This 220-page factory manual (OEM #50940008) delivers complete repair coverage for Mustang AL 406 and AL506 articulated loaders. It details chassis teardown, hydrostatic drive maintenance, axle service, and the PLUS+1 machine controller system. Mechanics will find serial-number-specific hydraulic schematics for every build variant, alongside wiring diagrams for the chassis, engine, steering column, and FOPS circuits. The guide features 20 pages of diagnostic flow charts dedicated to work hydraulics, drive, steering, and operator presence faults. It also covers Drive Controller error codes and PLUS+1 pedal calibration. Specifications are exact: torque the M10x1.0 hydraulic fitting (sealing washer) to 9 Nm and replace the hydraulic fluid and return filter at 500 hours. Fully bookmarked and searchable, this PDF loads instantly on any device.
What's Inside This Mustang AL 406, AL506 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 9-16 | - |
| Maintenance | 23-54 | Engine Air Cleaner, Engine Maintenance, Engine Oil, Maintenance Log, Maintenance Schedule, Check, Clean and Inspect, Functional Check |
| Operation | 55-66 | Operation Safety, Controls and Switches, Instrument Panel and Indicators |
| Chassis | 67-84 | Tilting the Platform, Lowering the Platform, Repairing or Replacing Platform Switch (Series: 41249 and Before, 51241 and Before), Hood Removal, Hood Installation |
| Engine | 85-94 | Engine Removal, Engine Installation, Drive Coupling Removal, Starter Removal |
| Cooling System | 95-100 | Radiator/Oil Cooler Removal, Radiator/Oil Cooler Installation |
| Axles | 101-108 | Front Axle Removal, Front Axle Installation, Rear Axle Removal, Rear Axle Installation |
| Hydraulics | 109-172 | Work Hydraulics Troubleshooting, Hydrostatic Drive System, Hydraulics Troubleshooting Diagnostic Flow Charts, Drive System Pressure Tests, Work System Pressure Tests |
| Machine/Drive Controllers | 173-188 | Machine and Drive Controllers, Machine Controller (Led/Indicator Assignments, Logic), Drive Controller (Error Codes) |
| Electrical System | 189-202 | Battery Removal, Battery Installation, Al 400 Series Complete Electrical Schematic, Al 400 Series Steering Column Electrical Schematic, Al 400 Series Chassis Electrical Schematic |
| Troubleshooting | 203-210 | Indicator Lamps / Seals and Hoses, Hydraulic System, Hydrostatic Drive System, Electrical |
| Torque Specifications | 215-219 | Hydraulic Fittings with Various Seals, With Coarse-Pitch Thread, With Fine-Pitch Thread |
| Back Cover | 220 | Mustang Manufacturing Co., Inc., P.O. Box 179, West Bend, 53095-0179 Usa, Www.Mustangmfg.Com |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hydraulic fluid and return filter replacement interval | 500 Hours (or annually) | p. 25 |
| Hydraulic oil filter installation (gasket tightening) | 3/4 rotation past point where gasket contacts filter head | p. 35 |
| Hydraulic hose replacement action (damaged/leaking) | Repair/replace as required | p. 109 |
| Hydraulic fitting torque (M10X1.0, Sealing washer) | 7 lb-ft (9 Nm) | p. 215 |
| Hydraulic cylinder seals replacement action | Remove and discard, then install new seals | p. 149 |
| Teflon piston seals installation temperature | 130°-140° F (54°-60° C) | p. 147 |
| Fuel filter replacement interval | 500 Hours (or annually) | p. 25 |
| Fuel filter installation (gasket tightening) | 3/4 turn past point where gasket contacts filter head | p. 31 |
| Starter power rating | 12V - 2.3 kW | p. 21 |
| Starter mounting bolts torque | 64 lb-ft (87 N•m) | p. 94 |
| Gear/Work Hydraulic Pump mounting bolts torque | 33 lb-ft (45 N•m) | p. 155 |
| Piston/Drive Hydraulic Pump mounting bolts torque | 92 lb-ft (125 N•m) | p. 158 |
Mustang AL 406, AL506 Common Problems This Manual Covers
Work hydraulics become weak, erratic, or stop entirely under heavy load p. 155
Verify the fluid level, adding up to 40 L (10.6 gal.) if the tank is empty. Inspect the gear hydraulic pump and torque the mounting bolts to 33 lb-ft (45 N•m) as shown on page 155. Finally, test the work hydraulics to confirm the system pressure reaches 207 bar (3000 psi).
Manual Section: HydraulicsHydrostatic drive system overheats and loses tractive power during continuous heavy loader operation p. 208
Clear debris from the oil cooler fins and replace the restricted hydraulic oil filter. Secure the new filter 3/4 rotation past the point where the gasket contacts the filter head, according to page 35. Inspect the hydrostatic pump relief valves on page 208 to adjust the relief pressure.
Manual Section: Hydrostatic Drive System TroubleshootingEngine turns over slowly but will not start or starter motor fails to engage p. 94
Inspect the 12V - 2.3 kW starter and replace it as needed following page 210. Torque the starter mounting bolts to 64 lb-ft (87 N•m) per page 94. Change the fuel filter and tighten it 3/4 turn past initial gasket contact.
Manual Section: EngineFrequently Asked Questions
What are the recommended service intervals?
The maintenance schedule outlines various service procedures with different maximum intervals. For example, cleaning the machine, checking engine oil level, and tire condition should be done every 10 hours (or daily). Changing engine oil/filter is recommended after the first 50 hours, then every 250 hours thereafter, as detailed on page 25.
What fluids and capacities does this machine require?
The machine requires specific fluids and capacities. For instance, the Diesel Engine Oil capacity is 7.4 L (2.0 gal.), Diesel Fuel capacity is 67 L (17.7 gal.), and Hydraulic Oil System/Tank capacity is 40 L (10.6 gal.) of UTTO Fluid (Mobil 424 or equivalent). The Engine Coolant System/Radiator capacity is 6.4 L (6.8 qts.) of long-life coolant ASTM D4985, D6210.
How to troubleshoot engine won't start?
If the engine does not turn over, check if the drive direction switch is in neutral, reset any tripped circuit breaker, or replace a blown fuse. If the engine turns over but won't start, check the battery and charge/replace if necessary, ensure the fuel tank is not empty, and replace a plugged or restricted fuel filter. For more details, refer to page 197.
What are the hydraulic system specifications?
The hydraulic system specifications include a Work Hydraulic System with a flow of 57 L/min (15 gpm) and a System Pressure of 207 bar (3000 psi). The Drive Hydraulic System has a flow of 117 L/min (31 gpm) and a System Pressure of 410 bar (5946 psi). The Reservoir Capacity for the hydraulic system is 42 L (11 gals.), and the Bucket Breakout Force is 10749 lbf (47.8 kN).
What format is this Mustang AL 406, AL506 manual in?
Instant PDF download. You get the full 220-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Can I print specific sections of this Mustang AL 406, AL506 Service Manual?
Yes. The PDF has no DRM restrictions — print any page or section you need for your shop. Works with any standard printer.
Does this Mustang AL 406, AL506 manual include hydraulic schematics?
Yes — complete hydraulic schematics with flow diagrams, valve configurations, and pressure specifications are included.
Document Quality
This document is a scanned PDF with an OCR layer, allowing you to search and copy the full text. The text quality is crisp and consistently easy to read throughout the manual. Diagrams and illustrations, including detailed schematics and torque tables, are clear raster images, with labels generally readable, though some fine print may soften at high zoom. Pages are clean and free of scan artifacts, stains, or skewed content. You will find a few blank pages used as section dividers or for notes.
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