenses when you weld or cut with a torch.
Excessively worn or damaged parts can fail and cause
injury or death. Replace any cracked or damaged part.
Care should be taken to assure that all replacement
parts are interchangeable with original parts and of
equal quality.
When working beneath a raised machine,
always use blocks, jack-stands or other rigid
and stable supports. Wear appropriate protective clothing, gloves, shoes. Keep feet, clothing, hands and hair away from moving parts.
Use care not to damage machined and polished surfaces. Clean or replace all damaged or painted over
plates and decals that cannot be read.
Always wear safety glasses or goggles for eye
protection from electric arcs from shorts, fluids under pressure, and flying debris or loose
material when the engine is running or tools
are used for grinding or pounding.
WARNING
NEVER leave guards off or access doors open
when the machine is unattended. Keep
bystanders away if access doors are open.
NEVER weld on bucket, forks, boom, support
frame or overhead guards without the consent
of the manufacturer. Special metals may be
used which require special welding techniques or have a design which should not
have welded repairs. NEVER cut or weld on
fuel lines or tanks.
After servicing, check the work performed, no parts
left over, etc. Install all guards, covers.
Service Every 10 Hours or Daily
If repair welding is ever required, BE SURE to
attach the ground (-) cable from the welder as
close as possible to the area to be repaired.
Also remove battery (+) positive terminal connection before welding.
CHECK FUEL TANK LEVEL
After operation each day, the fuel tank should be filled
to prevent water from condensing in the tank. To fill,
remove the filler cap and add fuel.
Choose a clean, level work area. Make sure you have
sufficient room, clearances, and adequate ventilation.
Clean the walking and working surfaces. Remove oil,
grease and water to eliminate slippery areas. Utilize
sand or oil absorbing compound, as necessary, while
servicing the Telescopic Forklift.
A drain plug is provided in the bottom of the fuel tank
for removing condensation and other foreign materials.
Open the plug and allow water and fuel to drain into a
container until only clear fuel is flowing from the tank.
CHECK FUEL FILTER
Before starting inspection and repair, move the
machine onto a level surface, shut down engine, and
release all hydraulic pressure. Always block the boom
securely, or lower it to full ground contact. Place all
controls in neutral.
907879/AP1198
NOTE: The fuel filter will require occasional
replacement to maintain a clean and adequate
fuel flow for maximum engine horsepower. The
frequency of filter replacement will be determined
by the cleanliness of available fuel, the care used
40
PRINTED IN U.S.A.
CHECK HYDRAULIC OIL LEVEL
in storing fuel supplies and the operating conditions in which the machine is used.
The machine must be on level ground and make sure
the boom is lowered and completely retracted. The
fluid MUST be cool when checking the reservoir level.
By doing this, you will reduce the possibility of overfilling the hydraulic system, and also reduce potential
injury due to hot fluid.
Small amounts of water can be drained from the fuel
filter. The drain plug should be removed weekly to
drain off water accumulation until clear fuel is flowing
from the outlet.
CHECK ENGINE OIL LEVEL
Remove the front cover from 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 amount of oil to bring the level to the FULL
mark. See the Lubricants chapter for the type of oil to
use.
With the machine on level ground, and the engine
stopped for ten minutes or more, slide open the side
engine panel and remove the engine dipstick. Wipe it
clean, re-insert it and remove to obtain a reading. If the
oil level is down, or below the ADD mark, fill with the
required amount of oil to bring the level to the FULL
mark. See the Lubrication chapter for the type of oil to
use.
IMPORTANT: Be careful when removing the
reservoir filler cap so that no dirt or other foreign
matter enters the hydraulic system while the cap
is removed. DO NOT OVERFILL.
CHECK RADIATOR COOLANT LEVEL
With the machine on level ground, remove the radiator
cap. Add 50/50 water and anti-freeze mixture (winter)
if the coolant level is below the filler neck. Replace the
radiator cap securely.
CHECK BRAKE RESERVOIR LEVEL
The brake booster master cylinder reservoir is under
the seat compartment. This compartment panel tilts
forward for access to the reservoir. Remove the reservoir caps to check the level. If low, fill to proper level
with hydraulic brake fluid (Type DOT3) only.
IMPORTANT: If the engine is operated with a
WARNING
DO NOT remove the radiator cap when the
engine is running hot or overheated. Coolant
is extremely hot and under pressure and it can
burn your skin. Allow sufficient time for the
radiator and hydraulic oil cooler to cool
BEFORE relieving the pressure and removing
the radiator cap.
CHECK PARK BRAKE HANDLE
Check the tension when pulled. Adjust, if necessary, to
a pull of 20 Lbs (89 N)
CHECK TIRE PRESSURES
Proper tire pressure should be maintained equally for
all four tires to enhance operating stability and extend
tire life.
loose radiator cap, the pressure bypass will not
work and the engine will run hot.
When installing tires on the machine, be sure that all
tires are of the same size and style. ALWAYS replace
tires with the same size furnished as original equipment. Replacement tires must be purchased locally.
CHECK TRANSMISSION OIL LEVEL
The machine must be on level ground and make sure
the boom is lowered and completely retracted. With
engine and transmission at operating temperature; park
brake on, transmission in neutral and engine speed at
low idle, remove the access cover to the transmission
and hydraulic pump. Remove the dipstick and check
the oil level. Add the required amount of oil to bring
the level to the FULL mark. See the Lubricants chapter for the type of oil to use.
PRINTED IN U.S.A.
Check the tire pressure “cold”. All 12 ply tires should
be inflated to 55 PSI (380 kPa).
