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Form No.

917152
Revision G

2066/2076/2086
Skid-Steer
Loader
Service Manual
Document PN (Order)
1. 915167
2. 917098
3. 917120
4. 915100
5. 917119
6. 915093
7. 917153
8. 917231
9. 917261
10. 917172
11. 917292

Description
2.00" Med White View Thru Binder
Manual/Service Mustang 2066/76/86
Poclain ML06 Hyd. Motor Repair
Haldex W Series Hyd. Gear Pump Motor
Eaton 7-06-629 EN-800 v-04 Repair
Eaton Repair Information #7-515
Joystick/T-Bar Controls Addendum
Dual Joystick Controls Addendum
Rexroth AA20VG Tandem Pump Repair Manual
Yanmar TNV Engine Workshop Manual
Tier 3 Yanmar Engine Addendum

Revision
NA
A
A
A
A
A
A
B
A
A
A

917152/GP1108

2008 MUSTANG MANUFACTURING CO., INC. PRINTED IN USA


All Rights Reserved.

Form No. 917152

Mustang 2066/2076/2086
Service Manual

Mustang 2066
Mustang 2076
Mustang 2086

SKID-STEER LOADERS
with Tier3 Yanmar Engine
SERVICE MANUAL
Addendum
PART #917292
Revision A - 10/08

INTRODUCTION
With correct maintenance and proper use, Gehl and Mustang skid-steer loaders will give
years of dependable service. This service manual is intended to be a guide in the assembly
and disassembly, installation and removal, adjustment and testing, troubleshooting and
replacement of components that together make up the Mustang 2066/76/86 family of
skid-steer loaders.
In many of the procedures found within, the installation steps are the exact opposite of the
removal steps and vice versa, and therefore, the opposite procedure is not written. Instead, a
note to reverse the procedure will be stated. This reduces redundancy and excessive pages in
the manual. In cases though, where the assembly and disassembly or removal and
installation procedures differ and additional steps or safety concerns are paramount, the
entire reverse procedure will be written out to include the new information.
The Table of Contents and Index can be used to make the procedure you need to find an
easier process. Also, there are black tabs extending off the pages highlighting the chapters
for those who prefer to thumb through the manual. Many schematics, photographs, and lineart drawings are used to help perform the necessary repairs, tests or adjustments that the
Mustang 2066/76/86 kid-steer loaders need to keep them in good running condition.
If you have any additional questions, please contact your authorized Gehl or Mustang dealer
or call the Gehl Service Department for assistance.

IMPORTANT
For maximum engine life, when shutting the engine down, allow the engine
to idle, without load, for five minutes. This will allow engine components
that operate at high temperatures to cool slightly before the engine itself is
shut down.

TABLE OF CONTENTS

TABLE OF CONTENTS
Specifications

Page 1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Tire Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Buckets and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Safety

Page 2-1

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1


Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Additional Safety Reminders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Liftarm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Liftarm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Liftarm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
ROPS, Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
ROPS, Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Lubrication

Page 3-1

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1


Crankcase Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic Oil Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cooling System Drain Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Grease Fitting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Mainframe

Page 4-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Rollover and Falling Object - Protective Structure Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Engine Access Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control Cover Components - Hand and Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Control Cover Components - Dual Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
PRINTED IN USA

917292/AP1008

TABLE OF CONTENTS
Control Cover Components - T-Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Control Cover Components - T-Bar/Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
ROPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
All-Tach Hitch Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Control Cover, Floor Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Rear Grille and Engine Cover Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Controls

Page 6-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lift and Tilt Components - Hand/Foot Control Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lift and Tilt Components - Dual Joystick and T-Bar/Joystick Control Models . . . . . . . . . . . . . . . . . . . . . . . 6-4
Lift and Tilt Components - T-Bar Control Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Drive Control Components - Hand/Foot Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Drive Control Components - Dual Joystick Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Drive Control Components - T-Bar and T-Bar/Joystick Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Lift/Tilt Control Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Electrical Hand Throttle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Electrical Foot Throttle Removal and Installation - Dual Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Electrical Foot Throttle Assembly - T-Bar, T-Bar/Joystick and Dual Joystick Controls . . . . . . . . . . . . . . . . 6-14

Hydrostatic System

Page 7-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Single-Speed Components - Dual Joystick Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Single-Speed Components - Hand/Foot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
2066/76 Two-Speed Components - Dual Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Two-Speed Components - Hand/Foot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Hydraulic/Hydrostatic Schematic - Dual Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Hydraulic/Hydrostatic Schematic - Hand/Foot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

All-Tach and Hydraglide are trademarks of the Gehl Company.


917292/AP1008

ii

PRINTED IN USA

TABLE OF CONTENTS
Hydraulic System

Page 8-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Standard Auxiliary Hydraulics - Dual Joystick, H/F and T-Bar/Joystick Controls . . . . . . . . . . . . . . . . . . . . 8-5
Standard Auxiliary Hydraulics - T-Bar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
High-Flow Auxiliary Hydraulics - Dual Joystick, H/F and T-Bar/Joystick Controls . . . . . . . . . . . . . . . . . . 8-7
High-Flow Auxiliary Hydraulics - T-Bar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Lift Arm Hydraulics Components - 2066/76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Lift Arm Hydraulics Components - 2086 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Lift Arm Hydraulics Components - 56/6640. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
High-Flow Lift Arm Hydraulics Option - Dual Joystick, Hand/Foot, T-Bar/Joystick . . . . . . . . . . . . . . . . . 8-12
Pressure Tests, Standard-Flow and High-Flow Auxiliary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Manifold Valve Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Control Valve Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Main Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Control Valve Components - Standard-Flow and High-Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Electrical System

Page 9-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Description of Operation - Right and Left Instrument Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Chassis Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
ROPS Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Engine Electrical Components - 2066/76/86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
High-Flow and Two-Speed Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Power Distribution Panel Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Fuse Box Panel Test and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Interlock Control Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Interlock Control Module Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Two-Speed, Ride Control and Float Module Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Two-Speed, Ride Control and Float Module Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Electrical Standard Auxiliary Hydraulic Flow System Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Electrical High-Flow Auxiliary Hydraulic Flow System Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Engine Throttle Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Pilot Oil Solenoid Valve Test and Operation - Dual Joystick and Hand/Foot . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Solenoid Lock Valves Test and Operation - T-Bar Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Electrical Schematics - ROPS, Chassis, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22

PRINTED IN USA

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TABLE OF CONTENTS
Engine

Page 10-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Engine Components - Yanmar 4TNV98 - 2066/76/86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Air Cleaner and Exhaust Components - 2066 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Air Cleaner and Exhaust Components - 56/6640 and 2076/86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Radiator Cooler Components - 2066/76/86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Radiator Cooler Components - 56/6640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Remote Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Air Cleaner Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Battery and Battery Tray Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Exhaust Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Fan Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Radiator Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Fan Shroud and Cooler Mount Plates Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Engine Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Engine Diagnostic Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21

Index

917292/AP1008

iv

PRINTED IN USA

SPECIFICATIONS
2066

2076/5640

2086/6640

Make of Engine

Yanmar

Yanmar

Yanmar

Model

4TNV98-ZNMS

4TNV98T-ZNMS

4TNV98T-ZNMS

Fuel

Diesel

Diesel

Displacement

202 in (3,31 L)

202 in (3,31 L)

202 in (3,31 L)

Horsepower - Net

68.4 hp (51,0 kW)


@ 2500 rpm

84.4 hp (62,9 kW)


@ 2500 rpm

84.4 hp (62,9 kW)


@ 2500 rpm

Peak Torque

182 lb-ft (247 Nm)


@ 1600 rpm

222 lb-ft (301 Nm)


@ 1850 rpm

222 lb-ft (301 Nm)


@ 1850 rpm

Operating Load - SAE*

2018 lbs. (915 kg)

2018 lbs. (915 kg)

2581 lbs. (1171 kg)

Operating Weight

7460 lbs. (3384 kg)

7460 lbs. (3384 kg)

7900 lbs. (3583 kg)

Shipping Weight

6716 lbs. (3046 kg)

6716 lbs. (3046 kg)

7106 lbs. (3223 kg)

Diesel

Specifications below apply to all 2066/76/86 and 56/6640 Models


Capacities
Engine Oil

11.8 U.S. qts. (11,2 L)

Fuel Tank

24 U.S. gal (91 L)

Chaincase (each)

9 U.S. qts. (8,5 L)

Hydraulic Reservoir

16 U.S. gal. (61 L)

Engine Coolant

12 U.S. qts. (11,4 L)


Electrical

Battery

12-Volt DC, 950 CCA

Starter

12-Volt DC (3,0 kW)

Alternator

14-Volt DC, 95 A
Hydraulic System

Hydraulic System Pressure

3000 psi (207 bar)

Standard Aux. Flow Rate

21.5 gpm (81,4 L/min)

Hi-Flow Aux. Flow Rate (2076/86 only)

35.8 gpm (135, L/min)

Travel Speed - Single-Speed

8.1 mph (13,03 km/h)

Travel Speed - Two-Speed

12.3 mph (19,8 km/h)


Tire Options

10 (12) x 16.5 - 8-ply (10-ply)

High Clearance Flotation tires

10 (12) x 16.5 - 8-ply (10-ply)

Heavy Duty Poly-filled tires

10 (12) x 16.5 - 8-ply (12-ply)

Severe Duty tires

10 (12) x 16.5 - 8-ply (12-ply)

Severe Duty Poly-filled tires

6.50 (7.50) x 16 Solid

Solid Rubber tires

33 x 15.50 x 16.5 - 12-ply

Heavy Duty 2000 II tires

14 x 17.5 - 14-ply

High Clearance Flotation tires


Buckets and Capacities

Width - inches (millimeters)

Bucket Description

Capacity (Heaped)

70 inches (1778 mm)

Dirt/Construction

15 cubic feet

0,42 cubic meters

70 inches (1778 mm)

Dirt/Construction

19 cubic feet

0,54 cubic meters

74 inches (1879 mm)

Dirt/Construction

20.4 cubic feet

0,58 cubic meters

74 inches (1879 mm)

Utility

27 cubic feet

0,76 cubic meters

74 inches (1879 mm)

Utility/Snow

32.5 cubic feet

0,92 cubic meters

92 inches (2336 mm)

Snow

41.1 cubic feet

1,16 cubic meters

67.5 inches (1715 mm)

Earth and Foundry

14 cubic feet

0,40 cubic meters

15.75, 19.68, 24 inches


(400, 500, 670 mm)

Pallet Fork

NA

NA

*Operating load rated with a 70.0" inch (1778 mm) 2066/2076 dirt and construction bucket in accordance with SAE J818.

PRINTED IN USA

1-1

917292/AP1008

SPECIFICATIONS

SPECIFICATIONS

SPECIFICATIONS

Dimensional Specifications

2066/2076/5640 (EU)

2086/6640 (EU)

in.

mm

in.

mm

Overall operation height - fully raised

164.5

4178

164.3

4173

Height to hinge pin - fully raised

123.1

3127

123.2

3129

Overall height - top of ROPS

80.5

2045

81.2

2062

Overall length - bucket down

134.1

3406

138.8

3526

Dump angle @ full height

40

41

Dump height

91.1

2314

91.6

Dump reach - bucket (full height)

32.0

813

36.0

Rollback at ground

24.1

26.6

Rollback angle at full height

94.5

94.5

Seat-to-ground height

40.2

1021

40.6

Wheelbase - nominal

43.2

1097

48.4

1229

Overall width - less bucket

66.3

1684

66.3

1684

Overall bucket width

69.8

1773

69.1

1755

7.6

193

7.6

Ground clearance to chassis (between wheels)

Maximum back grading angle

Overall length (less bucket)

Departure angle

Clearance circle - front (with bucket)

Clearance circle - front (less bucket)

83
99.1

2327
914

1031

193
83

2517

104.3

84.0

2134

86.3

2192

49.3

1252

52.2

1326

21

2649
21

1 - w/ 0.63 cu. yd. bkt., w/ 12 x 16.5 tires

917292/AP1008

1-2

PRINTED IN USA

SAFETY
Signal Words

DANGER indicates an imminently


hazardous situation which, if not avoided,
will result in death or serious injury.

General Information

WARNING

The above safety alert symbol means: ATTENTION!


BECOME ALERT! YOUR SAFETY IS INVOLVED!
It stresses an attitude of Heads Up for Safety and can
be found throughout this service manual and on the
decals on the machine.

WARNING indicates a potentially


hazardous situation which, if not avoided,
could result in death or serious injury.

Before operating or working on this machine, read and


study the following safety information. In addition, be
sure that everyone who operates or works on this
equipment is familiar with these safety precautions. It is
essential to have competent and careful operators, who
are not physically or mentally impaired, and who are
thoroughly trained in the safe operation of the machine
and the handling of loads. It is recommended that the
operator be capable of obtaining a valid motor vehicle
operators license.

CAUTION
CAUTION indicates a potentially
hazardous situation which, if not avoided,
may result in minor or moderate injury. May
also alert against unsafe practices.

Additional Safety Reminders


Read and understand the Service Manual
and all decals before maintaining, adjusting
or servicing this equipment.

The use of skid-steer loaders is subject to certain hazards


that cannot be eliminated by mechanical means, but only
by exercising intelligence, care and common sense.
Such hazards include, but are not limited to, hillside
operation, overloading, instability of the load, poor
maintenance and using the equipment for a purpose for
which it is not intended or designed.

Doors, Guards and Shields - Some


photographs in this manual may show doors, guards and
shields open or removed for illustrative purposes only.
BE SURE all doors, guards and shields are in their
proper operating positions BEFORE starting engine to
operate unit.

The Gehl Company and Mustang Manufacturing


Company ALWAYS considers the operators safety
when designing its machinery and guards exposed
moving parts for the operators protection. However,
some areas cannot be guarded or shielded in order to
assure proper operation. Furthermore, the Operators
Manual and the decals on the machine warn of
additional hazards and should be read and observed
closely.

Damaged or Worn-out Parts - For safe operation,


replace damaged or worn-out parts with genuine
Mustang service parts, BEFORE operating this
equipment.
Attachments - Gehl and Mustang skid-steer loaders are
designed and intended to be used only with Gehl
Company and Mustang Manufacturing Company
attachments or approved referral attachments. The Gehl
Company and Mustang Manufacturing Company
cannot be responsible for operator safety if the loader is
used with a non-approved attachment.

This section of the manual includes procedures, which


when followed, will allow safe performance of service
procedures: Mandatory Safety Shutdown Procedure,
Lift Cylinder Lift Arm Support Device, Roll Over
Protective Structure (ROPS)/Falling Object Protective
Structure (FOPS) Lock Mechanism, Loader Raising and
Lowering Procedures, and
Relieving Hydraulic
Pressure.
PRINTED IN USA

Battery Safety - To avoid injury from a


spark or short circuit, disconnect the
negative (-) battery cable before servicing
any part of the electrical system. Do not
tip the battery more than 45 to avoid spilling electrolyte.
2-1

917292/AP1008

SAFETY

DANGER

SAFETY
Loader Stability - A skid-steer loaders stability is
determined by its wheel base and tread width. The
following elements can affect stability: terrain, engine
speed, load being carried or dumped, and sudden control
movements. DISREGARDING ANY OF THESE
FACTORS CAN CAUSE THE LOADER TO TIP,
POSSIBLY RESULTING IN DEATH OR SERIOUS
INJURY. Therefore, ALWAYS have the operator
restraint bar lowered and wear the seat belt. Operate the
controls only from the operators seat. Operate the
controls smoothly and gradually at an appropriate
engine speed that matches the operating conditions.

DO NOT drive too close to an excavation or ditch. BE


SURE that the surrounding ground has adequate
strength to support the weight of the loader and the load.

DO NOT exceed the rated operating load of the


machine. For additional stability when operating on
inclines or ramps, ALWAYS travel with the heavier end
of the loader toward the top of the incline.

People - NEVER carry riders. DO NOT allow others to


ride on the machine or attachment, because they could
fall or cause an accident.

DO NOT smoke or have any spark


producing equipment in the area while
filling the fuel tank or while working on the
fuel or hydraulic systems.
Exhaust Gases - Exhaust fumes can kill. DO NOT
operate this machine in an enclosed area unless there is
adequate ventilation.
Engine - NEVER use ether or starting fluid.

BE SURE all persons are away from the machine and


give a warning before starting the engine.

ALWAYS look to the rear before backing up.


When parking machine, before leaving seat, check
restraint bar for proper operation. The restraint bar,
when raised, applies the parking brake and deactivates
lift/tilt controls and auxiliary hydraulics.

ALWAYS face machine and use handholds and steps


when getting on or off. DO NOT jump off machine.
Wear appropriate ear protection for
prolonged exposure to excessive noise.

Keyswitch - NEVER attempt to bypass the keyswitch to


start the engine. Use the jump-starting procedure
detailed in the Service chapter of your Operators
Manual.

ALWAYS perform a daily inspection of the


machine BEFORE using it. Look for
damage, loose or missing parts, leaks, etc.
Remove trash and debris from the machine and engine
compartment each day to minimize risk of fire.

Hydraulic Fluid Leaks - NEVER use hands to search


for hydraulic fluid leaks. Instead, use paper
or cardboard. Fluid under pressure can be
invisible, penetrate the skin and cause a
serious injury. If any fluid is injected into
skin, see a doctor at once. Injected fluid
MUST be surgically removed by a doctor or gangrene
may result.

New operators MUST operate loader in an open area


away from bystanders. Practice with controls until
loader can be operated safely and efficiently.

Mandatory Safety Shutdown Procedure


BEFORE cleaning, adjusting, lubricating, or
servicing the unit or leaving it unattended:

Wear Safety Glasses - ALWAYS wear safety glasses


with side shields when operating the
machine or striking metal against metal. In
addition, it is recommended that a softer
(chip-resistant) material be used to cushion
the blow. Failure to heed could lead to
serious injury to eyes or other parts of the body.

1. Move the drive control handle(s) to the


NEUTRAL position.
2. Lower the lift arm and attachment completely.
3. Move the throttle to the low idle position, shut off
the engine and remove the key.

ALWAYS wear safety glasses when searching for


hydraulic leaks or when working near batteries.

4. However, if the lift arm MUST be left in the


raised position, BE SURE to properly engage the
lift arm support device.

Loaded Bucket/Fork - DO NOT raise or lower a loaded


bucket or fork suddenly. Abrupt movements under load
can cause serious loader instability.

Only after these precautions can you be sure it is


safe to proceed. Failure to follow the above
procedure could lead to death or serious injury.

NEVER push the lift control into the float position


with the bucket or attachment loaded or raised, because
this will cause the lift arm to lower rapidly.
917292/AP1008

2-2

PRINTED IN USA

SAFETY
Lift Arm Support Device

BEFORE leaving the operators compartment


to work on the loader with the lift arm raised,
ALWAYS engage the lift arm support device.
Turn the keyswitch to OFF, remove the key
and take it with you.

Fig. 2-1

Many service procedures require a raised lift arm to


allow easier access to loader components. For operator
and service personnel safety, a lift arm support device is
standard on skid-steer loaders. Used as a cylinder block,
it is intended to prevent a raised lift arm from
unexpectedly lowering.

The lock pin secures the lift arm support device


underneath the left lift arm

BE SURE to engage the lift arm support device


whenever the lift arm is raised. When the device is not
being used, secure it to the anchor on the underside of the
lift arm using the lock pin and retainer provided.
The lift arm support device is a safety device, which
must be kept in proper operating condition at ALL
times.
The following procedures outline the correct way to
engage and disengage the lift arm support device.

Lift Arm Support Device Engagement


Fig. 2-2

1. Lower lift arm until contact with loader frame.

Flip lock pin down and grab with finger

2. Turn the keyswitch to the OFF position to stop the


engine.
3. Leave operators compartment. Flip lock pin ring
down and pull out of welded post to release its
locking mechanism. Allow support device to come
down into contact with lift cylinder. Figs. 2-1, 2-2
and 2-3
4. Return to the operators compartment and restart the
engine.
5. Use lift control to raise lift arm until lift arm support
device drops over the end of the lift cylinder and
around cylinder rod. Slowly lower lift arm until free
end of support device contacts top end of lift
cylinder. Fig. 2-4

Fig. 2-3

6. Make sure the support device is secure against the


base end of the lift cylinder. Then, stop the loader
engine, remove the key and leave the operators
compartment.

Pull ring out of welded post

PRINTED IN USA

2-3

917292/AP1008

SAFETY

WARNING

SAFETY
Lift Arm Support Device Disengagement

WARNING
NEVER leave the operators compartment to
disengage the lift arm support device with the
engine running.
To return the lift arm support device to its storage
position, proceed as follows:
1. Raise the lift arm completely.
2. Turn the keyswitch to the OFF position to stop the
engine, remove the key and take it with you.

Fig. 2-4

The lift arm support device dropped over and


around the cylinder rod

Fig. 2-5

Front right ROPS mounting area where the


ROPS is secured to the chassis, left side same

Fig. 2-6

Location of the self-actuating lock mechanism

WARNING
BEFORE testing the machine, ALWAYS clear
people from the area.
3. Before leaving the operators compartment, check
to be sure the lift arm is being held in the raised
position by the solenoid valve (See NOTE).
NOTE: With the keyswitch OFF, and the solenoid
valve functioning properly, the lift arm will not move
when the lift control is moved forward. If the valve does
NOT hold the lift arm, do NOT leave the operators
compartment. Instead, have someone store the support
device for you. Then, contact your Gehl or Mustang
dealer to determine the reason why the lift arm lowers
while the keyswitch is in the OFF position.
4. To store lift arm support device, lift it up and inside
the lift arm. Insert lock pin through the hole in the
lift arm and through the support device.

ROPS Raising
For service, the ROPS can be unbolted and tilted back.
Gas-charged springs help tilt it back. A self-actuating
lock mechanism engages to lock the ROPS in a
rolled-back position.
1. The lift arm should be lowered or locked in the
raised position as per the Lift Arm Support Device
Engagement procedure in this chapter.
2. Turn the keyswitch to the OFF position to stop the
engine. Remove the key and take it with you.
3. Leave the operators compartment.
917292/AP1008

2-4

PRINTED IN USA

SAFETY

DO NOT leave the operators compartment


with the engine running. Before leaving the
loader, shut off the engine according to the
Mandatory Safety Shutdown Procedure
described in this chapter.
4. Remove one capscrew and washer on each side of
the ROPS forward stantions. Fig. 2-5

Fig. 2-7

5. Lift ROPS up and tilt it back until the self-actuating


lock mechanism engages. The lock mechanism
locks the ROPS in a rolled-back position. Fig. 2-6

Push up on ROPS to release locking mechanism

IMPORTANT
BEFORE raising the ROPS, position the seat
as far back as it will go. Avoid damaging
control handles by slowly raising the ROPS.
BE SURE the control handles clear the ROPS.

ROPS Lowering

Fig. 2-8

1. Apply upward force on the ROPS and push the lock


mechanism handle toward the front of the loader.
Fig. 2-7

Lower the ROPS until it contacts the chassis

2. Lower the ROPS until it contacts the chassis. Fig.


2-8

IMPORTANT
Avoid damaging control handles by slowly
lowering the ROPS. BE SURE the control
handles clear the ROPS.
3. Be sure control handles clear the ROPS. Fig. 2-9
4. Reinstall the two capscrews and flat washers that
secure the ROPS front uprights to the chassis. Fig.
2-5
Fig. 2-9

Be sure control handles clear the ROPS

PRINTED IN USA

2-5

917292/AP1008

SAFETY

WARNING

SAFETY
Relieving Hydraulic Pressure
Lift and Tilt

The following procedure should be used to relieve


pressure in the hydraulic system prior to performing
service procedures on hydraulic system components.
1. Completely lower the bucket or attachment.
2. Turn keyswitch to OFF position to shut down
engine.
3. With the operator in the seat and the restraint bar
lowered, turn the keyswitch to the ON position but
DO NOT start the engine.

Auxiliary Hydraulics

4. Move the lift, tilt and auxiliary hydraulics controls


through several cycles. Figs. 2-10 - 2-12

Fig. 2-10 On Hand/Foot models, the lift and tilt functions


are controlled with the foot pedals on the floor of
the ROPS. The auxiliary hydraulics are
controlled in the right control handle.

5. Turn the keyswitch to the OFF position.

Lift and Tilt

Auxiliary Hydraulics

Fig. 2-11 On Dual Joystick and T-Bar/Joystick models, lift


and tilt functions are controlled with the right
control handle. The auxiliary hydraulics are
controlled with the right control handle.

Auxiliary Hydraulics

Lift and Tilt

Fig. 2-12 On Dual T-Bar models, lift and tilt functions are
controlled with the right control handle. The
auxiliary hydraulics are controlled with the left
foot on the auxiliary pedal assembly.
917292/AP1008

2-6

PRINTED IN USA

SAFETY
Loader Raising Procedure
The following procedure is used to raise the skid-steer
loader so that all four tires are off the ground.

WARNING
BEFORE servicing the machine, exercise the
Mandatory Safety Shutdown Procedure
described in this chapter.
Stand Placement Location

WARNING

Fig. 2-13 View of the stand placement and tie down


support locations at front of loader

DO NOT rely on a jack or hoist to maintain the


raised position without additional blocking
and supports. Serious personal injury could
result from improperly raising or blocking the
skid-steer loader.
1. To raise and block the skid-steer loader, obtain four
jack stands (or blocks) of sufficient strength to
support the loader.
2. Using a jack or hoist capable of raising the
fully-equipped loader, lift the rear of the loader until
the tires are off the ground.
3. Place two jack stands (or blocks) under the flat part
of the loader chassis. Place them parallel with, but
not touching, the rear tires.
4. Slowly lower the loader so that its weight rests on
the jack stands (or blocks).

Fig. 2-14 Location underneath the left rear skid loader to


position stands or blocks. View is from the rear
of the loader.

5. Repeat steps 2-4 for the front end. When the


procedure is finished, all four tires will be off the
ground, and the wheels can be removed as
necessary.

Loader Lowering Procedure


When the service procedures are complete, the
skid-steer loader can be taken down from the raised
position. To lower the loader onto its tires:
1. Using a jack or hoist, raise the front of the loader
until its weight no longer rests on the jack stands (or
blocks).
2. Carefully remove the jack stands (or blocks) under
the front of the loader.
Fig. 2-15 Location underneath the right rear skid loader to
position stands or blocks. View is from the rear
of the loader.

3. Slowly lower the loader until the front tires are on


the ground.
4. Repeat steps 1-3 for the rear of the loader.

PRINTED IN USA

2-7

917292/AP1008

SAFETY

Tie Down Support

SAFETY
NOTES

917292/AP1008

2-8

PRINTED IN USA

LUBRICATION
General Information

WARNING

Fig. 3-1

Routine lubrication is an important factor in preventing


excessive part wear and early failure. Loader and engine
operation depends on using correct grade, high-quality
lubricating oils. This chapter and the chart below list
locations, temperature ranges and types of
recommended lubricants to be used when servicing this
machine.

Hydraulic oil level indicator (1) and hydraulic


oil fill (2)

Fig. 3-2

Hydraulic oil drain plug located behind the right


rear tire

Hydraulic System
Reservoir

Fig. 3-3

Chaincases

Use a Mobil DTE 15M, or


Use hydraulic system oil or SAE
Petro-Canada Premium HVI60, or
grade 15W-40 motor oil.
equivalent that contains anti-rust,
Capacity (each side):
anti-foam, and anti-oxidation
9.0 Quarts (8,5 L)
additives & conforms to ISO
VG46 or ISO VG48.
Capacity:
16 Gallons (61 L)

PRINTED IN USA

Fuel tank drain (1) and remote engine oil drain


(2) located behind the left rear tire

Grease
Fittings

Crankcase Oil
(Diesel Engine)

Use lithium-based grease

Below 32F (0C) use SAE


Grade* 10 or 10W-30
Above 32F (0C) use SAE
Grade* 15W-40
*Service Classification: API CF-4/CG-4
Capacity:
11.8 Quarts (11,2 L)

3-1

917292/AP1008

LUBRICATION

NEVER service this unit when any part of the


machine is in motion. ALWAYS BE SURE to
exercise the Mandatory Safety Shutdown
Procedure (see Safety chapter) BEFORE
servicing this equipment.

