Gehl 883 Dynalift Telescopic Forklift Parts Manual

SERVICE PARTS Form No. 907365 Replaces 906147 883 Dynalift  Telescopic Forklift

Introduction 883 Dynalift The table of contents page shows 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 standing behind the unit and facing the direction of travel. 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 NOT illustrat- ed, except where a particular routing or special fas- tening arrangement MUST be maintained. 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 on the inside Back Cover. Unless otherwise specified, all cap screws are Grade 5, cadmium or zinc plated; hexagon nuts for Grade 5 cap screws or bolts are Grade A. List of Abbreviations Used in this Manual AR As Required ASY Assembly CYL Cylinder DIA Diameter FT Foot or Feet GR Grade HYD Hydraulic LH Left Hand LT Left NPTF National Pipe Threaded Fitting NSS Not Sold Separately RH Right Hand RT Right W/ With 883 J P 01 7378 Model Unit Number Engine Month Year (N=97, P=98, Q=99, etc.)

883 Dynalift Table of Contents Page Page Introduction . . . . . . . . . . . . . . . . . . . .Inside Front Cover Table Of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Chassis, Tanks & Covers Section Operator’s Station Outside Area & Inner Panels . . . . . . . . . . . . . . . . .14 Dash Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Floor Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Fuel Tank/Front Inner Frame Area Group . . . . . . . . . .20 Rear Inner Frame Area Group . . . . . . . . . . . . . . . . . . .22 Hoods & Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Outrigger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Cab Assembly (No A/C) . . . . . . . . . . . . . . . . . . . . . . .28 Cab Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . .32 Boom Components Section Outer Boom Section Group . . . . . . . . . . . . . . . . . . . . .34 Intermediate Section Group . . . . . . . . . . . . . . . . . . . . .36 Inner Boom Section Group . . . . . . . . . . . . . . . . . . . . .38 Standard Carriage Attachment Group . . . . . . . . . . . . . .40 Fork Shift Carriage Attachment Group . . . . . . . . . . . . .42 Rotate Carriage Attachment Group . . . . . . . . . . . . . . .44 Swing Carriage Attachment Group . . . . . . . . . . . . . . . .46 Truss Boom & Bucket Attachment Group . . . . . . . . . .50 6 Ft. Mast Attachment (Old Style) . . . . . . . . . . . . . . . .52 6 Ft. Mast Attachment (New Style) . . . . . . . . . . . . . . .54 Axles & Service Brakes Section Power Brake/Master Cylinder Assemmbly . . . . . . . . . .56 Axle Planetary & Wheel Group . . . . . . . . . . . . . . . . . .58 Brake Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . .60 Axle Outer Knuckle End Group . . . . . . . . . . . . . . . . . .62 Axle Differential Carrier Group . . . . . . . . . . . . . . . . . .64 Electrical System Section Main Electrical Schematic . . . . . . . . . . . . . . . . . . . . . .66 Light Package Wiring Hookup . . . . . . . . . . . . . . . . . . .74 Cab Enviroment Wiring Hookup w/o A/C . . . . . . . . . .78 Cab Enviroment Wiring Hookup w/ A/C . . . . . . . . . . .80 Ether Start Wiring Hookup . . . . . . . . . . . . . . . . . . . . .84 Hydraulic Systems Section Tank Return & Manifold Plumbing . . . . . . . . . . . . . . .86 Brake Control Plumbing . . . . . . . . . . . . . . . . . . . . . . .88 Steering Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Frame Level Plumbing . . . . . . . . . . . . . . . . . . . . . . . . .92 Boom Extend Plumbing . . . . . . . . . . . . . . . . . . . . . . . .94 Boom Lift Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . .96 Boom Carrier Tilt/Slave Plumbing . . . . . . . . . . . . . . . .98 Auxilliary Hydraulic Plumbing . . . . . . . . . . . . . . . . .100 Fork Shift Carriage Attachment Plumbing . . . . . . . . .102 Rotate Carriage Attachment Plumbing . . . . . . . . . . . .104 Swing Carriage Attachment Plumbing . . . . . . . . . . . .106 Winch Attachment Plumbing . . . . . . . . . . . . . . . . . . .108 6 Ft. Mast Attachment Plumbing (Old Style) . . . . . . .110 6 Ft. Mast Attachment Plumbing (New Styyle) . . . . .112 Outriggers Option Plumbing (Ext. Lock Valves) . . . .114 Outriggers Option Plumbing (Int. Lock Valves) . . . . .116 Power Train Transmission, External Components Group . . . . . . . . . . . . . . . .118 Internal Components Group . . . . . . . . . . . . . . . .120 Radiator/Coolers Group . . . . . . . . . . . . . . . . . . . . . . .122 Air Intake Group . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 Exhaust Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 External Engine/Fuel Lines Group . . . . . . . . . . . . . . .128 Hydraulic Components Section Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Frame Level Cylinders . . . . . . . . . . . . . . . . . . . . . . . .132 Boom Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . .136 Boom Extend Cylinders . . . . . . . . . . . . . . . . . . . . . . .142 Carrier Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . .148 Attachment Tilt Cylinders . . . . . . . . . . . . . . . . . . . . .156 Outrigger Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . .162 Fork Shift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .166 Rotate Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . .168 Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . .170 6 Ft. Mast Extend Cylinder (Old Style) . . . . . . . . . . .174 6 Ft. Mast Extend Cylinder (New Style) . . . . . . . . . .176 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 Power Steering Motor . . . . . . . . . . . . . . . . . . . . . . . .182 Winch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .184 V40 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186 V30 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188 4-Way Joystick Controller . . . . . . . . . . . . . . . . . . . . .190 2-Way Joystick Controller . . . . . . . . . . . . . . . . . . . . .192 Frame Level Control Valve . . . . . . . . . . . . . . . . . . . .194 Outrigger Control Valve . . . . . . . . . . . . . . . . . . . . . . .196 Priority Flow Divider . . . . . . . . . . . . . . . . . . . . . . . . .198 2 GPM Flow Divider . . . . . . . . . . . . . . . . . . . . . . . . .200 Joystick Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 Outrigger Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204 Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206 Winch Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208 Steer Select Valve (Old Style) . . . . . . . . . . . . . . . . . .210 Steer Select Solenoid Valve (New Style) . . . . . . . . . .212 Miscellaneous Components Section Numerical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . .214 Standard Fasteners Table . . . . . . . . . . . . . . . . . . . . . .226 Hardware Torque Specs . . . . . . . . . . .Inside Back Cover PRINTED IN U.S.A. 1 907365/AP1299

