Gehl SL4640E, SL5240E Skid Steer Loader Service Repair Manual

Service Repair Manual: 230 Pages
Operators Manual: 108 Pages
Parts Manual: 465 Pages
Manuals: Service Repair Manual, Operators Manual, Parts Manual

Table of Content SL4640E, SL5240E Manual

Specifications
Specifications
Safety
General Information
Signal Words
Additional Safety Reminders
Mandatory Safety Shutdown Procedure
Lift Arm Support Device
Lift Arm Support Device Engagement
Lift Arm Support Device Disengagement
ROPS – Raising
ROPS – Lowering
Relieving Hydraulic Pressure
Loader Raising Procedure
Loader Lowering Procedure
Lubrication System
General Information
Hydraulic Oil Reservoir
Crankcase Oil
Chaincases
Grease Fitting Locations
Cooling System Drain Procedure
Mainframe
Introduction
Mainframe (Chassis) Components
Rear Grille and Engine Cover Components
Engine Access Cover – Removal and Installation
Roll Over and Falling Object Protective Structure Components – ROPS/FOPS
ROPS Removal and Installation
Seat Removal and Installation
Seat Slide Replacement
Air Duct Removal and Installation
Air Duct Louver Replacement
ROPS Rear Window Removal and Installation
Restraint Bar Removal and Installation
Restraint Bar Components
All-Tach® Components
Power-A-Tach® Components
Gehl All-Tach® or Power-A-Tach® Hitch Removal and Installation
Lift Arm Components
Lift Arm Removal and Installation
Lift Arm Bushing Replacement
Lift Arm Stop Installation and Adjustment
Control Cover Components
Floor Cover/Control Cover Removal and Installation
Crossmember Removal and Installation
Fuel Sensor Removal and Installation
Rear Grille Removal and Installation
Rear Grille Latch Removal and Installation
Wheel Drives
Introduction
Wheel Drive Components
Drive Chain Adjustment
Axle Housing Assembly Removal and Installation
Drive Chain Removal and Installation
Axle Assembly Components
Axle and Wheel Bearing Disassembly and Assembly
Controls
Introduction
Control Locations – Dual Joysticks
Control Locations – Dual Hand
Control Locations – T-Bar
Control Locations – Hand/Foot
Control Locations – T-Bar/Joystick
Wheel Drive Components – Dual Hand and Hand/Foot Controls
Wheel Drive Components – T-Bar and T-Bar/Joystick Controls
Wheel Drive Components – Dual Joystick Controls
Lift and Tilt Components – Dual Hand Controls
Lift and Tilt Components – T-Bar Controls
Lift and Tilt Components – Hand/Foot Controls
Lift and Tilt Components – T-Bar/Joystick and Dual Joystick Controls
Control Handle Removal and Installation – T-Bar, Dual Hand, Hand/Foot and the Left T-Bar/Joystick Control
Control Handle Assembly Removal and Installation – Dual Joystick Controls / Right T-Bar/Joystick Control
Electrical Auxiliary Grip Removal and Installation – Joystick Controls
Control Handle Position Adjustment – T-Bar, Dual Hand, Hand/Foot and the Left T-Bar/Joystick Control
Control Handle Tracking Adjustment, Wheel Drive Controls – T-Bar, Dual Hand, Hand/Foot, T-Bar/Joystick
Control Handle Tracking Adjustment, Wheel Drive Controls – Dual Joysticks
T-Bar Control Handle Assembly
Hand/Foot and Dual Hand Control Handle Assembly
Dual Joystick Assembly
Pivot Tube Removal and Installation
Neutral Centering Device Adjustment – Dual Hand, Hand/Foot, T-Bar and T-Bar/Joystick
Neutral Centering Adjustment – Dual Joysticks
Pump Control Arm Assembly Removal and Installation
Lift/Tilt Controls Removal and Installation
Lift/Tilt Control Adjustment
Auxiliary Hydraulics Controls – T-Bar and Dual Hand Controls
High-Flow Auxiliary Hydraulics Controls – T-Bar and Dual Hand Controls
Auxiliary Hydraulics Controls – Hand/Foot Controls
High-Flow Auxiliary Hydraulics Controls – Hand/Foot Controls
Standard and High-Flow Auxiliary Hydraulics Controls – Dual Joystick Controls
Auxiliary Hydraulics Cable Removal and Installation
Auxiliary Hydraulics Cable Adjustment
Hand Throttle Controls – T-Bar and Dual Hand Controls
Hand Throttle Controls – Hand/Foot Controls
Hand Throttle Controls – T-Bar/Joystick and Dual Joystick Controls
Hand Throttle, Foot Throttle Pedal and Throttle Cable Removal and Installation – T-Bar, Dual Hand, T-Bar/Joystick and Dual Joystick
Hand Throttle Tension Adjustment
Hand Throttle and Throttle Cable Removal and Installation – Hand/Foot
Hand Throttle Adjustment – Hand/Foot