NOTE:If the tires have been filled with water or
calcium chloride for weight, a calcium chloride tire
pressure gauge MUST be used to check the tire
pressure.
41
907879/AP1198
CHECK INSTRUMENTS OPERATION
WARNING
Allow the engine to warm up for about five minutes
before beginning operation. Indicator lamps should be
OFF and gauges should register normal readings. Tilt
the frame from side to side with the level control and
note the angle indicator movement.
NEVER attempt to service tires if the bead lock
ring appears loose. Clear the area and call for
professional tire repair help.
Inflating or servicing tires can be dangerous.
Whenever possible, trained personnel should
service and mount tires. DO NOT place your
fingers on the tire bead or rim during inflation;
serious injury or amputation could result. To
avoid possible death or serious injury, follow
the safety precautions below:
CHECK GENERAL MACHINE
OPERATION & CONDITION
Are any decals missing or damaged? Are all guards,
shields and covers in place? Do all controls function
smoothly and properly? Are there any abnormal vibrations or noises? Are any hose or fitting connections
leaking? Is the engine exhaust color normal (light grey
or colorless)?
1. BE SURE the rim is clean and free of rust.
2. Lubricate both the tire beads and rim
flanges with a soap solution. DO NOT use oil
or grease.
Service Every 50 Hours or Weekly
3. Use a clip-on tire chuck with a remote hose
and gauge which allows you to stand clear of
the tire while inflating it.
LUBRICATE GREASE POINTS
Refer to the Lubrication chapter of this manual for
weekly grease fitting locations and other related
details.
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, reposition the tire
on the rim, relubricate both parts and reinflate. Inflation pressure beyond 35 PSI (240
kPa) with unseated beads may break the bead
or rim with explosive force sufficient to cause
death or serious injury.
100 Hours (New Machine Only)
The following initial oil and filter changes should be
made at this time on a new machine. Thereafter these
changes should be made at the regular maintenance
schedule listed. Refer to those schedules for procedures necessary.
5. After seating the beads, adjust the inflation
pressure to the recommended operating pressure listed.
Engine Oil & Filter
Transmission Oil & Filter
Hydraulic Oil Filter
6. DO NOT weld, braze, or otherwise attempt
to repair and use a damaged rim.
Service Every 250 Hours
When removing tires follow industry safety practices.
Deflate completely prior to removal. Following assembly of the tire on the rim, use a safety cage or restraining device while inflating.
NOTE: Perform all other service requirements
up to this point as well as the following:
CHECK WHEEL NUT TORQUE
CHANGE AIR FILTER ELEMENT
On NEW machines, re-torque until 450 ft-lbs (610
Nm) is maintained.
907879/AP1198
(250 Hours)
(1000 Hours)
(1000 Hours)
This air filter contains a single dry element. Wipe the
outside of the body with a rag or cloth. Blow off excess
dirt and dust with compressed air. Refer to illustration
on the next page.
42
PRINTED IN U.S.A.
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.
Remove the baffle. Wipe the cup and baffle completely clean. Reassemble the dust cup.
CHECK AXLE OIL LEVELS
2. Remove the element wing bolt and slide out the
element. Avoid knocking the element against the housing. Dirt accidentally transferred to the inside of the
outlet tube will reach the engine and cause wear.
NOTE: The Telescopic Forklift should be on a
level surface for this procedure.
Differential
See illustration. Remove the check/fill plug (located on
opposite side of the drive shaft U-joint). If low, fill
until oil overflows the hole. Replace the plug, wait 10
to 15 minutes and repeat the fill procedure. Continue
this process until the differential is full. See the
LUBRICANTS chapter for the proper oil specification.
Replace the oil level check/fill plug.
3. Wipe the entire inside of the main body and inlet
cap screen.
A streak of dust on the clean air side of the old element
indicates a leakage problem. Be sure to remove the
cause before installing a new element.
Planetary Hubs
4. Inspect the new element for possible damage.
Placing a bright light inside the element and inspecting
the outside will show up any holes or tears. Discard the
element if such damage appears.
NOTE: The planetary hubs can be checked without jacking up the machine.
See illustration. The planetary hubs have one plug each
used for filling and draining. For checking the level
and filling, position the Wheel until the arrow points
down. Remove the fill plug. If oil does not run out, add
oil until it overflows. Check the remaining hubs the
same way. Refer to the oil specifications found in the
Lubricants chapter of this manual.
IMPORTANT: NEVER use an element that is
damaged. Severe engine wear and eventual failure can result if dirt gets through a hole in the element.
5. Install the element and reassemble the end cup to
housing. Make sure the large o-ring is in place between
the end cup and the main body.
CHANGE FUEL FILTER
NOTE: Keep spare elements on hand to elimi-
The frequency of filter replacement will be determined
by the cleanliness of available fuel, the care used in
storing fuel supplies and the operating conditions in
which the machine is used.
nate down time.
PRINTED IN U.S.A.
43
907879/AP1198
NOTE: For proper replacement procedures refer
CHANGE ENGINE OIL & FILTER
to the engine manual for your machine.
Change the engine oil and filter using the following
procedure:
After fuel filter replacement, bleed the air out of the
fuel system following the procedures in the engine
manual.
1. With the engine warm, remove the crankcase drain
plug. Some plugs are equipped with a magnet to gather metal particles. Completely clean and flush away all
metallic filings from the plug and re-install it.
Fuel Bleeding Procedures
When the fuel filter is removed and replaced, or the
engine runs out of fuel, air must be bled from the system. Refer to the engine manual relative to proper
bleeding procedures.
IMPORTANT: DO NOT discharge onto ground.
Catch and dispose of per local waste disposal
regulations.
