GEHL 4640 4840 5640 6640 Loader Parts Manual

SL4640 & (EU) SL4640E & (EU) SL4840 & (EU) SL4840E & (EU) SL5640 & (EU) SL5640E & (EU) SL6640 & (EU) SL6640E & (EU) Skid-Steer Loaders PARTS MANUAL Form No. 917000 Revision I 12/07 ®

Introduction For your safety and continued proper operation, use only genuine GEHL service parts. When ordering service parts, specify the correct part number, full description, quantity required, the unit model number and serial number. The model and serial number decal for this unit is located on the left chassis upright. “Right” and “left” are determined from a position sitting on the seat and facing forward. 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 previously delivered units. NOTE: Purchase equivalent-quality tires for your loader. Contact your dealer for replacement tire information. NOTE: Replacement batteries are not provided by the GEHL Company. For battery specifications see “Electrical - Chassis” chapter. ALL RE- PLACEMENT BATTERIES MUST BE PURCHASED LOCALLY. Refer to the abbreviations table located on this page for the various fastener descriptions. Standard attaching hardware torque values are also provided on the inside back cover. If a part requires lubrication or a nonstandard torque value, it will be specified behind the part number description in parenthesis. Items shown in the parts list that do not have part numbers are shown for reference purposes only and are NOT available for purchase. Dimensions are in inches unless otherwise specified. NOTE: The following abbreviations and sym- bols may be used herein: AMP ....... Ampere AR ........ As Required ASSY ...... Assembly AUX ....... Auxiliary CCA ....... Cold Cranking Amperage CYL ....... Cylinder DJS........ Dual Joystick FRT ....... Front FL ........ Flare GA ........ Gauge HEX ....... Hexagon HF ........ High Flow HYD ....... Hydraulics JIC ........ Joint Industrial Council JS ........ Joystick kW ........ Kilowatt LBS ....... Pounds LT ........ Left M (m) ...... Meter MM (mm) .... Millimeter NA ........ Naturally-Aspirated N/A ....... Not Applicable NEG ....... Negative NILN....... Nylon Insert Lock Nut N-m ....... Newton Meter NO ........ Number NPT ....... National Pipe Thread OPER ...... Operator POS ....... Positive PSI ........ Pounds per Square Inch QTY ....... Quantity REF ....... Reference REQ’D ...... Required ROPS ...... Roll Over Protective Structure RPM ....... Revolutions Per Minute RT ........ Right SAE ....... Society of Automotive Engineers SN ........ Serial Number SQ ........ Square ST ........ Straight TURBO ..... Turbocharged V ......... Volt GEHL is a registered trademark of the Gehl Company.

TABLE OF CONTENTS SECTION A: MAIN LOADER COMPONENTS Chassis and Control Covers ........................................... 1 Wheel Drives .................................................. 13 Engine ..................................................... 19 Air Cleaner and Muffler ............................................ 33 Coolers ..................................................... 49 Hydrostatic System - Drive Motors ...................................... 57 Hydraulics - Chassis .............................................. 81 Hydraulics - Lift Arm ............................................. 91 Hydraulics - Auxiliary ............................................ 101 Controls - Auxiliary Hydraulics ....................................... 123 Controls - Lift and Tilt ............................................ 127 Controls - Traction .............................................. 139 Controls - Engine ............................................... 159 Lift Arm.................................................... 169 All-Tach™ and Power-A-Tach™ Attachment Bracket ........................... 171 ROPS and Interior .............................................. 177 Seat and Seat Belt Options .......................................... 183 Restraint Bar ................................................. 189 Grille and Engine Covers ........................................... 191 Electrical - Chassis .............................................. 193 Electrical - ROPS ............................................... 201 Electrical - Lights ............................................... 205 Ignition Switch (Earlier Models) ....................................... 207 Electrical - Control .............................................. 209 Sound Suppression .............................................. 211 Tires ...................................................... 217 Decals ..................................................... 222 SECTION B: HYDRAULIC COMPONENTS Lift Cylinder ................................................. 233 Tilt Cylinder ................................................. 235 Drive Motors - Single and Two-Speed .................................... 237 Tandem Pump ................................................ 249 Gear Pump - Single .............................................. 261 Gear Pump - Double ............................................. 265 Self-Level Valve ............................................... 269 Solenoids - Lift and Tilt ........................................... 271 Solenoids - Brake ............................................... 273 Main Control Valve.............................................. 275 Manifold - Hydraglide™ Ride Control .................................... 277 High-Flow Valve ............................................... 279 DESCRIPTION PAGE Hydraglide, Power-A-Tach and All-Tach are trademarks of the Gehl Company.

