GEHL 1648 Asphalt Paver Parts Manual

1648 Asphalt Paver Beginning with Serial Number 13101 ® Form No. 918217 PARTS MANUAL Revision B 02/09

INTRODUCTION When ordering service parts, specify the correct part number, full description, quantity required, the unit model number and serial number. For your safety and continued proper operation, use only genuine GEHL service parts. The model and serial number for this unit are on a tag located on the paver control panel. ''Right'' and ''left'' are determined from a position sitting 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 previously delivered units. If grease fittings and common attaching hardware, such as cotter pins, set screws, woodruff keys, screws, nuts, etc., are not illustrated, they may be in the parts list indented below the part they are associated with. The hardware listed is for mounting purposes and is NOT included when the part is ordered for replacement. Standard attaching hardware torque values are provided at the back of this manual. Unless otherwise specified, all capscrews are Grade 5, cadmium or zinc plated; hexagon nuts for Grade 5 capscrews and bolts are Grade A. An hydraulic O-ring sizing chart is alos provided on the inside cover of this manual. The numbers shown in the parts page headers are Engineering tracking numbers only and should not be used for parts ordering purposes. NOTE: The following abbreviations may be used herein: ASSD...................... Assembled ASY ........................ Assembly ASSY...................... Assembly AR .......................... As Required CB .......................... Carriage Bolt CP ........................... Cotter Pin CS ........................... Cap Screw (Hexagon Head) CYL ........................ Cylinder DIA......................... Diameter FHCS ...................... Flat Head Cap Screw FT ........................... Foot or Feet GR .......................... Grade HB .......................... Hex Bolt HLN........................ Hex Lock Nut HN .......................... Hex Nut HP ........................... High Pressure HYD ....................... Hydraulic INS ......................... Insert LH .......................... Left Hand LN .......................... Lock Nut LT ........................... Left LW .......................... Lock Washer M ............................ Metric MM/mm ................. Millimeter NPT ........................ National Pipe Threaded NSS ........................ Not Sold Separately RH .......................... Right Hand RT ........................... Right SHCS ...................... Socket Head Cap Screw SLTD ...................... Slotted SN........................... Serial Number or Slotted Nut SQ........................... Square W/ ........................... With