LUBRICATION
NOTE: Whenever service is performed on hydraulic
components (valves, cylinders, hoses, etc.), fuel tanks
and lines, care must be taken to prevent discharging
fluid onto the ground. Catch and dispose of fluid per
local waste disposal regulations.

Hydraulic Oil Reservoir


2

The oil reservoir for hydraulic and hydrostatic systems


has a capacity of 16 U.S. gallons (61 liters). A visual oil
level indicator (Fig. 3-1) is located on right riser for
convenient maintenance of hydraulic oil level.

The hydraulic oil reservoir should be drained (Fig. 3-2)


and filled after every 500 hours of operation or annually
(whichever happens first). Use Mobil DTE 15M or
Petro-Canada Premium HV I60 hydraulic oil (or ISO
VG46 or ISO VG48 equivalent) which contains
anti-rust, anti-foam and anti-oxidation additives.
Hydraulic oil filter element should be replaced when
filter indicator on filter head shows red (See NOTE, Fig.
3-9). For details, refer to Hydraulic Oil Filter Element
Replacement procedure in the Hydraulic chapter.

Fig. 3-4

Location of remote engine oil filter hoses (1), oil


fill (2), and dipstick tube (3) on left side of engine

Fig. 3-5

Battery access location behind the left engine


side cover

Fig. 3-6

Engine oil filter access location behind the rear


grille and left of the cooler/radiator

NOTE: Hydraulic filter indicator should be read with


engine running at full throttle and normal operating
temperature.

Crankcase Oil
The Yanmar diesel engine crankcase has a capacity of
11.8 qts. (11,2 L). The chart below lists recommended
oil viscosity for the Cummins engine.
Engine oil should be changed and filter element replaced
every 250 hours of service. A remote engine oil drain
can be found behind right rear tire. Refer to engine
operators manual (see NOTE) for details on changing
oil and to Oil Filter Removal and Oil Filter
Installation procedures in Engine chapter.
NOTE: Refer to engine operators manual for
additional information on oil change intervals,
including a 50-hour initial oil change interval.
Ambient Temperature

Viscosity

Below 32F (0C)

SAE 10 or 10W-30

Above 32F (0C)

SAE 15W-40

Service classification: API-CF-4/CG-4

917292/AP1008

3-2

PRINTED IN USA

LUBRICATION
Chaincases
Each chaincase requires 9 U.S. qts (8,5 L) of any high
grade motor oil. This quantity of oil should be
maintained at all times. The oil in both chaincases
should be drained and refilled every 500 hours of
operation or annually, whichever occurs first.

1. Remove drain plug on chaincase and drain the oil.


Fig. 3-10
2. Reinstall the drain plug.
Fig. 3-7

3. Remove both oil fill and oil level check plugs. Figs.
3-10, 3-11

Location of engine oil dipstick

4. Add oil through the fill plug (between tires on the


chassis) until the oil starts to flow out of the check
plug. Figs. 3-10, 3-11
5. Reinstall the check plug, then the fill plug.

Fig. 3-8

Location of engine oil fill


Fig. 3-10 Location of the chaincase oil drain check plug
behind left front tire. Right side same

Fig. 3-9

Location of the hydraulic filter indicator


underneath the muffler

PRINTED IN USA

Fig. 3-11 Location of the anti-freeze drain cock located at


the bottom left on the radiator/cooler
3-3

917292/AP1008

LUBRICATION

Change Chaincase Oil

LUBRICATION
Grease Fitting Locations
Use lithium-based grease on all grease fittings. Figs.
3-13, 3-14
Grease every 10 hours of operation (or daily)
1. Grease lift arm, lift and tilt cylinder pivots
2. Grease All-Tach attachment pivots

Cooling System Drain Procedures


Gehl 5640E/6640E and Mustang 2066/76/86 skid-steer
loaders use a radiator cooler design to help keep the
engine and hydraulic oil from overheating. Many
procedures in this Service Manual require you to
partially or fully drain the radiator cooler to perform
those procedures.

Fig. 3-12 Location of the left chaincase oil fill plug. Right
side same

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:

q Shut off the engine and allow to cool.


(For detailed instructions, refer to the Safety
chapter of this manual.)
Hydraulic Oil Drain Procedure
1. Place a 20-gallon (75,5 L) catch pan under the
hydraulic oil drain plug behind the right rear tire.
Fig. 3-2

Fig. 3-13 Grease fitting locations

2. Remove the drain plug and drain oil.


3. Replace the drain plug.
Engine Coolant Drain Procedure (Fig. 3-11)
1. Remove the rear belly pan underneath the chassis.
2. Place a 4-gallon (15,1 L) catch pan under the
opening in the chassis.
3. Loosen anti-freeze drain cock on bottom left of the
radiator and drain coolant fluid.
4. Retighten the drain cock.

Fig. 3-14 Grease fitting locations

917292/AP1008

3-4

PRINTED IN USA

MAINFRAME

Introduction
Gehl 5640E/6640E and Mustang 2066/76/86 skid-steer
loaders have a welded steel chassis. Maintenance,
service and repair may be performed through standard
access panels.

Oil is used inside these cases to ensure the chains always


receive proper lubrication.
The lift arm and the lift and tilt cylinders are mounted
with pivot pins. Capscrews are used to secure the pivot
pins. A Rollover Protective Structure/Falling Object
Protective Structure (ROPS/FOPS) is standard for
operator safety, and both the seat and restraint bar
include interlock switches.

Two side cases provide mounting for the drive motors


and for the front and rear axles. The side cases also serve
as sealed housings for the drive chains and sprockets.

Rollover & Falling Object - Protective Structure (ROPS/FOPS) Components


27

22

15
26

35

10

35

35
35

11
9

9
9
33
34

28

33

34

13

28
9
9
35

24

25

13

16

25
34

35

34

30

36
23

35

6
39
2
4

29
30

37

14

2
39

17

32

19

12

18

1 NUT/HEX WHIZLOCK
2 NUT/LOCK NYLON INSERT
3 NUT/LOCK
4 ISOLATOR/ROPS
5 SPRING/TORSION
6 BUSHING
7 TAG/RIP CORD
8 RING
9 NUT/SPIRALOCK
10 COVER/BOOK BOX
11 HINGE/PIANO
12 WINDOW/REAR
13 CHANNEL/WIRE HARNESS
14 PIN
15 WINDOW/SKYLIGHT
16 GROMMET/HOLE PLUG
17 SPRING/GAS ASSIST
18 WEATHERSTRIP/WINDOW
19 RIPCORD/WEATHERSTRIP
20 SUPPORT/ROPS
21 SPACER/TUBE
22 ROPS/FOPS
23 HEADLINER/MOLDED
24 COVER/WIRE
25 PLUG/HOLE
26 PLUG/RUBBER
27 SCREW/SEM
28 WASHER/FLAT
29 SCREW/CAP
30 SCREW/CAP
31 SCREW/CAP
32 SCREW/CAP
33 SCREW/CAP
34 BOLT/CARRIAGE
35 SCREW/MACHINE
36 SCREW/MACHINE
37 WASHER/FLAT
38 WASHER/FLAT
39 WASHER/FLAT
40 PIN/COTTER

38
1

40

21

31
20

5
3

Fig. 4-1

Exploded view of ROPS/FOPS components

PRINTED IN USA

4-1

917292/AP1008

MAINFRAME

27

MAINFRAME
Engine Access Cover - Removal and
Installation

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:

q It is recommended that this service

Welded Tab

procedure be performed by a certified


Gehl or Mustang dealer mechanic.

q Shut off the engine.


(For detailed instructions, refer to the Safety
chapter of this manual.)

Fig. 4-3

Capscrew, spacer and washer to remove from the


right ROPS bolt, left side same

Fig. 4-4

ROPS bolt turned out just enough to release


engine cover while still supporting the ROPS
structure

Fig. 4-5

View of ROPS bolt turned out just enough to


release the engine access cover, but not enough
to release the ROPS

Removal Procedure
1. Open engine access cover until gas spring is
completely extended.
2. Disconnect the gas spring from engine access cover
by removing gas spring clip at access cover end of
gas spring, then pull gas spring off ball stud on
access cover. Fig. 4-2
3. Remove two capscrews, spacers and washers on
ROPS bolts securing access cover to frame. Fig. 4-3
4. Turn both ROPS bolts out until flush with welded
tab, remove engine cover. Figs. 4-4, 4-5
Installation Procedure - Follow all warnings first,
then reverse the removal steps.

Gas Spring

Fig. 4-2

View of the gas spring that supports the engine


access cover

917292/AP1008

4-2

PRINTED IN USA

MAINFRAME
Chassis Components - 2066/76/86 Models

14
SEE NOTE 3

MAINFRAME

NOTES:
1. APPLY HI-TACK GASKET ADHESIVE
2. APPLY OIL-RESISTANT RTV
3. APPY PIPE THREAD SEALANT

REAR VIEW

23
SEE NOTE 2
22

20

29
8
3
12

16

17

11
9

29
8

27

29

18

12

12

12

30

27

30

31

13

29

SEE NOTE 3 19

1 SEE NOTE 1

SEE NOTE 2 15

21
6

(1 PER SIDE)

2
15 SEE NOTE 2
10
34
24

30

28

32
34

25

10

19 SEE NOTE 3
33
26

33
26

33
33
26

1 GASKET
2 SCREW/HEX
3 RESERVOIR CAP
4 BREATHER
5 PLUG
6 PLUG
7 PLUG
8 NUT/SPIRALOCK
9 STRAINER/FUEL

Fig. 4-6

10 WASHER/SEAL
11 SIGHT PORT
12 NUT/SPIRALOCK
13 FUEL SENSOR
14 PLUG/HS
15 CHAINCASE COVER
16 SEAT COVER RIGHT
17 CROSSMEMBER
18 SEAT COVER LEFT

26

19 PLUG/PIPE SOCKET
20 RESERVOIR COVER
21 WELDMENT/CHASSIS
22 ROPS FILLER
23 ROPS FILLER
24 COVER/TOEPLATE
25 BELLYPAN
26 SCREW/CAP
27 SCREW/CAP

28 SCREW/CAP
29 SCREW/CAP
30 SCREW/MACHINE
31 SCREW/MACHINE
32 SCREW/CAP TFS
33 WASHER/LOCK
34 WASHER/FLAT

Exploded view of the Mustang chassis

PRINTED IN USA

4-3

917292/AP1008

MAINFRAME
Chassis Components - 56/6640 Models
25
NOTE 2
24

22

31
8
3
16
17

11
9

31
8

29

31

18

12

12
32

29

32

12

33

13

31 20

NOTE 3 21

NOTE 1

NOTE 2 15
19
5

23
6

(1 PER SIDE)

2
15 NOTE 2
10
36
26

32

30

34
36

27

10

21 NOTE 3
35
28

35
28

35
35

28

28

NOTES:
1. APPLY HI-TACK GASKET ADHESIVE
2. APPLY OIL-RESISTANT RTV
3. APPY PIPE THREAD SEALANT

14
NOTE 3

REAR VIEW

1 GASKET/FUEL SENDER
2 SCREW/HEX
3 CAP/RESERVOIR
4 BREATHER/RESERVOIR
5 PLUG
6 PLUG
7 PLUG
8 NUT/SPIRALOCK
9 STRAINER/FUEL FILL

Fig. 4-7

10 WASHER/SEAL
11 SIGHT PORT/OIL
12 NUT/SPIRALOCK
13 FUEL SENSOR/VDO
14 PLUG/SCREW
15 CHAINCASE COVER
16 COVER/UNDER SEAT
17 PLATE/CROSS
18 COVER/UNDER SEAT

19 FENDER/LEFT
20 FENDER/RIGHT
21 PLUG/PIPE
22 RESERVOIR COVER
23 CHASSIS
24 ROPS FILLER
25 ROPS FILLER
26 COVER/TOEPLATE
27 BELLYPAN

28 SCREW/CAP
29 SCREW/CAP
30 SCREW/CAP
31 SCREW/CAP
32 SCREW/MACHINE
33 SCREW/MACHINE
34 SCREW/CAP
35 WASHER/LOCK
36 WASHER/FLAT

Exploded view of the Gehl chassis

917292/AP1008

4-4

PRINTED IN USA

MAINFRAME
Control Cover Components - Hand and Foot

1 SUPPORT/BOOT BEZEL
2 SPACER
3 COVER/BOOT
4 COVER/PUMP
5 COVER/PANEL LEFT
6 COVER/PANEL RIGHT
7 LATCH/SWELL
8 STRIP/FOAM
9 PAD/INTERIOR SOUND
10 PLUG/HARNESS
11 CONTROL COVER
12 SCREW/MACHINE
13 SCREW/CAP TFS
14 SCREW/TAPPING TF
15 SCREW/TORX

13

7
7

11
12
14

5
3

1
9
10

8
15

Fig. 4-8

Exploded view of the control covers

PRINTED IN USA

4-5

917292/AP1008

MAINFRAME
Control Cover Components - Dual Joystick

1 SPACER
2 WELDMENT/CONTROL COVER
3 PLATE/FLOOR FOOT
4 PLATE/FLOOR SUPPORT
5 SUBFLOOR/FRONT SUPPORT
6 COVER/PUMP
7 COVER/PANEL LEFT
8 LATCH/SWELL
9 STRIP/FOAM
10 WELDMENT/FOOT SUPPORT
11 PAD/INTERIOR SOUND
12 COVER/PANEL RIGHT
13 HARNESS/THROTTLE
14 SCREW/MACHINE
15 SCREW/THREAD FORMING
16 SCREW/TORX HEAD
15

15

15

15
15

10

10
12
4

13
8

15
8
2

9
15
15
7

14
15

15

11

5
1
16
14

Fig. 4-9

Exploded view of the control covers

917292/AP1008

4-6

PRINTED IN USA

MAINFRAME
Control Cover Components - T-Bar - 56/6640 Models

1 COVER/CONTROLS
2 SUPPORT/BOOT BEZEL
3 SPACER
4 COVER/BOOT
5 PLATE/FLOOR SUPPORT
6 COVER/PUMP
7 COVER/PANEL LEFT
8 LATCH/SWELL
9 STRIP/FOAM
10 FOOT SUPPORT
11 PAD/INTERIOR SOUND
12 COVER/PANEL RIGHT
13 FRONT FLOOR
14 SUBFLOOR/FRONT SUPPORT
15 SCREW/MACHINE
16 SCREW/CAP
17 SCREW/TAPPING
18 SCREW/TORX DRIVE

16
16

16

16

16
6

10

10

12
5

9
8

16
16

7
15
16
16

17

13

14
11
4
3
18

Fig. 4-10

2
15

Exploded view of the control covers

PRINTED IN USA

4-7

917292/AP1008

MAINFRAME
Control Cover Components - T-Bar/ Joystick - 56/6640 Models

1 CONTROL COVER
2 SUPPORT/BOOT BEZEL
3 SPACER
4 COVER/BOOT
5 PLATE/FLOOR FOOT PILOT
6 PLATE/FLOOR SUPPORT
7 SUBFLOOR/FRONT SUPPORT
8 COVER/PUMP
9 COVER/PANEL LEFT
10 LATCH/SWELL
11 STRIP/FOAM
12 FOOT SUPPORT
13 PAD/INTERIOR SOUND
14 COVER/PANEL RIGHT
15 SCREW/MACHINE
16 SCREW/CAP
17 SCREW/TAPPING
18 SCREW/TORX DRIVE

16
16

16

16

16
8

12

12

14
6

10

11
10

16

1
16

9
15

16

17

7
13
4
3
18

Fig. 4-11

11

2
15

Exploded view of the control covers

917292/AP1008

4-8

PRINTED IN USA

MAINFRAME
NOTES

PRINTED IN USA

4-9

917292/AP1008

MAINFRAME
ROPS Removal and Installation

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:

q Shut off the engine.


(For detailed instructions, refer to the Safety
chapter of this manual.)
Removal Procedure
1. Remove the engine access cover per the procedure
in this chapter.
2. Disconnect negative (-) battery cable from battery.
3. Disconnect instrument panel wiring harness
connector at harness bulkhead attached to chassis
bracket. Fig. 4-12

Fig. 4-12 The harness bulkhead is where the engine


harness assembly meets the instrument panel
harness. Remove instrument panel harness at
front of bulkhead.

4. Raise the ROPS per the procedure found in the


Safety chapter.
5. With the ROPS rolled and locked back, attach a
hoist so that it is supporting the weight of the ROPS.

WARNING
The hoist MUST BE situated precisely above
the ROPS, or else performing the following
steps may cause the ROPS to swing as the
bolts are removed. This could cause serious
bodily injury and/or damage the loader.

Fig. 4-13 Gas spring attached to ROPS, one on each side

6. Remove one capscrew and flat washer securing


each gas spring to the ROPS. Fig. 4-13
7. Disassemble ROPS lock mechanism by removing
cotter pin, torsion spring and pin. Remove limiter
assembly from ROPS. Fig. 4-14
8. On each side, carefully remove capscrew securing
ROPS pivot to frame. Figs. 4-1, 4-3

Cotter Pin

9. Lift the ROPS off the loader.

Pin

Installation Procedure - Follow all warnings first,


then reverse the removal steps.
Torsion Spring

Fig. 4-14 ROPS lock mechanism

917292/AP1008

4-10

PRINTED IN USA

MAINFRAME
All-Tach Hitch Components - 2066/76/86 Models
15
6
18

22
20

3
9
16

14
13

12
1
21
7

17
10

19
4

11

1 WASHER/FLAT
2 PIN/SPRING
3 NUT/LOCK
4 SPRING
5 ADAPTOR/ROD
6 SPRING

7 LINK/LATCH LEFT
8 LINK/LATCH RIGHT
9 PLATE/LATCH LINK
10 ADAPTOR/PUSH ROD
11 PIN/LATCH
12 WASHER/BEVEL

13 RING/RETAINING
14 SPACER
15 HANDLE
16 FAST-A-TACH
17 SCREW/CAP
18 GRIPS

19 FITTING/GREASE
20 SCREW/CAP
21 SCREW/CAP
22 WASHER/FLAT

All-Tach Hitch Components - 56/6640 Models


12

7
LEFT

20

22
6

21

19

13

16

NOTE 1

3
15

8
RIGHT

14

NOTES 1 & 2
18

1
19
10

NOTES :

1) USE LOCTITE 242


2) TORQUE TO 100 FT-LB

17 NOTES 1 & 2

11

1 WASHER/FLAT
2 PIN/SPRING
3 NUT/LOCK
4 SPRING
5 ROD/PUSH
6 SPRING
7 LINK/LATCH
8 LINK/LATCH
9 PLATE/LATCH LINK
10 ADAPTOR/ROD
11 PIN/LATCH
12 ALL-TACH
13 HANDLE
14 WASHER/BEVEL
15 RING/RETAINING
16 SPACER
17 SCREW/CAP
18 GRIPS
19 FITTING/GREASE
20 SCREW/CAP
21 SCREW/CAP
22 WASHER/FLAT

Fig. 4-15 Exploded view of the All-Tach hitches

PRINTED IN USA

4-11

917292/AP1008

MAINFRAME
Control Cover/Floor Cover Removal and
Installation
The control cover may be removed for access to handle
assemblies and connections to control rods.
ROPS Filler

WARNING
BEFORE beginning this Service procedure,
perform the following SAFETY procedures:

q Raise lift arm; engage lift arm support


device.

q Shut off the engine.

Fig. 4-16 Location of three screws securing ROPS filler

q Tilt back ROPS/FOPS until lock engages.


(For detailed instructions, refer to the Safety
chapter of this manual.)
Removal Procedure
1. On both left and right sides, remove three screws
securing the fender and ROPS filler on 56/6640
units or just the ROPS filler on 2066/76/86 units.
Fig. 4-16
Left Panel

2. Remove the two panels (right and left) on both sides


of the control cover area by releasing their swell
latches. Fig. 4-17
3. Remove three screws with their spacers at front of
sound pad and carefully remove the sound pad, up
and over the control handles. Fig. 4-18
4. Remove eight screws securing front two boot
flanges to the control cover. Fig. 4-19

Fig. 4-17 Location of swell latches securing the left side


panel in the foot area of the ROPS, right side is
the same

5. Remove two screws that secure the control cover to


the welded frame tab. Remove two screws that
secure floor cover to chassis.
6. Remove either cover at this time. Fig. 4-20
Sound Pad

Installation Procedure - Follow all warnings first,


then reverse the removal steps.

Fig. 4-18 Location of one of three screws securing the


sound pad to the control cover

917292/AP1008

4-12

PRINTED IN USA

MAINFRAME
NOTES
Boot Flange

MAINFRAME

Control Cover

Fig. 4-19 The front boot flanges secure the rubber boots to
the control cover. There are four screws to
remove the boot flange.

Control Cover

Fig. 4-20 The control cover removed from the skid-steer


loader

PRINTED IN USA

4-13

917292/AP1008

MAINFRAME
Crossmember Removal and Installation

Pivot Tube

The crossmember can be removed as a complete unit


with the control handles to facilitate work on the
hydraulic/hydrostatic tandem pump found beneath it or
to perform work on the control handles.

Removal Procedure

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:

Fig. 4-21 Disconnect wheel drive control rods at pivot tube


on hand/foot, t-bar and t-bar/joystick units

q Raise lift arm; engage lift arm support


device.

q Shut off the engine.


q Tilt back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual.)
1. Remove the control cover per the procedure found
in this chapter.
2. Hand/Foot, T-Bar and T-Bar/Joystick:
Underneath the crossmember, find the two wheel
drive control rods connecting the pivot tube to the
top of the hydrostatic pump at the pump control
arms. Disconnect both control rods at the pivot tube.
Fig. 4-21
3. Dual Joysticks:

Fig. 4-22 Location of two hose lines at front of the control


valve joined to the right dual joystick control
handle

a. Right Control Handle: Disconnect four hose


lines at the control valve(two front, two rear),
and two more hoses at the manifold. Figs. 4-22,
4-23, 4-24
b. Left Control Handle: Disconnect four hose
lines at the top of the hydrostatic pump, and two
more hoses, one on each side of the hydrostatic
pump. Fig. 4-25
NOTE: To prevent contamination, ALWAYS clean
the area around the hydraulic fittings before
disconnecting any hydraulic plug, hose or tube.
NOTE: To aid in the correct reassembly of the
hydraulic hoses, mark the hoses to be removed
BEFORE removal in step 3.
4. Disconnect any electrical connectors attached to the
control handles. Fig. 4-26
917292/AP1008

Fig. 4-23 Location of two hose lines at rear of the control


valve joined to the right dual joystick control
handle

4-14

PRINTED IN USA

MAINFRAME
5. Remove six locking capscrews securing the
crossmember to the chassis. Fig. 4-27
6. With an assistants help, carefully lift the
crossmember out of the chassis.
Installation Procedure - Follow all warnings first,
then reverse the removal steps.
Manifold

Fig. 4-24 Location of two hoses connected at the other end


of the right dual joystick control handle at the
manifold

Fig. 4-25 Six hoses to remove at the hydrostatic pump


joined to the left dual joystick control handle

Fig. 4-26 Left control handle electrical connector


underneath the crossmember, right side same

PRINTED IN USA

Fig. 4-27 Three capscrews securing crossmember on left


side, right side same

4-15

917292/AP1008

MAINFRAME
Rear Grille Removal and Installation
The rear grille is bolted onto the chassis and can be
removed to perform work on the cooler system, engine,
engine fan and shrouds.
Removal Procedure
1. Open the engine access cover and swing the rear
grille fully open.
2. Disconnect the rear grille electric lights at the
connector. Fig. 4-28
3. Remove lock pin from its storage position and set it
to keep rear grille from closing. Fig. 4-29
4. Remove one capscrew, washer, and locknut that
fasten the grille to the chassis. Fig. 4-30

Fig. 4-29 Rear grille lock pin shown in it's storage


position. The hole visible in the welded tab in
front of the pin keeps the rear grille from closing.

5. Support the rear grille with a suitable hoist and lift


the rear grille off its mounts.
Installation Procedure - Reverse the removal steps

Rear Grille Latch Removal and Installation


Removal Procedure
1. Open rear grille and lock open with lock pin. Fig.
4-29
2. Remove two locknuts securing latch to rear grille.
Fig. 4-31
3. Maneuver the handle rod out of the tab welded to the
rear grille and remove the latch assembly.

Fig. 4-30 Location of hardware fastening the rear grille to


the chassis

Installation Procedure - Reverse the removal steps


Handle Rod

Fig. 4-28 Location of the rear grille lights connector

917292/AP1008

Fig. 4-31 Location of hardware securing the rear grille


latch assembly to the rear grille

4-16

PRINTED IN USA

MAINFRAME
Rear Grille and Engine Cover Components - 2066/76/86

38

28

TO ROPS PIVOT BRACKETS


ON FRAME

44

38

20

32

36

13

40
4
38
1
5

14

31

14

42

21
40

43

27

11

36

24

39
11

30

16

35
6
40
25

10

34

8
9
2

41

36

3
41

5
15
22
STORE STOP PIN
IN LOWER PIVOT

37

12

15

41

33

29
29
39

11

18
38

19

38
19

38
17

38
38

23

FASTEN TO SIDE
PANELS OF ROPS
38

23

1 NUT/HEX WHIZLOCK
2 NUT/HEX
3 NUT/HEX
4 NUT/LOCK
5 NUT/LOCK
6 SPRING/COMPRESS
7 STUD/BALL
8 WASHER/FLAT
9 MOUNT/LATCH
10 ASSY/LATCH ROD
11 BUMPER

Fig. 4-32

23 SEAL/EDGE
24 ROD/HANDLE
25 LATCH/REAR DOOR
26 SEAL/BULB
27 TORSION BAR
28 TUBE/EXHAUST
29 SEAL/FOAM
30 SEAL/BULB
31 GAS SPRING
32 COVER/ENGINE
33 REAR GRILLE

12 BUSHING
13 BRACKET
14 CLIP/GAS SPRING
15 NUT/SPIRALOCK
16 BRACKET
17 COVER LEFT
18 COVER RIGHT
19 SEAL/BULB
20 HANDLE/GRAB
21 SCREEN
22 PIN/LOCK

34 PIN/COTTER
35 SCREW/CAP
36 BOLT/CARRIAGE
37 BOLT/CARRIAGE
38 SCREW/MACHINE
39 NUT/JAM
40 WASHER/FLAT
41 WASHER/FLAT
42 WASHER/LOCK
43 NUT/HEX
44 SCREW/CAP

Exploded view of the rear grille and engine cover

PRINTED IN USA

4-17

917292/AP1008

MAINFRAME
Rear Grille and Engine Cover Components - 56/6640

48

41
7

19

25
39
13
41
5

14

39

28
14

20
46
29

36
41

42

43
47

17
4

11

33

30

FASTEN TO
SIDE PANEL
OF ROPS
4

18
18

34

41 41

38
5

32

27
6

32
22

41

23

8
32

24

10

44

45

37
9

31
40
5

35
18

3
21

15
12
45

22
15

21

45

40

STORE STOP PIN


IN LOWER PIVOT

26

42

11
26

1 NUT/HEX
2 NUT/HEX
3 NUT/HEX
4 NUT/LOCK
5 NUT/LOCK
6 SPRING
7 STUD/BALL
8 WASHER/FLAT
9 MOUNT/LATCH
10 LATCH ROD
11 BUMPER
12 BUSHING
13 BRACKET
14 CLIP/GAS SPRING
15 NUT/SPIRALOCK
16 BRACKET

Fig. 4-33

17 SEAL/BULB
18 RECEPTACLE/CLIP ON
19 HANDLE/GRAB
20 SCREEN
21 PIN/LOCK
22 SEAL/EDGE
23 ROD/HANDLE
24 LATCH/REAR DOOR
25 TUBE/EXHAUST SHROUD
26 SEAL/FOAM
27 SEAL/BULB
28 GAS SPRING
29 COVER/ENGINE
30 REAR GRILLE
31 SIDE COVER
32 STUD

33 TORSION BAR
34 SEAL/BULB
35 COVER/SIDE
36 COVER/SIDE
37 PIN/COTTER
38 SCREW/CAP
39 BOLT/CARRIAGE
40 BOLT/CARRIAGE
41 SCREW/MACHINE
42 NUT/JAM
43 WASHER/FLAT
44 WASHER/FLAT
45 WASHER/FLAT
46 WASHER/LOCK
47 NUT/HEX
48 SCREW/CAP

Exploded view of the rear grille and engine cover

917292/AP1008

4-18

PRINTED IN USA

CONTROLS

Introduction
This chapter covers removal, installation, assembly, and
adjustment procedures for standard and optional control
equipment on Gehl 5640E/6640E and Mustang
2066/76/86 skid-steer loaders.
Equipment Identification
Because there are a variety of options available for
2066/76/86 models, it is IMPORTANT to properly
identify equipment BEFORE beginning service
procedures. Illustrations and photographs are provided
with procedures to aid in servicing this equipment.
Hand/Foot Controls
On loaders with Hand/Foot controls, left and right
drive control handles operate independently of each
other. Pushed forward together moves the loader
forward, but push either one further forward than the
other and the loader turns. Separate foot pedals control
lift and tilt functions of lift arm and bucket. Engine
speed is controlled with hand throttle dial located in the
right instrument panel. A yellow rocker switch in the
right control handle controls standard auxiliary
hydraulics in tandem with a lock-on (red) button switch.
On high-flow models, a rocker switch in the right
instrument panel activates high-flow hydraulics.