TABLE OF CONTENTS SECTION C: KITS AND ACCESSORIES Back-up Alarm Kit 810404 ......................................... 283 Horn Kit 810401 and the Rearview Mirror Kit 806894 .......................... 284 AM/FM Radio Kit 810429 (replaced by 810897 Radio Kit, see below) .................. 285 Power-A-Tach™ Kit 810417 (46/4840) and 810418 (56/6640) ...................... 286 Front Door Kit 810412 ........................................... 287 Seat Belt Kits - 2" 810424 and 3" 810425 ................................. 288 Seat Kits - Suspension 810422 and Standard 810423 ........................... 288 Side Window Kit 810413 .......................................... 289 3-Point Restraint - 2" Seat Belt 810426 and 3" Seat Belt 810427 ..................... 289 Pre-Cleaner Kit 808204 / 810909 and the Strobe Light Kit 805803 .................... 290 Counterweight Kit 810415 (SL46/4840) and 810416 (SL56/6640) .................... 291 Crossmember Auxiliary Tube Kit 810469 (SL46/4840); 810470 (SL56/6640) .............. 292 Cab Heater Kit 810414 ........................................... 293 Dual Flasher Kit 810421 .......................................... 294 Servo Bypass Plumbing Kit 187320 (4840) and 187317 (56/6640) .................... 294 Impact-Resistant Front Door Kit 810561 .................................. 295 Four-Point Lift Kit 810866 (replaced by 810945) ............................. 296 Remote Oil Filter Kit 810419 ........................................ 297 Single-Point Lift Kit 810834 ........................................ 298 Cab Heater Rework Kit 186935 - 810406 (Factory) or 810414 (Field) Heaters .............. 299 Interior Console Kit 810494 ........................................ 299 Power-A-Tach™ Actuator Kit 810455 ................................... 300 HVAC Kit 810471 (4840), 810472 (5640) and 810473 (6640) ...................... 301 Cab - HVAC Combination Kit Service Parts Assemblies ........................ 302 Cab Sound Suppression Kit 190785 (46/4840), 190787 (56/6640)..................... 303 Cab Sound Suppression Kit 190786 (46/4840), 190788 (56/6640)..................... 304 Dual Glow Upgrade Kit 189850 ...................................... 305 Remote Battery Terminal Kit 190759 and the Engine Block Heater Kit 808203 ............. 306 Backup Alarm Kit for Dual Joystick 810838 and the Cab Sound Suppression Kit 810776 ........ 307 Radio, AM-FM-WB Kit 810897 (replaces 810429) ............................ 308 Hydraulic Dampening Kit 810880 ..................................... 309 Four-Point Lift Kit 810945 (replaces 810866) ............................... 310 Hydraulic Power All-Tach™ Kit 810959 (46/4840), 810960 (5640) and 810961 (6640) ......... 311 14-Pin Connector for Auxiliary Attachments Kit 811226 ......................... 314 Other Available Accessories ........................................ 315 SECTION D: SCHEMATICS Hydrostatic/Hydraulic Schematic - Non-Dual Joystick Controls ...................... 317 Hydrostatic/Hydraulic Schematic - Dual Joystick Controls ........................ 318 Electrical Schematics - ROPS and Chassis ................................. 319 Heater Schematic .............................................. 323 HVAC Schematic .............................................. 324 Electrical Auxiliary Hydraulics Schematic - Dual Joystick ........................ 325 Electrical Auxiliary Schematic - 14-Pin Connector............................. 326 Numerical Index .............................................. 328 O-Ring Table, Coupling & Adapter Torque Table ............................. 345 Torque Specifications Table ................................ Inside Back Cover DESCRIPTION PAGE

SECTION A: MAIN LOADER COMPONENTS Chassis and Control Covers ................................. 1 Wheel Drives ........................................ 13 Engine ........................................... 19 Air Cleaner and Muffler .................................. 33 Coolers ........................................... 49 Hydrostatic System - Drive Motors ............................ 57 Hydraulics - Chassis .................................... 81 Hydraulics - Lift Arm ................................... 91 Hydraulics - Auxiliary .................................. 101 Controls - Auxiliary Hydraulics ............................. 123 Controls - Lift and Tilt .................................. 127 Controls - Traction .................................... 139 Controls - Engine ..................................... 159 Lift Arm .......................................... 169 All-Tach™ and Power-A-Tach™ Attachment Bracket ................. 171 ROPS and Interior ..................................... 177 Seat and Seat Belt Options ................................ 183 Restraint Bar ....................................... 189 Grille and Engine Covers ................................. 191 Electrical - Chassis .................................... 193 Electrical - ROPS ..................................... 201 Electrical - Lights ..................................... 205 Ignition Switch (Earlier Models) ............................. 207 Electrical - Control .................................... 209 Sound Suppression .................................... 211 Tires ............................................ 217 Decals ........................................... 222 SECTION A: MAIN LOADER COMPONENTS

