Gehl PowerBox 1639 Operator's Manual
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Gehl PowerBox 1639 Operator's Manual

Gehl PowerBox 1639 Operator's Manual

Self propelled paver
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Form No.
907389
1639/1649
PowerBox
Self Propelled
Paver
OPERATOR'S MANUAL
www.discount-equipment.com

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  • Page 1 Form No. 907389 1639/1649 PowerBox Self Propelled Paver OPERATOR’S MANUAL www.discount-equipment.com...
  • Page 2 Bartell, Bennar Newman, Haulotte, Ditch Runner, Blaw-Knox, Himoinsa, Best, Buddy, Crown, Edco, Wyco, Bomag, Laymor, Terremite, Barreto, EZ Trench, Takeuchi, Basic, Bil- Jax, Curtis, Gehl, Heli, Honda, ICS/PowerGrit, Puckett, Waldon, ASV, IHI, Partner, Imer, Clipper, MMD, Koshin, Rice, Gorman Rupp, CH&E, Cat Pumps, Comet, General Pump,...

  • Page 3: Table Of Contents

    International Symbols ......Inside Back Cover IDENTIFICATION INFORMATION Write your Gehl PowerBox Model (1639, or 1649) and Serial Numbers in the space provided below. Refer to these numbers when inquiring about parts or service from your Gehl dealer.

  • Page 4: Introduction

    A plastic container is provided on the unit for storing the Operator’s Manual. After using the Manual, please return it to the container and keep it with the unit at all times! If this machine is resold, GEHL Company recommends that this Manual be given to the new owner.
  • Page 5 Paver Identification RIGHT HAND LEFT HAND CONTROL LEVERS CONTROL LEVERS CONTROL PANEL MODULAR STEERING SPRAY DOWN HOSE (EA. SIDE) SCREED ADJUST SCREW (EA. SIDE) PROPANE ENGINE & SCREED TANK HYD. PUMP BACK WALL HOPPER HYDRAULIC RESERVOIR (LOWER FRAME) DRIVE TRACK (EA.

  • Page 6: Specifications

    Chapter 2 SPECIFICATIONS Gehl PowerBox Paver Models: 1639 1649 General Dimensions: Length ............
  • Page 7 SPECIFICATIONS (Continued) Gehl PowerBox Paver Models: 1639 1649 Service Capacities (Continued): Hydraulic Reservoir..........
  • Page 8 SPECIFICATIONS (Continued) Gehl PowerBox Paver Models: 1639 1649 Paving Performance: Minimum Variable Paving Width ........

  • Page 9: Checklists

    Chapter 3 CHECKLISTS PRE-DELIVERY I acknowledge that pre-delivery procedures were performed on this unit as outlined above. The following Checklist is an important reminder of valu- able information and inspections which MUST be made before delivering the Paver to the Customer. Check off each item after prescribed action is taken.

  • Page 10: Safety

    1. Bring machine to full parking stop on level sur- SAFETY PRECAUTIONS. face (NEVER park on a slope or hill side). The Gehl Company ALWAYS takes the operator’s 2. Lower the Hopper and Screed Assembly to the safety into consideration when designing its machinery “full down”...
  • Page 11 SAFETY (Continued) all controls in neutral BEFORE leaving the Some illustrations, used in this manual, may show Doors, Guards and Shields open or removed for machine! illustration purposes ONLY. Be SURE that all ALWAYS position the Safety Props when leaving Doors, Guards and Shields are in their proper oper- the Hopper raised for inspection, cleaning or ser- ating positions BEFORE starting the Engine to...
  • Page 12 Screed Propane Heater - General Safety To ensure continued safe operation, replace dam- aged or worn-out parts with genuine GEHL service parts, BEFORE attempting to operate this equip- CAUTION ment.
  • Page 13 SAFETY (Continued) Printed In U.S.A. 907389/AP297...
  • Page 14 SAFETY (Continued) 907389/AP297 Printed In U.S.A.

