Gehl 552 553 Dynalift Telescopic Boom Forklift Parts Manual

Form No. 908459 PARTS MANUAL 552/553 Dynalift ® Telescopic Boom Forklift

Introduction 552/553 Dynalift 553 J U 01 3822 Model Unit Number Engine Month Year (U=03, V=04, W=05, etc.) The table of contents pages show the page location of various component groups on the machine. When ordering service parts, specify the correct part number, full description, quantity required, and the unit model and serial number. Model and serial numbers for this unit are stamped on a plate located inside the operator’s station. The serial number is also stamped on the top front frame. The following reference shows the breakdown of the serial number: “Right” and “left” are determined from a position sit- ting on the seat and facing forward. Gehl Company reserves the right to make changes or improvements in the design or construction of any part of the unit without incurring the obligation to install such changes on any unit previously delivered. NOTE: On original tire replacement, Company policy prohibits the sale of replacement tires for all Gehl machinery. Replacement wheel sets are available and tire size information is called out with the wheel sets to facilitate replacement tire selection. ALL REPLACEMENT TIRES MUST BE PURCHASED LOCALLY. Grease fittings and common attaching hardware, such as cotter pins, set screws, woodruff keys, screws, nuts, etc., are included in the parts list, indented below the part it is (they are) associated with, but may NOT be illustrated, except where a particular routing or special fastening arrangement MUST be maintained. The hardware listed is for mounting purposes and is NOT included when the part is ordered for replacement. Part numbers for standard hardware are listed indented under the component being fastened. A complete listing of part numbers for attaching washers/nuts used on this machine is included in the table on the facing page. Refer to the abbreviations list on the facing page for descriptions. Standard attaching hardware torque values are provided on the inside back cover. Unless otherwise speci- fied, all cap screws are Grade 5, cadmium or zinc plat- ed; hexagon nuts for Grade 5 cap screws or bolts are Grade A.

PRINTED IN U.S.A. 1 908459/AP0603 552/553 Dynalift Introduction List of Abbreviations Used in this Manual AN Acorn Nut AR As Required ASY Assembly BHB Button Head Bolt CB Carriage Bolt CN Castellated Nut CYL Cylinder CS Cap Screw (Hexagon Head) DIA Diameter FHMS Flat Head Machine FLN Flanged Flexlock Nut FLS Flanged Lock Screw FT Foot or Feet GR Grade HLN Hexlock Nut HYD Hydraulic JN Jam Nut L Lock (Washer) LH Left Hand LT Left N Nut (Plain Hex) NIN Nylon Insert Lock Nut NPTF National Pipe Threaded Fitting P Plain (Washer) PB Plow Bolt PHS Pan Head Screw RH Right Hand RHMS Round Head Machine Screw RHSMS Round Head Sheet Metal Screw RNF Retained Nut Fastener RT Right SHCS Socket Head Cap Screw SHSS Socket Head Set Screw SFN Serrated Flange Nut SHSS Square Head Set Screw STS Self-Thread Screw Hex. Washer Head THMS Truss-Head Machine Screw TRS Thread Roll Screw W/ With WN Wing Nut FILTER REFERENCE TYPE PART NUMBER Engine Oil 552; w/JD Engine S/N 1021 & Up . . . . . . . . . . . L99420 553; w/JD Nat.Eng. S/N 3917 & Up 553; w/JD Turbo Eng S/N 3630 & Up 552; w/JD Engine Thru S/N 1020. . . . . . . . . . . . L99476 553; w/JD Nat. Eng Thru S/N 3916 553; w/JD Turbo Eng Thru S/N 3629 With Perkins Engine. . . . . . . . . . . . . . . . . . . . . . L98601 Engine Fuel 552; w/JD Engine S/N 1011 & Up . . . . . . . . . . . L99978 553; w/JD Engine S/N 3127 & Up 552; w/JD Engine Thru S/N 1010. . . . . . . . . . . . L98600 553; w/JD Engine Thru S/N 3126 With Perkins Engine . . . . . . . . . . . . . . . . . . . . . L98602 Engine Air . . . . . . . . . . . . . . . . . . . L120054 Transmission Oil . . . . . . . . . . . . . . . . . . . . L99184 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . L97489 Size & Part No. Size & Part No. Description Description #10-32 N L50050 1/4 L L50139 1/4-20 NIN L520003 1/4 P L50137 1/4-20 SFN L50051 5/16 L L50143 5/16-18 N L50230 5/16-18 NIN L520004 5/16 P L50141 5/16-18 RNF L530004 5/16-18 SFN L50056 3/8-16 L L50147 3/8-16 N L50066 3/8-16 NIN L520005 3/8-16 P L50145 3/8-16 SFN L50061 3/8-16 WN L530003 7/16 L L50150 7/16-14 NIN L50517 7/16 P L50149 1/2-13 NIN L520019 1/2 P L50151 5/8 L L50156 5/8-11 N L50081 3/4-10 N L50086 3/4-10 NIN L50519 3/4 P L50147 1-8 JN L50145 TABLE OF STANDARD WASHERS, NUTS