5 28 NOTES: 28 1. APPLY HI-TACK GASKET ADHESIVE 2. APPLY OIL-RESISTANT RTV 3. APPLY PIPE THREAD SEALANT 23 3 5 24 29 20 TO MTG. BLOCK ON LEFT INNER RISER 28 9 SEE NOTE 2 SEE NOTE 2 16 16 4 14 33 11 30 7 34 13 1 22 33 15 33 36 SEE NOTE 3 36 SEE NOTE 3 SEE NOTE 2 36 36 SEE NOTE 1 18 17 8 37 31 37 8 28 33 15 19 29 29 21 32 32 12 12 12 12 6 6 32 32 5 25 2 10 30 25 27 26 35 38 CHASSIS 917000/IP1207 1 PRINTED IN USA 139567_139570 4640 and 4840 Models

Ref. Part Quantity Quantity No. No. Description 4640 4840 1 072343 GASKET/FUEL SENDER 1 1 2 092164 SCREW/HEX 1/2 X 1-1/4 6 6 3 127342 CAP ASSEMBLY/FILLER 1 1 4 128591 BREATHER/RESERVOIR 1 1 5 131522 PLUG SAE12 3 3 6 131842 NUT/SPIRALOCK™ 5/16 4 4 7 132050 STRAINER/FUEL FILL 1 1 132051 CAP/FUEL FILL 1 1 650702 SCREW/MACHINE PHILLIPS HEAD #6 X 3/8 2 2 8 132298 WASHER/SEAL 2 2 9 134345 COVER/TOEPLATE 1 1 10 134558 COVER ASSEMBLY/HYDRAULIC RESERVOIR 1 1 11 134756 SIGHT PORT/OIL LEVEL 1 1 12 134853 NUT/SPIRALOCK™ 1/2 6 6 13 136013 SENSOR/FUEL 1 1 14 138289 CHASSIS 4640 1 - 138334 CHASSIS 4840 - 1 15 138593 COVER/CHAINCASE 2 2 16 139501 FILLER/ROPS 2 2 17 139602 PLATE/FLOOR 1 1 18 140376 BELLYPAN/FRONT 1 - 139743 BELLYPAN/FRONT - 1 19 139971 COVER/SEAT UNDER RIGHT 1 1 20 139975 PLATE/CROSSMEMBER 1 1 21 139995 COVER/SEAT UNDER LEFT 1 1 22 140142 FENDER/LEFT 1 1 23 140143 FENDER/RIGHT 1 1 24 140752 BRACKET/SOLENOID 1 1 25 184670 PLUG/PIPE SQUARE SOCKET 3/4 2 2 26 189376b WELDMENT/FILTER BRACKET - 1 187383a WELDMENT/FILTER BRACKET - 1 27 190560 TRAY ASSEMBLY/BATTERY 1 1 28 650569 SCREW/CAP 1/2 X 1-3/4 4 4 29 650486 SCREW/CAP 5/16 X 3/4 6 6 30 650488 SCREW/CAP 3/8 X 3/4 3 6 31 650494 SCREW/CAP 1/2 X 1 2 2 32 650495 SCREW/CAP 1/2 X 1-1/4 6 6 33 651042 SCREW/MACHINE HEX FLANGE 3/8 X 1 38 38 34 651312 SCREW/MACHINE PHILLIPS HEAD #10 X 1/2 5 5 35 651648d SCREW/CAP THREAD FORMING 5/16 X 3/4 3 3 651041c SCREW/MACHINE HEX FLANGE 3/8 X 3/4 3 3 36 654030 WASHER/LOCK 1/2 4 4 37 654046 WASHER/FLAT 7/16 2 2 38 183916e STRIP/TRIM 1 1 a) 4840: SN 408500 and Before b) 4840: SN 408501 and Up c) OLDER-STYLE PART NUMBER, CHECK YOUR SKID-STEER LOADER FOR CORRECT SCREW SIZE. d) NEWER-STYLE PART NUMBER, CHECK YOUR SKID-STEER LOADER FOR CORRECT SCREW SIZE. e) TRIM STRIP USED ON OLDER-STYLE SKID-STEER LOADERS. CHASSIS PRINTED IN USA 2 917000/IP1207