T-Bar Controls
On skid-steer loaders with T-Bar controls, the left
T-Bar operates the wheel drives and pumps for both
sides of the skid-steer loader. The right T-Bar controls
the lift and tilt functions of the lift arm and bucket.
Engine speed is controlled with a foot throttle pedal and
dial in the right instrument panel. Standard-flow
auxiliary hydraulics is controlled by a foot pedal. On
high-flow models, a rocker switch in the right
instrument panel activates the high-flow hydraulics.
Float Control
The float control on skid-steer loaders is controlled by a
momentary button switch in the right control handle and
lights a panel light.

Dual Joystick Controls


On loaders with "Dual Joystick controls," the left
control handle operates the drive wheels. The right
control handle operates lift and tilt functions of the lift
arm and bucket. Engine speed is controlled with a foot
throttle pedal and dial in the right instrument panel. A
yellow rocker switch in the right control handle controls
standard auxiliary hydraulics in tandem with a lock-on
(red) button switch. On high-flow models, a rocker
switch in the right instrument panel activates high-flow
hydraulics.

PRINTED IN USA

Two-Speed Control (Optional)


Skid-steer loaders have a high and low speed setting. It is
controlled by a button switch in left control handle and
lights a panel light in the left instrument panel.
Hydraglide Ride Control
The Hydraglide Ride Control is controlled by a button
switch in right control handle and lights a panel light in
the left instrument panel.

6-1

917292/AP1008

CONTROLS

T-Bar/Joystick Controls
On skid-steer loaders with T-Bar/Joystick controls,
the right joystick handle controls the lift and tilt
functions of the lift arm and bucket and the left T-Bar
operates the wheel drives for both sides of the skid-steer
loader. Engine speed is controlled with a foot throttle
pedal and dial in the right instrument panel. A yellow
rocker switch in the right control handle controls
standard auxiliary hydraulics in tandem with a lock-on
(red) button switch. On high-flow models, a rocker
switch in the right instrument panel activates the
high-flow hydraulics.

CONTROLS

Dual Joystick Controls

Hand/Foot Controls

4, 11
1, 7, 10

4, 11

2, 3, 6, 8, 9
1, 7, 10

1, 6, 8, 9

5
3

1 - Drive Control
2 - Lift Control
3 - Tilt Control
4 - Hand Throttle
5 - Foot Throttle
6 - Standard Auxiliary Hydraulics Control

7 - Two-Speed Button Switch (optional)


8 - Hydraglide Ride Control Switch
9 - Float Control Switch
10 - Horn Button Switch
11 - High-Flow Auxiliary Hydraulics Control

T-Bar/Joystick Controls

T-Bar Controls

4, 11
6
1, 7, 8, 10

4, 11
5
1, 3, 4

2, 3, 8, 9
2, 3, 6, 8, 9

917292/AP1008

6-2

PRINTED IN USA

CONTROLS
Lift and Tilt Components - Hand/Foot Control Models

15

12

11

10

15
13

E
17
B

17

10
14

A
C

16

4
1

4
REAR OF
MACHINE

1
F
9

6
B

A
C
D
7

1
2

9
E
4

5
4
1
8

P PORT
T PORT
PORT 1A
PORT 2A

1 FITTING/STRAIGHT
2 TEE/FEMALE RUN
3 PEDAL/FOOT
4 PLUG/O-RING
5 VALVE/FOOT
6 PLATE/FLOOR FOOT PILOT

Fig. 6-1

PORT 2B
PORT 1B

7 PLATE/FLOOR SUPPORT
8 SUBFLOOR/FRONT SUPPORT
9 TUBE/PILOT
10 HOSE/PRESSURE
11 HOSE/PRESSURE
12 HOSE/PRESSURE

13 HOSE/PRESSURE
14 HOSE/PRESSURE
15 ORIFICE/CHECK VALVE
16 SCREW/CAP TF
17 SCREW/CAP

Exploded view of Hand/Foot lift and tilt components

PRINTED IN USA

6-3

917292/AP1008

CONTROLS
Lift and Tilt Components - Dual Joystick and T-Bar/Joystick Control Models
NO. 2 PORT

T PORT

NO. 3 PORT

NO. 1 PORT
8

24
P PORT
9

ADD MEDIUM STRENGTH THREAD LOCKER


TO LOWER THREADS SO IT ADHERES TO
BOTH THE ATTACHMENT NUT AND LOCKNUT

NO. 4 PORT

18
TO JOYSTICK PORT P
TO JOYSTICK PORT T

26

17

12
PORTS T & P

PORTS
1,2,3 & 4

6
11

25

25

16
14

23
5

TO
PO JO
RT YST
2 IC

27
23

TO
PO JO
RT YST
1 IC

20

TO JOYSTICK
PORT 3
TO JOYSTICK
PORT 4

22

1
21

19
1
15

1 FITTING/STRAIGHT
2 BUSHING/PIVOT
3 PIN/TILT CONSOLE
4 MOUNT/TOWER
5 HANDLE/RATCHET
6 ADAPTER/QD/HD
7 ADAPTER/QD/HD
8 FLANGE/BOOT/JOYSTICK
9 FLANGE/BOOT/JOYSTICK

Fig. 6-2

10 BOOT/JOYSTICK
11 STAND/DRV/JOYSTICK
12 JOYSTICK/KAWASAKI
13 BOOT/JOYSTICK
14 COVER/CONSOLE
15 HOSE/LP
16 HOSE/LP
17 HOSE/LP
18 GRIP/AUX/ELEC

19 HOSE/LP
20 HOSE/LP
21 NUT/LOCK
22 SCREW/CAP
23 BOLT/CARRIAGE
24 SCREW/TORX TF
25 SCREW/MACHINE TF
26 SCREW/CAP TFS
27 WASHER/FLAT

Exploded view of Dual Joystick and T-Bar/Joystick lift and tilt components

917292/AP1008

6-4

PRINTED IN USA

CONTROLS
Lift and Tilt Components - T-Bar Control Models

23

10

11
14
24

24
15

22

18

25
1

16
9
21
7

22

7
21

6
12
13

19

25

3
24

20

17

NOTE 3

NOTES:

NOTE 1 & 2

1) ROUTE ELECTRICAL WIRES BEFORE INSTALLING


TERMINALS INTO CONNECTORS
2) INSERT RED WIRE INTO PIN 1, GRAY INTO 2,
BLUE INTO 3, AND BLACK INTO 4.
3) INSERT WEDGE AFTER TERMINALS ARE INSTALLED.

1 ROD END/FEMALE
2 WASHER/FLAT
3 SPACER
4 ROD END
5 BUSHING/PIVOT
6 T-BAR STOP
7 ROD END/ELASTOMERIC
8 NUT/SPIRALOCK
9 PIVOT

Fig. 6-3

10 KAWASAKI GRIP
11 LEVER/RH CONTROL
12 DEUTSCH 4-PIN PLUG
13 DEUTSCH 4-PIN WEDGE
14 BOOT/T-BAR
15 PIN/ CLEVIS
16 PIN/ CLIP/ RUE
17 ROD/CONTROL LIFT
18 ROD/CONTROL TILT

19 YOKE
20 SCREW/CAP
21 SCREW/CAP
22 SCREW/CAP
23 PIN/ROLL
24 NUT/JAM
25 WASHER/FLAT

Exploded view of T-Bar lift and tilt components

PRINTED IN USA

6-5

917292/AP1008

CONTROLS
Drive Control Components - Hand/Foot Models
1 WASHER/FLAT
2 NUT/HEX LOCK
3 PIN/ROLL
4 ROD END/FEMALE
5 ROD END/FEMALE
6 SPACER
7 SHAFT/PIVOT
8 BUSHING/PIVOT
9 BRACKET/PIVOT
10 ROD
11 ARM/ASSEMBLY
12 ROD END
13 NUT/SPIRALOCK
14 NUT/SPIRALOCK
15 DEVICE/CENTER
16 PLUG 4-PIN
17 WEDGE 4-PIN
18 NUT/LOCK
19 BOOT/T-BAR
20 ARM/PUMP
21 PILOT H-F/LEFT
22 PILOT H-F/RIGHT
23 BOOT/H-F PILOT
24 ASSEMBLY/PIVOT
25 STUD/ROD
26 ROD/THREADED
27 ROD/THREADED
28 PIVOT TUBE
29 BOOT/H-F PILOT
30 GRIP/AUXILIARY
31 GRIP
32 NUT/HEX LOCK
33 SCREW/CAP
34 SCREW/CAP
35 SCREW/CAP
36 SCREW/CAP
37 SCREW/CAP
38 SCREW/CAP
39 BOLT/CARRIAGE
40 NUT/JAM
41 WASHER/FLAT
42 WASHER/FLAT
43 NUT/HEX

32
2

25

11
9

30

40

20

1
8

40
18

39

39
23

37
20

40

40
32

35

13

7
13

28

27
20

19
35

18
8
31

18

14

33

43
18

22

26

39

40

18

41

36
42

12

43

24

13

34

8
43

11
43

29
15

12

40

13

38

3
18

40

5
32

41

19
38
39

42

15

36
21
13

10

18
5

13

12 38

40
SEE NOTES 16
1&2

13

36
42

38
18

42
36

17 SEE NOTE 3

10
13

40

12
NOTES:

1) ROUTE ELECTRICAL WIRES BEFORE INSTALLING


TERMINALS INTO CONNECTORS.
2) INSERT RED WIRE INTO PIN 1, GRAY INTO PIN 2,
BLUE INTO 3, AND BLACK INTO 4.
3) INSERT WEDGE AFTER TERMINALS ARE INSTALLED.

Fig. 6-4

Deutsch DTM04-12P

CLR

Circuit
Function

RED

Vehicle
Power

Power

1 12

BLK

Vehicle
Ground

Ground

2 11

GRY

Prop Coil
Return

Current
Feedback

3 10

YEL

Prop Coil
PWM Output

Coil #1
Current

SW3

Switch #3

BRN

PUR

Prop Coil
PWM Output

Coil #2
Current

SW2

Switch #2

GRN/
BRN

PNK

Switch
Common

Switch
Common

Pin
Function

Pin
Pin
Number Function

Constant
Active

Circuit
Function

Constant
Output

CLR
_
_
BLU

PIN CONNECTION CHART


FOR 194451 GRIP
(REF ONLY)

Exploded view of Hand/Foot wheel drives controls

917292/AP1008

6-6

PRINTED IN USA

CONTROLS
Drive Control Components - Dual Joystick Models
4

TO JOYSTICK
PORT #4
TO JOYSTICK
PORT #1

TO JOYSTICK
PORT #2
23

4
23
18

4
TO JOYSTICK
PORT #T
22

TO JOYSTICK
PORT #3

20
27
18
13

TO JOYSTICK
PORT #P

21

13

15

17

29
5

11

10

14
28
30

30
16
7

26
3

26

8
8
2
1

24
19

1 FITTING/TEE
2 FITTING/90
3 BUSHING/PIVOT
4 FITTING/90
5 JOYSTICK/DRIVE
6 VALVE/SOLENOID
7 PIN/TILT CONSOLE
8 TOWER MOUNT
9 HANDLE/RATCHET
10 ADAPTER
11 ADAPTER
12 FLANGE/BOOT
13 FLANGE/BOOT
14 JOYSTICK STAND
15 BOOT/JOYSTICK LEFT
16 COVER/CONSOLE
17 BOOT/JOYSTICK
18 HOSE/LOW PRESSURE
19 HOSE/PRESSURE
20 TUBE/JOYSTICK
21 HOSE/PRESSURE
22 HOSE/PRESSURE
23 HOSE/PRESSURE
24 NUT/HEX WHIZLOCK
25 SCREW/CAP
26 BOLT/CARRIAGE
27 SCREW/THREAD CUTTING
28 SCREW/MACHINE
29 SCREW/TAP/R
30 WASHER/FLAT

2
20

Fig. 6-5

Exploded view of Dual Joystick wheel drives controls

PRINTED IN USA

6-7

917292/AP1008

CONTROLS
Drive Control Components - T-Bar and T-Bar/Joystick Models - 56/6640

7
28

5
2

36

1
5

22

22

24

27

31

20

10

36
20

20

13

36

36

20

25

28

34

39

31
35

34

37

16

11

26

17

39

23

2
1

36

21

14

10

20
36

13

13

12

20

32

37

39
39

11

38

32

29

20

36

33
30

28

38
32

NOTE 3

13

15

19

34

12
8
3

18

Fig. 6-6

1) ROUTE ELECTRICAL WIRES BEFORE INSTALLING


TERMINALS INTO CONNECTORS

NOTE 1 & 2

1 WASHER/FLAT
2 PIN/ROLL
3 ROD END
4 SHAFT/PIVOT
5 BEARING
6 T-BAR STOP
7 BRACKET/PIVOT
8 ROD
9 ASSY/PIVOT
10 ARM/ASSEMBLY

NOTES:

36

2) INSERT RED WIRE INTO PIN 1, GRAY INTO 2,


BLUE INTO 3, AND BLACK INTO 4
3) INSERT WEDGE AFTER TERMINALS ARE INSTALLED.

20

11 DAMPER
12 ROD END
13 NUT/SPIRALOCK
14 NUT/SPIRALOCK
15 PIVOT/T-BAR
16 KAWASAKI GRIP
17 LEVER/CONTROL
18 DEUTSCH PLUG
19 DEUTSCH WEDGE
20 NUT/HEX

21 BOOT/T-BAR
22 ARM/PUMP
23 PIVOT ASSEMBLY
24 STUD/ROD
25 THREADED ROD
26 THREADED ROD
27 PIVOT TUBE
28 NUT/HEX
29 SCREW/CAP
30 SCREW/CAP

31 SCREW/CAP
32 SCREW/CAP
33 SCREW/CAP
34 BOLT/CARRIAGE
35 PIN/ROLL
36 NUT/JAM
37 WASHER/FLAT
38 WASHER/FLAT
39 NUT/HEX

Exploded view of T-Bar and T-Bar/Joystick wheel drives controls

917292/AP1008

6-8

PRINTED IN USA

CONTROLS
NOTES

PRINTED IN USA

6-9

917292/AP1008

CONTROLS
Lift/Tilt Control Removal and Installation

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:

q Raise lift arm; engage lift arm support


device.

q Shut off the engine.


q Tilt back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual.)

Fig. 6-7

Location of three of five capscrews securing


floor plate to the chassis

Fig. 6-8

View of six hoses attached to foot valves

Fig. 6-9

Location of electrical connector to disconnect.


Other control handle is similar

Removal Procedure - Hand/Foot Controls


1. Remove the control cover per the procedure found
in the Mainframe chapter.
2. Remove five capscrews securing floor plate to the
chassis. Fig. 6-7
3. Pull the floor plate up to expose the foot valves and
their hydraulic hose and tube connections. Fig. 6-8
4. Mark the hydraulic hoses prior to disconnecting
them for easier re-assembly. Disconnect six hoses
from foot valves. Fig. 6-8
NOTE: Hydraulic hoses and fittings should be
capped/plugged after they are disconnected to prevent
contaminants from entering the hydraulic system.
5. Lift foot pedal assembly out of chassis. Fig. 6-9
6. If needed, remove two capscrews securing each foot
pedal to its foot valve.
7. If replacing a foot valve, mark and remove
connecting hydraulic tubing and four capscrews on
each foot valve securing them to the floor plate.
NOTE: Hydraulic tubes should be capped/plugged
after they are disconnected to prevent contaminants
from entering the hydraulic system.
8. To reassemble, refer to exploded view as a guide.
Installation Procedure - Hand/Foot Control - Follow
all warnings first, then reverse the removal steps.

917292/AP1008

6-10

PRINTED IN USA

CONTROLS
R e moval Pr oc e dur e - D ual Jo ys t i ck an d
T-Bar/Joystick Controls

WARNING

Control Valve

BEFORE beginning this service procedure,


perform the following SAFETY procedures:

Manifold

q Raise lift arm; engage lift arm support


device.

q Shut off the engine.


q Tilt back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual.)
1. Remove control cover per the procedure in the
Mainframe chapter.
2. Disconnect four hydraulic hoses from the control
valve, two in the rear and two in front. Figs. 6-10,
6-11
NOTE: Hydraulic hoses and fittings should be
capped/plugged after they are disconnected to prevent
contaminants from entering the hydraulic system.
3. Disconnect two hydraulic hoses from the three- or
five-bank manifold located. Fig. 6-10

Fig. 6-11 Location of two hoses at the rear of the control


valve that help control lift and tilt functions on
dual joystick and t-bar/joystick control units

PRINTED IN USA

Installation Procedure - Dual Joystick and


T-Bar/Joystick Controls - Follow all warnings first,
then reverse the removal steps.

6-11

917292/AP1008

CONTROLS

Fig. 6-10 Location of two hoses on the manifold and two


hoses on the control valve that help control lift
and tilt functions on dual joystick and
t-bar/joystick control units

CONTROLS
Electrical Hand Throttle Removal and
Installation
Gehl 5640E/6640E and Mustang 2066/76/86 units have
an electric hand throttle located in the right instrument
panel for increasing/decreasing the engine's speed.

Hand Throttle
Knob

Removal Procedure

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:

q Shut off the engine.

Fig. 6-12 An Allen wrench is used to loosen the set screw


on the hand throttle control knob

(For detailed instructions, refer to the Safety


chapter of this manual.)
1. Use an Allen wrench to loosen the set screw
securing the throttle control knob to the instrument
panel. Fig. 6-12
2. Remove two cross-recessed machine screws
securing the throttle control to the instrument panel.
The throttle control module should fall to the inside.
Fig. 6-13
3. Remove four Phillips-head machine screws
securing the instrument panel to the ROPS
post/stanchion. Carefully pull the instrument panel
away from the stanchion and remove the throttle
control module. Fig. 6-14
Installation Procedure - Follow all warnings first,
then reverse the removal steps.

Fig. 6-13 Two cross-recessed machine screws to remove


on the throttle control module

Fig. 6-14 Location of two of three machine screws


securing the right instrument panel in the ROPS
stanchion
917292/AP1008

6-12

PRINTED IN USA

CONTROLS
Electrical Foot Throttle Removal and
Installation - Dual Joystick Controls
Gehl 5640E/6640E and Mustang 2066/76/86 dual
joystick control units have an electric foot throttle
located
above
the
right
foot
rest
for
increasing/decreasing the engine's speed.

Swell Latch

Removal Procedure

Throttle
Panel Cover

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:

Fig. 6-15 Location of two swell latches securing the right


panel cover to the side of the chassis

q Raise lift arm; engage lift arm support


device.

q Shut off the engine.

1. Remove the right panel cover by releasing its two


swell latches. Fig. 6-15
2. Unplug the electrical connector on the electric foot
throttle. Fig. 6-16
3. Remove to hex nuts on carriage bolts securing the
foot throttle assembly to the chassis. Fig. 6-17
4. Remove the entire electric foot throttle assembly
from the skid-steer loader.
Fig. 6-16 Unplug this electrical wire connector from the
throttle assembly

Installation Procedure - Follow all warnings first,


then reverse the removal steps.*
* The mechanical stop in Fig. 6-17 is there to prevent
physical stress on the throttle sensor associated with
pressing a foot down on the pedal.

Mechanical
Stop

Fig. 6-17 Location of two hex nuts securing the foot


throttle assembly to the front of the chassis

PRINTED IN USA

6-13

917292/AP1008

CONTROLS

(For detailed instructions, refer to the Safety


chapter of this manual.)

CONTROLS
Electrical Foot Throttle Assembly - T-Bar, T-Bar/Joystick and Dual Joystick Controls

12
16

15
18

13

6
19
1
7
14
7

16
15
17

11
10
14

17
19
4

1
5
2

21
9
2

3
20

1 ASSY/ BALL JOINT


2 WASHER/FLAT
3 PIN/ROLL
4 NUT/LOCK
5 BUSHING/PIVOT
6 NUT/SPIRALOCK
7 SPRING

8 BRACKET/THROTTLE
9 THROTTLE BRACKET
10 PEDAL/THROTTLE
11 ROD/THREADED
12 SENSOR/THROTTLE
13 THROTTLE LINK
14 NUT/HEX WHIZLOCK

15 SCREW/SOCKET CUP POINT


16 SCREW/CAP
17 NUT/HEX
18 BOLT/CARRIAGE
19 WASHER/FLAT
20 SCREW/CAP
21 NUT/JAM HEX

Fig. 6-18 Exploded view of the auxiliary hydraulics controls for T-Bar, T-Bar/Joystick and Dual Joystick control models

917292/AP1008

6-14

PRINTED IN USA

HYDROSTATIC SYSTEM

Introduction
This chapter covers troubleshooting, testing, removal,
installation, and adjustment procedures for the
hydrostatic system components on Gehl 5640E/6640E
and Mustang 2066/76/86 skid-steer loaders.

through a chain and sprocket system. The hydrostatic


pumps and drive motors are controlled individually
allowing complete flexibility in forward, reverse,
gradual, pivot and spin turns.

In this system, a hydrostatic pump assembly coupled to


the engine provides hydrostatic power to the two
fixed-displacement hydrostatic drive motors. The drive
motors drive the wheels on each side of the loader

For detailed information on hydrostatic pump or drive


motor internal repair, consult the Gehl or Mustang
Service Department and/or the hydrostatic component
manufacturers service manual.

HYDROSTATIC

NOTES

PRINTED IN USA

7-1

917292/AP1008

HYDROSTATIC SYSTEM
Hydrostatic System - Single-Speed Components - Dual Joystick Controls
BRAKE -08 ORB (N,P)

MAIN OUT -12 ORB (D,H)


CASE FLUSH-DRAIN -10 ORB (R,S)
MAIN IN -12 ORB (C,G)

DRIVE MOTOR PORT REFERENCE

APPLY LOCTITE 242 42


TORQUE TO 55 FT-LBS
L
A

46

23
1

11

10

20

16

22
16

25

28
6

40

30
G
31
H
44

15
16
38

12

G
21

13

41

17

DRAIN CONNECTION FOR


DUAL JOYSTICK
E

N
19

34

18
14

43

P
24

H
16

33

36

Q
7
N
C

37
2

27
45

9
Q

D
K

35
8

41
26

16
29

15
44

1 FITTING/STRAIGHT
2 FITTING/TEE
3 FITTING/45
4 FITTING/TEE
5 CAP/37 FLARE
6 FITTING/TEE
7 CAP/37 FLARE
8 FITTING/TEE
9 FITTING/STRAIGHT
10 FITTING/45
11 FITTING/90
12 HOSE/PRESSURE

Fig. 7-1

45

39

25 HOSE/CHARGE INLET
26 TUBE/BRAKE
27 TUBE/BRAKE
28 HOSE/PRESSURE
29 FITTING/STRAIGHT
30 HOSE/PRESSURE
31 HOSE/PRESSURE
32 HOSE/PRESSURE
33 FITTING/90
34 FITTING/90
35 TUBE/BRAKE
36 HOSE/PRESSURE

13 SWITCH/TEMP
14 NUT/SPIRALOCK
15 WASHER/FLAT
16 FITTING/STRAIGHT
17 SCREW/CAP
18 VALVE/SOLENOID
19 TUBE/DRAIN MOTOR
20 HOSE/PRESSURE
21 MANIFOLD/RETURN
22 PUMP/TANDEM
23 TUBE/CHARGE
24 TUBE/DRAIN MOTOR

37 HOSE/DRAIN
38 MOTOR/ONE SPEED
39 MOTOR/ONE SPEED
40 HOSE/PRESSURE
41 FITTING/STRAIGHT
42 SCREW/CAP
43 SCREW/CAP
44 SCREW/CAP
45 CLAMP/HOSE
46 WASHER/FLAT

Exploded view of the dual joystick hydrostatic single-speed system

917292/AP1008

7-2

PRINTED IN USA

HYDROSTATIC SYSTEM
Hydrostatic System - Single-Speed Components - T-Bar, T-Bar/Joystick and Hand/Foot
BRAKE -08 ORB (N,P)

MAIN IN -12 ORB (C,G)


CASE FLUSH-DRAIN -10 ORB (R,S)
MAIN OUT -12 ORB (D,H)

DRIVE MOTOR PORT REFERENCE

48 APPLY LOCTITE 242


TORQUE TO 55 FT-LBS
B
15

13
11

21

19

47

29

1
A

31

12

14

33
E
1
CONNECT TO INLET ON "3" OR
"5" BANK MANIFOLD VALVE

21

F
22

36

50

28

37

20
A

23

21

G
5

44

6
16

34
J

35

27
17

46

L
8

26

24

49

25
P

10

30

32

18

21

51

41
2

45
39

C
21

10

43

D
51

K
9

46

42
50

40
20
K
38

1 FITTING/90
2 FITTING/TEE
3 FITTING/45
4 FITTING/90
5 CAP/37 FLARE
6 FITTING/45
7 FITTING/TEE
8 CAP/37 FLARE
9 FITTING/TEE
10 FITTING/STRAIGHT
11 ADAPTER/90
12 FITTING/TEE
13 FITTING/90

Fig. 7-2

27 MANIFOLD/RETURN
28 PUMP/TANDEM
29 TUBE/TANDEM PUMP
30 HOSE/PRESSURE
31 HOSE/PRESSURE
32 TUBE/DRAIN MOTOR
33 HOSE/PRESSURE
34 HOSE/PRESSURE
35 HOSE/PRESSURE
36 HOSE/CHARGE
37 HOSE/CHARGE INLET
38 TUBE/BRAKE LEFT
39 TUBE/BRAKE RIGHT

14 TUBE/CHARGE
15 PLUG
16 HOSE/PRESSURE
17 SWITCH/TEMP
18 NUT/SPIRALOCK
19 WASHER/FLAT
20 WASHER/FLAT
21 FITTING/STRAIGHT
22 HOSE/PRESSURE
23 SCREW/CAP
24 VALVE/SOLENOID
25 TUBE/DRAIN MOTOR
26 HOSE/PRESSURE

40 FITTING/STRAIGHT
41 FITTING/90
42 TUBE/BRAKE
43 HOSE/DRAIN
44 MOTOR/ONE SPEED
45 MOTOR/ONE SPEED
46 FITTING/STRAIGHT
47 FITTING/TEE
48 SCREW/CAP
49 SCREW/CAP
50 SCREW/CAP
51 CLAMP/HOSE

Exploded view of the t-bar, t-bar/joystick and hand/foot hydrostatic single-speed system

