Form No.

913309
Revision B

For use on the following models:

Gehl: RS5-19
Mustang: 519

REPAIR

PUMP A 4 VG 40 - 56

Serie 3.2
 REPAIR INSTRUCTIONS

CONTENTS

- General Repair Instructions ................................................................................................................................. 1

- Seal kits and sub assembly groups ..................................................................................................................... 2

- Sub assemblies groups ......................................................................................................................................... 3

- Sealing of the drive shaft ...................................................................................................................................... 4

- Sealing of the boost pump ................................................................................................................................... 5

- Sealing of the control piston cover ..................................................................................................................... 6

- Sealing of the valves ............................................................................................................................................. 8

- Sealing of the pressure cut-off valve .................................................................................................................. 9

- Sealing of the control valve .................................................................................................................................. 10

- Removing of the control module ........................................................................................................................ 11

- Pump disassembly ................................................................................................................................................ 13

- Removal of the rotary group ................................................................................................................................ 15

- Disassembly of the positioning piston ............................................................................................................... 16

- Inspection notes ..................................................................................................................................................... 17

- Inspection of rotary group parts ......................................................................................................................... 18

- Installation of rotary group ................................................................................................................................. 20

- Assembly of the Pump ......................................................................................................................................... 24

- Tightening torques ................................................................................................................................................ 26

- Safety regulations ...................................................................................................................................... 27
- Adjusting Transmission .......................................................................................................................... 29
 REPAIR INSTRUCTIONS

General repair Instructions

Attention !
Observe the following notices when carrying out repair
work at hydraulic aggregates !

Close all ports of the hydraulic aggregates.

Replace all seals.

Use only original Gehl spare parts.

Check all seal and sliding surfaces for wear.

Attention : Rework of sealing area f. ex. with abrasive
paper can damage surface.

Fill up hydraulic aggregates with medium before start-

up.

1
 REPAIR INSTRUCTIONS

Seal kits and sub assembly groups

Seal kit for drive shaft.

External seal kit.

Housing.

Complete rotary group.

Positioning piston.

2
 REPAIR INSTRUCTIONS

Sub assemblies

Port block.

Control moduls DA.

Boost pump.

Control valve.

3
 REPAIR INSTRUCTIONS

Sealing of the drive shaft

Protecting the drive shaft.

Remove retaining ring.

Screw in sheet metal screw into the holes fitted with

rubber.
Pull out shaft seal with pliers.

Press-in shaft seal with bush to stop.

4
 REPAIR INSTRUCTIONS

Sealing of the boost pump

Note !
* Mount chamfered side facing cover.

Mark position, remove fixing screws.

Pry-off cover.

Inspect the parts of the boost pump ad wear parts.

Boost pump can only be interchanged completely.

5
 REPAIR INSTRUCTIONS

Sealing of the control piston cover

Loosen mounting screws.

Rotate cover and release by tapping gently with
hammer.

Check !

O-ring (1), groove (2), housing (3).

Remove locknut whilst holding setting screw.

Mark cover. Must be fixed, loosen counter nut.

6
 REPAIR INSTRUCTIONS

Sealing of the control piston cover

Pull cover off using zero position adjustment screw.

Check !
O-ring (1), groove (2), housing (3).

Cover threads, push on small O-ring.

Assemble in reversed order.

Attention !
Adjustment of the correct zero position to be carried
out after installation into the machine or on the test
bench.

Reset mechanical zero position. To do this, connect

X1 to X2
(> size 6).

7
 REPAIR INSTRUCTIONS

Sealing of the valves

Valve P HP with bypass-function

Valve P SP

Cover threads before fitting new O-rings.

(Damage protection).

Remove valve poppet with spring.

* with bypass-function

Cover threads before fitting new O-rings.

(Damage protection).

8
 REPAIR INSTRUCTIONS

Sealing of the pressure cut-off valve

Change of the sealing nut.

Note setting measure (*).

Attention !
After assembly check "valve setting".

9
 REPAIR INSTRUCTIONS

Sealing of the control valve

Remove control valve.

Do not damage throttle diameter.

Before installing the new O-ring, tape the threads.

10
 REPAIR INSTRUCTIONS

Removing of the control module

Remove fixing screws.

Pry-off the control module.

Check :
Sealing surface (1), gasket (2), o-rings (3).

11
12
 REPAIR INSTRUCTIONS

Pump disassembly

Locking screw / pin

Timing adjustment screw

Mark position of the boost pump and the port plate.

Remove the boost pump.

Mark the position of the indexing screw (1).

Set the indexing screw to disassembly position (2).

Release port plate fitting.

Take off port plate. If necessary, use screwdriver.
Attention ! Sealing surface.

13
 REPAIR INSTRUCTIONS

Pump disassembly

Lift off control plate.

Note position.

Check !
O-ring and groove (1), housing (2), Quad-ring and
groove (3).

Press the cylinder to the bottom (1).

Remove fiming indexing screw (2).
Lift out rotary group (3).

Remove
1. cylinder
2. swash plate
3. joint pin

14
 REPAIR INSTRUCTIONS

Removal of the rotary group

Remove retaining ring, radial seal ring.

Remove drive shaft with slight hammer strokes.

Remove bearing cups.

15
 REPAIR INSTRUCTIONS

Disassembly of the positioning piston

Remove control module.

Pull out control piston (1).

Mount fixture and tension spring.

Remove receiving ring.

Take out rings.

Remove retaining ring.
Note ! Parts are spring loaded.

16
 REPAIR INSTRUCTIONS

Inspection notes

Replace all bearings.