2. The engine oil filter should be changed at every oil
change interval. Remove and discard the throw away
filter canister. Wipe the gasket sealing area of the block
with a clean cloth.
WARNING
NEVER service the fuel system while smoking, while near an open flame, or after the
engine has been operated and is hot.
NOTE: Your OEM engine oil filters have special
by-pass valves built in. Use only genuine OEM
engine replacement filters.
If the engine still will not start, consult your nearest
authorized engine dealer.
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 the Lubrication chapter for
type and viscosity of new oil to put in.
NOTE: Only an authorized engine dealer can
perform WARRANTY Service on the engine.
Whenever faulty or plugged injectors are indicated, see
your nearest authorized engine dealer.
4. After new oil has been added, run the engine at idle
speed until the oil pressure light is OFF. Check for
leaks at the filter and drain plug. Re-tighten only as
much as necessary to eliminate leakage.
Diesel Injection Pump Timing
CHECK THE BATTERY
Whenever injection pump timing, or other pump service is indicated by abnormal engine operation, contact
your nearest engine dealer.
The battery furnished with this machine is a 12 volt,
wet-cell battery.
Diesel Fuel Injectors
Handling Battery Safely
WARNING
The top of the battery must always be kept clean. Clean
the battery with a brush dipped in an alkaline solution
(ammonia or baking soda and water). After the foaming has stopped, flush the top of the battery with clean
water. If the terminals and cable connection clamps are
corroded or have a buildup, disconnect the cables and
clean the terminals and clamps with the same alkaline
solution.
Escaping diesel fuel under pressure can have
sufficient force to penetrate the skin. Before
applying pressure to the fuel system, BE
SURE all connections are tight and lines and
hoses are NOT damaged. Use a piece of wood
or cardboard to search for suspected leaks. If
injured by escaping fuel, see a doctor familiar
with this type of injury at once or gangrene
may result.
907879/AP1198
NOTE: The battery in this machine is warranted
by the supplier. See the punch tag on the top of
the battery for warranty information.
44
PRINTED IN U.S.A.
Jump Starting
WARNING
If the battery becomes discharged or does not have
enough power to start the engine, use jumper cables
and the following procedure to jump-start the engine.
The ONLY safe method for jump-starting a
disharged battery is for TWO PEOPLE to perform the following procedure. The second person is needed for removing the jumper cables
so that the operator does not have to leave the
operator’s compartment while the engine is
running. NEVER connect the jumper cables
directly to the starter solenoid of either
engine. DO NOT start the engine from any
position other than the operator’s seat, and
then ONLY after making sure all controls are in
“neutral.”
NOTE: BE SURE that the jumper battery is also a
12 volt D. C. battery.
1. Turn the keyswitches on both vehicles to OFF.
Make sure that both vehicles are in “Neutral” and NOT
touching.
2. Remove the battery filler caps and make sure that
electrolyte solution is up to the proper level. In addi-
Closely follow the jump-start procedures, in
the order listed, to avoid personal injury. In
addition, wear safety glasses to protect your
eyes, and avoid leaning over the batteries
while jump-starting.
WARNING
Explosive gas is produced while a battery is in
use or being charged. Keep flames or sparks
away from the battery area. Make sure battery
is charged in a well-ventilated area.
DO NOT attempt to jump-start the machine if
the battery is frozen because this may cause it
to rupture or explode.
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:
tion, place a clean cloth over the uncapped filler holes
to prevent the electrolyte solution from overflowing.
1. IMMEDIATELY remove any clothing on
which acid spills.
3. Connect one end of the positive (+) jumper cable
to the positive (+) battery terminal on the disabled
vehicle first. DO NOT allow the jumper’s positive (+)
cable clamps to touch any metal other than the positive
(+) battery terminals. Connect the other end of the positive jumper cable to the jumper battery positive (+)
terminal.
2. If acid contacts the skin, rinse the affected
area with running water for 10 to 15 minutes.
3. If acid comes in contact with the eyes,
flood the eyes with running water for 10 to
15 minutes. See a doctor at once. NEVER
use any medication or eye drops unless
prescribed by the doctor.
4. Connect one end of the negative (-) jumper cable
to the jumper battery negative (-) terminal.
4. To neutralize acid spilled on the floor, use
one of the following mixtures:
5. Make the final negative (-) jumper cable connection to the disabled Telescopic Forklift’s engine block
or frame (ground) -- NOT to the disabled battery negative post. If making the connection to the engine, keep
the jumper clamp away from the battery, fuel lines, or
moving parts.
a. 1 Pound (0.5 kg) of baking soda in 4
quarts (4 liters) of water.
b. 1 Pint (0.4 liters) of household ammonia in 4 quarts (4 liters) of water.
NOTE: Twist the jumper cable clamps a couple
Whenever battery is removed from the unit,
BE SURE to disconnect the negative (-) battery terminal connection cable first.
PRINTED IN U.S.A.
of time on the battery terminals to insure a good
electrical path for conducting current.
45
907879/AP1198
6. Proceed to start the machine. If it does not start
immediately, start the jumper vehicle engine to avoid
excessive drain on the booster battery.
12.375” (314.3 mm), the chain should be discarded.
DO NOT repair sections of a chain. Replace the complete chain.
7. 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 while
making sure NOT to short the two cables together.
Chain anchors and sheaves also require inspection for
wear or broken fingers and worn flanges. If a chain has
been replaced, operate under load conditions and recheck the torque. Chains are adjusted by torquing the
Anchors to 25 ft-lb (34 Nm). Lubricate with 80/90 wt.
oil.
Allow sufficient time for the alternator to buildup a
charge in the battery before operating the machine or
shutting off the engine. Be sure to discard the cloths
and reinstall the vent caps removed in Step 2, above.
