This is the factory service manual for the Gehl 480 all-wheel-steer loader, Form No. 918117, for the 2005 build. Across 204 pages it documents the Deutz F4M 2011 diesel, rated at 59 hp (44 kW), and covers the machine from overview and specifications through the electrical system.The content is organized into overview, engine, power train, axles, brakes, steering, hydraulic system, and electrical system sections, with tightening torques, fluid capacities, and test procedures throughout. Schematics and diagrams support the repair, test, and adjustment work.Owners and independent mechanics use it to service the engine and cooling system, test the hydrostatic power train, seal the steering cylinders, set the axle and wheel hardware, work the brake circuit, and trace wiring faults. The PDF has a text layer and bookmarks, downloads instantly after purchase, and prints on standard paper.
What's Inside This Gehl 480 Manual
| System | Pages | Key Topics |
|---|---|---|
| Overview | 9-16 | Important Information, Type Decals and Component Numbers, Machine Overview, Cab Overview, Instrument Panel, Multifunctional Lever and Drive Lever: Overview |
| Engine | 65-80 | F4M 2011 Engine: Overview, Engine Oil Cooling, Fuel System, Engine Level 2, Checking and Adjusting Valve Tip Clearance, Replacing the Fuel Injection Pump |
| Power Train | 81-104 | Variable Displacement Pump 12.5 Mph, Hydraulic Motor – Hydraulic Connections 12.5 Mph, Hydraulic Motor – Control Element 12.5 Mph, Power Train Circuit with Cooling 12.5 Mph |
| Axles | 105-128 | Type Decal – Axle, Front Axle Screw Connections, Rear Axle Screw Connections, Drain, Fill and Check Plug – Front Axle, Fill and Check Plug – Rear Axle |
| Brakes | 129-132 | Brake Circuit, Brake Diagram, Service Brake (Important Information on the Brake System, Bleeding the Brake System with Bleed Equipment) |
| Steering | 133-140 | Mph (20 Km/H) Steering Circuit, 25 Mph (40 Km/H) Steering Circuit, Hydraulic Ports on Servostat, Sealing the Steering Cylinder 12.5 / 25 Mph (20 Km/H / 40 Km/H) |
| Hydraulic System | 141-158 | Test Report, Control Valve: Overview – Connections, Work Hydraulics Oil Supply (Priority Valve for Work Hydraulics and Steering), Control Valve, Pilot Control Unit: Design |
| Electrical System | 159-204 | Ohm’s Law; Power, Measuring Equipment, Measuring Methods, Terminal Description, Cable Color Coding (Other Color Codes) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Wheel nut torque | 295 ±15 lb.-ft. (400 ±20 Nm) | p. 25 |
| Track-rod end (steering cylinder) torque | 148 lb.-ft. (200 Nm) | p. 25 |
| Engine Displacement | 190 in.³ (3109 cm³) | p. 17 |
| Engine Output | 59 DIN hp (44 kW) at 2400 rpm | p. 17 |
| Engine Max. Torque | 144 lb.-ft. (195 Nm) at 1700 rpm | p. 17 |
| Intake Valve Clearance (cold) | 0.012'' (0.3 mm) | p. 17 |
| Exhaust Valve Clearance (cold) | 0.020'' (0.5 mm) | p. 17 |
| Engine Oil Capacity | 11 qts. (10.5 L) | p. 27 |
| Hydraulic Oil Tank Capacity | About 17 gal. (65 L) | p. 27 |
| Fuel Tank Capacity | About 21 gal. (80 L) | p. 27 |
| Rated Operating Load (Loader Unit) | 3748 lbs. (1700 kg) | p. 21 |
| Operating Weight | 9921 lbs. (4500 kg) | p. 24 |
Gehl 480 Common Problems This Manual Covers
Loader will not drive or travels weakly
Very weak travel or no drive usually starts with the hydrostatic power train: overfull or aerated oil, low drive pressure, or pump and motor wear. The Power Train section covers the variable displacement pump and hydraulic motor.
Manual Section: Power Train p. 81Hydraulic leak near the steering valve
A leak under the cab or around the steering area is often a failed seal or O-ring in the steering valve rather than the hose first suspected. The Steering section covers the steering circuit and sealing the steering cylinder.
Manual Section: Steering p. 133All hydraulic functions weak at once
When boom, bucket, and auxiliary functions are all weak, the cause is usually the main relief or pilot pressure rather than a single line. The Hydraulic System section covers the control valve and test report procedures.
Manual Section: Hydraulic System p. 141Engine overheating
Overheating typically means low coolant, a clogged radiator, restricted airflow, or a thermostat or fan fault. The Engine section covers the F4M 2011 and its oil cooling circuit.
Manual Section: Engine p. 65Intermittent electrical operation
Corroded battery terminals, damaged wiring, or broader system faults can cause intermittent controls and hard starting. The Electrical System section covers terminal descriptions, cable color coding, and measuring methods.
Manual Section: Electrical System p. 159Loose wheel or axle hardware
Wheel and axle fasteners that loosen cause vibration and poor handling. The Axles section covers front and rear axle screw connections and their tightening torques.
Manual Section: Axles p. 105Frequently Asked Questions
Which machine does this manual cover?
It covers the 2005 Gehl 480 all-wheel-steer loader, Form No. 918117, including the 480T variant, built with the Deutz F4M 2011 diesel engine.
What engine and power does it document?
The Engine section covers the Deutz F4M 2011, rated at 59 hp (44 kW) at 2400 rpm, including oil cooling, the fuel system, and valve clearance procedures. p. 65
Does it list torque specifications?
Yes. The Tightening Torques section gives general and specific values, including the 295 lb-ft wheel nut torque and steering cylinder track-rod and piston rod torques. p. 25
Can it help me troubleshoot the hydraulics?
Yes. The Hydraulic System section starts on page 141 with the test report, control valve, work hydraulics oil supply, and pilot control unit design. p. 141
Is this Service Manual a digital download?
Instant PDF download. The full 204-page searchable Service Manual is yours immediately after payment. Open it on a laptop, tablet, or phone, right in the shop.
Am I able to print pages from this manual?
Yes, print as many copies as you want. There are no restrictions, and many mechanics print only the section they need to bring to the shop floor.
Does this Gehl 480 Service Manual cover the hydraulic system?
Full hydraulic system diagrams are included, covering circuits, valve locations, and hydraulic component specs for the Gehl 480.
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