  • Page 15: Controls, Attachments & Accessories

    ALL safety devices and controls on the Paver START BEFORE attempting to operate it. Know how to stop the machine operation BEFORE attempting to operate it. This GEHL Power AUTO Box Paver is designed and intended to be RETURN used ONLY with GEHL Company accessories or a GEHL Company approved or referral accessory.
  • Page 16 1649 MODELS 1639 MODELS TOP CONSOLE Fig. 2 Choke (1639) Circuit Breaker (1639) Engine Oil Pressure (1649) Throttle Keyswitch Spray Down Pump Switch Battery Gauge Glow Plug Indicator (1649) Hourmeter Water Temperature Gauge (1649) Exhaust Diverter 1649 SHOWN 1649 SHOWN Fig.
  • Page 17 Engine Throttle: This controls the Engine speed. Idle CAUTION position is with the Cable fully in. Operating position is with the cable 1 to 1-1/2 inches out. Release the Lock Ring, depress the red button on the Knob and pull Do NOT spray releasing agent on a HOT the Knob out to set speed.
  • Page 18 RT. SIDE CONTROL Fig. 5 - Travel Controls Left Track Travel Pump Speed Right Track Travel Modular Steering Hydraulic Fluid Reservoir: The Access/Fill Plug on also turning of the Paver. Both Levers are mechanical- top may be removed to check fluid level.. ly linked to Levers on the right side for control from either side.
  • Page 19 LOWER FRAME Fig. 7 - Side Gates (Left Side Shown) Shut Off Valve Side Gate Cylinder Side Gate Right & Left Flow Gates: These control flow of asphalt out of the Hopper. One Lever controls each Gate. Move Lever BACK to open Gate. Move Lever FORWARD to close Gate.
  • Page 20 RT. SIDE CONTROL Fig. 8 - Hopper Controls On Backwall Console Hopper Floor Left Auger Left Gate Right Auger Right Gate RT. SIDE CONTROL Fig. 9 - Screed Controls On Backwall Console Vibrator Left Extension Screed Lift Right Extension turn the Vibrator on. Allow the Lever to return to “neu- Extension outward.
  • Page 21 The following choice of otherwise noted. Information and parts for field Extensions are available and must be ordered separate installing of all of the accessories will be provided by stock number below: by the Factory or GEHL Paver dealers. 907389/AP297 Printed In U.S.A.
  • Page 22 Description Stock Number 6” (152.4mm) for left or right side 805464 12” (304.8mm)for left or right side 805466 18” (457.2mm)for left or right side 805468 Screed Propane Heat Kit: When desired or where operating conditions require, this kit (without tank) is optional with either 1639 or 1649 models.

  • Page 23: Operation & Adjustments

    Chapter 6 OPERATION & ADJUSTMENTS GENERAL INFORMATION For 1639 Gas Models 1. Pull the Throttle control 1/4 to 1/2 open. CAUTION 2. Pull Choke control to full “out” position (close Choke Valve) for cold Engine starts. If re-starting BEFORE starting the Engine and operating the a warm Engine, little or no choking is required..
  • Page 24 CAUTION CAUTION Be SURE the area being used for test-running Follow the manufacturer recommendations is clear of spectators and obstructions. For regarding the use of proper fuel, lubricants the first time operate the Paver with an empty and oil. Hopper. To prevent a fire or explosion, allow the Engine to cool down BEFORE attempting to refill the Fuel Reservoir.
  • Page 25 rial. When operating, the Throttle should CAUTION ALWAYS be at full RPM’s. The exhaust can be re- diverted out through the Muffler periodically if desired. NEVER operate the Paver with safety Guards or Covers removed. 2. Maneuver the Paver into position for laying asphalt with the Track Control Levers.
  • Page 26 Engine Throttle should be set at full power. Signal to 15 minute intervals using asphalt remaining in the driver to leave the truck in neutral with the- the Hopper until next load arrives. dump body raised a sufficient height to allow If the Paver is to be used independently of the dump asphalt to flow slowly but continuously inth the truck, disregard procedures involving pushing the...
  • Page 27 sible without spilling asphalt. Close one Flow Gate and asphalt, opening both Flow Gates as the windrow then the other. Lowering the Hopper substantially asphalt begins to run thin. decreases the weight being lifted by each Flow Gate. If this is not the case, open both Flow Gates Make sure Screed Extensions are also closed.
  • Page 28 Fig. 11 NOTE: A matched pair of ramps is required. 1. (Fig. 11) The ramps MUST be of sufficient strength to support the machine. Whenever possi- ble, the use of strong wood covered steel ramps is recommended as well as some type of center sup- porting block.
  • Page 29 Loading With ramps ADJUSTMENT SCREW 1. Move the Paver to a position that aligns with the ramps so the Paver will be in position to load in reverse. Stop the Paver. 2. Move the Pump Speed Control Lever at 1/3 to 1/2 speed.
  • Page 30 STRONG DETERRENT TO THIEVERY OF CON- 10. Rear Loading: After the Paver is on the vehicle STRUCTION EQUIPMENT! GEHL has recorded bed, place one Track Lever in “forward” and one in Part Numbers and Serial Numbers. Users should take “reverse”.