NOTES 907365/AP1299 2 PRINTED IN U.S.A.

883 Dynalift Decals PRINTED IN U.S.A. 3 907365/AP1299 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. 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: For Units From S/N 7355 & Up Except 7357, 7358: 906213 One Gal. Yellow 906317 One Gal. Charcoal Grey 906214 6 (12 oz. Spray Cans) Yellow 906318 6 (12 oz. Spray Cans) Charcoal Grey Decal Kits L98861 S/N 7355 & Up Except 7357 & 7358 L500175 S/N thru 7354, including 7357, 7358 NOTE: Decals may be purchased in kits or individually. 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.

Decals 883 Dynalift Inside Operator Station Area Units S/N 7355 & Up, Except 7357, 7358 907365/AP1299 4 PRINTED IN U.S.A. 1011-77.dwg/83dec1.wmf 24 11 10 9 8 26 23 21 20 19 18 17 25 13 14 15 16 12 5 27 4 6 7 1 2 3 22

883 Dynalift Decals Inside Operator Station Area Units S/N 7355 & Up, Except 7357, 7358 PRINTED IN U.S.A. 5 907365/AP1299 NOTE: Decals may be ordered as kit or individually. L98861 DECAL KIT - 883 01 L65934 BRAKE FLUID LEVEL . . . . . . . . . . 1 (On Seat Mount Panel) 02 L65928 DANGER - PERSONNEL LIFT . . . . 1 03 L66042 WARNING - TRUSS BOOM TILT . . 1 04 093475 WARNING - CARRY LOAD LOW . . 1 05 L65930 WARNING - MACHINE LEVEL . . . . 1 06 L65929 DANGER - HIGH VOLTAGE . . . . . . 1 07 L65948 DANGER - PANEL IN PLACE . . . . 1 08 L64810 FRAME LEVEL CONTROL. . . . . . . 1 09 L64812 BOOM CONTROL . . . . . . . . . . . . . 1 10 L65208 ATTACHMENT CONTROL . . . . . . . 1 11 L97963 LOAD CHART SET - INCL: L65198 STD./ROTATE CARR. 883 . . . . . . 1 L65207 SWING CARR. 883 . . . . . . . . . . . . 1 L65648 WINCH - 883 . . . . . . . . . . . . . . . . 1 L65438 BUCKET - 883 . . . . . . . . . . . . . . . 1 L65594 6 FT. MAST EXTENSION 883 . . . . 1 12 094951 MADE IN U.S.A. . . . . . . . . . . . . . . 1 13 L65440 WARNING - SEAT BELT . . . . . . . . 1 14 L65922 OPER. MANUAL INSIDE . . . . . . . . 1 15 L68052 IGN. SW./HORN BUTTON . . . . . . . 1 16 L68513 IGN. SW/HORN BUTTON. . . . . . . . 1 17 L60936 F-N-R SHIFT . . . . . . . . . . . . . . . . . 1 18 L64945 1-2-3 SHIFT . . . . . . . . . . . . . . . . . . 1 19 L64797 CLUTCH DUMP SWITCH . . . . . . . 1 20 L64814 STEER SELECT . . . . . . . . . . . . . . 1 21 L66582 GEHL, 2” DIA. . . . . . . . . . . . . . . . . 1 22 L65923 WARNING - BRAKE FAILURE . . . . 1 23 L64643 HYD. PRESS. SETTINGS . . . . . . . 1 24 L65925 WARNING - PARK BRAKE. . . . . . . 1 25 L63690 WARNING - OPERATOR . . . . . . . . 1 26 L65138 OUTRIGGERS CONTROL . . . . . . . 1 27 L65512 AUTO-TROLL . . . . . . . . . . . . . . . . 1 Ref. Part Description Qty. Ref. Part Description Qty. No. No. Req. No. No. Req.