CHECK BOOM SLIDE PADS
WEAR & CLEARANCE
This boom is equipped with special nylon low friction
slide pads between the telescopic sections (see illustration). These are pre-greased and initially worn-in at the
factory. Normally greasing is not required, except for
maintaining a light film of grease on the pad tracking
areas of the boom sections. An exception would be if a
boom section has been replaced.
NOTE: If the battery frequently becomes discharged, have the battery checked for possible
dead cells or troubleshoot the entire electrical
system for possible short circuits or damaged wire
insulation.
CHECK ALTERNATOR &
FAN BELT TENSION
Rear Inner
Refer to the engine manual relative to proper belt tension adjustment and replacement procedures. If the belt
shows wear or cuts, it should be replaced. Order
replacement belt from your engine dealer.
Shim
Pad
CHECK BOOM LEAF CHAINS & SHEAVES
Inspect the leaf chains for wear and proper tension.
Two of the chains and sheaves are on the top of the
boom. A third is accessible from inside the rear of the
boom (see illustration). Run the boom out slowly to
inspect. Conditions to look for includes cracked or broken plates, protruding or turned pins, excessive wear.
With a steel tape, measure 16 links of the strand that
flexes over the sheaves. When the distance measures
Rear Chain
Sheave
Front
Outer
Slide Pad Detail
Visually check for loose pad bolts. The bolts are
torqued to 30 ft-lb (40 Nm). If the bolts are re-torqued
at any time, Loctite thread lock must be re-applied to
the bolts.
Front Chain
Sheaves
If the boom starts to chatter under load, grease the slide
pads and wipe off the excess. If a top or side slide pad
shows excessive wear, loosen bolts. Insert shims to
each side or top and bottom for even distribution of
clearance. Re-apply Loctite® thread lock to the bolts
and re-torque to 30 ft-lbs (40 Nm). Bottom slide pads
should be replaced when the thickness is worn down to
3/8” (9.5 mm).
Inner Section
Outer
Section
Intermediate
Section
Chain Hookup Detail
907861/AP698
46
PRINTED IN U.S.A.
2. Open the radiator drain cock. Remove the water
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.
Service Every 1000 Hours
NOTE: Perform all other service requirements
up to this point, as well as the following:
3. Replace all drain plugs and tighten the radiator
drain cock. Clean out the cooling fins in the radiator
with water pressure or steam.
CHANGE TRANSMISSION OIL & FILTER
Operate the machine long enough to warm up the
transmission oil. Shut down the engine. Access to filter
and drain plug is from underneath the machine.
Proceed as follows:
NOTE: When cold weather is expected, fill the
cooling system with a 50-50% mixture of water
and ethylene glycol anti-freeze.
4. Inspect the radiator cap seal before installing it.
Replace it if it appears defective. The 10 PSI (69
kPa)pressure cap and engine thermostat work in conjunction with each other to maintain proper engine
cooling.
1. Remove the drain plug and drain out old oil.
Replace the drain plug.
IMPORTANT: DO NOT discharge oil onto
ground. Catch and dispose of per local waste disposal regulations.
NOTE: Check the engine temperature lamp,
every minute or two, after coolant has been
changed. Air pockets can form. It may be necessary to refill the cooling system after a short period of use, as the air will naturally bleed out of the
system.
2. Remove and discard the oil filter. Wipe the sealing
surface on the transmission with a clean cloth. Apply a
thin coat of clean oil to the new oil filter gasket. Spin
tighten.
3. Refill the transmission with new oil as shown in
the Lubrication chapter of this manual.
CHANGE HYDRAULIC RETURN
FILTER ELEMENT
IMPORTANT: DO NOT OVERFILL! lf the oil
level is too high, oil foaming, excessively high oil
temperature and oil leakage at the seal could
result.
WARNING
When servicing the hydraulic system, lower
the boom to the ground.
4. Start and run the machine long enough for the oil
to circulate and warm slightly. Recheck the level with
the dipstick.
CHANGE RADIATOR COOLANT
This element is a cartridge type accessible from a housing on top of the hydraulic reservoir. Initial replacement is after the first 100 hours. See illustration.
Drain, flush and refill the cooling system as follows:
IMPORTANT: DO NOT discharge coolant onto
ground. Catch and dispose of per local waste disposal regulations.
Housing Top
WARNING
Filter Element
Remove the radiator cap only when the engine
is cool, or painful burns could result.
Filter Housing
1. Loosen the radiator cap to its stop. This will
release any system pressure. Remove the cap when all
pressure is bled off.
PRINTED IN U.S.A.
TOP OF
RESERVOIR
Reservoir Filter Removal
47
907879/AP1198
Remove the top cover of the housing. Remove the element and discard. Insert the new element onto the
housing and Replace the cover.
2. Re-position the hub so the arrow points down. Fill
with fresh oil as specified in the LUBRICATION chapter. When the oil runs out, install the drain/fill plug.
Repeat this procedure on the three remaining hubs.
CHANGE AXLE DIFFERENTIAL
& PLANETARY OIL
CHECK EXHAUST SYSTEM
Examine the muffler and tail pipe for possible holes.
Re-tighten any loose clamps and make sure the manifold outlet gasket is not leaking.
Differential
1. Remove the drain plug and drain out the old oil.
Replace the drain plugs (see illustration).
IMPORTANT: DO NOT discharge oil onto
Service Every 2000 Hours
ground. Catch and dispose of per local waste disposal regulations.
NOTE: Perform all other service requirements
PLANETARY
up to this point, as well as the following.