Foot Throttle Adjustment – T-Bar, Dual Hand, T-Bar/Joystick and Dual Joystick
Hydrostatic System
Introduction
Single-Speed Hydrostatic Components – T-Bar, Hand/Foot, Dual Hand and T-Bar/Joystick
Single-Speed Hydrostatic Components – Dual Joystick Controls
Two-Speed Hydrostatic Components – T-Bar, Hand/Foot, Dual Hand and T-Bar/Joystick
Two-Speed Hydrostatic Components – Dual Joystick Controls
Charge Pressure Test and Adjustment
Hydrostatic Pump Relief Valves
Hydrostatic Pump Removal / Installation
Hydrostatic Pump Drive Coupling Removal and Installation
Drive Motor Removal and Installation
Troubleshooting Guide
Hydrostatic/Hydraulic Schematic – Dual Joystick Controls
Hydrostatic/Hydraulic Schematic – Non-Dual Joystick Controls
Hydraulic System
Introduction
Standard Auxiliary – T-Bar, Dual Hand and Hand/Foot Controls
High-Flow Auxiliary – T-Bar, Dual Hand and Hand/Foot Controls
Standard Auxiliary – T-Bar/Joystick Controls
High-Flow Auxiliary – T-Bar/Joystick Controls
Standard Auxiliary – Dual Joystick Controls
High-Flow Auxiliary – Dual Joystick Controls
Standard Lift Arm Hydraulics – 4640 Models
Standard Lift Arm Hydraulics – 5240 Models
High-Flow Lift Arm Hydraulics
Chassis Hydraulics
Pressure Tests, Control Valve and High-Flow
Tilt Cylinder Test
Self-Leveling Valve Test
Lift Cylinder Test
Solenoid Valve Test – Tilt, Lift, Brake and Two-Speed
Hydraulic Oil Filter Element Replacement
Tilt Cylinder Removal and Installation
Lift Cylinder Removal and Installation
Lift Cylinder Components
Tilt Cylinder Components
Lift/Tilt Cylinder Disassembly / Assembly
Gear Pump Removal and Installation
Self-Leveling Valve Removal and Installation
Self-Leveling Valve Adjustment
Safety Lock Valves – Removal/Installation
Lift and Tilt Solenoid Valve – Disassembly and Assembly
Control Valve Removal and Installation
Manifold Valve Removal and Installation
Control Valve Disassembly and Assembly
Main Relief Valve Removal and Installation
Auxiliary Hydraulics Spool Lock Solenoid Removal and Installation
Hydraglide™ Ride Control Hydraulics
Hydraglide™ Ride Control Accumulator Removal and Installation
Electrical System
Introduction
Description of Operation – Right and Left Instrument Panels
Electrical Chassis Components
Electrical Battery Disconnect Switch Components
Electrical Two-Speed Control Components
Electrical ROPS/FOPS Components
Master Fuse, Module and Relay Test and Operation
Master Fuse Test
Power Relay Test
ISO SPDT Interlock, Joystick, EGR, Fuel and Horn Relays Test
Starter and Glow Solenoid Test
Glow Control Module Test
Glow Control Module
Glow Control Module Time/Temp Cycle
Interlock Control Module Test
Interlock Control Module Truth Table
Two-Speed, Ride Control and Float Module Test
Two-Speed, Ride Control and Float Module Truth Table
Control Handle Actuation Buttons – Two-Speed and Ride Control and Float Module
Seat Switch Removal and Installation
Restraint Bar Components
Restraint Bar Switch Removal and Installation
Engine Disconnect Switch – Remote Battery Terminal Removal and Installation
Electrical Lights Components
Front and Rear Work Light Bulb Replacement
Dome Light Bulb Replacement
Electrically-controlled Standard Auxiliary Hydraulic Flow System Test and Operation
Electrically-controlled High-Flow Auxiliary Hydraulic Flow System Test and Operation
Lift and Tilt Solenoid Test and Operation
Traction Solenoid Test and Operation
Auxiliary Neutral Start Switch
2-Bank and 4-Bank Coil Function Colored Wire Connector Chart
Chassis – Electrical Schematic
ROPS/FOPS – Electrical Schematic
Engine – Electrical Schematic
Electrical Auxiliary Schematic
EGR Solenoid – Electrical Schematic
Heater Schematic
Engine
Introduction
Troubleshooting Guide
Engine Components
Air Cleaner and Exhaust Components
Radiator/Cooler Components
Remote Oil Filter Element Removal and Installation
Air Cleaner Assembly Removal and Installation
Air Filter Element Removal and Installation
Battery and Battery Tray Removal and Installation
Starter Removal and Installation
Exhaust Assembly Removal and Installation
Fan Belt Adjustment
Radiator/Oil Cooler Removal and Installation
Fan Shroud and Radiator/Oil Cooler Mounting Brackets Removal and Installation
Fan Shroud Adjustment
Fan Removal and Installation
Engine Removal and Installation
Index