Printed in U.S.A 1 918217/BP0209 TABLE OF CONTENTS Introduction .........................................................i Table of Contents ............................................... 1 Decal Locations .................................................. 4 General ............................................................... 7 Filters ........................................................... 7 Chassis ................................................................ 8 430030 - Main Screed .................................. 8 430032 - Pullarms ...................................... 10 430021 - Screed Extensions without Augers11 430030 - Screed Extensions with Augers ........................................................ 12 430042 - Flow Gate without Augers.......... 14 430015 - Flow Gate with Augers ............... 15 Screed Cutoff Option ................................. 16 430342 - Propane Kit ................................. 17 430019 - Spraydown Tank ......................... 18 430339 - Fuel System ................................ 19 430013 - Hopper ........................................ 20 430336 - Wings / Side Gates ..................... 21 430335 - Chassis / Backwall ...................... 22 430343 - Covers ......................................... 23 430012 - Track ........................................... 24 430350 - Hydrostatic Pump Linkage ......... 25 430337 - Engine ......................................... 26 Yanmar Engine ................................................. 28 Model 4TNV88-BDGP - Cylinder Block (SN 13208 and up) .......................................... 28 Model 4TNV88-XGP - Cylinder Block (SN 13207 and before).................................... 30 Model 4TNV88-BDGP - Gear Housing (SN 13208 and up) .......................................... 32 Model 4TNV88-XGP - Gear Housing (SN 13207 and before).................................... 34 Models 4TNV88-BDGP/4TNV88-XGP - Flywheel Housing and Oil Sump ............ 36 Models 4TNV88-BDGP/4TNV88-XGP - Cylinder Head and Cover ........................ 38 Model 4TNV88-BDGP - Intake Manifold (SN 13208 and up) .......................................... 40 Model 4TNV88-XGP - Intake Manifold (SN 13207 and before).................................... 41 Model 4TNV88-BDGP - Camshaft and Driving Gear (SN 13208 and up).......................... 42 Model 4TNV88-XGP - Camshaft and Driving Gear (SN 13207 and before) ................... 43 Models 4TNV88-BDGP/4TNV88-XGP - Crankshaft and Piston.............................. 44 Model 4TNV88-BDGP - Lub. Oil System (SN 13208 and up) .......................................... 46 Model 4TNV88-XGP - Lub. Oil System (SN 13207 and before) ................................... 48 Models 4TNV88-BDGP/4TNV88-XGP - Cooling System....................................... 50 Models 4TNV88-BDGP/4TNV88-XGP - Exhaust Manifold.................................... 52 Models 4TNV88-BDGP/4TNV88-XGP - Fuel Injection Pump ........................................ 53 Models 4TNV88-BDGP/4TNV88-XGP - Fuel Injection Valve........................................ 54 Models 4TNV88-BDGP/4TNV88-XGP - Fuel Line ......................................................... 56 Models 4TNV88-BDGP/4TNV88-XGP - Governor ................................................. 58 Models 4TNV88-BDGP/4TNV88-XGP Starter 59 Models 4TNV88-BDGP/4TNV88-XGP Generator ................................................ 60 430337 - Engine Exhaust / Air Inlet .......... 61 Hydraulics ........................................................ 62 Main Hydraulics ........................................ 62 Track Drive................................................ 64 Screed Lift and Vibrator ............................ 66 Screed Extension ....................................... 67 Hopper ....................................................... 68 Gate ........................................................... 69 Auger Motors on Screed............................ 70 Auger Motors on Gate ............................... 72 Electrical .......................................................... 73 430340 - Electrical Components ............... 73 Component Detail ............................................ 74 P473265 - Screed Extend Cylinder ........... 74 P471225 - Side Gate Cylinder ................... 75 100893 - Hopper Lift Cylinder .................. 76 P480118 - Track Tension Cylinder ........... 77 100713 - Gate Cylinder ............................. 78 101355 - Screed Lift Cylinder ................... 79 P473287 - Hydraulic Pump - Front (Piston) Section ....................................... 80 P700552 - Hydraulic Pump - Rear (Gear) Section......................................... 82 P271900 - Torque Hub .............................. 84 P480071 - Auger Drive Motor .................. 86 P349450 - Screed Vibrator Motor ............. 87 101282 - Track Drive Control Valve ........ 88 101280 - 7- Stack Control Valve with Relief90 101281 - Auger Control Valve .................. 92 Index ................................................................ 95 Numerical Index............................................... 97

