Gehl SL4640E, SL5240E Skid Steer Loader Service Repair 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