908459/AP0603 2 PRINTED IN U.S.A. Page INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Filter Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 DECALS General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 New Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 OPERATOR STATION Safety Guards, Windows and Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Front and Rear Windows (552: S/N 1015 and Up ; 553: S/N 3368 and Up) . . . . . . . . . . . . . . . . . . .14 Front and Rear Windows (552: Thru S/N 1014; 553: Thru S/N 3367) . . . . . . . . . . . . . . . . . . . . . . .16 Windshield Wipers / Top and Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Side Door and Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Cab Mounts and Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Steering Column Group (552: S/N 1057 and Up; 553: S/N 4519 and Up) . . . . . . . . . . . . . . . . . . . .24 Steering Column Group (552: Thru S/N 1056; 553: Thru S/N 4518) . . . . . . . . . . . . . . . . . . . . . . . .26 Seat Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Top Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Under Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Accelerator and Brake Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Heater (No Air Conditioning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Air Conditioning Group (w/Heater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 CHASSIS Frame Hoods and Covers (552: S/N 1015 and Up; 553: S/N 3340 and Up) . . . . . . . . . . . . . . . . . . .40 Frame Hoods and Covers (552: Thru S/N 1014; 553: Thru S/N 3339) . . . . . . . . . . . . . . . . . . . . . . .42 Hydraulic and Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Battery Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 ENGINE External Engine Components Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Radiator and Cooler Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Engine Air Intake Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Engine Exhaust Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 TRANSMISSION External Transmission and Drive Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Table of Contents 552/553 Dynalift