918217/BP0209 4 Printed in U.S.A DECAL LOCATIONS GENERAL INFORMATION Decal location information is provided to assist in the proper selection and application of new decals, in the event the original decals become damaged or the machine is repainted. Refer to the listing for the illustration reference number, part number, description and quantity of each decal provided in the kit. Refer to the appropriate illustrations for replacement locations. To ensure proper selection of the correct replacement decals, compare all of the various close-up location drawings to your machine before starting to refinish the unit. Then circle each decal shown (applicable to your machine) while checking off its part number in the listing. After you have verified all the decals needed for replacement, place any extra unnecessary decals aside for disposal. NOTE: Refer to the SAFETY chapter of this Operator's Manual for the specific information provided on all of the various safety decals furnished in the decal kit. If there is any part being replaced that has a safety decal applied to it, be sure that the replacement part has the decal applied to it as well. NEW DECAL APPLICATION Surfaces MUST be free from dirt, dust, grease and other foreign material before applying the new decal. To apply, 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. Peel the other portion of the backing paper off slowly while applying hand pressure to smooth out the decal surface. CAUTION ALWAYS follow safety precautions on decals. Replace the decals if they are damaged, or if the unit is repainted. If repainting, BE SURE all applicable decals are affixed to your unit. The decal kit for the model 1648 Paver is listed below: PAINT NOTICE Use this list to order paint for refinishing: 167788 4 qts. Construction Yellow (GEHL) 167758 4 qts. Charcoal Gray (GEHL) 167789 6 (12.8 oz. Spray Cans) Yellow (GEHL) 167760 6 (12.8 oz. Spray Cans) Charcoal Gray (GEHL) Ref. No. Part No. Description & Quantity 176063 Decal Kit - 1648 Plus 1 072798 WARNING - Coolant Under Pressure 2 184306 Gehl 4.75 X 20.16 (2 Places) 3 101115 Drive Control 4 101116 7 Stack Valve 5 101118 Auger Control 6 101119 5 Position Rt 7 101481 "Powerbox" corp gray (2 Places) 8 175774 Gauge Panel 9 L65924 DANGER - Rotating Components 10 175862 1648 Maintenance 11 175806 Pump Control 12 175805 Filter Reference 13 P480087 Depth Adj (2 Places) 14 P473204 1648 Pressure Test 15 P471816 Asphalt Release 16 P210200 Safety Prop (2 Places) 17 P207300 On/Off (2 Places) 18 P204101 WARNING - Tip-Over Hazard 19 P204100 WARNING 20 L65942 WARNING - Hot Surface 21 L65927 WARNING - Pinch Point (7 Places) 22 101986 Steer Valve 23 137628 WARNING - Read Manual 24 137632 Hydraulic Oil 26 137634 Diesel Fuel 27 137660 Ether 28 137661 Tie Down (3 Places) 29 140516 Flag 30 175900 1648 Right 175932 1648 Left (not shown) 31 195775 Fuel Sulfur

Printed in U.S.A 5 918217/BP0209 DECAL LOCATIONS 18 4 3 11 26 10 12 27 8 15 23 9 19 5 14 20 6 1 21 2 30 7 17 29 28 13 22 24 16 28 31

918217/BP0209 6 Printed in U.S.A NOTES

Printed in U.S.A 7 918217/BP0209 1648 - GENERAL FILTERS Ref. No. Part No. Description Qty. 1 195568 ENGINE OIL FILTER 1 2 186340 WATER SEPARATOR FILTER 1 3 203888 FUEL FILTER 1 4 420-36075 AIR CLEANER ELEMENT 1 5 128299 STRAINER/W/BY PASS 1 6 074830 HYDRAULIC OIL FILTER 2 1 Engine Oil Filter Air Cleaner Filter Hydraulic Reservoir Sump Filter Hydraulic System Filter Engine Fuel Filter Fuel/Water Separator Filter 2 3 4 5 6

918217/BP0209 8 Printed in U.S.A 1648 - CHASSIS 430030 - MAIN SCREED 16 16 9 9 9 9 16 36 13 13 16 32 40 26 14 19 3 34 53 52 47 46 45 46 21 21 46 47 43 42 41 35 46 45 33 11 19 33 19 19 3 11 26 40 31 14 10 49 48 49 48 8 15 25 49 49 42 42 18 38 50 49 47 48 19 19 12 7 5 6 12 5 37 1 37 20 22 37 1 37 23 47 39 39 17 30 2 28 4 27 17 29 17 29 39 39 23 24 47 43 43 47 43 43 43 17 30 47 43 42 43 55 56 56 54 42 42 42 41 43 42 43 43 43 42