PRINTED IN USA

7-3

917292/AP1008

HYDROSTATIC SYSTEM
Hydrostatic System - Two-Speed Components - Dual Joystick Controls
BRAKE -08 ORB (N,P)

MAIN OUT -12 ORB (D,H)


CASE FLUSH-DRAIN -10 ORB (R,S)
2-SPEED -08 ORB (O,Q)
MAIN IN -12 ORB (C,G)

DRIVE MOTOR PORT REFERENCE

46 APPLY LOCTITE 242


TORQUE TO 55 FT-LBS
A

50

25

13

12

E
22
18
8

24
18
36

37

48

31

17
18
G
26

19
7

23

11

34
44

14

Q
45

DRAIN CONNECT FOR


DUAL JOYSTICK
E
F

P
21

20
47

16

42

15

45

29

10

30

H
18

49
40

P
C

L
N

39

33

27

10

18

43

49

28

41
N

11
48

32

35

17

D
45

1 FITTING/STRAIGHT
2 FITTING/TEE
3 FITTING/STRAIGHT
4 FITTING/45
5 FITTING/TEE
6 FITTING/90
7 CAP/37 FLARE
8 FITTING/TEE
9 CAP/37 FLARE
10 FITTING/TEE
11 FITTING/STRAIGHT
12 FITTING/45
13 FITTING/90

Fig. 7-3

27 MOTOR/TWO-SPEED
28 TUBE/TWO-SPEED
29 TUBE/TWO-SPEED
30 TUBE/MOTOR DRAIN
31 HOSE/CHARGE INLET
32 TUBE/BRAKE
33 TUBE/BRAKE
34 HOSE/PRESSURE
35 FITTING/STRAIGHT
36 HOSE/PRESSURE
37 HOSE/PRESSURE
38 HOSE/PRESSURE
39 FITTING/90

14 HOSE/PRESSURE
15 SWITCH/TEMP
16 NUT/SPIRALOCK
17 WASHER/FLAT
18 FITTING/STRAIGHT
19 SCREW/CAP
20 MANIFOLD/VALVE
21 TUBE/MOTOR DRAIN
22 HOSE/PRESSURE
23 MANIFOLD/RETURN
24 PUMP/TANDEM
25 TUBE/CHARGE
26 MOTOR/TWO-SPEED

40 TUBE/CASE DRAIN
41 TUBE/BRAKE
42 HOSE/PRESSURE
43 HOSE/DRAIN
44 HOSE/PRESSURE
45 FITTING/STRAIGHT
46 SCREW/CAP
47 SCREW/CAP
48 SCREW/CAP
49 CLAMP/HOSE
50 WASHER/FLAT

Exploded view of the dual joystick hydrostatic two-speed system

917292/AP1008

7-4

PRINTED IN USA

HYDROSTATIC SYSTEM
Hydrostatic System - Two-Speed Components - T-Bar, T-Bar/Joystick and Hand/Foot
BRAKE -08 ORB (N,P)

MAIN IN -12 ORB (C,G)


CASE FLUSH-DRAIN -10 ORB (R,S)
2-SPEED -08 ORB (O,Q)
MAIN OUT -12 ORB (D,H)

DRIVE MOTOR PORT REFERENCE

1
A

APPLY LOCTITE 242


51 TORQUE TO 55 FT-LBS

30

20

50

15

22

46

14

12 16

13
K

47

E
1

8
48

48

22

C
F
D
G
29

53

38

21
7

24

22
28

32

17

23

11

49

27

25

19
4

18

42
J

49

31

26

35

10

52

H
36

22

33
N

54

40

22

43

45

10

34
49

Fig. 7-4

11
53

41

39

1 FITTING/90
2 FITTING/TEE
3 FITTING/STRAIGHT
4 FITTING/45
5 FITTING/90
6 CAP/37 FLARE
7 FITTING/45
8 FITTING/TEE
9 CAP/37 FLARE
10 FITTING/TEE
11 FITTING/STRAIGHT
12 ADAPTER/90
13 FITTING/TEE
14 FITTING/90

54

M
O

21

15 TUBE/CHARGE
16 PLUG
17 HOSE/PRESSURE
18 SWITCH/TEMP
19 NUT/SPIRALOCK
20 WASHER/FLAT
21 WASHER/FLAT
22 FITTING/STRAIGHT
23 HOSE/PRESSURE
24 SCREW/CAP
25 MANIFOLD/VALVE
26 TUBE/DRAIN MOTOR
27 HOSE/PRESSURE
28 MANIFOLD/RETURN

44

29 PUMP/TANDEM
30 TUBE/TANDEM PUMP
31 HOSE/PRESSURE
32 MOTOR/TWO-SPEED
33 MOTOR/TWO-SPEED
34 TUBE/TWO-SPEED
35 TUBE/TWO-SPEED
36 TUBE/DRAIN MOTOR
37 HOSE/CHARGE
38 HOSE/CHARGE INLET
39 TUBE/BRAKE
40 TUBE/BRAKE
41 FITTING/STRAIGHT
42 FITTING/90

43 TUBE/CASE DRAIN
44 TUBE/BRAKE
45 HOSE/DRAIN
46 HOSE/PRESSURE
47 HOSE/PRESSURE
48 HOSE/PRESSURE
49 FITTING/STRAIGHT
50 FITTING/TEE
51 SCREW/CAP
52 SCREW/CAP
53 SCREW/CAP
54 CLAMP/HOSE

Exploded view of the t-bar, t-bar/joystick and hand/foot hydrostatic two-speed system

PRINTED IN USA

7-5

917292/AP1008

HYDROSTATIC SYSTEM

Troubleshooting Guide
The following troubleshooting guide lists potential
hydrostatic system problems, as well as possible causes
and remedies, for Gehl 5640E/6640E and Mustang
2066/76/86 skid-steer loaders.

IMPORTANT
DO NOT attempt to service or repair major
hydrostatic system components, such as the
hydrostatic pumps or drive motors, unless
authorized to do so by your Gehl or Mustang
dealer. Any unauthorized repair will void the
warranty.

When a problem occurs, dont overlook simple causes.


A malfunction can be caused by something as simple as
low oil level. After a mechanical failure has been
corrected, be sure to locate and correct the cause of the
problem.

Problem

Possible Cause

Remedy

No response from the


hydrostatic drive or the
lift/tilt systems.

Restraint bar or seat switch malfunction.

Check switches.

Pilot oil solenoid is malfunctioning.

Check electrical connections to solenoid


and repair.

Hydraulic oil viscosity is too high.

Allow longer warm-up or replace oil with the


proper viscosity oil.

Hydraulic oil supply is too low.

Check for low oil level in reservoir. Add oil


as needed.

Hydrostatic pump drive is disconnected.


Drive coupling failure.

Check for broken or worn pump Drive


Coupling and replace, as needed.

Blown fuse or relay.

Replace fuse or relay.

Parking brake is engaged.

Disengage parking brake.

Hydraulic oil supply too low.

Check for low oil level in reservoir. Add oil if


necessary.

Control rod linkage disconnected.

Check linkage connection at control levers


and neutral centering mechanisms.
Reconnect linkage.

Low or no charge pressure.

See hydrostatic pump manual.

Hydrostatic pump relief valves are


malfunctioning.

Inspect and clean the relief valves. Replace


them as needed.

Inadequate pilot supply oil pressure to


joystick control.

Check pilot supply oil pressure. Check pilot


supply cut-out solenoid.

High pressure hydraulic hoses between


hydrostatic pump and drive motors are
connected wrong.

Reconnect hoses to proper ports on the


drive motors. Refer to schematic and
figures in the Hydrostatic System chapter.

Traction drive will not


operate in either direction.

Drive wheels do not turn in


proper direction.

917292/AP1008

7-6

PRINTED IN USA

HYDROSTATIC SYSTEM
Problem

Possible Cause

Remedy

Neutral is difficult to
maintain.

Rod ends loose on centering mechanism or


servo rod.

Check and tighten or replace components.

Neutral centering mechanism(s) out of


adjustment.

Adjust neutral centering mechanism(s).

Clamping bolt is loose.

Tighten clamp bolt.

Hydrostatic pump out of adjustment.

See hydrostatic pump manual.

Joystick control valve malfunction.

Replace joystick control valve.

Air in the hydraulic system.

Cycle the lift and tilt cylinders to maximum


stroke and maintain pressure for a short time
to clear air from system. Check hydraulic oil
reservoir, fill as needed.

Hydraulic oil supply is too low.

Check hydraulic oil reservoir. Add oil, if


necessary.

Low hydrostatic system charge pressure.

See hydrostatic pump manual.

Drive motor(s) or hydrostatic pump(s) have


internal damage or leakage.

Refer to component manufacturers service


manual.

Engine is not responding under load.

Troubleshoot engine.

Drive system overloaded continuously.

Improve efficiency of operation.

Lift and tilt system overloaded continuously.

Improve efficiency of operation.

Sluggish response to
acceleration.

Hydrostatic drive is
overheating.

Drive motor(s) or hydrostatic pump(s) have


internal damage or leakage.

Refer to component manufacturers service


manual.

Oil cooler is plugged with debris.


Clean oil cooler fins.
Loader being operated in a high temperature
area with no air circulation.
Reduce duty cycle and improve air
circulation.
Hydrostatic oil filter plugged or restricted.
Replace the filter.
Creeps in NEUTRAL.

Hydrostatic pump needs adjustment.

Refer to the "Neutral Centering Adjustment"


procedure in the Controls chapter of the
Form No. 917231 service manual
addendum.

Turns slightly left or right Hydrostatic pump needs adjustment.


in FORWARD or REVERSE
position when using the
traction drive control
handle.

Refer to the "Neutral Centering Adjustment"


procedure in the Controls chapter of the
Form No. 917231 service manual
addendum.

PRINTED IN USA

7-7

917292/AP1008

HYDROSTATIC SYSTEM
Problem

Possible Cause

Remedy

Hydrostatic (drive)
system is noisy.

Hydraulic oil viscosity is too high.

Allow longer warm-up or replace existing oil


with the proper viscosity oil.

Drive motor(s) or hydrostatic pump(s) have


internal damage or leakage.

Refer to component manufacturers service


manual.

Air in hydraulic system.

Cycle lift and tilt cylinders to maximum stroke


and maintain pressure for a short time to clear
air from system. Check oil level in reservoir,
fill as needed.

Excessive internal leakage in right drive


motor.

Repair or replace as needed. Refer to motor


manufacturers service manual.

Excessive leakage in engine-end hydrostatic


pump.

Refer to the pump manufacturers manual for


service procedures. Repair or replace rear
pump as needed.

Servo controller malfunctioning.

Refer to the pump manufacturers manual for


service procedures. Repair or replace rear
pump as needed.

Right side doesnt drive


in either direction. Left
side operates normally.

Relief valves on engine-end hydrostatic pump Switch valves with those on front hydrostatic
pump. Problem should switch to the left side.
malfunctioning.
Replace defective relief valve.

Right side doesnt drive


in one direction.

Control rod linkage to engine-end hydrostatic


servo is disconnected.

Reattach control rod linkage.

Relief valve on engine-end hydrostatic pump


is malfunctioning.

Switch one relief valve with the other relief


valve on rear pump; problem should switch to
reverse direction. Clean or replace the faulty
valve as needed.

Engine-end hydrostatic pump malfunctioning.

Refer to pump manufacturers manual for


service procedures. Repair or replace rear
pump as needed.

Servo controller malfunctioning.


Refer to pump manufacturers manual for
service procedures. Repair or replace rear
pump as needed.
Joystick control valve malfunction.
Replace joystick control valve.
Lift/tilt controls fail to
respond.

Hydraulic oil viscosity is too heavy.

Allow longer warm-up or replace with proper


viscosity oil.

Hydraulic oil level is low.

Check oil level in reservoir. If oil is low, check


for an external leak. Repair and add oil.

Solenoid valve(s) malfunctioning.

Check electrical connections to lift solenoid


and repair.
Check switches.

Restraint bar or seat switch malfunction.

917292/AP1008

7-8

PRINTED IN USA

HYDROSTATIC SYSTEM
Problem

Possible Cause

Remedy

Left side doesnt drive in


either direction. Right side
operates normally.

Excessive internal leakage in left drive


motor.

Perform Case Drain Test on left drive


motor. Repair or replace as needed. Refer
to motor manufacturers service manual.

Excessive leakage in gear-end hydrostatic


pump.

Refer to pump manufacturers manual for


service procedures. Repair or replace the
front pump as needed.

Relief valves on gear-end hydrostatic pump


malfunctioning.

Switch valves with those on rear hydrostatic


pump. See Hydrostatic Pump Relief Valves
information in this chapter; problem should
switch to the right side. Replace defective
relief valve as needed.

Servo controller malfunctioning.

Refer to the pump manufacturers manual


for service procedures. Repair or replace
rear pump as needed.

Control rod linkage to gear-end hydrostatic


servo is disconnected.

Reattach control rod linkage.

Left side doesnt drive in


one direction.

Relief valve on gear-end hydrostatic pump is Switch relief valve with other relief valve on
malfunctioning.
front pump; problem should switch to the
reverse direction. Clean or replace the faulty
valve as needed.
Gear-end hydrostatic pump malfunctioning.

Refer to pump manufacturers manual for


service procedures. Repair or replace front
pump as needed.

Servo controller malfunctioning.


Refer to pump manufacturers manual for
service procedures. Repair or replace front
pump as needed.

PRINTED IN USA

7-9

917292/AP1008

917292/AP1008

7-10

TILT CYLINDERS

AUXILIARY HYD
COUPLERS

OPTIONAL HYD
ALL-TACH

A-B.....HIGH PRESSURE PORTS


T.......CASE DRAIN PORT
MA......GAUGE-OPERATING
PRESSURE A
MB......GAUGE-OPERATING
PRESSURE B
R.......AIR BLEED
X1-X2...CONTROL PRESSURE PORTS
(BEFORE THE ORFICE)
G-G1-G2.PRESSURE PORT FOR
AUXILIARY CIRCUIT
S.......BOOST SUCTION PORT
MG......GAUGE-OPERATING
PRESSURE G
Y.......CONTROL PRESSURE
GAUGE PORT

REXROTH A20VG PORT KEY

CASE DRAIN COUPLER

OPTIONAL HIGH FLOW


HYD COUPLERS

TRAVEL
JOYSTICK

LIFT/TILT
JOYSTICK

LEFT
DRIVE
MOTOR

RIGHT
DRIVE
MOTOR

STANDARD
HYDRAULIC
PUMP

OPTIONAL
HIGH FLOW
HYDRAULIC
PUMP

AC

HYDRAGLIDE
MANIFOLD

G2

X2

JOYSTICK PILOT
SUPPLY SOLENOID

X1

HYD
ALL-TACH
VALVE

MB B G

MA A

PILOT SUPPLY
SOLENOID VALVE
MANIFOLD

MG

B MB

G1A MA

SELF LEVEL VALVE

X1

SHOWN WITH
OPTIONAL
TWO-SPEED
SOLENOID
VALVE

X2

BRAKE
SOLENOID
VALVE

P1

P2

HYDROSTATIC
PUMP

LIFT

TILT

STD
AUX

MAIN CONTROL VALVE


SHOWN OPTIONAL
HIGH FLOW SECTION

LIFT CYLINDERS

RESERVOIR

HEAT
EXCHANGER

FILTER
ASSEMBLY
WITH BYPASS

HYDROSTATIC SYSTEM
Hydraulic/Hydrostatic Schematic - Dual Joysticks
Tier3 Yanmar Engine

PRINTED IN USA

HYDROSTATIC SYSTEM

OPTIONAL HIGH FLOW


HYD COUPLERS

TILT
FOOT
PEDAL

LIFT
FOOT
PEDAL

RIGHT
DRIVE
MOTOR

LEFT
DRIVE
MOTOR

OPTIONAL
HIGH FLOW
HYDRAULIC
PUMP

STANDARD
HYDRAULIC
PUMP

HYDROGLIDE
MANIFOLD

AC

PILOT SUPPLY
SOLENOID VALVE
MANIFOLD

SHOWN WITH
OPTIONAL
TWO SPEED
SOLENOID VALVE

HYDRAULIC
ALL-TACH
VALVE

A B

STD AUX

LIFT

TILT

SELF
LEVEL
VALVE

HYDROSTATIC
PUMP

BRAKE
SOLENOID
VALVE

MAIN CONTROL VLAVE


SHOWN WITH OPTIONAL
HIGH FLOW SECTION

RESERVOIR

LIFT CYLINDERS

FILTER
WITH

HEAT
EXCHA

917292/AP1008

7-11

PRINTED IN USA

CASE DRAIN

OPTIONAL HYD
ALL-TACH

TILT CYLINDERS

AUXILIAR HYD
COUPLERS

Hydraulic/Hydrostatic Schematic
Hand/Foot with Foot Valves
Tier3 Yanmar Engine

HYDROSTATIC SYSTEM
NOTES

917292/AP1008

7-12

PRINTED IN USA

HYDRAULIC SYSTEM

Introduction and Troubleshooting Guide


This chapter covers troubleshooting, testing, removal,
installation, and adjustment procedures for hydraulic
system components on Gehl 5640E/6640E and Mustang
2066/76/86 skid-steer loaders.

The following troubleshooting guide lists potential


hydraulic system problems, as well as possible causes
and remedies, for Gehl 5640E/6640E and Mustang
2066/76/86 skid-steer loaders.

Power for the lift arm functions and auxiliary hydraulics


is provided by a gear pump attached to the front of the
hydrostatic pumps.

If you cannot locate a particular hydraulic system


problem in this chart, you should also consult the
Hydrostatic System chapter troubleshooting chart.

Standard and high-flow models include a standard-flow


auxiliary hydraulics system with connections on the lift
arm for attachment hookup. High-flow models are
equipped with high-flow hydraulics, which includes a
connectors on the right side of the lift arm, for operating
attachments that require higher hydraulic flow.

When a problem occurs, dont overlook simple causes.


A malfunction could be caused by something as simple
as low fluid level in the hydraulic reservoir. After a
mechanical failure has been corrected, be sure to locate
the cause of the problem.

Information on recommended hydraulic fluids,


capacities and filter change intervals is in the
Lubrication chapter. For detailed information on gear
pump or control valve internal repair, consult the Gehl
or Mustang Service Department and/or the hydraulic
component manufacturers service manual. Hydraulic
components related to the drive system are covered in
the Hydrostatic System chapter.

IMPORTANT

Problem

Possible Cause

Remedy

Lift/tilt controls fail to respond.

Hydraulic oil viscosity is too heavy.

Allow longer warm-up or replace with


proper viscosity oil.

Solenoid valve(s) malfunctioning.

Check electrical connections to solenoid


and repair connections as needed.
Perform Solenoid Valve Test. Replace
solenoid as needed.

Hydraulic oil level is low.

Check oil level in reservoir. If oil is low,


check for an external leak. Repair and
add oil.

Hydraulic oil flow to the gear pump is


blocked.

Inspect suction hose. Clean or replace


as needed.

System relief valve is malfunctioning.

Adjust or replace relief valve as needed.

Drive is disconnected.

Check for broken or worn pump drive


coupling and replace as needed.

Sheared spline or broken shaft in


hydrostatic pump assembly.

Check splined shaft of pump closest to


engine. Replace shaft if broken or if
splines are sheared.

Sheared spline or broken shaft in gear


pump.

Restraint bar switch or seat switch not


closing.

PRINTED IN USA

8-1

Remove gear pump from hydrostatic


pump, inspect the splined shaft and
coupler. Replace components as
needed.
Check switches and wiring. Replace as
needed.

917292/AP1008

HYDRAULICS

DO NOT attempt to service or repair major


hydraulic system components, such as the
gear pump, unless authorized to do so by
your Gehl or Mustang dealer. Any
unauthorized repair will void the warranty.

HYDRAULIC SYSTEM
Troubleshooting Guide
Problem

Possible Cause

Remedy

Hydraulic cylinder action is slow


for lift/tilt functions.

Low engine speed.

Operate engine at higher speed.

Hydraulic oil viscosity is too heavy.

Allow longer warm-up or replace existing


oil with proper viscosity oil.

Hydraulic oil leaking past cylinder


piston seals.

Replace cylinder seals and o-rings as


needed.

Hydraulic oil level is low.

Check oil level in reservoir. If oil is low,


check for an external leak. Repair and add
oil.

Inadequate pilot supply oil pressure to


joystick, t-bar or foot controls.

Check pilot supply oil pressure.

Inadequate pilot signal from control to


the main control valve.

Check signal pressure, clean or replace as


needed.

Lift Arm does not raise, bucket


tilt works properly.

Lift spool in control valve not actuated


or leaking.

Check hose or tube connection to valve.


Check pressure and flow.

Jerky lift arm and bucket action.

Restraint bar switch or seat switch


malfunction.

Check electrical connections to the switch.


Replace switch as needed.

Air in the hydraulic system.

Cycle lift and tilt cylinders to maximum


stroke and maintain pressure for short time
to clear air from system.

Oil in hydraulic reservoir low.

Check and add oil to reservoir as needed.

Low engine speed.

Operate engine at higher engine speed.

Hydraulic oil level low.

Add oil to reservoir.

Hydraulic oil viscosity is too heavy.

Allow long warming period.

Auxiliary spool in control valve is


leaking or is not fully activated.

Repair any leak found; readjust the


auxiliary spool for full travel.

Standard-flow auxiliary
hydraulics function slowly.

917292/AP1008

8-2

PRINTED IN USA

HYDRAULIC SYSTEM
Troubleshooting Guide
Problem

Possible Cause

Remedy

Lift Arm doesnt maintain raised Oil leaking past lift cylinder seals (internal
position with lift control in
or external).
NEUTRAL.

Check cylinder tube bore condition.


Replace seals or cylinder tube as
needed.

Oil leaking past lift spool in control valve.

Check valve body for scores or cracks.


Replace control valve as needed.

Self-leveling valve is malfunctioning.

Repair or replace as needed.

Leaking hydraulic hoses, tubes, or fittings


between control valve and cylinders.

Inspect hoses and tubes, tighten fittings


as needed. Replace hoses or tubes as
needed.

Hydraglide/Float control block with internal


leakage.

Repair or replace as needed.

Float control is activated.


Deactivate float control by pressing the
button on the control handle.
Lift cylinder lift arm support device
engaged.

Raise lift arm and disengage the lift arm


support device.

Solenoid valve is malfunctioning.

Check electrical connections to solenoid.


Repair or replace as needed.

Restraint bar not lowered.

Lower restraint bar.

Restraint bar switch or seat switch


malfunction.

Check electrical connections to the


switch. Replace switches as needed.

Blown fuse or relay.

Replace fuse or relay.

Bucket drifts downward with tilt Oil leaking past tilt cylinder seals (external
control in NEUTRAL.
or internal).

Lift Arm will not raise a heavy


load or any load at all.

Slow or no response for bucket


tilt, lift works properly
(Hand/Foot units only)

PRINTED IN USA

Check cylinder tube bore condition.


Replace seals, o-rings, or cylinder as
needed.

Self-leveling valve is malfunctioning.

Repair or replace as needed.

Leaking hydraulic hoses, tubes, or fittings


between control valve and cylinders.

Inspect hoses and tubes, tighten fittings


as needed. Replace hoses or tubes as
needed.

Lift port relief in the control valve is


malfunctioning.

Replace lift port relief or contact the Gehl


or Mustang Service Department.

Float control is activated.

Deactivate float control by pressing the


button on the control handle.

Main relief valve is malfunctioning.

Check pressures in relief valve, repair or


replace as needed.

Pilot control lines have air in them.

Bleed the pilot control line from the main


control valve.

Low charge pressure.

See hydrostatic pump manual.

Linkage misadjusted.

Readjust for full travel without restriction.

8-3

917292/AP1008

HYDRAULICS

Lift Arm will not lower or raise.

HYDRAULIC SYSTEM
Troubleshooting Guide
Problem

Possible Cause

Remedy

No downward pressure on
the bucket.

Control valve in float position.

Take control out of float position.

Tilt cylinders are malfunctioning.

Check condition of cylinder tube bore.


Replace seals, O-rings, and/or cylinder
tube as needed.

Float control is activated.

Deactivate float control by pressing the


button on the control handle.

Bucket does not level on the


lift cycle.

Self-leveling valve misadjusted or


malfunctioning.

Repair or replace self-leveling valve as


needed.

Bucket will not tilt; lift arm


works properly.

Tilt solenoid valve is malfunctioning.

Check electrical connections to tilt


solenoid and repair connections as
needed. Replace solenoid as needed.

Tilt spool in control valve not actuated or


leaking.

Check hose or tube connection to Valve.


Check pressure and flow.

Solenoid valves malfunctioning.

Check electrical connections to solenoid.


Repair or replace solenoid

Restraint bar is raised.

Lower the restraint bar.

Restraint bar switch or seat switch


malfunctioning.

Replace the malfunctioning switch.

Faulty fuse connections.

Check fuse connections for security,


damage or broken wires; Repair or
replace as needed.

Control modules malfunctioning.

Contact your authorized Gehl or Mustang


dealer.

Control linkage misadjusted.

Check linkage, readjust for full spool


travel.

Low engine speed.

Operate engine at higher speed.

Hydraulic oil level low.

Add oil to reservoir.

Hydraulic oil viscosity is too heavy.

Allow for longer warming period.

Control valve relief pressure is low.

Check pressure at control valve and


readjust if necessary.

Restraint bar is raised.

Lower the restraint bar.

Restraint bar switch or seat switch


malfunctioning.

Replace the malfunctioning switch.

Blown fuse or relay.

Replace fuse or relay.

Faulty electrical connections.

Check electrical connections for security,


broken or damaged wires and replace as
needed.

Solenoid valve is malfunctioning.

Check electrical connections to solenoid.


Repair or replace as needed.

High-flow auxiliary does not


function.

Standard auxiliary or
high-flow auxiliary functions
slowly.

Standard-flow auxiliary
hydraulics do not function.