907365/AP1299 6 PRINTED IN U.S.A. Decals 883 Dynalift Frame & Boom Area Units S/N 7355 & Up, Except 7357, 7358 590-5014/63dec2.tif 25 24 25 9 25 21 22 3 11 23 3 3 12 19 20 17 16 7 13 14 3 1 10 4 5 7 12 3 11 23 3 8 3 9 10 6 2 1 3 15 18

PRINTED IN U.S.A. 7 907365/AP1299 08 L65933 DANGER - JUMP START . . . . . . . . 1 09 L65932 WARNING - NO RIDERS . . . . . . . . 1 10 L65920 GREASE DAILY . . . . . . . . . . . . . . . 2 11 L65924 DANGER - ROTATE FAN . . . . . . . . 2 12 L66567 GEHL, 8.0” . . . . . . . . . . . . . . . . . . . 2 13 L66584 GEHL, 2.0” . . . . . . . . . . . . . . . . . . . 1 14 L65928 DANGER - PERSONNEL LIFT . . . . 1 15 L66613 DYNATTACH UNLOCK . . . . . . . . . 1 (Red Stripe) 16 L65921 HYD. OIL LEVELS . . . . . . . . . . . . . 1 17 072794 HYD. OIL FILL . . . . . . . . . . . . . . . . 1 18 072797 DIESEL FUEL . . . . . . . . . . . . . . . . 1 19 072798 COOLANT UNDER PRESS.. . . . . . 1 20 056859 ANTI-FREEZE . . . . . . . . . . . . . . . . 1 21 L65931 LUBE CHART . . . . . . . . . . . . . . . . 1 22 L68083 FILTER REFERENCE CHART . . . . 1 23 L66565 GEHL, 4.5” . . . . . . . . . . . . . . . . . . . 1 24 L66568 DYNALIFT, 2.0” . . . . . . . . . . . . . . . 2 25 L64012 AUTOTROL . . . . . . . . . . . . . . . . . . 2 NOTE: Decals may be purchased as kit or individually. L98861 DECAL KIT - 883 . . . . . . . . . . . . . . 1 01 L66569 DYNATTACH, 1-1/8”. . . . . . . . . . . . 2 02 L65937 DYNATTACH DIAGRAM . . . . . . . . 1 03 L65927 WARNING - PINCH PONT . . . . . . 10 04 BOOM EXTEND MARKERS (Operator Side) L62573 NO. “6” . . . . . . . . . . . . . . . . . . . . . 1 L62574 NO. “8” . . . . . . . . . . . . . . . . . . . . . 1 L62575 NO. “10” . . . . . . . . . . . . . . . . . . . . 1 L62576 NO. “12” . . . . . . . . . . . . . . . . . . . . 1 L62577 NO. “14” . . . . . . . . . . . . . . . . . . . . 1 L62578 NO. “16” . . . . . . . . . . . . . . . . . . . . 1 L62579 NO. “18” . . . . . . . . . . . . . . . . . . . . 1 L62580 NO. “20” . . . . . . . . . . . . . . . . . . . . 1 L62581 NO. “22” . . . . . . . . . . . . . . . . . . . . 1 L62582 NO. “24” . . . . . . . . . . . . . . . . . . . . 1 05 L62583 ODD FT. MARKER (Oper. Side). . . 9 06 L65926 WARNING - CARRY LOAD LOW . . 1 07 L66579 883 . . . . . . . . . . . . . . . . . . . . . . . . 2 883 Dynalift Decals Frame & Boom Area Units S/N 7355 & Up, Except 7357, 7358 Ref. Part Description Qty. Ref. Part Description Qty. No. No. Req. No. No. Req.

Decals 883 Dynalift Inside Operator Station Area Units Thru S/N 7354, Incl. 7357, 7358 907365/AP1299 8 PRINTED IN U.S.A. 1 4 27 5 6 7 23 24 11 10 9 8 26 12 15,16 or 29 14 2 25 17 18 19 20 21 22 13 1011-77/83dec1.tif 3 28

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Gehl 883 Dynalift Telescopic Forklift Parts Manual

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