CHECK HYDRAULIC SYSTEM
RELIEF PRESSURES
Horizontal
Side Opposite
Drive Shaft
Mount
Pressure settings for relief valves are pre-set at the factory. Two test ports are provided on the dash front.
Drain
Before conducting any test port pressure checks, check
the engine RPM. Engine speed must be 950 to 1000
RPM at idle and 2700 to 2750 RPM at high idle.
DIFFERENTIAL
Steering Relief Pressure
Plug a 3000 PSI (206 bar) oil or liquid filled gauge in
the test port. Cramp the steering full to the right or left.
The gauge should read 2000 PSI (138 bar).
Fill
Drain
Check Main Relief Pressure
Axle Oil Plug Locations
With the gauge in the test port and the boom extended,
retract the boom fully. The gauge should read 2850 PSI
(196 bar).
2. Remove the check/fill plug. Fill the differential
with oil as specified in the LUBRICATION chapter.
When the oil overflows the check hole, replace the
plug. Wait 10 to 15 minutes and repeat this process
until the axle is full. Repeat the procedure with the
other axle.
CHANGE HYDRAULIC RESERVOIR
OIL & STRAINER
Clean all dirt and debris from around the top of the
reservoir, especially around the access cover. Refer to
illustration on next page and use the following procedure:
Axle Planetary Hubs
The hubs have one plug each used for draining and filling (see illustration).
1. Remove the drain plug and drain out all used oil.
Wash or blow off all collected particles from the magnetic drain plug.
1. Position the wheel until the arrow points to the left.
Remove the drain/fill plug and allow the oil to drain
out. Replace the plug.
IMPORTANT: DO NOT discharge oil onto
ground. Catch and dispose of per local waste disposal regulations.
IMPORTANT: DO NOT discharge oil onto
ground. Catch and dispose of per local waste disposal regulations.
907879/AP1198
48
PRINTED IN U.S.A.
STORAGE
Element
If the Telescopic Forklift will not be operated for a
long period of time, prepare and store it using the procedures as follows.
Fill Cap
Dipstick
Before Storage
Access
Cover
Perform the following prior to placing the machine in
storage:
Gasket
1
Wash off the entire machine.
2. Lubricate all grease fittings as described in the
Lubrication chapter of this manual.
3. Change engine oil as outlined in the Service &
Storage chapter of this manual.
TOP OF
RESERVOIR
4. Apply grease to all exposed hydraulic cylinder rod
areas.
5. Disconnect the battery cable clamps and cover the
battery or remove the battery from the machine and
store it separately.
Hydraulic Reservoir Sump Strainer Removal
2. Remove the access cover and wash the inlet screen
with clean solvent. Remove the sump filter strainer
from the bottom inside of the reservoir. Wash it also. If
the strainer has any damage, holes, etc. it should be
replaced.
6. If the ambient temperature (at anytime during the
storage period) is expected to drop below freezing,
make sure the engine coolant is either completely
drained from the radiator and engine block or that the
amount of anti-freeze in it is adequate to keep the
coolant from freezing. Refer to the separate engine
manual provided for anti-freeze recommendations and
quantities.
3. Flush out the bottom of the tank with clean
hydraulic oil. Re-install all cleaned components and
put the top back on the reservoir with a new gasket.
Clean the filter/breather cap.
During Storage
4. Fill the tank with fresh oil. Follow specifications
found in Lubrication chapter of this manual.
1. About once each month, connect the battery and
check all fluid levels to make sure they are at the proper level before starting the engine.
IMPORTANT: Hydraulic fluid and filters should
be replaced any time contamination is present
before the normally scheduled change.
2. Start the engine and allow it to run until it warms
up and then move the machine a short distance to help
relubricate the internal parts. Run the engine until the
battery has a chance to recharge and then shut it off.
WARNING
IMPORTANT: If it is desired to operate the
Escaping hydraulic oil under pressure can
have sufficient force to penetrate the skin.
Before applying pressure to the hydraulic system, be sure all connections are tight and
lines and hoses are not damaged. Use a piece
of wood or cardboard to search for suspected
leaks. If injured by escaping hydraulic oil, see
a doctor familiar with this type of injury at
once or gangrene may result.
PRINTED IN U.S.A.
hydraulic cylinders at this time, BE SURE to wipe
the protective grease (and any adhering dirt) from
the cylinder rods prior to starting the engine. After
operating, BE SURE to recoat the cylinder rods
with grease if the machine is going to be returned
to storage.
49
907879/AP1198
After Storage
After removing the machine from storage and
BEFORE operating it, perform the following:
1. Change engine oil and filter to remove condensation or other 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 the starting and warm-up procedures as
outlined in the OPERATION & ADJUSTMENTS
chapter of this manual.
907879/AP1198
50
PRINTED IN U.S.A.
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
apply a solid-formed decal, remove the smaller portion
of the decal backing paper and apply this 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 smooth-out decal surface. To
apply a die-cut decal, first remove the backing paper.
Then, properly orient and position the decal onto the
clean mounting surface. After the decal is firmly
applied and smoothly pressed down, remove the front
covering paper.
CAUTION
ALWAYS read and follow the safety precautions on decals. Replace decals if they are
damaged, or if the unit is repainted. If repainting, BE SURE that all applicable decals are
affixed in their proper locations.
Decal Locations information is provided to assist in the
proper selection and application of new decals, in the
event the original decal(s) become(s) damaged or the
machine is repainted.
PAINT FINISH
Use this list to order paint for refinishing:
For correct replacement of decal(s) compare the location illustrations to your machine before starting to
refinish the unit. Check-off each required decal using
the illustration reference number to find the part number, description and quantity in the list. Refer to the
appropriate illustration(s) for replacement location(s).