Check !
1. splines for damage or fretting.
2. running surfaces.
3 groove cut by shaft seal.

Check that the control piston guide bush (1) is free of

grooves and has not worn out.

Check !
Control piston (1) is not scored.

17
 REPAIR INSTRUCTIONS

Inspection of rotary group parts

Check !
Sliding surface free of grooves.

Check !
Make sure sliding ring/swivel pin are free of play.

Check !
Check that return device is free of grooves (1) no wear
in slipper pad area (2).

Check !
Check that there are no scratches or metal deposits on
sliding surface (1), and there is no axial play (2),
(otherwise : pistons must be replaced in sets).

Check !
Cylinder bores (1), splines (2).

18
 REPAIR INSTRUCTIONS

Inspection of rotary group parts

Check !
Cylinder gilding surface (1), free of scratches, no traces
of wear and no embedded foreign particles. No
scratches on the valve plate (2) (Replace ONLY in sets).

Check !
DU-bearing bush (1) is not worn out.

Information :
Boring for DA-control open.
Without DA-control closed.

Check !
Bearing surfaces (1).

19
 REPAIR INSTRUCTIONS

Installation of the rotary group

Insert bearing cup set.

Insert positioning piston into the housing.

Instruction :
Oil positioning piston before assembly.

Assemble bearing, wire, gliding stone and articulating pin.

Assistance :
Devices e.g. - Clamp / rubber rings / grease

Insert completely swivel cradle into the housing.

Pay attention for correct seat of the swivel cradle in the
housing.

Remove auxiliary device.

20
 REPAIR INSTRUCTIONS

Installation of the rotary group

Assemble articulating pin.

Assemble device for fixation of the swivel cradle.

Assemble drive shaft with bearings and radial seal

rings !

Disc 1, 2

21
 REPAIR INSTRUCTIONS

Installation of the rotary group

Assemble piston with retaining plate.

Note :
Oil piston and piston pad.

Assemble cylinder completely.

Remove assembly device.

22
 REPAIR INSTRUCTIONS

Installation of the rotary group

Control plate clockwise rotation - indexed in the

direction of rotation.
Note !
Noise grooves are machined - in based on direction of
rotation.

Control plate counter clockwise rotation - indexed in

the direction of rotation.
Note !
Noise grooves are machined - in based on direction of
rotation.

Oil the running surfaces of the cylinder barrel and the

DU-bearing. Grease the O-rings and insert in grooves.

Basic setting - indexing screw

A4VG... 40 * = 24 +_ 0,75 mm.
A4VG... 56 * = 21 +_ 0,75 mm.

Press the cylinder to the bottom (1).

Screw in the indexing screw (2).
Groove in mounting position.

23
 REPAIR INSTRUCTIONS

Assembly of the pump

Insert the control plate - clockwise rotation.

Insert the control plate - Counter - clockwise rotation.

Place in correct position.

Note :
HW, HD, EP - Put control plate with greas to the port
block.

Tighten screws (Cross-corner).

Turn the indexing screw to marking.

Assemble boost pump.

24
 REPAIR INSTRUCTIONS

Assembly of the pump

Mount control module.

25
 REPAIR INSTRUCTIONS

26
 REPAIR INSTRUCTIONS

Safety regulations

General advice

• Make yourself familiar with the equipment of the machine.

• Only operate the machine if your are completely familiar with the operating and control elements as well as
the functioning of the machine.
• Use your safety equipment like helmet, safety shoes and hearing protection.
• Make yourself familiar with your working field.
• Only operate the machine for its intended purpose.

Please observe the guidelines of the Professional Association and the machine manufacturer.

Before starting

• Observe the operating instructions before starting.

• Check the machine for obvious faults.
• Do not operate the machine with defective instruments, warning lights or control elements.
• All safety devices must be in a secure position.
• Do not carry with you movable objects or secure them to the machine.
• Keep oily and inflammable material away from the machine.
• Before entering the driver's cabin, check if persons or obstacles are beside or beneath the machine.
• Be careful when entering the driver's cabin, use stairs and handles.
• Adjust your seat before starting.

27
 REPAIR INSTRUCTIONS

Safety regulations

Start

• When starting all operating levers must be in "neutral position".

• Only start the machine from the driver's seat.
• Check the indicating instruments after start to assure that all functions are in order.
• Do not leave the machine unobserved when the motor is running.
• When starting with battery connection cables connect plus with plus and minus with minus.
Always connect negative (-) cable last and disconnect negative cable first.

Attention

• Exhaust gas is dangerous. Assure sufficient fresh air when starting in closed rooms !

Hydraulic equipement

1. Hydraulic equipment is standing under high pressure.

High pressure fluids (fuel, hydraulic oil) which escape under high pressure can penetrate the skin and
cause heavy injuries.
Therefore immediately consult a doctor as otherwise heavy infections can be caused.
2. When searching leakages use appropriate auxiliary devices because of the danger of accidents.
3. Before working at the hydraulic equipment, lower pressure to zero and lower working arms of the
machine.
4. When working at the hydraulic equipment, absolutely stop motor and secure tractor against rolling away
(parking brake, shim) !
5. When connecting hydraulic cylinders and motor pay attention to correct connection of hydraulic flexible
hoses.
6. In case of exchanging the ports, the functions are vice versa (f. ex. lift-up/lower) - danger of accidents !
7. Check hydraulic flexible hoses regularly and replace them in case of dammage or wear ! The new hose
pipes must comply with the technical requirements of the machine manufacturer !

Orderly disposal or recycling of oil, fuel and filters !

28