  • Page 31: Lubrication

    Chapter 7 LUBRICATION GENERAL INFORMATION Hydraulic System Reservoir Use SUNVIS 846, or equivalent CAUTION which contains anti-rust, anti-foam and anti- oxidation additives & conforms to ISO VG46. Capacity: NEVER attempt to lubricate or service this unit 20 Gallons (75.7 liters) when any part of the machine is in motion.
  • Page 32 Replacement Filters Chart 6. Check Track Torque Hub Fluid Level (2 ea.). 1649 Diesel Engine 7. Change Engine Oil. Oil Filter Element Gehl P/N P700122 Every 500 Hours Fuel Filter Element Gehl P/N 123828 8. Grease Pump Speed Control Linkage (2 ea.).
  • Page 33 BASIC MACHINE LUBRICATION CHART Printed In U.S.A. 907389/AP297...

  • Page 34: Troubleshooting

    When a problem occurs, don’t overlook simple causes. components, unless authorized to do so by A malfunction could be caused by something as simple your GEHL Dealer. Any Unauthorized Repair as an empty Fuel tank. After a mechanical failure has will Void the Warranty.
  • Page 35 GENERAL PAVER PROBLEMS DURING OPERATION (Cont.) PROBLEM POSSIBLE CAUSE REMEDY Screed not hot enough. Engine not running at high enough RPM. Refer to Engine troubleshooting. Excessive exhaust leakage. Check for and correct leaks. Exhaust ports at end of Screed plugged. Clear ports.
  • Page 36 PAVER RELATED MAT PROBLEMS (Cont.) PROBLEM POSSIBLE CAUSE REMEDY Mat texture not uniform See Causes “1, 2, 4, 7-9, 12” Screed marks See Cause “3”. Screed not responding See Causes “2-4”. to correction. Poor pre-compaction. See Cause “2”. 13. Screed riding on Lift Cylinder. Lower Cylinder completely.
  • Page 37 MATERIAL-DELIVERY-COMPACTION RELATED MAT PROBLEMS (Cont.) PROBLEM POSSIBLE CAUSE REMEDY Tearing of mat See Causes “3-7”. (full width) 11. Improper mat thickness. Mat thickness must be twice size of. the largest aggregate. 12. Cold mix temperature.. Check with asphalt plant for hotter asphalt mix.
  • Page 38 DRIVE AND MAIN CONTROL VALVES PROBLEM POSSIBLE CAUSE REMEDY Incapable of maintaining. Internal oil leak at the spool. Replace entire valve housing & spool. the load. Oil leaking at relief valve port. Disassemble and clean or replace relief valve. Load check poppet or seat damaged Replace poppet and seat assembly.
  • Page 39 HYDRAULIC PUMP AND MOTORS SYSTEM PROBLEM POSSIBLE CAUSE REMEDY System will not operate 1. Oil supply low. Check oil level and fill. in either direction 2. Oil Filters clogged. Replace Filter Element. 3. Oil too heavy. Use proper viscosity oil. 4.
  • Page 40 HYDRAULIC CYLINDERS PROBLEM POSSIBLE CAUSE REMEDY Insufficient hydraulic Relief Valve pressure setting Readjust Valve pressure setting. Cylinder power decreased. Cylinder internal oil leakage Replace seals. Cylinder piston or seals defective. Replace piston or seals. Control Valve internal oil leakage. Replace entire Valve housing. Hydraulic Cylinder Cylinder seals defective.
  • Page 41 ENGINE PROBLEM POSSIBLE CAUSE REMEDY Engine will NOT turn Starter motor defective or Replace motor and/or repair over. faulty wiring connections. wiring connections. Starter motor has Battery is run down, Starter is Charge Battery, repair/replace insufficient power to defective and/or wiring connections Starter, and/or tighten connections.