906213
906317
906214
906318
One Gal. Yellow
One Gal. Charcoal Grey
6 (12 oz. Spray Cans) Yellow
6 (12 oz. Spray Cans) Charcoal Grey
Decal Kits
L98860
Model 663
NOTE: Decals may be purchased in kits or individually.
PRINTED IN U.S.A.
51
907879/AP1198
12,13
C
7
8
A
14
B
11
8
15
1
3
10
9
2
3
(Frame)
6
5
4
3
(Frame)
DETAILS “A-C” SHOWN ON PAGE 54
DECAL LOCATIONS - LEFT SIDE OF MACHINE (EXCEPT DETAILS “A-C”)
REF.
NO.
DESCRIPTION
663
01
02
03
04
05
06
DANGER - ROTATING FAN (1 ea.)
GEHL 4.5” (1 ea.)
WARNING - PINCH POINT (3 ea.)
WARNING - JUMP START (1 ea.)
DYNALIFT, 2.0” (1 ea.)
AUTO TROL, When Used (1 ea.)
L659244
L65565
L65927
L65933
L66568
L66611
07
08
09
10
11
12
WARNING - NO RIDERS (1 ea.)
GREASE DAILY (1 ea.)
DYNATTACH, 1-1/8” (1 ea.)
DYNATTACH DIAGRAM (1 ea.)
GEHL, 8.0” (1 ea.)
HALF ZONE MARKER (5 ea.)
L65932
L65920
L66569
L65937
L66567
L62583
13
13
13
13
13
13
14
15
NO. “0” EXTENSION MARKER (1 ea.)
NO. “1” EXTENSION MARKER (1 ea.)
NO. “2” EXTENSION MARKER (1 ea.)
NO. “3” EXTENSION MARKER (1 ea.)
NO. “4” EXTENSION MARKER (1 ea.)
NO. “5” EXTENSION MARKER (1 ea.)
663 (1 ea.)
DANGER - PERSONNEL LIFT (1 ea.)
L67718
L67719
L67720
L67721
L67722
L67723
L66578
L65928
907879/AP1198
52
PRINTED IN U.S.A.
17
11
18
16
14
28
3
27
3
3
(Frame)
9
26
1
21,22
19
24
3
(Frame)
23
20
DECAL LOCATIONS - RIGHT SIDE OF MACHINE
REF.
NO.
DESCRIPTION
663
01
03
09
11
14
16
DANGER - ROTATING FAN (1 ea.)
WARNING - PINCH POINT (3 ea.)
DYNATTACH - 1-1/8” (1 ea.)
GEHL, 8.0” (1 ea.)
663 (1 ea.)
HYDRAULIC OIL FILL (1 ea.)
L65924
L65927
L66569
L66567
L66578
072794
17
18
19
20
21
22
COOLANT UNDER PRESSURE (1 ea.)
ANTI-FREEZE (2 ea.)
WARNING - NO RIDERS (1ea.)
HYDRAULIC OIL LEVEL (1 ea.)
FILTER CHART, Under Lid (1 ea.)
LUBE CHART, Under Lid (1 ea.)
072798
056859
L65932
L65921
L68083
L64931
23
24
26
27
28
DYNALIFT, 2.0” (1 ea.)
AUTO TROL, When Used (1 ea.)
DYNATTACH UNLOCK, RED STRIPE (1 ea.)
GEHL, 2.0” (1 ea.)
WARNING - CARRY LOAD LOW (1 ea.)
L66568
L66611
L66613
L66584
L65926
PRINTED IN U.S.A.
53
907879/AP1198
34
35
36
37
38
(INSIDE ROPS)
43
33
39
32
40
31
SIDE
CONTROL
DETAIL (A)
44
45
46
47
15
49
41
30
42
29
DASH
DETAIL (B)
INSIDE OPER. STATION
DETAIL (C)
DECAL LOCATIONS - DETAILS “A-C” IN OPERATOR STATION
REF.
NO.
DESCRIPTION
663
15
29
30
31
32
DANGER - PERSONNEL LIFT(1 ea.)
WARNING - OPERATOR (1 ea.)
STEER SELECT (1 ea.)
F-N-4 SHIFT (1 ea.)
GEHL, 2.0” DIA. (1 ea.)
L65928
L63690
L64814
L68295
L66584
33
34
35
36
37
HYDRAULIC PRESSURE SETTINGS (1 ea.)
WARNING - PARK BRAKE (1 ea.)
LOAD ZONES FLIP CHART SET (1 ea.)
ATTACHMENT CONTROL (1 ea.)
BOOM CONTROL (1 ea)
L64643
L65925
L66603
L65208
L64812
38
39
40
41
42
FRAME SWAY CONTROL (1 ea.)
MADE IN USA (1 ea.)
IGNITION/START/HORN (1 ea.)
WARNING - SEAT BELT (1 ea.)
OPERATOR MANUAL INSIDE (1 ea.)
L64810
094951
L68052
L65440
L65922
43
44
45
46
47
WARNING - CARRY LOAD LOW (1 ea.)
WARNING - MACHINE LEVEL (1 ea.)
DANGER - HIGH VOLTAGE (1 ea.)
DANGER - PANEL IN PLACE (1 ea.)
WARNING - TRUSS BOOM TILT (1 ea.)
093475
L65930
L65929
L65948
66042
907879/AP1198
54
PRINTED IN U.S.A.
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 recording the maintenance procedures performed. Recording the 10 Hour (or Daily) service intervals would be impractical and is therefore not recommended.
IMPORTANT: Under extreme operating conditions more frequent service than the recommended
intervals may be required. You must decide if your operation requires more frequent service.