917292/AP1008

8-4

PRINTED IN USA

HYDRAULIC SYSTEM
Standard Auxiliary Hydraulics - Dual Joystick, Hand/Foot and T-Bar/Joystick
60

12 13

34

12
NOTE 3
NOTE 4
5

NOTE 2
39
H

42

64
19

9
39

30

43
49
J

NOTE 1

L
48

17

REPLACEMENT
FILTER 074830

45

X
44

20

50

46

3 65

41

12

T
32

14

13

21

12

20

23

21

26

25

NOTE
1) CONNECT TO ROD END OF LIFT CYLINDER.
2) CONNECT TO BASE END OF LIFT CYLINDER.
3) CONNECT TO ROD END OF TILT CYLINDER.
4) CONNECT TO BASE END OF TILT CYLINDER.
5) RELIEF SETTING 3000PSI 25PSI

16

24

52

54

67

55
16
53

37

40

R
58

R
W

36

15

33

S
68

13

35

57
29

61 12

15

63

S
J

12 15

56

17

28

18
59
12

C
A

69

62

51

58

9
27

11

2
2

47

22

66
31

8
7
20
2

2
38

10

1 FITTING/STRAIGHT
2 FITTING/STRAIGHT
3 ELBOW/FITTING 90
4 WASHER/FLAT
5 NUT/HEX
6 SCREW/CAP
7 FITTING/90
8 FITTING/STRAIGHT
9 FITTING/STRAIGHT
10 FITTING/TEE
11 SCREW/CAP
12 PLATE/TWIN COVER
13 CLAMP/TUBE
14 CAP/37 FLARE
15 CLAMP/TUBE
16 CLAMP/HOSE
17 FITTING/90

Fig. 8-1

18 FITTING/90
19 ASSY/FILTER
20, 21 NUT/SPIRALOCK
22 VALVE/SELF LEVEL
23 PUMP/GEAR SINGLE
24 HYDRAGLIDE
25 ACCUMULATOR
26 PLATE/SPACER
27 FITTING/TEE
28 TUBE/TILT
29 TUBE/TILT
30 TUBE/TILT
31 SPACER
32 TUBE/AUXILIARY
33 TUBE/AUXILIARY
34 TUBE/FILTER
35 TUBE/HYDRAGLIDE

36 TUBE/HYDRAGLIDE
37 VALVE/CONTROL
38 3-BANK/VALVE
39 TUBE/TILT
40 TUBE/LIFT
41 TUBE/LIFT
42 TUBE/LIFT
43 TUBE/LIFT
44 TUBE/AUX FEED
45 TUBE/AUX RETURN
46 TUBE/CASE DRAIN
47 PORT/TEST
48 CLAMP/ACCUM
49 ACCUMULATOR
50 TUBE/ACCUM
51 TUBE/SUCTION
52 FITTING/45

53 HOSE/PRESSURE
54 FITTING/90
55 HOSE/DRAIN
56 HOSE/PRESSURE
57 BRACKET/HARNESS
58 CLAMP/T-BOLT
59 SCREW/CAP
60 SCREW/CAP
61 SCREW/CAP
62 BOLT/CARRIAGE
63 SCREW/CAP
64 SCREW/MACHINE
65 SCREW/CAP
66 BOLT/CARRIAGE
67 BOLT/CARRIAGE
68 WASHER/LOCK
69 CLAMP/HOSE

Exploded view of the standard auxiliary hydraulics for dual joystick, hand/foot and t-bar/joystick controls

PRINTED IN USA

8-5

917292/AP1008

HYDRAULICS

HYDRAULIC SYSTEM
Standard Auxiliary Hydraulics - T-Bar Controls
10

47

3
9

41

1
29

52

24 21

54

28 51

17

24

16

20

20
4
46

18
23

4
45

27
23

20

TO HYDRAULIC TANK

43

18

33

42
TO HYDRAULIC TANK

32

15

44

14

6
34
48
50

38

26

12

12
5
6

12

10

39
25

37

30

31

19
9

11
3

22

10

40
40

13

10
19

13

3
2

56

55

49

57

53
36

55

35

NOTES:
1 CONNECT TO ROD END OF LIFT CYLINDER.
2 CONNECT TO BASE END OF LIFT CYLINDER.
3 CONNECT TO ROD END OF TILT CYLINDER.
4 CONNECT TO BASE END OF TILT CYLINDER.
5. RELIEF SETTING 3000PSI 25PSI.

ASSEMBLED VIEW

1 ELBOW/FITTING 90
2 WASHER/FLAT
3 NUT/HEX
4 FITTING/90
5 FITTING/STRAIGHT
6 FITTING/STRAIGHT
7 FITTING/TEE
8 SCREW/CAP
9 PLATE/TWIN COVER
10 CLAMP/TUBE
11 CAP/37 FLARE
12 CLAMP/TUBE
13 CLAMP/HOSE
14 FITTING/90
15 PLUG

Fig. 8-2

16 FILTER ASSEMBLY
17 NUT/SPIRALOCK
18 NUT/SPIRALOCK
19 NUT/SPIRALOCK
20 STRAP
21 VALVE/SELF LEVEL
22 PUMP/GEAR SINGLE
23 VALVE/SOLENOID
24 FITTING/TEE
25 TUBE/TILT
26 TUBE/TILT
27 TUBE/TILT
28 BRKT/SOLENOID LIFT
29 SPACER
30 TUBE/AUXILIARY

31 TUBE/AUXILIARY
32 TUBE/LIFT
33 TUBE/LIFT
34 TUBE/SUCTION
35 FITTING/45
36 HOSE/PRESSURE
37 HOSE/PRESSURE
38 BRACKET/HARNESS
39 VALVE/CONTROL
40 CLAMP/T-BOLT
41 TUBE/TILT
42 TUBE/LIFT
43 TUBE/TILT
44 TUBE/LIFT
45 TUBE/FILTER

46 SCREW/CAP
47 SCREW/CAP
48 SCREW/CAP
49 BOLT/CARRIAGE
50 SCREW/CAP
51 SCREW/CAP
52 SCREW/MACHINE
53 SCREW/CAP
54 BOLT/CARRIAGE
55 WASHER/LOCK
56 CAP/TUBE
57 CLAMP/HOSE

Exploded view of the standard auxiliary hydraulics for t-bar controls

917292/AP1008

8-6

PRINTED IN USA

HYDRAULIC SYSTEM
High-Flow Auxiliary Hydraulics - Dual Joystick, Hand/Foot and T-Bar/Joystick
66
12
P

13

42
54

46

48

20

T
53

REPLACEMENT
FILTER 074830

18

N
CC

50

47

DD

55

EE

51
FF

GG
3

62

13 16

18

X DD
Y

FF

19
65
13

EE

CC BB

21

P
59

49

70
NOTE 4

31

32

13

45

5
NOTE 1
33

66

13 14
NOTE 2
NOTE 3
42

37

13

BB

43

X
29
AA

44

71

13
38

63

30

16 67

69
56

14

39

16

V
74

Z
V

B
Z

F
GG

AA

35 36

64

21

27

13

13
5

14

22
17

57

24

15

26

22
25

NOTES:

73
60

1) CONNECT TO ROD END OF LIFT CYLINDER.

17

61

2) CONNECT TO BASE END OF LIFT CYLINDER.

68

3) CONNECT TO ROD END OF TILT CYLINDER.


4) CONNECT TO BASE END OF TILT CYLINDER.
58

5) STANDARD FLOW RELIEF SETTING 3000PSI 25PSI.


6) HIGH FLOW RELIEF SETTING 2900PSI 25PSI.

40

75

64

28

72

11

23
34

52

6
8

2
7

3
2

21
2

41

10

1 FITTING/STRAIGHT
2 FITTING/STRAIGHT
3 ELBOW/FITTING 90
4 WASHER/FLAT
5 NUT/HEX
6 SCREW/CAP
7 FITTING/90
8 FITTING/STRAIGHT
9 FITTING/STRAIGHT
10 FITTING/TEE
11 SCREW/CAP
12 CLAMP/TUBE
13 PLATE/TWIN COVER
14 CLAMP/TUBE
15 CAP/37 FLARE
16 CLAMP/TUBE
17 CLAMP/HOSE

Fig. 8-3

18, 19 FITTING/90
20 FILTER ASSEMBLY
21, 22 NUT/SPIRALOCK
23 VALVE/SELF LEVEL
24 HYDRAGLIDE
25 ACCUMULATOR
26 PLATE/SPACER
27 PUMP/GEAR DOUBLE
28 FITTING/TEE
29, 30, 31 TUBE/TILT
32, 33 TUBE/HIGH-FLOW
34 SPACER
35, 36 TUBE/AUXILIARY
37 TUBE/FILTER
38 TUBE/HYDRAGLIDE
39 TUBE/HYDRAGLIDE
40 VALVE/CONTROL

41 5-BANK/VALVE
42 TUBE/TILT
43, 44 TUBE/LIFT
45, 46 TUBE/LIFT
47 TUBE/FEED
48 TUBE/RETURN
49 TUBE/AUX FEED
50 TUBE/AUX RETURN
51 TUBE/CASE DRAIN
52 PORT/TEST
53 CLAMP/ACCUM
54 ACCUMULATOR
55 TUBE/ACCUM
56 TUBE/SUCTION
57 FITTING/45
58 HOSE/PRESSURE
59 HOSE/PRESSURE

60 FITTING/90
61 HOSE/DRAIN
62 HOSE/PRESSURE
63 BRACKET/HARNESS
64 CLAMP/T-BOLT
65 SCREW/CAP
66 SCREW/CAP
67 SCREW/CAP
68 BOLT/CARRIAGE
69 SCREW/CAP
70 SCREW/MACHINE
71 SCREW/CAP
72 BOLT/CARRIAGE
73 BOLT/CARRIAGE
74 WASHER/LOCK
75 CLAMP/HOSE

Exploded view of the high-flow auxiliary hydraulics for dual joystick, hand/foot and t-bar/joystick controls

PRINTED IN USA

8-7

917292/AP1008

HYDRAULIC SYSTEM
High-Flow Auxiliary Hydraulics - T-Bar Controls
13
58

58

12

12

1
35

3
50 12

63

28 25

65

34 62

21

11

28

20

24

12
24

6
57

22
26

6
31

33
32

26

24

56

52

22

39

51
TO HYDRAULIC TANK

38

53

19

8
8

17

41

59

TO HYDRAULIC TANK
61
55
54
10
1

40
5

12

47

30

15

15

1
7

67 18

15

44
8

29

46

36

37

13

23
12

14
4

45
18

23

16

49

3
68

66

16

13
12

49

27

48

13
12

60

69
64
43

66

42

NOTES:
1 CONNECT TO ROD END OF LIFT CYLINDER.
2 CONNECT TO BASE END OF LIFT CYLINDER.
3 CONNECT TO ROD END OF TILT CYLINDER.
4 CONNECT TO BASE END OF TILT CYLINDER.
5. STANDARD FLOW RELIEF SETTING 3000PSI 25PSI.
6. HIGH FLOW RELIEF SETTING 2900PSI 25PSI.

1 FITTING/STRAIGHT
2 ELBOW/FITTING 90
3 WASHER/FLAT
4 NUT/HEX
5 SCREW/CAP
6 FITTING/90
7, 8 FITTING/STRAIGHT
9 FITTING/TEE
10 SCREW/CAP
11 CLAMP/TUBE
12 PLATE/TWIN COVER
13 CLAMP/TUBE
14 CAP/37 FLARE
15 CLAMP/TUBE
16 CLAMP/HOSE
17 FITTING/90

Fig. 8-4

18 PLUG/O-RING
19 FITTING/90
20 FILTER ASSEMBLY
21 NUT/SPIRALOCK
22 NUT/SPIRALOCK
23 NUT/SPIRALOCK
24 STRAP
25 VALVE/SELF LEVEL
26 VALVE/SOLENOID
27 PUMP/GEAR DOUBLE
28 FITTING/TEE
29, 30, 31 TUBE/TILT
32 TUBE/HIGH-FLOW
33 TUBE/HIGH-FLOW
34 BRACKET/SOLENOID
35 SPACER

36, 37 TUBE/AUXILIARY
38, 39 TUBE/LIFT
40 TUBE/FEED
41 TUBE/SUCTION
42 FITTING/45
43 HOSE/PRESSURE
44 VALVE/CONTROL
45 HOSE/PRESSURE
46 HOSE/PRESSURE
47 BRACKET/HARNESS
48 VALVE/PROPORTION
49 CLAMP/T-BOLT
50 TUBE/TILT
51 TUBE/LIFT
52 TUBE/TILT SOLENOID
53 TUBE/LIFT

ASSEMBLED VIEW

54 TUBE/RETURN
55 TUBE/CASE DRAIN
56 TUBE/FILTER
57, 58, 59 SCREW/CAP
60 BOLT/CARRIAGE
61, 62 SCREW/CAP
63 SCREW/MACHINE
64 SCREW/CAP
65 BOLT/CARRIAGE
66 WASHER/LOCK
67 TEST PORT
68 CAP/TUBE
69 CLAMP/HOSE

Exploded view of the high-flow auxiliary hydraulics for t-bar controls

917292/AP1008

8-8

PRINTED IN USA

HYDRAULIC SYSTEM
Lift Arm Hydraulics Components - 2066/76 Models

28
28
32
16
33
TO TOP OF HYDRAULIC RESERVOIR

4
8
7
9
21

34
13

32

10
10

18

27
14
17

35

8
1
2

18

24

18

5
1

23

PRESSURE
25

18

18
5

18
29

33

11

13
16
15

5
21

PRESSURE

26
3

22

POSITION GREASE ZERKS


TOWARDS CHASSIS

4
32

34
17

12
5
29
4

19 34

32

HYDRAULICS

20

34
20
31

22
19

30
31
29

POSITION GREASE ZERKS


TOWARDS CHASSIS

5
29
31
30

31

NOTE: APPLY LITHIUM GREASE TO PINS 220-32579, 135301 AND 135302.

1 FITTING/STRAIGHT
2 NUT/HEX
3 FITTING/TEE
4 NUT/HEX
5 NUT/LOCK
6 CLAMP/HOSE
7 CLAMP/HOSE
8 HOSE/PRESSURE
9 PLUG
10 HOSE/PRESSURE
11 COUPLER/MALE
12 COUPLER/FEMALE

Fig. 8-5

13 TUBE/LIFT CYLINDER
14 TUBE/LIFT CYLINDER
15 TUBE/LIFT CYLINDER
16 PIN
17 PIN
18 CLAMP/LINE
19 ASSY/HOSE
20 ASSY/HOSE
21 CYLINDER/LIFT
22 CYLINDER/TILT
23 TUBE/TILT INNER
24 TUBE/TILT OUTER

25 TUBE/AUX TOP
26 TUBE/AUX BOTTOM
27 SCREW/CAP
28 HOSE/PRESSURE
29 PIN/ PIVOT
30 SEAL
31 WASHER/ SPECIAL
32 FITTING/GREASE
33 SCREW/CAP
34 SCREW/CAP
35 WASHER/FLAT

Exploded view of the 2066/76 lift arm hydraulic system

PRINTED IN USA

8-9

917292/AP1008

HYDRAULIC SYSTEM
Lift Arm Hydraulics Components - 2086 Models

32
33

28

15

TO TOP OF HYDRAULIC RESERVOIR

28

4
7

34

21

17

12
1

32

27

13

16

35

8
20

5
17

24

17

20

5
PRESSURE
23
1
25

17

12

33

14
15

1
5
29

17

17

10

32

PRESSURE

21
26

3
22

POSITION GREASE ZERKS


TOWARDS CHASSIS

19

34

3
5

16
11
32

29

18 34

34
19
31

22
18

30
31
29

POSITION GREASE ZERKS


TOWARDS CHASSIS

5
29
31
30
31

NOTE: APPLY LITHIUM GREASE TO PINS 220-32579, 135301, AND 135302.

1 FITTING/STRAIGHT
2 NUT/HEX
3 FITTING/TEE
4 NUT/HEX
5 NUT/LOCK
6 CLAMP/HOSE
7 CLAMP/HOSE
8 HOSE/PRESSURE
9 PLUG
10 COUPLER/MALE
11 COUPLER/FEMALE
12 TUBE/LIFT

Fig. 8-6

13 TUBE/LIFT
14 TUBE/LIFT
15 PIN
16 PIN
17 CLAMP/LINE
18 ASSY/HOSE
19 ASSY/HOSE
20 HOSE/PRESSURE
21 CYLINDER/LIFT
22 CYLINDER/TILT
23 TUBE/TILT
24 TUBE/TILT

25 TUBE/AUXILIARY
26 TUBE/AUXILIARY
27 SCREW/CAP
28 HOSE/PRESSURE
29 PIN/ PIVOT
30 SEAL
31 WASHER/ SPECIAL
32 FITTING/GREASE
33 SCREW/CAP
34 SCREW/CAP
35 WASHER/FLAT

Exploded view of the 2086 lift arm hydraulic system

917292/AP1008

8-10

PRINTED IN USA

HYDRAULIC SYSTEM
Lift Arm Hydraulics Components - 56/6640 Models

39

10

TO TOP OF HYDRAULIC RESERVOIR


33
9

34
32

22

33

32
3

33
7

35

29
2

17

34

16
6

18

23
3

4
41

27

26

1
37
16

30
28

26

38

11

17

39

19
12
40

22

31

37
14

36

20

34

36
5

13

29

38

35

24

23

15
8

13
11

24

34
3

8
20
40

GREASE TAPER
OF PINS
35

12
NOTES:

35

25
21

1. DO NOT OVERTIGHTEN CAPSCREWS 650545,


650568, AND 650547

21

2. APPLY LOCTITE 242 TO CAPSCREWS 651366 AND


TORQUE TO 80FT-LBS

3. APPLY LITHIUM GREASE TO PINS 135301 AND 135302


3
25

1 FITTING/STRAIGHT
2 NUT/HEX
3 NUT/HEX
4 CLAMP/HOSE
5 PLATE/TWIN COVER
6 CLAMP/TUBE
7 CLAMP/HOSE
8 CLAMP/TUBE
9 HOSE/PRESSURE
10 PLUG
11 HOSE/PRESSURE
12 HOSE/PRESSURE
13 TUBE/TILT
14 COUPLER/MALE

Fig. 8-7

15 COUPLER/FEMALE
16 SPACER/TILT TUBE
17 TUBE/LIFT CYLINDER
18 TUBE/LIFT CYLINDER
19 TUBE/LIFT CYLINDER
20 WASHER/FLAT
21 PIN
22 PIN
23 PIN
24 PIN/TILT CYLINDER
25 CYLINDER/TILT
26 HOSE/PRESSURE
27 TUBE/TILT OUTER
28 TUBE/TILT INNER

29 CYLINDER/LIFT
30 TUBE/LIFT ARM AUX INNER
31 TUBE/LIFT ARM AUX OUTER
32 HOSE/PRESSURE
33 HOSE/PRESSURE
34 FITTING/GREASE
35 SCREW/CAP
36 SCREW/CAP
37 SCREW/CAP
38 SCREW/CAP
39 SCREW/CAP
40 SCREW/CAP
41 WASHER/FLAT

Exploded view of the 56/6640 lift arm hydraulic system

PRINTED IN USA

8-11

917292/AP1008

HYDRAULIC SYSTEM
High-Flow Lift Arm Hydraulics Option - Dual Joystick, Hand/Foot, T-Bar/Joystick

10

12
3

9
1

4
REFERENCE HARDWARE FROM
HYDRAULIC GROUP

11
13
15

1 FITTING/STRAIGHT
2 CLAMP/TUBE
3 CLAMP/TUBE
4 PLATE/TWIN COVER
5 HOSE/PRESSURE
6 COUPLER/MALE
7 COUPLER/FEMALE
8 COUPLER/MALE
9 HOSE/PRESSURE
10 TIE/DUAL CLAMP
11 TUBE/HIGH-FLOW UPPER
12 TUBE/HIGH-FLOW LOWER
13 TUBE/HIGH-FLOW CASE DRAIN
14 PLATE/COUPLING
15 SCREW/CAP

14
6

Fig. 8-8

Exploded view of the high-flow lift arm hydraulic system

917292/AP1008

8-12

PRINTED IN USA

HYDRAULIC SYSTEM
Pressure Tests, Standard-Flow and
High-Flow Auxiliary
The control valve on the skid loader controls lift and tilt
functions of the lift arm, standard and high-flow
auxiliary hydraulics. It is located on the right side of the
chassis. The relief valve(s) inside the control valve can
be tested at the lift arm couplers.
Test Procedure

WARNING
Fig. 8-9

BEFORE beginning this service procedure,


perform the following SAFETY procedures:

System pressure test location on the left lift arm


for standard flow hydraulic couplers

q Shut off the engine.


q Relieve hydraulic system pressure.
(For detailed instructions, refer to the Safety
chapter of this manual.)
NOTE: To prevent contamination, ALWAYS clean
the area around the hydraulic fittings before
disconnecting any hydraulic plug, hose or tube.

Fig. 8-10 System pressure test location on the right lift arm
for high-flow hydraulic couplers

2. Perform the pressure reading test at the auxiliary


hydraulic couplers located on the left lift arm and
the high-flow couplers (if so equipped) located on
the right lift arm of high-flow auxiliary loaders.
Figs. 8-9, 8-10
3. Install the pressure gauge in the end of the male
coupler and activate the auxiliary hydraulic (or turn
on high-flow) to pressurize the line. Figs. 8-9, 8-10
4. For this test, engine should be running at HIGH
IDLE.
5. Have assistant observe the pressure reading on the
gauge. The pressure reading on your respective
loader should be:
a. for standard flow units, at least 2975 PSI (205
bar), but NOT more than 3025 PSI (209 bar),
and
b. for high-flow units, at least 2875 PSI (198 bar),
but NOT more than 2925 PSI (202 bar).
6. If the pressure reading is NOT between the
abovementioned pressures, adjust pressure as
follows:

PRINTED IN USA

8-13

917292/AP1008

HYDRAULICS

1. What youll need: an assistant and a minimum 5000


PSI (345 bar) pressure gauge.

HYDRAULIC SYSTEM

WARNING
BEFORE continuing this service procedure,
perform the following SAFETY procedures:

q Shut off the engine.


q Tilt back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter in this manual.)
a. Remove the cap on the relief valve adjuster
screw(s). Figs. 8-11, 8-12
b. With a flat-edge screwdriver, turn the adjuster
screw IN to increase pressure or OUT to
decrease pressure. Fig. 8-13

Fig. 8-11 Standard flow relief valve location at the bottom


rear of the control valve

c. Repeat steps 4 through 5.


d. Once the pressure is within the correct PSI
optimum setting, tighten the locknut on the
control valve adjuster screw to secure the
adjustment.
7. If, after the adjustment, there is NO CHANGE in the
pressure reading, this indicates a defective
hydraulic gear pump or relief valve cartridge (on the
control valve). To determine which is the cause, first
replace the relief valve cartridge. If the pressure
reading still does not change, the hydraulic gear
pump should be repaired or replaced.
Fig. 8-12 An additional high-flow relief valve location at
the top rear of the control valve

Fig. 8-13 View of the adjuster screw beneath the cap on the
relief valve

917292/AP1008

8-14

PRINTED IN USA

HYDRAULIC SYSTEM
Hydraulic Oil Filter Element Replacement
Gehl 5640E/6640E and Mustang 2066/76/86 skid-steer
loaders have one hydraulic oil filter. The hydraulic oil
filter needs to be replaced when the restriction indicator
shows red.
NOTE: When reading the restriction indicator, run the
engine at HIGH idle with the hydraulic oil temperature
at 70F (21C) or warmer.
Replacement Procedure

WARNING

Fig. 8-14 Location of hydraulic reservoir drain plug


behind the right rear tire

BEFORE beginning this service procedure,


perform the following SAFETY procedure:

q Shut off the engine.


(For detailed instructions, refer to the Safety
chapter in this manual.)

Muffler

1. Open the engine access cover and rear grille.


2. Remove hydraulic reservoir drain plug and drain oil
(into a suitable container) to a level BELOW the
point where the filter attaches to reservoir. Fig. 8-14
4. Using a filter wrench, turn the filter element
counterclockwise to remove it from the filter head.
Fig. 8-15
Fig. 8-15 Location of the hydraulic oil filter on the right
riser, below the muffler

5. Install correct filter element (refer to Gehl or


Mustang Parts Manual). BEFORE installation,
apply a light coat of oil to gasket, then install it on
filter head.
6. Hand tighten element until gasket contacts filter
head. Turn element another 3/4 turn to seat gasket.
Fig. 8-16
7. Refill the hydraulic reservoir. Refer to the
Lubrication chapter in this manual for hydraulic
fluid requirements and specifications.

WARNING
Fig. 8-16 Use a filter wrench on the element and turn the
element counterclockwise to remove, clockwise
to install
PRINTED IN USA

8-15

NEVER use your hands to search for


hydraulic fluid leaks. Use a piece of
cardboard or paper. Escaping fluid
under pressure can be invisible and penetrate
the skin causing serious injury. If any fluid is
injected into your skin, see a doctor at once.
917292/AP1008

HYDRAULICS

3. Reinstall the drain plug.

HYDRAULIC SYSTEM
Injected fluid MUST be surgically removed by a
doctor familiar with this type of injury or
gangrene may result.

NOTES

WARNING
ALWAYS wear safety glasses when
checking for hydraulic fluid leaks.
Escaping fluid under pressure can be
invisible and can cause permanent eyesight
damage if safety glasses are not worn.
8. ALWAYS check for hydraulic fluid leaks after
assembling components of the hydraulic system.

917292/AP1008

8-16

PRINTED IN USA

HYDRAULIC SYSTEM
Control Valve Removal and Installation

The main hydraulic control valve is located on the right


side of the chassis, in front of the engine. The control
valve ports have been numbered for reference.

2
11

Removal Procedure

7
9

WARNING

4
10

BEFORE beginning this service procedure,


perform the following SAFETY procedures:

8
6

q Raise lift arm; engage lift arm support


device.

Fig. 8-17 Control valve port reference numbers (high-flow


valve shown)

q Shut off the engine.


q Relieve hydraulic system pressure.
q Tilt back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual.)

Port #1
Port #9

Port #2

NOTE: If hydraulic hoses and tubes are plugged to


prevent oil leakage, it should not be necessary to drain
hydraulic reservoir. BE SURE to plug/cap ALL
hydraulic hose and tube fittings to prevent
contamination of the hydraulic system.

Ports #4

Fig. 8-18 Location of ports 1, 2, 4 and 9 on the high-flow


control valve

NOTE: To aid in reassembly of hydraulic hoses and


tubes, mark hoses and tubes to be removed BEFORE
disassembly. Figs. 8-17, 8-22, 8-26
2. Ports 1 and 2 (high-flow only): Disconnect the
high-flow tubes at the straight fittings on the control
valve.

Port #3

3. Port 3: Disconnect the hydraulic filter tube from the


straight fitting on control valve.
4. Ports 4: Disconnect the auxiliary feed tube and
high-flow feed tube (high-flow only) from straight
fittings on the control valve.
5. Ports 5: Disconnect the auxiliary return tube and
high-flow return tube (high-flow only) from straight
fittings on the control valve.

Fig. 8-19 Location of port 3 at rear of control valve

PRINTED IN USA

6. Port 6: Disconnect the pressure hose from the


straight fitting on the control valve, other end
connects to gear pump.

8-17

917292/AP1008

HYDRAULICS

1. If necessary (see following NOTE), drain oil from


hydraulic reservoir. For this procedure refer to
Hydraulic Reservoir in the Lubrication chapter.

HYDRAULIC SYSTEM
7. Ports 7: Disconnect a lift, tilt and auxiliary tube
from the straight fittings on the control valve.
8. Ports 8: Disconnect a lift, tilt and auxiliary tube
from the straight fittings on the control valve.
9. Port 9 (high-flow only): Disconnect the pressure
hose from the 90 fitting on the control valve, other
end connects to gear pump.

Ports #5

10. Ports 10 and 11: Disconnect four remaining hoses


from straight fittings on the control valve, two hoses
in front and two more in the rear.
11. Remove four locking capscrews securing the
control valve to the welded mounting bracket.
12. Lift the control valve out. Removal may require
loosening the opposite ends of some of the
disconnected tubes.

Fig. 8-20 Location of port 5 on the control valve

NOTE: Cap or plug ALL hydraulic hoses, tubes,


fittings and control valve ports immediately after being
disconnected to prevent fluid loss and contamination of
the hydraulic system.

Port #4

Installation Procedure
1. Secure the control valve to the welded bracket with
four locking capscrews. If straight or 90 fittings are
not in the control valve, install them at this time.
2. Ports 10 and 11: Connect four hoses to straight
fittings on the control valve, two hoses in front and
two more in the rear.
3. Port 9 (high-flow only): Connect the pressure hose
to the 90 fitting on the control valve, other end
connects to gear pump.

Ports #10

Port #6

Fig. 8-21 Location of ports 4, 6 and 10 on the standard


control valve

4. Port 8: Connect a lift, tilt and auxiliary tube to the


straight fittings on the control valve.

3
2

5. Port 7: Connect a lift, tilt and auxiliary tube to the


straight fittings on the control valve.

11

6. Port 6: Connect the pressure hose to the straight


fitting on the control valve, other end connects to
gear pump.

7
9

7. Port 5: Connect the auxiliary return tube and


high-flow return tube (high-flow only) to straight
fittings on the control valve.
8. Port 4: Connect the auxiliary feed tube and
high-flow feed tube (high-flow only) to straight
fittings on the control valve.

917292/AP1008

4
10

8
6

Fig. 8-22 Control valve port reference numbers (high-flow


valve shown)

8-18

PRINTED IN USA

HYDRAULIC SYSTEM
9. Port 3: Connect the hydraulic filter tube to the
straight fitting on control valve.
10. Ports 1 and 2 (high-flow only): Connect the
high-flow tubes at the straight fittings on the control
valve.