PRINTED IN U.S.A. 3 908459/AP0603 Page AXLES External Components Group (552: S/N 1075 and Up; 553: S/N 4832 and Up) . . . . . . . . . . . . . . . . .62 External Components Group (552: Thru S/N 1074; 553: Thru S/N 4831) . . . . . . . . . . . . . . . . . . . . .64 Outer End Group (552: S/N 1075 and Up; 553: S/N 4832 and Up) . . . . . . . . . . . . . . . . . . . . . . . . .66 Outer End Group - Part I (552: Thru S/N 1074; 553: Thru S/N 4831) . . . . . . . . . . . . . . . . . . . . . . .68 Outer End Group - Part II (552: Thru S/N 1074; 553: Thru S/N 4831) . . . . . . . . . . . . . . . . . . . . . .70 Differential Housing Group (552: S/N 1075 and Up; 553: S/N 4832 and Up) . . . . . . . . . . . . . . . . .72 Differential Group (552: S/N 1075 and Up; 553: S/N 4832 and Up) . . . . . . . . . . . . . . . . . . . . . . . .74 Differential Housing Group - Part I (552: Thru S/N 1074; 553: Thru S/N 4831) . . . . . . . . . . . . . . .76 Differential Housing Group - Part II (552: Thru S/N 1074; 553: Thru S/N 4831) . . . . . . . . . . . . . .78 Differential Housing Group - Part III (552: Thru S/N 1074; 553: Thru S/N 4831) . . . . . . . . . . . . . .80 Brake Group (552: S/N 1075 and Up; 553: S/N 4832 and Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Brake Group (552: Thru S/N 1074; 553: Thru S/N 4831) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 BOOM 552-Outer Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 552-Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 553-Outer Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 553-Intermediate Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 553-Inner Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Dynattach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 HYDRAULIC SYSTEMS Hydraulic Pump, Tank and Flow Divider (552: S/N 1057 and Up; 553: S/N 4519 and Up) . . . . . . .98 Hydraulic Pump, Tank and Priority (552: Thru S/N 1056; 553: Thru S/N 4518) . . . . . . . . . . . . . . .100 Steer Motor and Steer Select Valve (552: S/N 1057 and Up; 553: S/N 4519 and Up) . . . . . . . . . . .102 Steer Motor and Steer Select Valve (552: Thru S/N 1056; 553: Thru S/N 4518) . . . . . . . . . . . . . . .104 Main Valve Group (552: S/N 1057 and Up; 553: S/N 4519 and Up) . . . . . . . . . . . . . . . . . . . . . . .106 Main Valve Group (552: Thru S/N 1056; 553: Thru S/N 4518) . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Joystick Group (552: S/N 1057 and Up; 553: S/N 4519 and Up) . . . . . . . . . . . . . . . . . . . . . . . . . .110 Joystick Group (552: Thru S/N 1056; 553: Thru S/N 4518) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Frame Level Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Lift Cylinder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Tilt / Slave Cylinder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Boom Extend Cylinder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Auxilary Hydraulics Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 HYDRAULIC COMPONENTS Hydraulic Pump Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 Flow Divider Breakdown (552: S/N 1057 and Up; 553: S/N 4519 and Up) . . . . . . . . . . . . . . . . . .125 Main Valve Hyd. Breakdown (552: S/N 1057 and Up; 553: S/N 4519 and Up) . . . . . . . . . . . . . . .126 Main Valve Breakdown (552: Thru S/N 1056; 553: Thru S/N 4518) . . . . . . . . . . . . . . . . . . . . . . .128 Priority Valve/Flow Divider Breakdown (552: Thru S/N 1056; 553: Thru S/N 4518) . . . . . . . . . . .129 (Continued on next page) 552/553 Dynalift Table of Contents

908459/AP0603 4 PRINTED IN U.S.A. Table of Contents 552/553 Dynalift Page HYDRAULIC COMPONENTS (CONTINUED) Frame Level Valve Breakdown (552: Thru S/N 1056; 553: Thru S/N 4518) . . . . . . . . . . . . . . . . . .130 Auxilary Hydraulics Work Section Breakdown (552: S/N 1057 and Up; 553: S/N 4519 and Up) . .126 Auxilary Hydraulics Valve Breakdown (552: Thru S/N 1056; 553: Thru S/N 4518) . . . . . . . . . . . .131 Steer Cylinders Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 Steer Valve Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 Steer Motor Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Brake Valve Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 Joystick Breakdown (552: S/N 1057 and Up; 553: S/N 4519 and Up) . . . . . . . . . . . . . . . . . . . . . .136 Auxilary Hydraulic Joystick Breakdown (552: S/N 1057 and Up; 553: S/N 4519 and Up) . . . . . . .138 Joystick Breakdown (552: Thru S/N 1056; 553: Thru S/N 4518) . . . . . . . . . . . . . . . . . . . . . . . . . .140 Auxilary Hydraulic Joystick Breakdown (552: Thru S/N 1056; 553: Thru S/N 4518) . . . . . . . . . .142 Dual Relief Valve Breakdown (552: S/N 1042 and Up; 553: S/N 4207 and Up) . . . . . . . . . . . . . . .144 Dual Relief Valve Breakdown (552: Thru S/N 1041; 553: Thru S/N 4206) . . . . . . . . . . . . . . . . . . .145 Frame Level Cylinder Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 Lift Cylinder Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148 Slave Cylinder Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 Tilt Cylinder Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 Boom Extend Cylinder Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 Fork Shift Carriage Cylinder Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156 Rotate Carriage Cylinder Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157 ATTACHMENTS Standard Carriage Attachment Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158 Shift Fork Carriage Attachment Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 Rotate Carriage Attachment Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162 Boom Attachment Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164 Bucket Attachment Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166 NUMERICAL INDEX Numerical Index List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