MAINTENANCE INTERVAL CHART
SERVICE PROCEDURE
Every 10
Hours
(or Daily)
Check Fuel Tank Level
z
Check Fuel Filter (Drain Water If Required)
z
Check Engine Oil
z
Check Hydraulic Oil Level
z
Check Tire Pressures
z
Check Instruments Operation
z
Check General Machine Operation & Condition
z
Every 50
Hours
(or Weekly)
Every 100
Hours
z
Lubricate Weekly Grease Points
z
Check Axle Oil Levels
z
Check Air Filter Element
z
Change Fuel Filter
Check Wheel Nut Torque
Every 250
Hours
z1,2
Check Transmission Oil Level
z
Check Battery
z
Check Boom Leaf Chains & Torque
z
Change Engine Oil & Filter
z2
Change Hydraulic Oil & Filter
z2
z
1 - Only Until 450 Ft-Lbs (610 Nm) Is Maintained.
2 - Only New Machines.
PRINTED IN U.S.A.
55
907879/AP1198
MAINTENANCE INTERVAL CHART (CONT.)
SERVICE PROCEDURE
Every
250
Hours
Every
1000
Hours
Every
2000
Hours
z
Change Transmission Oil and Filter
Change Air Filter Element
z
Check Alternator & Fan Belt Tension
z
Check Boom 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
Check Hydraulic Reservoir Oil & Strainer
z
MAINTENANCE LOG
Date
907879/AP1198
Hours
Service Procedure
56
PRINTED IN U.S.A.
MAINTENANCE LOG
Date
PRINTED IN U.S.A.
Hours
Service Procedure
57
907879/AP1198
Index
A
Floor & Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Other Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . .23
Access To Components Chart . . . . . . . . . . . . . . . . . . . . 39
Cylinders
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Servicing
Adjustments
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
D
Slide Pads Clearance . . . . . . . . . . . . . . . . . . . . . . . .46
Wheel Lug Nuts Torque
. . . . . . . . . . . . . . . . . . . . . .42
Dealer Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Air Filter
Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Service Element . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Decals, applying new . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Alternator
Dimensions - See Chapter 2
Belt Service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Dynattach® System
Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Attach/Detach Mechanism . . . . . . . . . . . . . . . . . . . . .27
Anti-freeze - See Radiator
E
Attachment Tools
Electrical Components
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Characteristics - See Chapter 2
Operating Methods - See Chapter 6
Controls & Indicators - See Chapter 4
Axles
Servicing
Description - See Chapter 2
Greasing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Cold Weather Start Procedures . . . . . . . . . . . . . . . . .26
See Also Service
Description - See Chapter 2
Axle Oil
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Oil Pressure Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .20
Check Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Recommended Grades . . . . . . . . . . . . . . . . . . . . . . .35
Temperature Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .20
Change
Engine Oil
B
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,24
Check Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Battery
Recommended Grades . . . . . . . . . . . . . . . . . . . . . . .35
Charging Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Engine Oil Filter, replacing . . . . . . . . . . . . . . . . . . . . . . .44
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Exhaust System, check . . . . . . . . . . . . . . . . . . . . . . . . .48
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
F
Boom Travel
Function Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Fan Belt - See Alternator Belt
Function Indicators . . . . . . . . . . . . . . . . . . . . . . . . . .22
Frame Level - See Sway Control
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Fuel - See Separate Engine Manual
Fuel Filter
C
Check & Drain Water
Capacities - See Chapter 2
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Carriage Lifting Applications
Load Capacity & Reach
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
. . . . . . . . . . . . . . . . . . . . . .31
G
Load Carry, Elevation & Placement . . . . . . . . . . . . . .31
Grease Fittings
Checklists, delivery & pre-delivery . . . . . . . . . . . . . . . . . .7
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Controls,
Dash
. . . . . . . . . . . . . . . . . . . . . . . .40
Types Of Grease
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Guards
Right Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
907879/AP1198
58
. . . . . . . . . . . . . . . . . . . . . . . . . . .35
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
PRINTED IN U.S.A.
Grade & Slope Precautions . . . . . . . . . . . . . . . . . . . . . .29
Operator’s Station
Grade Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Environment Controls . . . . . . . . . . . . . . . . . . . . . . . .21
H
P
Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Park Brake
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Hydraulic Components, servicing . . . . . . . . . . . . . . . . . .38
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Hydraulic Oil
Change
Paint, refinish
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Check level
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Pump, Delivery Rates - See Chapter 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
R
Recommended type . . . . . . . . . . . . . . . . . . . . . . . . .35
Radiator
Hydraulic Maintenance
Oil Filters, replacing . . . . . . . . . . . . . . . . . . . . . . . . .47
Check coolant
Oil Sump Strainer, replacing . . . . . . . . . . . . . . . . . . .48
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Pressure Checks
. . . . . . . . . . . . . . . . . . . . . . . . . . .48
Flushing & Refilling . . . . . . . . . . . . . . . . . . . . . . . . . .47
Hydraulic Pump, servicing . . . . . . . . . . . . . . . . . . . . . . .38
Road Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Hydraulic Valves, servicing
. . . . . . . . . . . . . . . . . . . . . .38
S
I
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Schematics
Identification Reference . . . . . . . . . . . . . . . . . . . . . . . . . .3
Indicators
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Indicator Symbols . . . . . . . . . . . . . . . . .Inside Front Cover
Electrical
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Hydraulic
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Seat, operator’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Service Intervals
L
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
100 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Lubrication,
250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
See also Service
1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Shields
Side Mirror
M
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Specifications
Main Relief pressure check . . . . . . . . . . . . . . . . . . . . . .48
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Steering - See Controls
Maintenance
Steering Relief Pressure Check . . . . . . . . . . . . . . . . . . .48
Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Scheduled Intervals
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
. . . . . . . . . . . . . . . . . . . . . . . . .55
Suspended Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Mandatory SAFETY Shutdown Procedure . . . . . . . . .10
Sway Control & Indicator . . . . . . . . . . . . . . . . . . . . . . . .22
O
T
Oils - See Lubrication
Tables
Operation
Load Handling
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Paint Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Replacement Filters . . . . . . . . . . . . . . . . . . . . . . . . . .36
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Theft Deterrents
Symbols . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover
Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Operator Manual, storing . . . . . . . . . . . . . . . . . . . . . . . . .2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Operator Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
PRINTED IN U.S.A.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
59
907879/AP1198
Traffic Flow Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Transmission
Description - See Chapter 2
Temperature Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .20
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 Wiper/Washer Switch . . . . . . . . . . . . . . . . . .21
907879/AP1098
60
PRINTED IN U.S.A.