Ports #7
Ports #8

11. Install hydraulic reservoir drain plug and refill with


correct type of hydraulic oil. Refer to Lubrication
chapter for hydraulic oil requirements and
specifications.
12. ALWAYS check for hydraulic fluid leaks after
assembling any component of the hydraulic system.

Fig. 8-23 Location of ports 7 and 8 on the control valve

WARNING

ALWAYS wear safety glasses when


checking for hydraulic fluid leaks.
Escaping fluid under pressure can be
invisible and cause permanent eyesight
damage if safety glasses are not worn.

Ports #11

Fig. 8-24 Location of port 11 on the control valve

1
2
11
7

9
4
10

8
6

Fig. 8-25 View of 2 of 4 locking capscrews securing the


control valve to a welded tab on the chassis

PRINTED IN USA

Fig. 8-26 Control valve port reference numbers (high-flow


valve shown)

8-19

917292/AP1008

HYDRAULICS

NEVER use your hands to search for


hydraulic fluid leaks. Use a piece of
paper or cardboard. Escaping fluid
under pressure can be invisible and penetrate the skin causing serious injury. If any
fluid is injected into your skin, see a doctor at
once. Injected fluid MUST be surgically removed by a doctor familiar with this type of
injury or gangrene may result.

HYDRAULIC SYSTEM
Manifold Valve Removal and Installation
Gehl 5640E/6640E and Mustang 2066/76/86 skid-steer
loaders are equipped with a 3-bank or 5-bank manifold
valve.
Removal Procedure

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:

q Raise lift arm; engage lift arm support


device.

Fig. 8-27 View of 5-bank high-flow manifold valve on


inside right of the chassis. Note the many
electrical connectors attached to it

q Shut off the engine.


q Relieve hydraulic system pressure.
q Tilt back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter in this manual.)
1. Disconnect the three or five electrical connectors
from the manifold valve. Figs. 8-27, 8-28
2. Disconnect seven or nine hydraulic tubes/hoses
from the manifold valve. Fig. 8-27, 8-28
3. Remove two locking capscrews securing the
manifold valve to the chassis and remove the valve.
Removal may require loosening the opposite ends
of some of the disconnected tubes. Fig. 8-29
Installation Procedure - Follow all warnings first,
then reverse the removal steps.

Fig. 8-28 View of 3-bank standard-flow manifold valve on


inside right of the chassis

NOTE: After removing and/or replacing any


component in the hydraulic system, ALWAYS check
the level of the hydraulic fluid in the reservoir. Add fluid
if necessary. Refer to the Lubrication chapter for
hydraulic fluid requirements and specifications.
ALWAYS check for hydraulic fluid leaks after
assembling any component of the hydraulic system.

Fig. 8-29 Location of two locking capscrews securing the


manifold valve to the right side of the chassis
wall
917292/AP1008

8-20

PRINTED IN USA

HYDRAULIC SYSTEM
Control Valve Disassembly and Assembly
The main control valve is a mono-block designed
control valve with spools.
Disassembly Procedure
1. Remove the main control valve per the procedure in
this chapter and place valve on a flat surface that can
retain or collect any hydraulic oil runoff.
2. To access the spools, use an Allen wrench to loosen
two hex socket capscrews, one on each side of the
spool cap. Fig. 8-30

Spool Cap

Fig. 8-30 View of a hex socket capscrew, 1 of 2, used to


securing the spool cap to the control valve

3. Pull spool cap off the spool and retain the o-ring.
Fig. 8-31
4. Grab the spring assembly on the end of the spool and
pull the spool out of the control valve and retain all
o-rings. Fig. 8-32
5. Repeat steps 1-4 for all spools needing removal
from the control valve.
6. To remove port relief valves from the control valve,
use a wrench to loosen the valve from the
mono-block control valve. Fig. 8-33

HYDRAULICS

Assembly Procedure - Reverse the disassembly steps.

Fig. 8-31 Locate the o-ring found in the spool cap

Spool

Spring Assy

Fig. 8-32 Pull the spool out of the control valve by


grabbing the spring assembly on the end of the
spool
PRINTED IN USA

Fig. 8-33 A wrench can be used to remove a port relief


valve from the control valve body

8-21

917292/AP1008

HYDRAULIC SYSTEM
Main Relief Valve Removal and Installation
An anti-cavitation relief valve is integrated within the
standard-flow control valve, two anti-cavitation relief
valves are integrated within the high-flow control valve.
A relief valve(s) activates when oil pressures inside the
control valve reach unacceptable levels; to relieve that
pressure and prevent damage to valve and hydraulic
system.
Removal Procedure

WARNING

Fig. 8-34 Use a wrench to remove the relief valve(s) from


the control valve

BEFORE beginning this service procedure,


perform the following SAFETY procedures:

q Shut off the engine.


q Relieve hydraulic system pressure.
q Roll back ROPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual.)
1. W i t h a w r e n c h , l o o s e n a n d r e m o v e t h e
anti-cavitation relief valve from the main control
valve. Fig. 8-34
2. Check condition of o-rings and clean off any debris.
Fig. 8-35
Installation Procedure - Follow all warnings first,
then reverse removal steps

917292/AP1008

Fig. 8-35 Location of o-rings on the relief valve

8-22

PRINTED IN USA

HYDRAULIC SYSTEM
Control Valve Components - Standard-Flow and High-Flow

7
1

4
8

1 KIT/PLUG
2 KIT/CHECK VALVE
3 CONTROL/REAR
4 KIT/PLUG
5 VALVE/RELIEF
6 CONTROL/ANTERIOR
7 VALVE/PORT RELIEF
8 VALVE/PORT RELIEF
9 VALVE/RELIEF
10 KIT/CHECK VALVE

7
1

High-Flow Control Valve

HYDRAULICS

4
8

10

6
9

Fig. 8-36 Exploded view of the main control valve components


PRINTED IN USA

8-23

917292/AP1008

HYDRAULIC SYSTEM

HYDRAULICS

NOTES

917292/AP1008

8-24

PRINTED IN USA

ELECTRICAL SYSTEM

Introduction
Description of Operation - Right and Left
Instrument Panels
Right Instrument Panel
Hourmeter

The right instrument panel for Gehl 5640E/6640E and


Mustang 2066/76/86 skid-steer loaders includes gauges,
a light switch, a keyswitch, indicator lights, a manual
engine speed control knob and an (optional) high-flow
auxiliary switch.

Fuel Level
Gauge

The following items describe the normal operation of


electrical system components on the skid-steer loaders.
1. When the operator is in the seat, the restraint bar is
down, and the keyswitch is turned to the ON
position, the following indicator lamps will light:

Engine
Coolant
Temperature
Gauge

q Fasten Seat Belt (momentary and buzzer will


sound for five seconds)

q Engine malfunction lamp on left panel (two


seconds)

Fasten Seat Belt

q Battery

Engine Oil
Pressure

NOTE: The engine ECU (Electronic Control Unit)


automatically controls the engine intake grid heater.
When the operator is in the seat, the restraint bar is
down, and the keyswitch is turned to the ON position,
the pre-heat indicator lamp will light when active. Do
not start engine until the engine pre-heat light has gone
out.

Battery
Pre-Heat Indicator
Lamp

Light
Switch
High-Flow
Auxiliary
Switch

2. The keyswitch can then be turned to the START


position.

q The battery lamp will go out after the engine

On

starts.

Off
Key
Switch

NOTE: To verify that the seat and restraint bar


switches are working properly, after the keyswitch is
turned to ON, raise the restraint bar or lift body off the
seat. Either action should prevent the engine from
cranking with the keyswitch turned to START.

Start

Engine
Speed
Control
Knob

Fig. 9-1

Right instrument panel

PRINTED IN USA

9-1

917292/AP1008

ELECTRICAL

Engine Air Filter


Restriction
Engine Coolant
Temperature
Hydraulic Oil
Restriction
Hydraulic Oil
Temperature

ELECTRICAL SYSTEM
Left Instrument Panel
The left instrument panel for Gehl 5640E/6640E and
Mustang 2066/76/86 skid-steer loaders holds the
manual parking brake switch, indicator lights and the
accessory plug. Optional switches and HVAC controls
are also on this panel.
1. Two-speed Indicator Lamp - it lights when
skid-steer loaders two-speed HIGH range is
engaged.
2. Parking Brake Indicator Lamp - it lights when
skid-steer loader's parking brake is engaged.
3. Hydraglide Ride Control Indicator Lamp - it
lights when loaders (optional) ride control is
engaged.
4. Fan Switch - controls the (optional) fan on heater
and/or air conditioning package.
5. HVAC Switch - controls the (optional) selection of
heat or air conditioning.
6. 12-VDC Power Outlet - a plug-in outlet with rubber
boot used for external electrical connections.
7. Parking Brake Switch - used to apply the parking
brake.

Engine Malfunction

8. Power Fast-A-Tach /Power All-Tach - used to


actuate the (optional) Power Fast-A-Tach/Power
All-Tach .

High-Speed
Control (Optional)

Ride Control
(Optional)

Parking Brake

Float Indicator

10. Float Indicator Switch - it lights when the float


Power
Fast-A-Tach/All-Tach
function is electrically activated.

Parking Brake
Switch

9. Engine Malfunction - engine warning light also


displays flash codes.

Switch (Optional)

Fan Speed Switch


(Optional)

HVAC Selector
Switch (Optional)

12-VDC Power
Outlet

Fig. 9-2
917292/AP1008

9-2

Left instrument panel and switches


PRINTED IN USA

ELECTRICAL SYSTEM
Troubleshooting Guide
Problem

Possible Cause

Remedy

Entire electrical system


does not function.

Battery disconnect switch OFF

Turn battery disconnect switch to ON.

Faulty keyswitch

Replace keyswitch.

10 A fuse blown (keyswitch)

Replace fuse (in power distribution center).

Main wiring harness connectors at rear of Check main connectors.


ROPS not properly plugged-in

No instrument panel lamps


light with keyswitch turned
to ON.

Battery terminals or cables loose or


corroded

Clean battery terminals and cables and


tighten them.

Battery faulty

Test battery and replace as needed.

Fuse blown

Replace fuse.

Power relay has failed.

Replace relay.

Main wiring harness connectors at rear of Check main connectors.


ROPS not properly plugged-in
Replace fuse.

Battery terminals or cables loose or


corroded.

Clean battery terminals and cables and


tighten them.

Seat belt buzzer indicator


not sounding when key
turned to ON, indicator
lamps work properly.

Plugged or obstructed buzzer

Clean out buzzer.

Faulty buzzer

Replace interlock control module.

Fuel gauge does not work.

Faulty fuel gauge sender

Replace fuel gauge sender.

Loose wiring/terminal connections

Verify wiring connections.

Faulty fuel gauge

Replace fuel gauge.

Gauge has blown fuse

Replace fuse.

Faulty sender

Replace temperature sender.

Loose wiring/terminal connections

Verify wiring connections.

Faulty temperature gauge

Replace temperature gauge.

Gauge has blown fuse

Replace fuse.

Loose wiring/terminal connections

Verify wiring connections.

Faulty alternator

Repair or replace alternator.

Faulty hourmeter

Replace hourmeter.

Engine temperature gauge


does not work.

Hourmeter does not work.

PRINTED IN USA

9-3

ELECTRICAL

Distribution fuse failed

917292/AP1008

ELECTRICAL SYSTEM
Troubleshooting Guide
Problem

Possible Cause

Remedy

Starter will not engage


when key is turned to
START.

Seat or restraint bar switch malfunctioning or Operator is in the seat with the restraint bar
down. Replace switches as needed.
not activated
Poor connections to starter relay in
instrument panel

Verify relay connections.

Faulty starter safety relay

Test starter safety relay, replace as needed.

Battery terminals or cables loose or corroded Clean battery terminals and cables and
tighten them.

Battery will not


recharge.

Work lights not


functioning properly.

Lift/Tilt and/or Drive


Solenoids do not work.

917292/AP1008

Battery discharged or defective

Recharge or replace battery.

Starter solenoid in chassis malfunctioning


(Located on panel near battery)

Troubleshoot circuit per wiring diagram,


locate trouble, replace starter solenoid.

Ignition wiring, seat switch, restraint bar switch,


etc. loose or disconnected

Check wiring for poor connections, broken


leads; repair wiring or connection.

Starter or pinion faulty

Remove starter; repair/replace as needed.

Engine fault code: ECU will not allow crank if


certain faults are present

Contact your dealer.

Engine starter solenoid malfunctions

Replace engine starter solenoid.

Battery terminals or cables loose or corroded Clean battery terminals and cables and
tighten them, replace cables as needed.
Battery or alternator defective

Test battery and alternator, replace as


needed.

Single light doesnt work: Light bulb burned


out, faulty wiring

Check and replace light bulb as needed.


IMPORTANT: When changing the halogen
bulb, DO NOT directly touch the light bulb.
Use a clean rag to handle the bulb. Check
wiring connection to light.

No lights at all: 30 A light fuse blown

Check circuit and find trouble before


replacing fuse.

Faulty light switch/poor ground/bad


connection

Replace light switch. Check ground wire


connections.

Wiring to solenoids disconnected; faulty

Refer to wiring diagram, locate trouble and


repair as needed.

Faulty seat or restraint bar switch

Replace seat and/or restraint bar switches as


needed.

Faulty solenoid valve coil

Test and replace solenoid valve coil(s) as


needed.

Faulty hydraulic solenoid relay

Test relay; replace as needed.

Faulty interlock module

Test module; replace as needed.

9-4

PRINTED IN USA

ELECTRICAL SYSTEM
Chassis Electrical Components
3

10
GREEN/PURPLE
STARTER

34

WHITE
STARTER

30

34

12

29

19
PINK/BLACK
GRID HEATER
29
30
14
18

RED
GRID HEATER

18

ELECT. PANEL DETAIL VIEWS


DETAIL

GRAY

DETAIL
A

GREEN

LEFT JOYSTICK
44

HYD ALLTACH
28

25

17

27

FRONT OF
MACHINE
RIGHT JOYSTICK
6

11

24

BLUE/BLACK
PILOT SOLENOID (1)

PINK/BROWN
HIGH FLOW-REVERSE SOLENOID (2)
GREEN/GRAY
HIGH FLOW-FORWARD SOLENOID (3)
YELLOW/GRAY
LOW FLOW-REVERSE SOLENOID (4)
PINK/GRAY
LOW FLOW-FORWARD SOLENOID (5)

8
1

22

WHITE
START
SOLENOID

37
41
40

GRAY PLUG TO
THE OUTSIDE OF
THE MACHINE
23

7
33

GREEN PLUG TO
THE INSIDE OF
THE MACHINE

33

22

31

36

43

36

15

43

16
17

33

35

PURPLE/BLACK
TWO-SPEED
SOLENOID
YELLOW/BLACK
R/C-FLOAT

13

16

PURPLE/BLACK
TWO-SPEED
SOLENOID
1
2
32

13

35

16

20

45

21

BROWN/BLACK
R/C-FLOAT

6
LEFT JOYSTICK

28

TO REAR
DOOR
HARNESS

13 16

13

26

39

13

8
8

37

TO FUEL PUMP

9
26

38

SERVICE PARTS:
26

FUSE/ATM/5 AMP
FUSE/ATM/7.5 AMP
FUSE/ATM/10 AMP
FUSE/ATM/15 AMP
FUSE/ATM/20 AMP
FUSE/ATM/25 AMP
FUSE/ATM/30 AMP
FUSE/MAXI/60 AMP

184633
184632
184631
184630
184629
184628
184627
195073

ELECTRICAL

16

OIL TEMP
SWITCH
POWER TAP

RELAY/20 AMP/MICRO
183733
RELAY/ISO/SPST/30 AMP 195076
RELAY/ISO/SPST/50 AMP 195075
COVER/FUSE/4 WAY
COVER/FUSE/2 WAY
DIODE

1 TIE/WIRE
2 CLAMP/HOSE
3 NUT/HEX WHIZLOCK
4 NUT/SERRATED LOCK
5 NUT/HEX WHIZLOCK
6 NUT/HEX
7 CLAMP/TUBE
8 TIE/NYLON
9 CLAMP/HOSE
10 ANGLE/BATTERY
11 CLAMP/TUBE

Fig. 9-3

194554
194633

187347

12 BATTERY
13 NUT/SPIRALOCK
14 NUT/SPIRALOCK
15 CLAMP/TUBE
16 NUT/SERRATED FL
17 MODULE/2-SPEED
18 CLIP/CONDUIT
19 BRACKET/BATTERY
20 BRACKET/MATING
21 RELAY 20AMP
22 HARNESS/CHASSIS

23 BRACKET/HARNESS
24 PLATE/ELECTRICAL
25 CABLE/POSITIVE
26 SOLENOID
27 COVER/FUSE
28 COVER/FUSE
29 ROD/BATTERY
30 COVER/ELECTRICAL
31 SCREW/TAPPING
32 SCREW/CAP
33 NUT/HEX

34 BOLT/CARRIAGE
35 SCREW/CAP TF
36 WASHER/FLAT
37 NUT/HEX
38 NUT/HEX
39 NUT/HEX
40 COVER/HARNESS
41 COVER/HOLDDOWN
43 WASHER/FLAT
44 FOAM/COVER
45 FOAM/COVER

Exploded view of the chassis electrical components

PRINTED IN USA

9-5

917292/AP1008

ELECTRICAL SYSTEM
ROPS Electrical Components
TO RADIO
OPTION
TO RIGHT
WORK LIGHT

TO DOME LIGHT

17
17

TO STROBE
LIGHT OPTION
17
TO LEFT WORK LIGHT

TO RESTRAINT BAR

22
14

20

TO SEAT
SWITCH
TO SEAT
PAN GROUND

26

11

12

5
6

12

7
13

12

23

KEYED
POWER

10
16
HIGH FLOW

TO FLASHER
OPTION

15

22
8

18
9
BROWN - START
RED 05 - BAT
GREEN - BAT
RED - ACC 2
THROTTLE

25
24

24
NOTE:
TORQUE KNOB SET
SCREW TO 20-30 in-lb.

TO DOOR
SWITCH

20

20

LEFT INSTRUMENT PANEL DETAIL

RIGHT INSTRUMENT PANEL DETAIL

1 TIE/WIRE
2 NUT/SPEED
3 NUT/LOCK
4 GAUGE/HOURMETER
5 HOUSING/DISPLAY
6 BULB/LAMP
7 GASKET/HOUSING
8 CONNECTOR/POWER PORT
9 COVER/POWER PORT

Fig. 9-4

10 SWITCH/PARK BRAKE
11 MODULE/INTERLOCK
12 NUT/SERRATED FL
13 GAUGE/FUEL
14 CLAMP/TUBE
15 SWITCH/LIGHT
16 KNOB/LIGHT SWITCH
17 GROMMET
18 CONTROL/THROTTLE

19 ASSY/PANEL RIGHT
20 HARNESS/ROPS
21 ASSY/PANEL LEFT
22 SWITCH/IGNITION
23 GAUGE/TEMP
24 SCREW/MACHINE
25 SCREW/MACHINE
26 WASHER/LOCK

Exploded view of the ROPSs electrical components

917292/AP1008

9-6

PRINTED IN USA

ELECTRICAL SYSTEM
Engine Electrical Components - Mustang 2066/76/86 Models
20

13

15

13

11

21

22
18
12
6

4
9

10
14

20

ELECTRICAL

19

19

16
17

1 NUT/LOCK
2 CLAMP/TUBE
3 CLAMP/TUBE
4 LOOM/CABLE
5 BRACKET/HARNESS
6 CABLE/POSITIVE
7 CABLE/NEGATIVE
8 HARNESS/ENGINE

Fig. 9-5

9 CLAMP/TUBE
10 CLAMP/TUBE
11 P-CLAMP
12 WIRE/ALTERNATOR
13 SENDER/TEMP
14 SCREW/CAP
15 SCREW/CAP
16 WASHER/LOCK

20

17 SCREW/CAP
18 NUT/HEX
19 SCREW/CAP
20 SCREW/CAP
21 NUT/HEX
22 SCREW/CAP

Exploded view of the engine's electrical components

PRINTED IN USA

9-7

917292/AP1008

ELECTRICAL SYSTEM
High-Flow and Two-Speed Electrical Components

High-Flow Control

MOUNTED IN ENGINE
COMPARTMENT BELOW
2 SPEED/RIDE CONTROL
MODULE(REAR LEFT SIDE)

MOUNTED IN THE OPERATORS


COMPARTMENT IN THE RIGHT
SIDE INSTRUMENT PANEL
BETWEEN THE KEYSWITCH
AND LIGHT SWITCH

EXTEND ICON TO BE ON
RIGHT HAND SIDE OF
SWITCH WHEN INSTALLED

1 NUT/SERRATED
2 MODULE/HIGH-FLOW
3 SWITCH/HIGH-FLOW

Two-Speed Control

1 BULB/LAMP
2 NUT/SERRATED
3 MODULE/TWO-SPEED SHIFT

Fig. 9-6

Exploded view of the High-Flow and Two-Speed electrical components

917292/AP1008

9-8

PRINTED IN USA

ELECTRICAL SYSTEM
NOTES

PRINTED IN USA

9-9

917292/AP1008

ELECTRICAL SYSTEM
Power Distribution Panel Test and
Operation
Gehl 5640E/6640E and Mustang 2066/76/86 skid-steer
loaders utilize a power distribution panel in the
electrical system to maximize the efficiency of engine,
hydraulic, power and electrical operations. This panel is
attached on the left riser, just behind the battery.
Power Distribution Panel Fuse Test (Figs. 9-7 - 9-10)
The following procedure can be used to test the fuses
found inside the power distribution panel.
Fig. 9-7

WARNING

Location of the power distribution panel on the


left riser (behind the battery)

BEFORE beginning this service procedure,


perform the following SAFETY procedure:

q Shut off the engine.

Test Points

q Raise engine cover and lock open the


rear grille.

Vehicle Power

(For detailed instructions, refer to the Safety


chapter of this manual.)
1. Using a volt/ohm multimeter or a test lamp, measure
between test points and the chassis ground for 12 V
with the wiring connected and the keyswitch in the
ON position. The test lamp lights for functioning
fuses, or the volt/ohm multimeter will read 12 V on
both sides of the fuses.
u

Three 60 A fuses at the top of the panel are


used for machine power. The fourth 60 A
fuse at the bottom of the panel is used for the
engine starter, and while the bottom 60 A
fuse is used for the grid heater.

The upper 10 A mini-fuse is used by the


engine's ECU (electronic control unit). The
lower 10 A mini-fuse is used for the live
power supply to the keyswitch.

Engine Starter
Grid Heater

Fig. 9-8

View of the inside the power distribution panel

ECU
Keyswitch
Power
Diode

For units with HVAC: Two 25 A fuses are


used for the air conditioning condenser fan
and the blower motor for the HVAC unit.

Electrical Auxiliary Relay

2. To test the micro-relay, the keyswitch must be in the


ON position. This relay is used by the electrical
auxiliary system. Fig. 9-9
u

The relay may be tested by removing it and


taking it to a work bench. Apply a ground to
terminal #85 and a 12 V source to terminal

917292/AP1008

Fig. 9-9

9-10

View of the inside the power distribution panel

PRINTED IN USA

ELECTRICAL SYSTEM
#86. The relay should actuate. There should
be continuity between terminal #30 and
terminal #87.
u

Fig. 9-10 Illustration of the electrical auxiliary relay


terminals

The relay may be checked on the machine as


well. An assistant is required. Have the
assistant sit in the operators seat with the
keyswitch in the ON position and the
restraint bar lowered. Slowly remove the
relay. You should hear and feel a click
when it is removed from the panel.

3. Replace any fuse that did not have power at each test
point. Replace any relay that does not have
continuity between powered terminals.

Fuse Box Panel Test and Operation


Gehl 5640E/6640E and Mustang 2066/76/86 skid-steer
loaders utilize a fuse box panel in the electrical system to
maximize the efficiency of engine, hydraulic, power and
electrical operations. This panel is near the operator's
left knee inside the ROPS, behind a metal panel with two
swell latches.
Fuse Box Panel Fuse Test (Figs. 9-11 and 9-12)
The following procedure can be used to test the fuses
inside the fuse box panel. The plastic cover has a decal
that identifies the fuses.

BEFORE beginning this service procedure,


perform the following SAFETY procedure:

q Shut off the engine.

Fuses

(For detailed instructions, refer to the Safety


chapter of this manual.)

Power Relays

1. Remove the left metal panel in the ROPS by


unlatching the two swell latches.
2. Unlatch the fuse box panel cover to access the fuses.

Relays

Fig. 9-12 Identification of fuses and relays inside the fuse


box panel

PRINTED IN USA

3. Using a volt/ohm multimeter or a test lamp, measure


between test points and the chassis ground for 12 V
with the wiring connected and the keyswitch in the
ON position. The lamp lights for functioning
fuses, or the volt/ohm multimeter will read 12 V on
both sides of the fuses.

9-11

917292/AP1008

ELECTRICAL

WARNING

Fig. 9-11 View of inside the fuse box panel located near
the left knee of the operator inside the ROPS
(shown with cover off)

ELECTRICAL SYSTEM
Fuse Box Panel Relay Test (Figs. 9-11 and 9-12)
There are three power relays inside the fuse box panel
that supply power to the fuses for individual circuits.
The cover has a decal that identifies the fuses. These
relays can be tested as:
1. Turning the keyswitch to the ON position should
produce an audible "click" from each relay closing.
2. To test each relay individually, pull one relay out of
the panel at a time, listening for the audible "click"
of the relay opening.
3. Plug the relay back into the panel and listen for the
audible "click" of the relay re-closing.
4. Replace any relay where there is no discernible
"clicking" sound heard at keyed power or opening
(removing) of the relay.
u

Fig. 9-13 Location of two solenoids on the power


distribution panel

The solenoid lock relay and start safety


relay will actuate only with the keyswitch in
the ON position, the restraint bar down
and an assistant in the seat. The horn relay
will actuate only when the horn button is
actuated.

#85

#86

Load

Solenoid Test (Figs. 9-13 and 9-14)

Live Power

There are two solenoids located near the battery on the


power distribution panel. The most rearward solenoid is
used for the engine glow circuit. The most forward
solenoid is used by the engine starter.
Fig. 9-14 Illustration of the solenoid

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:

The engine's ECU provides both the control current


and ground for the solenoid:

q Shut off the engine.


q Raise engine cover and lock open the

With keyswitch in OFF position, there


should be 12-VDC on the left large copper
stud of each solenoid.

Unplug the control current connector and


install a test lamp between #85 and #86.
Have a second operator turn the keyswitch
to ON position, the engine and the test
lamp should light if ambient temperature is
low enough.

rear grille.
(For detailed instructions, refer to the Safety
chapter of this manual.)
1. Using a volt/ohm multimeter or a test lamp, confirm
the following conditions with the wiring connected.
u

With keyswitch in the OFF position, there


should be 12-VDC only on the left large
copper stud of each solenoid.

3. For the engine starter solenoid:

2. The most rearward solenoid, the engine glow


circuit, will only engage when the engine ECU
senses an ambient temperature below 22 F (-6 C).
917292/AP1008

9-12

With keyswitch in OFF position, there


should be 12-VDC on the left large copper
stud of each solenoid.
PRINTED IN USA

ELECTRICAL SYSTEM
u

The external starter solenoid will engage


when the keyswitch output calls for
START. The engine's ECU provides the
ground (#85) for the ECU.

Unplug the control current connector and


install a test lamp between #85 and #86.
Have a second operator turn the keyswitch
to crank the engine and the test lamp should
light.

Interlock Control Module Test (Figs 9-15 - 9-17)


The following procedure can be used to test the interlock
control module located inside the left instrument panel.
Fig. 9-15 Location of the interlock control module inside
the left instrument control panel

WARNING

3. Refer to truth table (Fig. 9-17) to analyze


functionality of module. The module controls
operation of components listed in OUTPUTS
section of truth table. The ON or OFF state of
various outputs is determined by ON or OFF state of
various input conditions listed in INPUTS section of
truth table. The keyswitch must be in ON position.

q Shut off the engine.