  • Page 42: Service & Storage

    (or under the direction of) an PRECAUTIONS authorized GEHL Paver dealer. WARRANTY repairs can only be done by a GEHL dealer. He will know Do NOT perform any maintenance or repair without what portions of the Paver are covered under the terms the owner’s prior authorization.
  • Page 43 ELECTRICAL COMPONENTS WARNING An Electrical system diagram is provided which includes instrumentation, electrical components and Do NOT smoke or allow any open flames in the switch connections. The schematic (located at the end area while checking and/or servicing of this chapter) can be used as a guide for trou- hydraulic, battery or fuel systems;...
  • Page 44 4. Hydraulic Fluid Reservoir WARNING 5. Asphalt Depth Adjustment Screws 6. Drive Tracks 7. Any other part of the machine which Do NOT remove the Radiator Cap when the contacts asphalt Engine is running HOT, or overheated. Coolant is extremely HOT and under pressure NOTE: Do NOT spray releasing agent into and it can burn your skin.
  • Page 45 NOT have a separate safety element so extreme care Before removing the Fill Plug, release pressure in the must be taken when cleaning or inspecting. hydraulic system by allowing pressure to bleed-off when loosening the Fill Plug. This can also be done by CHECK INSTRUMENTS OPERATION loosening the Breather Cap on top of the Backwall Console.
  • Page 46 WARNING WARNING Explosive gas is produced while a Battery is in The ONLY safe method for jump-starting a use or being charged. Keep flames or sparks dicharged Battery is for TWO PEOPLE to away from the Battery area. Make sure Battery carry-out the following process.
  • Page 47 dead cell(s) or troubleshoot the entire electrical Service Every 100 Hours system for possible short circuits or damaged wire insulation. NOTE: Perform all other service requirements CLEAN AIR CLEANER ELEMENT (Fig. 14) up to this point as well as the following. Completely wipe the outside of the Air Cleaner Body HYDRAULIC FILTERS (Fig.
  • Page 48 CHECK SCREED BOTTOM PLATE 1639 MODEL The bottom plate of the Screed should be inspected FUEL for possible wear. RESERVOIR Service Every 250 Hours NOTE: Perform all other service requirements FUEL PUMP up to this point as well as the following. CHANGE ENGINE OIL 1649 MODEL Change the Engine Oil using the following procedure:...
  • Page 49 NOTE: Only an authorized Engine dealer can WARNING perform WARRANTY Service on the Engine. CHANGE RADIATOR COOLANT NEVER service the fuel system while smok- (1649 Diesel) ing, while near an open flame, or after the Engine has been operated and is hot. Drain, flush and refill the cooling system as follows: NOTE: DO NOT discharge onto ground.
  • Page 50 sary to refill the cooling system after a short peri- od of use, as the air will naturally bleed out of the system. CHECK EXHAUST SYSTEM The exhaust provides heating for the Screed surface contacting the asphalt mat, when diverted to that area. Make sure there are no leaks or loose connections.
  • Page 51 NOTE: 6. For 1649 Diesel Engine only. If the ambient tem- Tracks are NOT adjusted if Engine is perature (at anytime during the storage period) is NOT running. expected to drop below freezing, make sure the CHECK ENGINE COMPRESSION Engine coolant is either completely drained from the Radiator and Engine block or that the amount Refer to OEM Engine manual.
  • Page 52 1639/1649 Hydraulic Schematic 907389/AP297 Printed In U.S.A.
  • Page 53 1639/1649 Hydraulic Schematic Printed In U.S.A. 907389/AP297...
  • Page 54 1639 Electrical Schematic 907389/AP297 Printed In U.S.A.
  • Page 55 1649 Electrical Schematic Printed In U.S.A. 907389/AP297...