TO MTG. BLOCK ON LEFT INNER RISER 16 SEE NOTE 1 24 5 5 25 16 1. APPLY HI-TACK GASKET ADHESIVE 2. APPLY OIL-RESISTANT RTV 3. APPY PIPE THREAD SEALANT NOTES: SEE NOTE 3 SEE NOTE 2 SEE NOTE 2 SEE NOTE 2 SEE NOTE 3 9 15 8 39 33 39 8 38 30 38 30 38 30 30 38 35 35 31 5 18 19 1 13 36 7 32 3 35 12 10 4 17 17 6 11 6 11 11 34 31 22 11 34 31 20 34 21 34 35 26 27 23 2 32 SEE NOTE 3 14 REAR VIEW 27 29 29 28 37 CHASSIS 917000/IP1207 3 PRINTED IN USA 139527_139563 5640 and 6640 Models

Ref. Part Quantity Quantity No. No. Description 5640 6640 1 072343 GASKET/FUEL SENDER 1 1 2 092164 SCREW/HEX 1/2 X 1-1/4 6 6 3 127342 CAP ASSEMBLY/FILLER 1 1 4 128591 BREATHER/RESERVOIR 1 1 5 131522 PLUG SAE12 3 3 6 131842 NUT/SPIRALOCK™ 5/16 4 4 7 132050 STRAINER/FUEL FILL 1 1 132051 CAP/FUEL FILL 1 1 650702 SCREW/MACHINE PHILLIPS HEAD #6 X 3/8 2 2 8 132298 WASHER/SEAL 2 2 9 134345 COVER/TOEPLATE 1 1 10 134756 SIGHT PORT/OIL LEVEL 1 1 11 134853 NUT/SPIRALOCK™ 1/2 6 6 12 135769 COVER ASSEMBLY/HYDRAULIC RESERVOIR 1 1 13 136013 SENSOR/FUEL 1 1 14 137907 PLUG/HEX SCREW 1/4 1 1 15 138386 CHASSIS 5640 1 - 138355 CHASSIS 6640 - 1 16 138593 COVER/CHAINCASE 2 2 17 139501 FILLER/ROPS 2 2 18 139602 PLATE/FLOOR 1 1 19 139603 BELLYPAN/FRONT 5640 1 - 139605 BELLYPAN/FRONT 6640 - 1 20 139971 COVER/SEAT UNDER RIGHT 1 1 21 139975 PLATE/CROSSMEMBER 1 1 22 139995 COVER/SEAT UNDER LEFT 1 1 23 140135 FENDER/LEFT 1 1 24 140136 FENDER/RIGHT 1 1 25 140752 BRACKET/SOLENOID 1 - 26 183916e STRIP/TRIM 1 1 27 184670 PLUG/PIPE SQUARE SOCKET 3/4 2 2 28 189376b WELDMENT/FILTER BRACKET 1 1 187383a WELDMENT/FILTER BRACKET 1 1 29 190560 TRAY ASSEMBLY/BATTERY 1 1 30 650569 SCREW/CAP 1/2 X 1-3/4 4 4 31 650486 SCREW/CAP 5/16 X 3/4 6 4 32 650488 SCREW/CAP 3/8 X 3/4 6 6 33 650494 SCREW/CAP 1/2 X 1 2 2 34 650495 SCREW/CAP 1/2 X 1-1/4 6 6 35 651042 SCREW/MACHINE HEX FLANGE 3/8 X 1 38 38 36 651312 SCREW/MACHINE PHILLIPS HEAD #10 X 1/2 5 5 37 651648d SCREW/CAP THREAD FORMING 5/16 X 3/4 3 3 651041c SCREW/MACHINE HEX FLANGE 3/8 X 3/4 3 3 38 654030 WASHER/LOCK 1/2 4 4 39 654046 WASHER/FLAT 7/16 2 2 a) 5640: SN 506600 and Before. 6640: SN 605500 and Before b) 5640: SN 506601 and Up. 6640: SN 605501 and Up c) OLDER-STYLE PART NUMBER, CHECK YOUR SKID-STEER LOADER FOR CORRECT SCREW SIZE. d) NEWER-STYLE PART NUMBER, CHECK YOUR SKID-STEER LOADER FOR CORRECT SCREW SIZE. e) TRIM STRIP USED ON OLDER-STYLE SKID-STEER LOADERS. CHASSIS PRINTED IN USA 4 917000/IP1207 Spiralock is a trademark of H.D. Holmes, licensed to Detroit Tool Industries. License includes U.S. and foreign patent rights. Loctite is a registered trademark of the Loctite Corporation.

6 9 5 8 8 1 2 4 10 3 7 CHASSIS 917000/IP1207 5 PRINTED IN USA Covers - Hand Controls 190458_190507

GEHL 4640 4840 5640 6640 Loader Parts Manual

You're Reading a Preview

Recently Viewed