(For detailed instructions, refer to the Safety
chapter of this manual.)

1. Remove four Phillips-head screws securing left


instrument panel to ROPS. It should be possible to
expose wiring and interlock control module without
disconnecting any wires from panel.
2. Most module troubleshooting can be done by
observing green diagnostic LED indicators.
u

Example 1 (initial keyswitch ON): At


initial keyswitch ON, input LED 12-VDC
In should light and internal seat belt alarm
should sound for five seconds.

4. The truth table section Diagnostic LED States


specifies active (ON) state of each input and output.

Disconnect 12-pin and 6-pin connectors


and inspect terminals. Be sure no pins are
bent on module and no sockets are damaged
on harness. Replace damaged components
and reconnect harness to control module.

Example: Active (ON) state of engine oil


pressure switch input (connector #1, pin #8)
is a low or grounded input. Active state of
seat switch input (connector #1, pin #3) is a
high or 12-VDC input.

OIL PSI SW IN

AUTO-GLOW TIME IN

HYD TEMP SW IN
ENG TEMP SW IN

DOOR SW IN

SEAT SW IN
PARK BRAKE SW IN

PARK BRAKE LT OUT


RESTRAINT BAR SW IN

+12VDC IN

BRAKE SOL OUT


FUEL SOL OUT
START RELAY OUT
HYD RELAY OUT
SEAT BELT LT OUT

GREEN LED
DIAGNOSTIC
INDICATORS (15)

ALARM BUZZER
OUTPUT CONNECTOR
6 PIN DEUTSCH
DT15-06

INPUT CONNECTOR
12 PIN DEUTSCH
DT15-12PA

OUTPUT PIN DESCRIPTIONS:

INPUT PIN DESCRIPTIONS:

1. BLUE - PARK BRAKE SOLENOID,


(5 AMP MAX CONTINUOUS)
2. YELLOW - HYD RELAY,
(3 AMP MAX CONTINUOUS)
3. BROWN - SEAT BELT LIGHT,
(2 AMP MAX CONTINUOUS)
4. GREEN - PARK BRAKE LIGHT,
(2 AMP MAX CONTINUOUS)
5. RED - FUEL SOLENOID,
(5 AMP MAX CONTINUOUS)
6. PINK - START RELAY,
(3 AMP MAX CONTINUOUS)

1. RED - KEYED POWER


2. BLACK - GROUND
3. WHITE - SEAT SWITCH
4. GREEN - RESTRAINT BAR SWITCH
5. PURPLE - PARK BRAKE SWITCH
6. GRAY - HYD TEMP SWITCH
7. ORANGE - ENG TEMP SWITCH
8. PURPLE - OIL PSI SWITCH
9. WHITE - DOOR SWITCH
10. BLUE - AUTO-GLOW TIME
11. NC
12. NC

MATING CONNECTOR:
DEUTSCH PNB DT06-06S

MATING CONNECTOR:
DEUTSCH PNB DT06-12S

Fig. 9-16 Illustration of the interlock control module


PRINTED IN USA

9-13

917292/AP1008

ELECTRICAL

BEFORE beginning this service procedure,


perform the following SAFETY procedure:

917292/AP1008

9-14
X

OFF

ON

OFF

ON

Pin No.
1.1
2.1
2.5
2.6
2.2
2.3
2.4
1.4
1.9
1.3
1.5
1.6
1.7
1.8
1.10

OFF

ON

Type of Active Input/Output


HIGH (12VDC)
HIGH (12VDC)
HIGH (12VDC)
HIGH (12VDC)
HIGH (12VDC)
LOW (GND)
LOW (GND)
HIGH (12VDC)
HIGH (12VDC)
HIGH (12VDC)
HIGH (12VDC)
LOW (GND)
LOW (GND)
LOW (GND)
LOW (GND)

DIAGNOSTIC LED STATES

ON

LED Title
+12VDC (IN)
Brake Sol (OUT)
Fuel Sol (OUT)
Start Relay (OUT)
Hyd Relay (OUT)
Seat Belt Lt (OUT)
Park Brake Lt (OUT)
Restraint Bar Sw (IN)
Door Sw (IN)
Seat Sw (IN)
Park Brake Sw (IN)
Hyd Temp Sw (IN)
Engine Temp Sw (IN)
Oil PSI Sw (IN)
Auto-Glow Time (IN)

ON

SAFETY RELAYS
DISABLE

OFF

ON

SAFETY RELAYS
DISABLE

ON

OFF
AFTER
1 SEC

ON

ON

ON

ON

ON

ON

ENGINE OVER TEMP


SHUT DOWN
ENGINE LOW OIL
PSI
SHUT DOWN
PARK BRAKE
RELEASE
SOLENOID ON
PARK BRAKE
RELEASE
SOLENOID OFF
PARK BRAKE
RELEASE
SOLENOID OFF
PARK BRAKE
RELEASE
SOLENOID OFF
SAFETY RELAYS
ENABLE
SAFETY RELAYS
DISABLE
X

ON

AUTO-GLOW TIME

ON

ON

HYD OVER TEMP


WARNING

ON

AT POWER ON

ON

Pin No.

Function

ON

LED State
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON

ON

ON

ON

OFF

9
11
12

ID

L
RE

AY

AM

ON

OFF

OFF

OFF

OFF

ON

OFF

OFF

ON FOR
5 SEC

OFF
AFTER
30 SEC
OFF
AFTER
30 SEC

ON

ON

INTERNAL INTERNAL NOTES


Seat Belt Warning
ON FOR
Light and Intermitent
5 SEC
Chirp Alarm
Intermitent Alarm Sounds
ON when Input Signal is
Present or until Power Off
Engine Shut Down Timer
and Alarm Disabled
During Auto-Glow
Fuel Solenoid Shut Down
ON and Intermitent Alarm
Sounds Until Power Off
Fuel Solenoid Shut Down
ON
and Intermitent Alarm
Sounds Until Power Off
Solenoid "ON" Releases
Hyd Brake to Allow
Loader Movement
Seat Switch has
1 Second Delay for
Park Brake Function
Instantaneous,
Park Brake Stops
Loader Movement
Instantaneous,
Park Brake Stops
Loader Movement
Instantaneous, Hydraulics
ON
and Start Functions are
Able to Operate
Instantaneous, Hydraulics
OFF
and Start Functions are
Disabled
Instantaneous, Hydraulics
OFF
and Start Functions are
Disabled
Instantaneous, Hydraulics
ON
and Start Functions are
Disabled

OUTPUTS (6 Pin Connector #2.X)

ON

ON

T
FE

OFF

ON

NO

M
AR )
AL und
N
o
E
W S
)
L
O
AS
SA
RM irp T D arm
1
N
S
LE
P
ID
#
O
LA Ch
ID
M
U Al
O
RE
Y
A
E
A
H
O
t
t
N
E
S
N
LA
LT n
TL
AK
LE
E en
AK
LE
O
RE
BE ite
EL
BR
IN it
BR
K
SO
LS
TB
RT
AT term NG term
R
D
E
E
A
A
D
Y
E In
S (In
ST
H
PA
FU
SE
(
HY
SO

LE

INTERLOCK CONTROL MODULE TRUTH TABLE

ON

10

n)
n)
n)
s)
)
io
tio H itio
Po
)
di ITC nd ITCH dit
wn
n
F
T W
o
n
)
F
o W Co W o T )
H D
nt
PU LO
S
O
S
C
S
C r
se
P p RE SI C PU en E IN -G
in WIT Ba CH in W p
e
r
R
)
M
T
r
S
t
P
N
p
I w
I
m E m U l
O
E
S
o
or
W CP
at AR train SWel S MP r Te ERT r Te ESS Oi CH r O TIMAUT
at
H er
E n
R w
B s
V ve
IT oo OW G
TE e
PO VD
ic
2 D Ind
ITC Op INT Re RAK Pa VER Ov E O O IL P Lo SWh D
L
C
N
D
D
I
1
O ith R it
-G UR USE
SE
SW ith RA ith K B ith O ith IN ith
VD ith
UN ED
TU
AT N w EST N w AR N w YD N w NG N w OW N w OON w UTON D OT
12N w ROo L
E
O
L (O
D (O
E (O
R (O
A (O
P (O
H (O
S (O
+O
G (N
N
N
(
INPUTS (12 Pin Connector #1.X)
t
ea

ELECTRICAL SYSTEM
Interlock Control Module Truth Table

Fig. 9-17 Truth table for the interlock control module

PRINTED IN USA

ELECTRICAL SYSTEM
Two-Speed, Ride Control and Float Module Test
The following procedure can be used to test the
two-speed, ride control and float module mounted on the
left riser, just below the engine cover.

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:

q Shut off the engine.


q Raise engine cover and lock open the
rear grille.

Fig. 9-18 Location of the two-speed, ride control and float


module inside the engine compartment

(For detailed instructions, refer to the Safety


chapter of this manual.)

harness. Replace any damaged components


and reconnect harness to control module.

1. Most troubleshooting of the two-speed, ride control


and float module can be done by observing the green
diagnostic LED indicators on the module.
u

2. Refer to truth table (Fig. 9-20) to analyze


functionality of module.

Disconnect 12-pin connector and inspect


terminals. Be sure no pins are bent on the
module and no sockets are damaged on the

With keyswitch ON, press #1 button on left


control handle. The High/Low Toggle
LED should be lit while button is depressed.

Two-Speed, Ride Control and Float Module

12

PIN DESCRIPTIONS:
1. BLK GROUND
2. TAN FLOAT LAMP
3. GRY RIDE CONTROL TOGGLE
4. PNK FLOAT SWITCH
5. RED +12VDC
6. WHT LOW/HIGH GEAR TOGGLE
7. BLU RIDE CONTROL LAMP
8. BRN RIDE CONTROL SOLENOID
(5 AMP OUTPUT)
9. YEL FLOAT/RIDE SOLENOID
(10 AMP OUTPUT)
10. OPERATOR PRESENCE INPUT
11. ORG HIGH GEAR LAMP
12. PUR HIGH GEAR SOLENOID
(5 AMP OUTPUT)

MATING CONNECTOR:
DEUTSCH PNB DT06-12S

12 PIN DEUTSCH
PN DT15-12PA

Fig. 9-19 Illustration of the two-speed, ride control and float module

PRINTED IN USA

9-15

917292/AP1008

ELECTRICAL

HIGH GEAR SOL

FLOAT/RIDE SOL

+12 VDC

RIDE CTRL SOL

FLOAT SW

LO/HI GEAR SW

SEAT SW

RIDE CTRL SW

GREEN LED
DIAGNOSTIC
INDICATORS (8)

9-16

Operator Taking
Seat

Operator Leaving
Seat

Float No Effect

Toggle Float OFF

Float Hold ON

Activate Float

Ride Control
No Effect

(hold
for
5 sec)

Toggle Ride
Control ON

Toggle Ride
Control OFF

Toggle High
Gear OFF

Low
Tog /Hig
gle h G
Sw ear
itch

Rid
To e C
g
gle ontro
Sw l
itch

Toggle High
Gear ON

Flo
Sw at Mo
itch m
en
tar
y

ACTION

Se
(Re at Sta
la
y O te
utp
ut)

At Power Up

Flo
So at/R
le
no ide C
id
on
tro
l
0

Prev
State

0
(after
.25 S
delay)

Prev
State

0
(after
.25 S
delay)

0
(after
.25 S
delay)

Rid
Sole e Co
no ntro
id
l

917292/AP1008
Hig
Sole h Ge
no ar
id
0

Co
n
tro
l La
mp
0

0
(after
.25 S
delay)

Prev
State

Rid
e

MODULE TRUTH TABLE

Hig
h
Ge
ar
Lam
p
0

Flo
at
Lam
p
0

Momentary Press Has No Effect


Seat State Overrides Press

Mom press when float hold


condition is engaged causes
float/ride sol, ride sol &
ride lamp to revert to previous
condition and turns off float lamp

Lamp blinks at 2Hz rate for


5 sec. then locks to continuous
ON state. Solenoid output
locks ON after 5 sec.

Float is activated only as long


as switch is pressed.
Lamp blinks at 2Hz rate.
Float action has priority over
ride control.
If ride control is ON when float
is pressed, ride control solenoid
has .25 sec. OFF delay.
Ride control sol, float/ride sol,
& ride control lamp return to
prior state when float deactivated

Momentary press has no effect.


Seat state overrides press.

Momentary press toggles


ride control.

Momentary press toggles


high gear.

COMMENTS

ELECTRICAL SYSTEM
Two-Speed, Ride Control and Float Module Truth Table

Fig. 9-20 Truth table for the two-speed, ride control and float module

PRINTED IN USA

ELECTRICAL SYSTEM
The High Gear Sol LED should toggle
ON (light) and OFF with alternate pushes of
button.
u

With keyswitch ON, press #2 button on


right control handle. The Ride Ctrl
Toggle LED should be lit while button is
depressed. The Ride Ctrl Sol LED should
toggle ON (light) and OFF with alternate
pushes of button.

With keyswitch ON, press #1 button on


right control handle. The Float Toggle
LED should blink while button is
depressed. The Float Sol LED should
blink ON (light) and OFF with alternate
pushes of button. Press and hold the #1
button for five seconds to lock the Float
into a continuous ON state.

Fig. 9-21 Location of the standard flow coils on the 3-bank


proportional solenoid valve

Standard Flow

Electrically-controlled Standard Auxiliary


Hydraulic Flow System Test and
Operation

Fig. 9-22 Location of the standard flow coils and


high-flow coils on the 5-bank proportional
solenoid valve

Troubleshooting Test
1. Check the auxiliary control fuse in the fuse box
panel.
2. Check the diode and micro-relay in the power
distribution panel. Fig. 9-9
3. Check connections at the control handle and coils.
4. Be sure that the interlock control module is
outputting a signal for the hydraulic solenoid safety
relay.
u

Fig. 9-23 Location of the standard-flow auxiliary


hydraulics slide and trigger switch on the right
control handle
PRINTED IN USA

The relay will actuate only with the


keyswitch in the ON position, the
restraint bar down and the seat switched
closed.

5. Using a volt/ohm multimeter or a test lamp, probe


the two wires going into pin 1 and pin 2 of the coil.
DO NOT disconnect the plug. If the plug is
disconnected the controller will shut down.

9-17

917292/AP1008

ELECTRICAL

High Flow

The standard auxiliary hydraulics flow is controlled by


the slider and trigger switch (Fig. 9-23) in the right
control handle, except on T-Bar control models. The
control handle contains an integrated circuit that
controls the signal to two proportional solenoid valves
(a 3-bank or 5-bank) (Figs. 9-21 and 9-22) located on
the right chaincase beneath and to the right of the
operators seat.

ELECTRICAL SYSTEM
u

The solenoid will actuate only with the


keyswitch in the ON position, the
restraint bar down and the seat switched
closed. If the solenoid is unplugged, turn the
keyswitch to OFF, wait two seconds and
then turn the keyswitch to the ON
position to reset the circuit.

Monitor the voltage between pin 1 and pin 2


while operating the slider switch. Probe the
wires going into pin 1 and 2 of the connector
and monitor the voltage. With the help of an
assistant, apply pressure to the operators
seat and actuate the slider switch. The
voltage should vary between 5.5 volts and
7.0 Volts. Fig. 9-24

If performing this test alone, make a test


harness to plug in between the chassis
harness and the solenoid valve. Sit in the
operators seat and monitor the voltage
while actuating the slider switch. Figs. 9-25
- 9-27

The coil resistance can be checked as well


and should read 5.4 Ohms (W).

Fig. 9-25 Setup to measure voltage between pins A and B


on solenoid coils

Fig. 9-26 View of the jumper wires attached at the


standard auxiliary flow coils

Fig. 9-24 View of voltmeter pins probing the wires going


into pin 1 and pin 2 of the connectors on the coils

917292/AP1008

Fig. 9-27 View of the jumper wires attached at the


voltmeter pins

9-18

PRINTED IN USA

ELECTRICAL SYSTEM
Electrically-controlled High-Flow Auxiliary
Hydraulic Flow System Test and
Operation
The high-flow auxiliary hydraulics flow is controlled by
a rocker switch located beneath the light switch in the
right instrument panel and a high-flow module located
in the engine compartment on the left riser tower, below
the two-speed ride control and float module. The rocker
switch contains an integrated circuit that controls the
signal to a proportional solenoid valve (5-bank) (Fig.
9-22) located on the right chaincase beneath and to the
right of the operators seat. Figs. 9-26, 9-28, 9-29
Fig. 9-28 Location of the high-flow auxiliary hydraulics
control rocker switch in the right instrument
panel

Troubleshooting Test
1. There are indicators on the high-flow module to aid
in diagnosis. Have an assistant actuate the rocker
switch and monitor the indicators on the module.
This will provide direction on what to troubleshoot.
2. Check the auxiliary control fuse in the fuse box
panel.
3. Check the electrical connections at the 5-bank
proportional solenoid valve.
4. Be sure that the module is outputting a signal for the
hydraulic solenoid safety relay.
u

Fig. 9-29 Location of the high-flow auxiliary hydraulics


high-flow module

Fig. 9-30 Location of the electronic rotary throttle on the


right instrument panel

PRINTED IN USA

The relay will actuate only with the


keyswitch in the ON position, the
restraint bar down and the seat switched
closed.

5. Using a test lamp, probe the wire going into pin 1 of


the coil. DO NOT disconnect the plug. If the plug is
disconnected the controller will shut down. Fig.
9-24
u

The solenoid will actuate only with the


keyswitch in the ON position, the
restraint bar down and the seat switched
closed. If the solenoid is unplugged, turn the
keyswitch to OFF, wait two seconds and
then turn the keyswitch to the ON
position to reset the circuit.

With the help of an assistant, apply pressure


to the operators seat and actuate the
high-flow switch. The light will be dimmer
than normal due to reduced voltage in this
circuit. Fig. 9-24

6. The coil resistance can be checked as well and


should read 5.4 Ohms (W).

9-19

917292/AP1008

ELECTRICAL SYSTEM
Engine Throttle Test and Operation
The engine speed is controlled by an electronic rotary
throttle (Fig. 9-30). The throttle is located on the right
instrument panel. Dual Joystick and T-Bar controls
models have a second throttle located near the
operators right foot. If there are problems with the
throttle, the engines ECU will supply an error message
on the left instrument panel. See the Engine chapter for
error code identification.

Solenoid Lock Valves Test and Operation


- T-Bar Only
The solenoid locks for lift and tilt are located on the right
side of the chassis in front of the muffler (Fig. 9-31). The
solenoids are controlled by the interlock control module.
When the restraint bar and seat switch are closed, the
module sends a signal to the solenoid lock relay in the
fuse box panel. The relay will close and send power to
the solenoids. The circuit is protected by the solenoid
lock pilot fuse.

Fig. 9-31 Location of the solenoid lock valves for the lift
and tilt functions of the T-Bar control skid-steer
loader

Pilot Oil Solenoid Valve Test and


Operation - Dual Joystick and Hand/Foot
Lift and Tilt Solenoid Test and Operation
The oil supply for the lift and tilt control functions is
supplied by a solenoid valve (and coil) located on the
same valve as the auxiliary hydraulics (Fig. 9-32). It is
located on the right chaincase beneath and to the right of
the operators seat The solenoid is controlled by the
interlock control module. When the restraint bar and
seat switch are closed, the module sends a signal to the
solenoid lock pilot relay in the fuse box panel. The relay
will close and send power to the solenoids. The circuit is
protected by the solenoid lock pilot fuse.

Fig. 9-32 Location of the pilot oil solenoid coil on the


5-bank proportional solenoid valve

Traction Solenoid Test and Operation


The solenoid valve that supplies oil to the left joystick
(wheel drive functions) is located on the left side of the
chassis in front of the battery (Fig. 9-33). The solenoid is
controlled by the interlock control module. When the
restraint bar and seat switch are closed, the module
sends a signal to the solenoid lock pilot relay in the fuse
box panel. The relay will close and send power to the
solenoids. The circuit is protected by the solenoid lock
pilot fuse.

917292/AP1008

Fig. 9-33 Location of the traction solenoid valve located in


front of the battery

9-20

PRINTED IN USA

ELECTRICAL SYSTEM
Control Handle Actuation Buttons - Two-Speed and Ride Control and Float Module

Two-Speed

Horn

LEFT
CONTROL
HANDLE

Ride
Float
Control Control

Rocker
Auxiliary
Hydraulics

Auxiliary Hydraulics
Lock-on Button
Switch - In Front

RIGHT
CONTROL
HANDLE

SWITCH 1

SWITCH 2

SWITCH SCHEMATIC

Fig. 9-34 Illustration of control handle buttons and their functions

PRINTED IN USA

9-21

917292/AP1008

ELECTRICAL SYSTEM

Electrical-ROPS Schematic - Tier3 Yanmar Engine

84 RD-14

39

44

43

TO WIPER/WASHER/
DOOR SWITCH

0 BK-14

ELECTRICAL - ROPS SCHEMATIC

43 0R-14
0 BK-14

AB C

RIGHT CONSOLE
ASSEMBLY

43 OR-14
0 BK-14

60 OR-14
61 GN-16
84 RD-14

0 BK-16

43 OR-14

LEFT CONSOLE
ASSEMBLY

0 BK-16

84 RD-14
43 OR-14

0 BK-16

59 RD-14
52 WH-16

FLOOD LAMP
LEFT
FRONT
6 WORK
LIGHT

RIGHT
FRONT
WORK
LIGHT

DOME
LIGHT

RADIO CONNECTION STROBE


LIGHT
(OPT)
40
123

0 BK-16
0 BK-16
0 BK-16
HOURMETER
34 YL-16

15 BR-16

34

0 BK-14
52 WH-16

36

52 WH-16

53 RD-16

18

SAFETY
INTERLOCK
CONTROL
MODULE

0 BK-16

6
5
4
3
2
1

52 WH-16

TO EU
LIGHTS

24 BU-16

53 RD-14

0 BK-14

40 GY-16

30
27

53 RD-16
15 BR-16
19 WH-16
53 RD-16

14 PU-16
31 OR-16
53 RD-16
29
34 YL-16
32 GN-16
53 RD-16
28
4 BU-16

87 TN-16
1
3
2
4

11 RD-14
48 WH-14
11C43 OR-14
INSERTION SIDE
RED

48 WH-14

89 RD-14 A
110 WH-14 B

0 BK-14

33
33A

40 GY-16
53 RD-16
23 OR-16

POWER ALL
TACH SWITCH PARK BRAKE
(OPT)
SWITCH
30 PU-16
8
3
12
A 9
2
B
54 RD-16

43 OR-14
43 OR-14

0 BK-12

53 RD-16
87 TN-16

53 RD-16
53 RD-16

31

GLOW
HYD
TEMP

13

11 RD-14
0 BK-16

A B 23

0 BK-16

53 RD-16

32

OIL
BATT
PSI
ENG HYD
TEMP FILTER

0 BK-14
0 BK-14
0 BK-14
0 BK-14

53 RD-16

SEAT
BELT
AIR
FILTER

TWO-SPEED PARK BRAKE

FLOAT
SHUTDOWN
RIDE
WARNING CONTROL CONTROL

53 RD-16
37 GN-16 15

ROPS
GROUND
20

53 RD-16
24 BU-16

22 GN-16

53 RD-16

67 PK-16
53 RD-16

14

S
(I)
ENG TEMP
37

53 RD-16

15 BR-16

53 RD-16

53 RD-16
16
23 OR-16

25 BR-16

38

0 BK-16

40 GY-16

17

S
(I)
FUEL
35

53 RD-16
0 BK-16
53 RD-16

0 BK-14

37 GN-16
15 BR-16
29 YL-16
36 BU-14

54 RD-14
0 BK-16
10 WH-16
17 GN-16
30 PU-16
40 GY-16

0 BK-14
0 BK-14

33 PK-16

43 OR-14

40 GY-16

19

1
2
3
4
5
6
7
8
9
10
11
12

22
RESTRAINT
BAR
SWITCH

11B

21

DGN
RED ORGWHT

SEAT
SWITCH

5
6

42 GN-14
11 RD-14
126 GN-16
123 TN-16
124 YL-16
125 PK-16

62 RD-14

25

LIGHT SW
1 7

10 3
41

48 WH-14
122 PU-16

A B CD E

POWER ALL TACH

20 BR ST OFF
ON
ST
2 RD BAT

26

43 OR-14
42 GN-14

54 RD-14

20 BR-16
02 RD-14
61 GN-16

04 DBL-16
14 PUR-16
19 WHT-16
22 DGN-16
23 ORG-16
24 DBL-16
25 BRN-16
31 ORG-16
32 DGN-16
34 YL-14
40 GRY-16
87 TAN-16

21

10 WH-16
A B CD E F

ROPS 5 PIN
CONNECTION

1 2 3 4 5 6 7 8 9 101112 1

24

109 BK-16
69 WH-16
70 RD-14

21

5 RD IGN

60 OR-16
53 RD-14
125 PK-16
59 RD-14
62 RD-14
84 RD-14
54 RD-14
123 TN-16
122 PU-16
124 YL-16
126 GN-16
67 PK-16

0 BK-14

56 RD-12

11

55 WH-12
11 RD-12
0 BK-12

56 RD-12

89 RD-14
110 WH-14
AB

0 BK-12

10 WH-16
54 RD-14

ACCESSORY PLUG

05 RD-14

17 GN-16
54 RD-14

55 WH-12
0 BK-12

IGNITION SW

54 RD-14

17 GN-16

A
B

67 PK-16

17 GN-16
10 WH-16

AC/HEAT POWER
56 RD-12
55 WH-12
0 BK-12
11 RD-12

33 PK-16
29 YL-16
36 BU-14
50 WH-14

[ OPT. ]

24 BU-16
87 TN-16
4 BU-16
40 GY-16
32 GN-16
34 YL-16
31 OR-16
14 PU-16
19 WH-16
23 ORG-16
22 GN-16
25 BR-16

FLASHER

1 2 3 4 5 6 7 8 9 101112 2

12 PIN GRAY
KEYED CONNECTION
PLUG

05 RD-16
69 WH-16
70 RD-16
36 BU-14
42 GN-14
43 OR-14
33 PK-16
50 WH-16
109 BK-16
20 BR-14
29 YL-16
02 RD-14

33 PK-16
29 YL-16
36 BU-14
50 WH-14
05 RD-16
20 BR-14
02 RD-14
42 GN-14
43 OR-14
109 BK-16
69 WH-16
70 RD-14

12 PIN GRAY
NON-KEYED CONNECTION
RECEPTACLE

1 2 3 4 5 6 7 8 9 101112 3

12 PIN GRAY
KEYED CONNECTION
PLUG

917292/AP1008

9-22

PRINTED IN USA

ELECTRICAL SYSTEM
A B C D E F G H J

104 16-GY
31 OR-14
106 PU-16

ELECTRICAL SCHEMATIC
4TNV98 ENGINE

K L
M N P R S T
U V W X

103 BR-16
94 RD-14
105 YL-16
101 GN-16
115 BU-16
114 GY-16
22 GN-16
99 OR-16
69 WH-16
14 PU-16
98 TN-16
102 OR-16
96 PK-16
34 YL-16
111 PU-16
111 GY-16

14 PU-16

ENGINE
OIL PRES
SWITCH

TO CHASSIS

Electrical-Engine Schematic - Tier3 Yanmar Engine

101 GN-16
96 PK-16

104 16-GY
94 RD-14
106 PU-16
103 BR-16

RACK POSITION/ACTUATOR

1 2 3 4 5 6

1 2

SPEED
SENSOR

1 2 3 4 5 6

69 WH-16
114 GY-16
115 BU-16

105 YL-16

COLD START
COIL

99 OR-16

EGR VALVE

34 YL-16
98 TN-16

TO STARTER
SEE CHASSIS
SCHEMATIC

22 GN-16

102 OR-16
69 WH-16

31 OR-14

ENGINE
TEMP
SENDER

B+

9-23

1 2

PRINTED IN USA

ENGINE
TEMP
SENDER
(ECU)

