Description
The Factory Service Manual for the Gehl And Mustang skid steer loader. Includes detailed illustrations, instructions, and diagrams that facilitate step-by-step processes for the removal and installation, assembly and disassembly, servicing, inspection, repair, troubleshooting, tune-ups.
Pub.No: 50950037
Issued: february 2012
Language: English
Pages: 263
Searchable
Wiring Diagrams
Hydraulic Diagrams
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Models
Gehl And Mustang Skid Steer Loader
Gehl 4640E Power2
Gehl 5240E Power2
Mustang 2056
Series II
With Tier 4i Yanmar 4TNV98-ZNMS2 Engine
Contents
-SPECIFICATIONS
Specifications
-SAFETY
General Information
Signal Words
Additional Safety Reminders
Mandatory Safety Shutdown Procedure
Lift Ann Support Device
Lift Ann Support Device Engagement
Lift Ann Support Device Disengagement
ROPS/FOPS – Raising
ROPS/FOPS – 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 Dram 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/FOPS Removal and Installation
Seat Removal and Installation
Seat Slide Replacement
Air Duct Removal and Installation
Air Duct Louver Replacement
ROPS/FOPS Rear Window Removal and Installation
Restraint Bar Components
All-Tach Components
Power-A-Tach Components – 4640 Models
Power-A-Tach Components
Restraint Bar Removal and Installation
All-Tach , Multi-Tach or Power-A-Tach Hitch Removal and Installation
Lift Arm Components
Lift Ann Removal and Installation
Lift Arm Bushing Replacement
Lift Ann 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
Wheel Drive Components
Lift and Tilt Components
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 and
the 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 and 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 Ann 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-Toot Controls
High-Flow Auxiliary Hydraulics Controls – Hand/Foot Controls
Auxiliary’ Hydraulics Cable Removal and Installation
Auxiliary’ Hydraulics Cable Adjustment
Foot Throttle Controls – T-Bar, Dual Hand, T-Bar/Joystick and Dual Joystick
Foot Throttle Pedal Removal and Installation – T-Bar, Dual Hand, T-Bar/Joystick and Dual Joystick
-HYDROSTATIC SYSTEM
Introduction
Single-Speed Hydrostatic Components
Two-Speed Hydrostatic Components
Brake Release Components – Single-Speed and Two-Speed
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
-HYDRAULIC SYSTEM
Introduction
Standard Auxiliary Components
High-Flow Auxiliary Components
Standard Auxiliary Components
High-Flow Auxiliary Components
Standard Auxiliary Components
High-Flow Auxiliary Components
Standard Lift Ann Hydraulics Components
High-Flow Lift Arm Hydraulics Components
High-Flow Lift Ann Hydraulics Components – 2056 Models
Chassis Hydraulics Components
Standard Power-A-Tach Components
Pressure Tests, Control Valve and High-Flow
Tilt Cylinder Test
Tilt Circuit Spool Leakage Test
Self-Leveling Valve Test
Lift Cylinder Test
Lift Circuit Spool Leakage Test
Solenoid Valve Test – Tilt, Lift, Brake and Two-Speed
Hydraulic Oil Filter Element Replacement
Tilt Cylinder Removal and Installation
Lift Cylinder Components
Tilt Cylinder Components
Lift Cylinder Removal and Installation
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
Hydraglide Ride Control Hydraulics Components
Main Relief Valve Removal and Installation
Auxiliary Hydraulics Spool Lock Solenoid Removal and Installation
Hydraglide Ride Control Accumulator Removal and Installation
Troubleshooting Guide
-ELECTRICAL SYSTEM
Introduction
Description of Operation – Right and Left Instrument Panels
Troubleshooting Guide
Electrical Chassis Components
Electrical Battery’ Components
Electrical Two-Speed Control Components
Electrical ROPS/FOPS Components
Electrical Engine Components
Fuse Panel Decal Illustration and Photo
Power Distribution Panels Test / Operation
Fuse Box Panels Test and Operation
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
Engine Throttle Test and Operation
Seat Switch Removal and Installation
Restraint Bar Switch Removal and Installation
Restraint Bar Components
Engine Disconnect Switch – Remote Battery Terminal Removal and Installation
Front and Rear Work Light Bulb Replacement
Dome Light Bulb Replacement
Electrical Lights Components
Lift and Tilt Solenoid Test and Operation
Traction Solenoid Test and Operation
2-Bank and 4-Bank Coil Function Colored Wire Connector Chart
ROPS/FOPS – Electrical Schematic
Engine – Electrical Schematic
Heater Schematic
HVAC Schematic – 5240 and 2056
Cab Door Electrical Schematic
14-Pin Auxiliary Connector Schematic
Chassis – Electrical Schematic
Power-A-Tach – Electrical Schematic
-ENGINE
Introduction
Troubleshooting Guide
Engine Components – 4640 Models
Engine Components – 5240 And 2056 Models
Air Cleaner And Exhaust Components
Radiator/Cooler Components – 4640 Models
Radiator/Cooler Components – 5240 And 2056 Models
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
Engine ECU Fault Codes
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