PRINTED IN U.S.A. 5 908459/AP0603 552/553 Dynalift Notes

908459/AP0603 6 PRINTED IN U.S.A. Decals 552/553 Dynalift GENERAL INFORMATION 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. 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). NEW DECAL APPLICATION 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. CAUTION ALWAYS read and follow the safety precau- tions on decals. Replace decals if they are damaged, or if the unit is repainted. If repaint- ing, BE SURE that all applicable decals are affixed in their proper locations. 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. PAINT FINISH Use this list to order paint for refinishing: 552: Thru S/N 1007; 553: Thru S/N 3062: 903891 6-12 oz Industrial Yellow 906317 6-12 oz Black 552: S/N 1008 & Up; 553: S/N 3063 & Up: 906213 One Gal. Yellow 906317 One Gal. Charcoal Grey 906323 One Qt. Charcoal Grey 906214 6 (12 oz. Spray Cans) Yellow 906318 6 (12 oz. Spray Cans) Charcoal Grey Decal Kits L98556 thru S/N 1007 Model 552 L98863 S/N 1008 & up Model 552 L98557 thru S/N 3062 Model 553 L98864 S/N 3063 & up Model 553 NOTE: Decals may be purchased in kits or individually.

PRINTED IN U.S.A. 7 908459/AP0603 REF. DESCRIPTION 552 553 NO. 01 DANGER - ROTATING FAN L65924 L65924 02 DYNALIFT L66568 L66568 03 552 L66585 --- 03 553 --- L66581 04 WARNING - PINCH POINT L65927 L65927 05 GEHL 6.38” 122288 122288 06 DYNATTACH 1-1/2” L66569 L66569 07 WARNING - HOT SURFACE L65942 L65942 08 WARNING - NO RIDERS L65932 L65932 09 GEHL 2” L66584 L66584 10 DYNATTACH UNLOCK RED STRIPE L66613 L66613 11 DANGER - PERSONNEL L65928 L65928 12 GREASE DAILY L65920 L65920 DECAL LOCATIONS - RIGHT SIDE OF MACHINE 1 4 8 2 10 6 4 11 9 3 5 7 4 12 552/553 Dynalift Decals

908459/AP0603 8 PRINTED IN U.S.A. REF. DESCRIPTION 552 553 NO. 01 DANGER - ROTATING FAN L99863 L98864 02 GEHL 4.5” L66565 L66565 03 DYNALIFT L66568 L66568 04 552 L66585 --- 04 553 --- L66581 05 WARNING - PINCH POINT L65927 L65927 06 WARNING - NO RIDERS 122288 122288 07 WARNING - JUMP START L65933 L65933 08 GEHL 6.38” L65932 L65932 09 BRAKE FLUID LEVEL L63474 L63474 10 OPERATOR MANUAL INSIDE L65922 L65922 DECAL LOCATIONS - LEFT SIDE OF MACHINE 8 4 6 3 7 1 2 9 5 10 Decals 552/553 Dynalift

Gehl 552 553 Dynalift Telescopic Boom Forklift Parts Manual

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