  • Page 56: Decal Locations

    Chapter 10 DECAL LOCATIONS NEW DECAL APPLICATION GENERAL INFORMATION Before applying the new decals, surfaces MUST be CAUTION free from dirt, dust, grease and other foreign material. To apply a solid-formed decal, remove the smaller por- tion of the decal backing paper and apply this part of ALWAYS read and abide by the Safety Rules the exposed adhesive backing to the clean surface and information shown on Decals.
  • Page 57 DECAL LIST - LOWER FRAME, HOPPER & SCREED AREAS REF. DESCRIPTION 1639 1649 0-6 Thickness Indicator (2 ea.) P201400 P201400 Up/Down Screed (2 ea.) P214000 P214000 Hydraulic Fluid (1 ea.) P471425 P471425 PowerBox Logo (2 ea.) P470323 P470323 WARNING - Pinch Point (3 ea.) L65927 L65927 Floor Safety Prop (2 ea.)
  • Page 58 LH Model Number - 1639 (1 ea.) P471680 RH Model Number - 1649 (1 ea.) P471638 LH Model Number - 1649 (1 ea.) P471681 GEHL Lettering, 5.25” (2 ea.) L66566 L66566 Made In USA (2 ea.) 122719 122719 Maintenance Chart (1 ea.)
  • Page 59 Printed In U.S.A. 907389/AP297...
  • Page 60 Chapter 11 MAINTENANCE This Maintenance Interval 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 follow the Interval Chart for recording the Maintenenace Procedures performed. Recording the 10 Hour (or Daily) service intervals would be impractical and is therefore not recommended.

  • Page 61: Maintenance Log

    MAINTENANCE INTERVAL CHART (CONT.) SERVICE PROCEDURE Every 250 Every 500 Every Hours Hours 2000 Hours Change Engine Oil Check Torque Hubs Oil Level Lubricate Appropriate Grease Points Change Engine Oil Filter Element Check Radiator Coolant (1649) Check Exhaust System Change Fuel filter Inspect Fuel Injection System (1649) Check/Replace Spark Plugs (1639) Check Track Hydraulic Pressure Adjustment...

  • Page 62: Index

    Index Engine Clean Air Intake Screen, 46 Accessories, 22 Description, 5 Adjustments Oil Pressure Indicator, 17, 18 Screed Platform, 21 Starting, 24 Track Pressure, 52 Temperature Gauge, 17,18 Air Cleaner Troubleshooting, 43 Check, 46 Engine Oil Cleaning & Service Element, 49 Changing, 50 Anti-freeze, See Radiator Check Level, 46...
  • Page 63 Identification Numbers, 1 Radiator Ignition Switch, See Keyswitch Check coolant, 46 Index, 65 Cleaning, 51 Indicators, 17,18 Flushing & Refilling, 51 International Symbols, Inside Front Cover Replacement Filters, 34 Introduction, 2 SAFETY, 10 Jump Starting Battery, 47 Schematic, Electrical, 56 Schematic, Hydraulic, 54 Service, 44 Keyswitch, 16...
  • Page 64 Torque Specifications Use these torque values when tightening GEHL hardware (excluding: Locknuts and Self-tapping, Thread-forming and Metal Screws) unless otherwise specified. Grade 2 Grade 5 Grade 8 Unified National Thread Lubed Lubed Lubed 8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18...

  • Page 65: International Symbols

    INTERNATIONAL SYMBOLS...
  • Page 66 OPERATION, AND COSTLY BREAKDOWN. IF YOU HAVE ANY QUESTIONS ON PROPER OPERATION, ADJUSTMENT OR MAIN- TENANCE OF THIS MACHINE, CONTACT YOUR DEALER OR THE SERVICE DEPART- MENT 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.

This manual is also suitable for:

Powerbox 1649

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