Notes
PRINTED IN U.S.A.
61
907879/AP1198
663 Electrical Schematic
(J.D. Engine)
907879/AP1198
62
PRINTED IN U.S.A.
663 Electrical Schematic
(Perkins Engine)
PRINTED IN U.S.A.
63
907879/AP1198
663 Hydraulic Schematic
A
907879/AP1198
64
PRINTED IN U.S.A.
663 Hydraulic Schematic
A
PRINTED IN U.S.A.
65
907879/AP1198
Torque Specifications
Use these torque values when tightening GEHL hardware (excluding: Locknuts and Self-tapping, Thread-forming and Metal
Screws) unless otherwise specified.
Unified National
Thread
Grade 5
Grade 2
Dry
8-32
8-36
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14
1-8
1-14
19*
20*
27*
31*
66*
76*
11
12
20
23
32
36
35
40
55
60
75
85
130
150
125
140
190
210
Metric Course
Thread
Grade 8.8
M6-1
24M8-1.25
M10-1.5
M12-1.75
M14-2
M16-2
8
19
37.5
65
103.5
158.5
Dry
Grade 8
Lubed
Dry
Lubed
14*
15*
21*
23*
50*
56*
9
9
15
17
24
27
35
40
55
60
75
85
130
150
125
140
190
210
30*
31*
43*
49*
9
10
17
19
30
35
50
55
75
90
110
120
150
180
260
300
430
470
640
710
22*
23*
32*
36*
75*
86*
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
360
480
530
Grade 10.9
Lubed
Dry
6
14
28
48
76.5
117.5
11
27
53
91.5
145.5
223.5
Dry
Lubed
41*
43*
60*
68*
12
14
25
25
45
50
70
80
110
120
150
170
220
240
380
420
600
660
900
1000
31*
32*
45*
51*
9
10
18
20
35
35
55
60
80
90
110
130
170
180
280
320
460
500
680
740
Grade 12.9
Lubed
7
20
39
67.5
108
165.5
Dry
Lubed
13.5
32.5
64
111.5
176.5
271
10*
24*
47
82
131
200
* All torque values are in lb-ft except those marked with an * which are in lb-in.
For metric torque value (Nm) muiltiply lb-ft x 1.355 or lb-in value x 0.113.
907879/AP1198
66
PRINTED IN U.S.A.
Load Zone Charts
663
663
Standard Carriage
1 Cu. Yd. Bucket
663
663
Rotating Carriage
12 Ft. Truss Boom
PRINTED IN U.S.A.
67
907879/AP1198
Load Zone Charts
663
Winch Boom
907879/AP1198
68
PRINTED IN U.S.A.
GEHL®
NEW CONSTRUCTION EQUIPMENT
663 DYNALIFT®
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 workmanship for a period of twelve (12) months from the Warranty Start Date.
GEHL CONSTRUCTION WARRANTY SERVICE INCLUDES:
Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer’s
business location.
GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND,
EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE),
EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT.
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 equipment.
3. Components covered by their own non-Gehl warranties, such as tires, trade accessories and
engines.
4. Normal maintenance service and expendable, high-wear items.
5. Repairs or adjustments caused by: improper use; failure to follow recommended maintenance
procedures; use of unauthorized attachments; accident or other casualty.
6. Liability for incidental or consequential damages of any type, including, but not limited to lost profits and expenses of acquiring replacement equipment.
No agent, employee or representative of GEHL has any authority to bind GEHL to any warranty except as specifically set forth herein. Any of these limitations excluded by local law shall be deemed deleted from this warranty;
all other terms will continue to apply.
THIS OPERATOR’S MANUAL IS
PROVIDED FOR OPERATOR USE
DO NOT REMOVE
FROM THIS MACHINE
THANK YOU
DO NOT START, OPERATE OR WORK ON THIS MACHINE UNTIL YOU HAVE CAREFULLY READ AND THOROUGHLY UNDERSTAND THE CONTENTS OF THE OPERATOR’S MANUAL.
FAILURE TO FOLLOW SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS
COULD RESULT IN SERIOUS INJURY TO THE OPERATOR OR BYSTANDERS, POOR
OPERATION, AND COSTLY BREAKDOWN.
IF YOU HAVE ANY QUESTIONS ON PROPER OPERATION, ADJUSTMENT OR MAINTENANCE OF THIS MACHINE, CONTACT YOUR DEALER OR THE SERVICE DEPARTMENT OF GEHL COMPANY BEFORE STARTING OR CONTINUING OPERATION.
CALIFORNIA
Proposition 65 Warning
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
All Rights Reserved
Printed In USA
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