Printed in U.S.A 9 918217/BP0209 1648 - CHASSIS 430030 - MAIN SCREED Ref. No. Part No. Description Qty. 1 100930 CHAIN / SCREED LIFT 2 2 P473278 CHAIN 1 3 P473265 CYLINDER / SCREED EXTEND (SEE PAGE 74 FOR DETAIL) 2 4 P472251 WRENCH / RACHET 1 5 P471297 PIN / CYLINDER END 2 6 P471084 SPACER / SCREED CYLINDER 1 7 101355 CYLINDER / SCREED LIFT (SEE PAGE 79 FOR DETAIL) 1 8 P349450 MOTOR / VIBRATOR (SEE PAGE 87 FOR DETAIL) 1 9 P272700 ISOLATOR / BUMPER 4 10 L60253 ADPTR / STRAIGHT 2 11 L50962 CLAMP / 1-3/4” 2 12 655024 COTTER PIN / 3/16 X 2 4 13 654030 LOCK WASHER 1/2” 4 14 653116 HJN 1 F2ZY 2 15 650818 BOLT / 3/8 X 3 4 16 650494 BOLT / 1/2 X 1 4 17 650416 BOLT / 3/4 X 2-1/2 4 18 650201 SHSS CP 5/16 X 5/16 1 19 110227 ADPTR / 90DEG 6 20 101161 WRENCH HOLDER 1 21 100978 TOP PLATFORM 2 22 100865 CHAIN CLEVIS ANCHOR 1 23 100864 TORCH BOX 2 24 100863 MIDSCREED FLOOR COVER 1 25 100862 VIBRATOR MOUNT 1 26 100861 PLATFORM HINGE PIN 2 27 101272 CROWN ADJUST, LARGE 1 28 101271 CROWN ADJUST, SMALL 1 29 100849 LEFT BALL JOINT 2 30 100847 RIGHT BALL JOINT 2 31 100830 RIGHT PLATFORM 1 32 100828 LEFT PLATFORM 1 33 100816 SCREED EXHAUST TUBE 2 34 101981 LEFT SCREED 1 35 101980 RIGHT SCREED 1 36 101977 WEAR PLATE 1 37 100592 CLEVIS / DOUBLE LINK 4 38 100504 VIBRATOR COUNTERWEIGHT 1 39 079209 LOCK NUT / 3/4” 4 40 040775 SPRING PIN / .25X1.25 2 41 101228 SCREED ALIGNMENT BAR 2 42 650491 BOLT / 3/8 X 1-1/4 18 43 654026 LOCK WASHER / 3/8 22 45 650495 CS 1/2X1-1/4 C5ZY 8 46 654030 LW 1/2 RZY 8 47 650490 CS 3/8X1 C5ZY 16 48 654006 3/8 / FLAT WASHER 6 49 L520022 FLEXLOCK NUT 3/8-16 20 50 175275 GUARD/RUBBER 1 52 176434 MOUNTING CHANNEL 1 53 L62459 HOLDER/MANUAL PLASTIC 1 54 L50208 SCREW / HX HEAD .25-20 X .50 4 55 072916 CS FL LOCK 1/4 X 3/4 C5ZY 4 56 070634 LN LG. FL. SERR. 1/4 CZ 4 Ref. No. Part No. Description Qty.

918217/BP0209 10 Printed in U.S.A 1648 - CHASSIS 430032 - PULLARMS Ref. No. Part No. Description Qty. 1 067847 LOCK NUT 3/8” 2 2 071706 LOCK NUT 1/2” 4 3 100772 LEFT PULLARM (Augers on flow gates) 1 100917 LEFT PULLARM (Augers on screed) 1 4 100780 RIGHT PULLARM (Augers on flow gates) 1 100915 RIGHT PULLARM (Augers on screed) 1 5 100782 PIN, PULLARM 4 6 100783 DEPTH INDICATOR 2 7 100784 PULLARM SWIVEL 2 8 100866 SCREED ADJUST ROD 2 9 100891 ADJUST BALL JOINT 2 10 101103 ADJUSTER HANDLE 2 11 124976 BOLT, 1-8X6” 2 12 650490 BOLT, 3/8-16X1 4 13 650528 BOLT, 3/8-16X2 2 14 650809 BOLT, 5/16-18X7/8 4 15 654024 LOCK WASHER, 5/16” 4 16 L50109 NUT, STOVER 1-8 2 17 L68048 SPRING BUSHING 2 18 L69597 SPINNER KNOB 2 19 P472066 SCREED ADJUST BEARING 2 20 P472798 ROD END 4 21 P472101 BALL JOINT ONLY 1 Ref. No. Part No. Description Qty. 1 19 8 3/4 11 7 17 16 6 2 9 2 5 20 15 14 14 20 15 5 13 12 18 10 21

GEHL 1648 Asphalt Paver Parts Manual

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