ALTERNATOR

917292/AP1008

WIRE #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

COLOR
BLACK
RED
RED
BLUE
BLUE
RED
ORANGE
RED
ORANGE
NA
WHITE
RED
RED
RED
PURPLE
BROWN
RED
GREEN
YELLOW
WHITE
BROWN
GREEN
GREEN
ORANGE
BLUE
BROWN
WHITE
GRAY
GRAY
YELLOW
PURPLE
ORANGE
GREEN
PINK
YELLOW
BLUE
BLUE
GREEN
PURPLE
YELLOW
GRAY
YELLOW
GREEN
ORANGE
PINK

WIRE #
FUNCTION
45
GROUND
BATT POWER DIRECT
46
BATT POWER FUSED
47
GLOW COIL
48
GLOW CONTROL LAMP
49
IGN SW/PWR RELAY
50
51
HORN BUTTON/RELAY
PWR RELAY/CIRCUIT BREAKERS
52
53
HORN RELAY/HORN
NA
54
SEAT SW
55
LIGHTS POWER(KEYED)
56
IGN (KEYED) PWR
57
CHASSIS POWER (KEYED)
58
59
OIL PRESSURE SW
60
SEAT BELT LAMP
ROPS POWER (KEYED)
61
62
RESTRAINT BAR SW
63
SAFETY RELAY/ALTERNATOR
AIR FILTER RESTRICTION SW
64
65
IGN SW/START RELAY #1
66
START RELAY/SAFETY RELAY
67
ENG TEMP SENDER
68
2 SPEED LAMP
RIDE CONTROL LAMP
69
70
FUEL SENDER
2 SP SW/CONTROL MODULE
71
RIDE CONT SW/MODULE
72
ENG TEMP SENDER/GLOW MODULE73
74
INTERLOCK MOD/ RELAY 1 & 2
75
BRAKE SW/INTERLOCK MOD
76
ENG TEMP SW
77
HYD FILTER SW
CONTROL MOD/START RELAY
78
79
ALTERNATOR/HOUR METER
HYD SOLENOIDS
80
PARK BRAKE SOLENOID
81
82
PARK BRAKE LITE
83
CONTROL MOD/2 SP SOL.
CONTROL MOD/RIDE CONT SOL. 84
HYD TEMP SW
85
START SIGNAL TO GLOW MOD
86
87
REAR WORK LTS.
88
HEAD LTS & TAIL LTS
GLOW MODULE
S
COLOR
YELLOW
PURPLE
WHITE
WHITE
GREEN
WHITE
RED
WHITE
RED
RED
WHITE
RED
BROWN
YELLOW
RED
ORANGE
GREEN
RED
WHITE
BLACK
BLUE
PURPLE
PINK
TAN
WHITE
RED
BLACK
BLUE
ORANGE
BLUE
TAN
ORANGE
GRAY
GRAY
PINK
YELLOW
RED
WHITE
TAN
RED
PINK
BROWN
TAN
GRAY
WHITE

WIRE #
FUNCTION
89
PULL COIL TIMER
90
PULL COIL TIMER
91
PULL COIL RELAY/FUEL SOL
92
LIGHT SW/FLASHER
93
BACK UP ALARM
94
FLASHER/CONNECTOR
FUEL SOL (HOLD)
95
DOOR SWITCH/SAFETY MOD
96
GAUGE POWER
97
INTERLOCK POWER
98
99
AC/HEAT POWER
ACCESSORY POWER
100
101
FAN CLUTCH
102
GLOW RELAY SIGNAL
WIPER/WASH POWER
103
104
RADIO POWER
105
RADIO MEMORY
ALL TACH POWER (SWITCH)
106
107
ALL TACH POWER
GLOW RELAY GRND TO ECM
108
INJ PUMP RELAY GRND TO ECM 109
LIFT PUMP RELAY GRND TO ECM 110
STOP/SHUTDOWN INDICATOR - ECM
111
WARN/COLD INDICATOR - ECM 112
114
THROTTLE SENSOR GRND
THROTTLE SENSOR POWER
115
116
THROTTLE SENSOR SIGNAL
THROTTLE SWITCH SIGNAL
117
118
THROTTLE SWITCH POWER
SOLENOID LOCK POWER
119
INJ PUMP POWER
120
121
HORN POWER
122
LIFT PUMP POWER
123
POWER TO LIFT PUMP
RIDE/2 SPEED MODULE POWER
124
125
BACK UP ALARM POWER
GLOW PLUG POWER
126
127
START SOL
FAN CLUTCH POWER
128
DOME/STROBE POWER
129
FLOAT SW/CONT MOD
130
CONT MOD/RIDE CONT SOL
131
FLOAT LAMP
132
133
EXTRA START FUEL SOL
134
SAFETY RELAY/STARTER

917292/AP1008
AUXILIARY CONTROL POWER
AUXILIARY COIL POWER - LF FORWARD
AUXILIARY COIL POWER - LF REVERSE
AUXILIARY COIL FEEDBACK
AUXILIARY COIL POWER - HF FORWARD
AUXILIARY COIL POWER - HF REVERSE
AUXILIARY HF SWITCH POWER
FORWARD SIG FROM SWITCH TO HF MODULE
REVERSE SIG FROM SWITCH TO HF MODULE
POWER IND HF FORWARD
POWERE IND HF REVERSE
AUX COIL FEEDBACK HF FORWARD
AUX COIL FEEDBACK HF REVERSE
RIGHT TURN SIGNAL
LEFT TURN SIGNAL
FRONT POSITION LIGHT
ROAD LTS/LOW BEAM
LIGHTS POWER 2 (KEYED)
FLASHER/TURN SIG. POWER

RH TURN SIG./FLASHER
LH TURN SIG./FLASHER
TURN SIGNAL SW PWR

GREEN
YELLOW
ORANGE

RED
PINK
YELLOW
GRAY
PINK
GREEN
PURPLE
TAN
YELLOW
PINK
GREEN
BRN
GRY
YELLOW
TAN
GRAY
GRN
ORANGE
PINK

FUNCTION
SEAT AIR COMPRESSOR PWR
REAR WIPER/WASH PWR
REAR WIPER SW PWR
REAR WASHER SW PWR
FRT WIPER PWR
FRT WASHER SW PWR
STROBE SWITCH PWR
ROAD LTS/HI BEAM
FRONT WORKLIGHTS
LICENSE PLT LIGHT
ROADLIGHTS SW PWR
TAILLIGHTS SW PWR
STOP LIGHT
POSITION LIGHT SW PWR
FLASHER POWER TO RELAY

COLOR
YELLOW
PURPLE
YELLOW
ORANGE
TAN
GRAY
PINK
BLUE
BROWN
PUR
YELLOW
PINK
RED
ORANGE
BROWN

WIRE #
FUNCTION
ALL-TACH POWER (LOCKING)
135
GLOW MODULE POWER
136
ELECTRIC AUXILIARY POWER
137
138
START RELAY GRND TO ECU
ECU POWER RELAY GRND TO ECU 139
ECU/EGR POWER - KEYED
140
FUEL RACK RELAY GRND TO ECU 141
FUEL RACK POWER - KEYED
142
GLOW RELAY CONTROL TO ECU 143
ALTERNATOR SPEED OUTPUT
144
145
COLD START COIL TO ECU
RACK POS SENSOR TO ECU
146
FUEL RACK COIL GRND TO ECU 147
148
ENG TEMP SENSOR TO ECU
149
EGR1 TO ECU
EGR2 TO ECU
150
151
EGR3 TO ECU
152
EGR4 TO ECU
THROTTLE SENSOR (2) GRND
153
THROTTLE SENSOR (2) POWER
THROTTLE SENSOR (2) SIGNAL
ALL-TACH POWER UNLOCK
COLD START SWITCH
AUX INTERLOCK TO START

COLOR
RED
RED
RED
PURPLE
GREEN
RED
YELLOW
PINK
PINK
TAN
ORANGE
BLUE
GREEN
ORANGE
BROWN
GRAY
YELLOW
PURPLE
WHITE
RED
BLACK
WHITE
TAN
PURPLE

ELECTRICAL SYSTEM
Electrical Schematics - Wire Number and Color Legend - Tier3 Yanmar Engine

9-24

PRINTED IN USA

TO FLASHERS
LEFT TOWER

14

50A WHT-14

DCB A

00 BLK-14
49A DGN-14
43 ORG-14
42 DGN-14

21C DGN-16

RIDE CONT/
2 SPEED
1211109 8 7 6 5 4 3 2 1

10

40

TO FLASHERS
RIGHT TOWER

50B WHT-14

1211109 8 7 6 5 4 3 2 1
CHASSIS
CONNECTION
3

1 2
57 NEUTRAL
58 START
1

21D DGN-16
21B DGN-16
38 PUR-16
23 ORG-14
35A4 DBL-16
39 YEL-16
86 BRN-16
24 DBL-14
26 WHT-16
79 PNK-16
85 PNK-16
27 GRY-16
87 TAN-14
OH BLK-18

38

REAR
WORK
LIGHT

REAR
WORK
LIGHT

125 RED/WHT-18

12

12
CAN
12
TERMINATOR 12A
12

17
FORWARD HORN

BACKUP
50 ALARM
SWITCH

BACKUP
ALARM
51 SWITCH

86 BRN-16
OA2 BLK-16

38 PUR-16
OA3 BLK-16

52
LEFT CONTROL
HANDLE SWITCHES

0S BLK-12
55 WHT-12
56 RED-12
11 RED-12

E D CB A
4
CHASSIS
CONNECTION

654321

TAIL
LIGHT

DIAGNOSTIC
CONNECTOR
11

FUSE PANEL
53

74 DB 14
55 WT 12
80 YL 14
60 OG 14
56 RD 12

1
2

1
2

1
2
3
4

30

28

49 DGN-14
49A DGN-14
A
B

49 GN-14
0 BK-14

CHASSIS
CONNECTION
2

A
BB

1 2 3 4 5 6 7 8 9 101112

86+

87

30

85-

30

0B6 BK 16

76B OG 14

0B1 BK 16

20 BR 14

0V BLK-16

16
FUEL
SENDER

O2C RD 10

05A RD 14

O2D RD 10

05C RD 14

0 BK-16

32 GN-16

0D BLK-16

25 BRN-14

HYD TEMP
SWITCH
43

HYD FILTER
RESTRICT
SWITCH
39

40 GRY-14

HIGH FLOW
9

1 2 3 4 5 6 7 8 9 101112

BACKUP
ALARM

80 YL-14
49 DGN-14
A
B

FLOAT
CONTROL
SOLENOID

2 SPEED
SOLENOID

79B PNK-16
76 ORG-14
O6 ORG-14
26 WHT-16

0E BLK-16

08 ORG-16

CHASSIS
CONNECTION
1

1 2 3 4 5 6 7 8 9 101112

PUMP

FUEL

O8 OG 16
HORN
06 OG 14

ALLTACH

85-

RADIO

86+

ACCESS
20

SOL LOCK
20

HORN
20

87

ACCESS
30
30
62 WT 14

7.5
7.5
53 RD 14

20 WIPE/WASH

20
78 GY 16
FUEL
PUMP
20
116C RD-14
AU
CONTROL

87

85-

87

85-

30

86+

30

86+

87

85-

30

86+

RIDE/2SP

RIDE
CONTROL
SOLENOID

41

B A

1
2

HIGH FLOW
SOL-REVERSE

19 WH-16

27

31

44

1
2

HIGH FLOW
SOL-FORWARD

7
AIR FILTER
RESTRICT
SWITCH (OPT)

1
2

1
2

GROUND STUD
LEFT SIDE TOWER

GROUND STUD
LEFT SIDE TOWER

39A YEL-16
OA5 BLK-16

42

1
2

RIDE
CONTROL
SOLENOID

36B DBL-14
0A6 BLK-16

39B YEL-16
OA1 BLK-16

121 DGN-14
128 GRY-16

0L BLK-14

1
2

JOYSTICK
SUPPLY SOL

36A DBL-14
OA4 BLK-18

BRAKE
SOLENOID

1
2

PILOT
PRESSURE
SOLENOID

02I RD-10

02H RD-10

02G RD-10

13 RD 14
59 RD 14
76A OG 14
79C PK 16
11 RD 12

02H RD 10
POWER
0B2 BK 16

02G RD 10
POWER
0B5 BK 16

02I RD 10
POWER
0B4 BK 16

35A1 DBL-16
0M BLK-16

120 PNK-14
127 BRN-16

20

LIGHTS
20

O2B RD 10

29

32

30

02 RED-14

117 PNK-16
119A GRY-14

118 YEL-16
119B GRY-14

TO POWER
DISTRIBUTION
PANEL

1
2

1
2

35B DBL-16
85 PNK-16
27 GRY-16

116 RD-16

116 RD-16

45

37

STARTER

46

STD FLOW
SOL-FORWARD

85
+
86

25

87

35

35C BL-16

87

30

AC

BATTERY

82 WH-14

36
A

KEY

ECU

POWER

POWER

POWER

GRID

+86

26

ENGINE
HEATER
(GRID)

30
87
GLOW SOL.
RELAY

-85

20

34

+
86
AU CONTROL
RELAY

START

CB A

FOOT THROTTLE
47

ECU 6
1B 1D 1F 1H 1K 1M 2B 2D 2F 2H 2K 2M 3B 3D 3F 3H 3K 3M 4B 4D 4F 4H 4K 4M
1A 1C 1E 1G 1J 1L 2A 2C 2E 2G 2J 2L 3A 3C 3E 3G 3J 3L 4A 4C 4E 4G 4J 4L

TO BATTERY
POSITIVE
TERMINAL

3A3B3C3D3E3F3G
1A1B1C1D1E1F1G1H1J1K1L1M2A2B2C2D2E2F2G2H2J2K2L2M
3H3J3K3L3M4A4B4C4D4E4F4G4H4J4K4L4M

21A DGN-16
92 PUR-18
97 PNK-16
0T BLK-16

02 RD-8

02D RED-10

02C RED-10

02B RED-10

PANEL 18,19,20,21,55,56

HEAT

85

54

POWER DISTRIBUTION

ACESSORY
KEY POWER RT
13B RED-14
A
0 BLK-14
B

12
11
10
9
8 48
7
6
5 RIGHT
4 JOYSTICK
3
2
1

START SOL.
RELAY

30

- 85

OK BK

+86

FUEL RACK
RELAY

18

35A2 BL-14

79A PNK-16
118 YEL-16
117 PNK-16
119 GRY-16
0P BLK-16
116 RED-16
STD FLOW
SOL-REVERSE

79A PNK-16
116 RED-16
0P BLK-16
119 GRY-16
117 PNK-16
118 YEL-16

30

87

56 AC PWR

35G BL-16

02 RD-14

2A RED-14

55 HEATER PWR

94B RED-16

27 GRY-16
85 PNK-16
35B DBL-16

ENGINE
GROUND

+
86

85

93 DGN-18

ECU RELAY

87

19

A
B

ACESSORY
KEY POWER LT
13B RED-14
0N BK-14

96 PNK-16

05B RD 14

95 YEL-16

21D DG 16
START SAFETY
33 PK 14

60 ORG-14
62 WHT-14
53 RED-14
84 RED-14
54 RED-14
59 RED-14
67 PNK-18
125 PNK-14
123 TAN-14
122 PUR-14
124 YEL-14
126 DGN-14

94C RED-16

0B3 BK 16

25

BACK
10 ALARM
GAUGES

126 DGN-14
124 YEL-14
122 PUR-14
123 TAN-14
125 PNK-14
35A DBL-16
01 BLK-16
116A RED-14
120 PNK-14
127 BRN-16
121 DGN-14
128 GRY-16

60

10 AC/HEAT

10
84 RD 14
DOME
STROBE
10
54 RD 14
INTERLOCK

01 BLK-16
127 BRN-16
128 GRY-16
123 TAN-14
124 YEL-14
122 PUR-14
116 RED-14
35A DBL-16
125 PNK-14
120 PNK-14
126 DGN-14
121 DGN-14

05F RED-14
82 10-WHT

10

10

25

60

60

60

60

74 DB 14

02 RD-10
02 RD-10

4 DBL-18
94D RED-18

30

69A WHT-18

85-

49
ENGINE
CONNECTION

A B CD E F GH J K L MNP R S T U V W

132 PNK-18
0J BLK-16
14A PUR-18
102 ORG-18

86+

105 YEL-18
67 PNK-18

50 WHT-14
29 YEL-14
20 BRN-14
33 PNK-14
42 DGN-14
43 ORG-14
05 RED-14
02 RED-14
36 DBL-14
71 BLK-18
70 RED-14
69 WHT-14
02 RED-14
29 YEL-14
20 BRN-14
71 BLK-18
50 WHT-14
33 PNK-14
43 ORG-14
42 DGN-14
36 DBL-14
70 RED-14
69 WHT-14
05 RED-14
132 PNK-18
0F BK-16

102 ORG-18
105 YEL-18

87

81 RED-8
81 RD-8

70B RED-16
69C WHT-16
109 BLK-18
14A PUR-18
103 BRN-18
104 GRY-18
106 PUR-18

56 RED-12
0S BLK-12
11 RED-12
55 WHT-12
SHIELD DRAIN
GROUND

23 ORG-14
24 DBL-14
87 TAN-14
OH BLK-18
79 PNK-16
85 PNK-16
27 GRY-16
39 YEL-16
35A4 DBL-16
86 BRN-16
38 PUR-16
26 WHT-16

REAR DOOR,LIGHTS,
BACKUP ALARM

TAIL
LIGHT

00 BK-14
49 DGN-14
43 ORG-14
42 DGN-14

130 BLK-16
05D RED-16
0G BLK-16
C1 RED-18
0G BLK-16
130 BLK-16
C1 RED-18
05D RED-16

111 GRY-18
111 PUR-18
92 PUR-18
114 GRY-16
97 PNK-16
106 PUR-18
101 DGN-16
100 DBL-18
114 GRY-16
99 ORG-16
98 TAN-18
111 PUR-18

60 ORG-14
53 RED-14
125 PNK-14
59 RED-14
62 WHT-14
84 RED-14
54 RED-14
123 TAN-14
122 PUR-14
124 YEL-14
126 DGN-14
67 PNK-18
23 ORG-14
24 DBL-14
87 TAN-14
4 DBL-18
14B PUR-16
22 DGN-14
31 ORG-14
34 YEL-14
19 WHT-16
32 DGN-14
40 GRY-14
25 BRN-14
4 DBL-18
14B PUR-16
19 WHT-16
22 DGN-14
23 ORG-14
24 DBL-14
25 BRN-14
31 ORG-14
32 DGN-14
34 YEL-14
40 GRY-14
87 TAN-14

05E RED-18
21 DGN-18

02A RD-14
0 BK-0

103 BRN-18
109 BLK-18
34 YEL-14
31 ORG-14
22 DGN-14
104 GRY-18
31 ORG-14
106 PUR-18

95 YEL-18
93 DGN-18
71 BLK-18
100 DBL-18
109 BLK-18
70A RED-18
C1 BLK-18
C1 RED-18
0 BLK-16
94A RED-16
104 GRY-18

69A WHT-18
70A RED-18
67 PNK-18
71 BLK-18
4 DBL-18
21 DGN-18
132 PNK-18
C1 RED-18
94A RED-16
94D RED-18
05E RED-18
0J BLK-16
C1 BLK-18
0 BLK-16
14 PUR-18
94 RED-14
69B WHT-14
102 ORG-18
104 GRY-18
106 PUR-18
103 BRN-18
105 YEL-18
101 DGN-16
100 DBL-18
114 GRY-16
99 ORG-16
98 TAN-18
111 PUR-18T
111 GRY-18T
96 PNK-16

9-25

103 BRN-18
94 RED-14
105 YEL-18
101 DGN-16
100 DBL-18
114 GRY-16
22 DGN-14
99 ORG-16
69B WHT-14
14 PUR-18
98 TAN-18
102 ORG-18
96 PNK-16
34 YEL-14
111 PUR-18T
111 GRY-18T

98 TAN-18
99 ORG-16
101 DGN-16

917292/AP1008
111 GRY-18
92 PUR-18
97 PNK-16
95 YEL-18
93 DGN-18

35A3 DB 16
SOL LOCK PILOT
29 YL 14

ELECTRICAL SYSTEM

Electrical-Chassis Schematic - Tier3 Yanmar Engine

PRINTED IN USA

ENGINE

Introduction

The skid-steer loaders are equipped with either a


Yanmar 4TNV98 naturally-aspirated or turbocharged
diesel engine. The four-cylinder engines are 202 cubic
inch displacement (3,31 L) engines. The non-turbo
engine compression ratio and the turbo engine
compression ratio is 18.5:1. The four-cylinder engines
are direct injection four-stroke engines with a firing
order of 1, 2, 3, 4.

ordered from the Gehl Company or Mustang


Manufacturing Company.

Troubleshooting Guide
The following troubleshooting guide lists potential
engine problems, as well as possible causes and
remedies, for Gehl 5640E/6640E and Mustang
2066/76/86 skid-steer loaders.
When a problem occurs, dont overlook simple causes.
A malfunction could be caused by something as simple
as an empty fuel tank. After a mechanical failure has
been corrected, be sure to locate the cause of the
problem. For further troubleshooting information, refer
to the engine manufacturers manual.

A full-flow oil filter is used in the lubrication system.


As in any engine, clean oil, fuel and air are critical to
satisfactory performance and long engine life. If
properly maintained, this engine will provide thousands
of hours of trouble-free operation.
When ordering engine parts, always check the Gehl or
Mustang Parts Manual to see if a special part has been
fitted to the engine. If parts are required, they can be

IMPORTANT
DO NOT attempt to service or repair major
engine components unless authorized to do
so
by
your
Gehl
or
Mustang
dealer/distributor. Any unauthorized repair
will void the warranty.

Problem

Possible Cause

Remedy

Engine turns over but will not start

Engine cranking speed too slow

Battery requires recharging or


replacing, or, in cold temperatures,
pre-warm the engine.

Fuel tank empty or faulty fuel gauge


sender

Refill fuel tank. Replace fuel gauge


sender.

Pre-heat module malfunctioning


(below 81 F - (27C))

Check connection and voltage.


Replace as needed.

Ambient temperature too low

Install a block heater.

Fuel pump not working

Check electrical circuit. Contact


Gehl/Mustang Service.

Moisture in the fuel line.

Bleed water out of fuel filter and fuel


tank.

Fuel valves turned off

Open fuel valves.

Engine fault codes displayed

Identify problem and correct.

Fuel filter plugged

Replace fuel filter.

PRINTED IN USA

10-1

917292/AP1008

ENGINE

This chapter covers troubleshooting, removal,


installation and adjustment procedures for engine
components on Gehl 5640E/6640E and Mustang
2066/76/86 skid-steer loaders. The primary engine
system components are shown below and on following
pages.

ENGINE
Problem

Possible Cause

Remedy

Starter will not crank engine

Battery terminals or cables corroded or


loose

Clean battery terminals and cables and


secure them tightly.

Battery discharged or defective

Recharge or replace battery.

Safety interlock malfunction

Troubleshoot/replace

Starter solenoid not functioning

Troubleshoot circuit per wiring


diagrams to locate trouble and repair or
replace starter solenoid.

Seat switch or restraint bar switch


malfunctioning

Sit on seat and lower restraint bar; if


engine still doesnt start, troubleshoot
circuit. Replace faulty switch as
needed.

Wiring to and from ignition, seat switch, Check wiring for poor connections or
broken leads and repair wiring or
restraint bar switch, etc. loose or
connection.
disconnected

Engine overheats.

917292/AP1008

Starter or pinion faulty

Remove starter and repair or replace


as needed.

Engine ECU faulty

Record flash code and remedy


problem.

Crankcase oil level too low or too high

Add or remove oil as required.

Engine overloaded

Reduce operating load.

Fan air circulation blocked or restricted

Turn engine OFF, wait for fan to stop,


remove blockage or restriction.

Grade of oil improper or excessively


dirty

Drain and replace with clean oil of


proper grade.

Exhaust restricted

Allow exhaust to cool and remove the


restriction.

Air filter is restricted

Replace the filter(s).

Low coolant level

Add coolant.

Fan shroud improperly positioned

Contact your dealer.

Fan belt loose

Tighten the fan belt.

10-2

PRINTED IN USA

ENGINE
Engine Components - Yanmar 4TNV98 - Mustang 2066/76/86 Models

5
42
40

46

57

39

30

43

50

16

42

23

24
58

10

13

1
35
44
4

16
28

29

37

26

47

18
27

22
17

25

41

48

20

52 NOTE
1&5

14
38

15
NOTE 2

11
21

NOTES

25

14

1. APPLY LOCTITE 242 OR EQUIVALENT


2. PIPE THREAD SEALANT
3. 80 FT-LBS
4. 47 FT-LBS
5. 28 FT-LBS
6. RE-USE WASHER SUPPLIED
WITH ENGINE OIL DRAIN PLUG

7
28

55
NOTE
1&4

12

33

11

31

51
45

NOTE 2

NOTE 6

54

41

49
53

9
8

NOTE
1&3

NOTE
1&5

7
7
NOTE
1&3

19

49

27

34

32

30

34

3
3
36

37

2
34
26

TO FUEL
RETURN

56

59
34
15

25

FUEL
SUPPLY

28

41
34

1 FITTING/STRAIGHT
2 NUT/LOCK
3 NUT/LOCK
4 FITTING/STRAIGHT
5 NUT/SPIRALOCK
6 WASHER/HARD
7 WASHER/SNUBBING
8 ISOLATOR
9 HOUSING/FLYWHEEL
10 CLAMP/TUBE
11 NUT/SPIRALOCK
12 FITTING/90
13 PUMP/FUEL
14 ISOLATOR
15 VALVE/SHUT OFF

56

16 ENGINE
17 COUPLER
18 FILTER/FUEL
19 MOUNT/ENGINE
20 ENGINE MOUNT
21 ENGINE MOUNT
22 MATING FILTER
23 BRACKET/ALT.
24 SPACER/ALT.
25 HOSE/FUEL
26 HOSE/FUEL
27 HOSE/FUEL
28 HOSE/FUEL
29 SPACER/ALT.
30 MOUNT/FILTER

31 ADAPTER/FILTER
32 ALTERNATOR
33 CLAMP/HOSE
34 CLAMP/HOSE
35 FILTER/OIL
36 STARTER
37 SEPARATOR/FUEL
38 BELT/ALT. FAN
39 HOSE/FILTER
40 HOSE/FILTER
41 HOSE OIL DRAIN
42 ASSY/DIPSTICK
43 BRACKET/DIPSTICK
44 WASHER/FLAT
45 SCREW/SET

46 SCREW/CAP
47 SCREW/CAP
48 SCREW/CAP
49 BOLT/CARRIAGE
50 SCREW/CAP
51 SCREW/CAP
52 SCREW/CAP
53 SCREW/CAP
54 SCREW/CAP
55 SCREW/CAP
56 NUT/HEX
57 SCREW/CAP
58 SCREW/CAP
59 SCREW/CAP

Fig. 10-1 Exploded view of the Yanmar 4TNV98 naturally-aspirated and turbocharged engine

PRINTED IN USA

10-3

917292/AP1008

ENGINE
Air Cleaner and Exhaust Components - 2066 Models

12

4
5

19

14

12

15
2
12
21

20

13

1
GASKET PROVIDED
WITH ENGINE
1

18

3.84

2.68
9

17
22

1 NUT/HEX
2 SCREW/CAP
3 CLAMP/MUFFLER
4 CLAMP/AIR CLEANER
5 ELBOW/90
6 ELEMENT/PRIMARY
7 ELEMENT/SECONDARY
8 COUPLING/HOSE

16
11

9 CLAMP/T BOLT
10 ASSY/AIR CLEANER
11 CLAMP/T-BOLT
12 CLAMP/HOSE
13 VALVE/VACUATOR
14 END CAP/AIR CLEANER
15 INDICATOR/RESTRICTION
16 HOSE/MOLDED

17 COUPLER/FLEX
18 MOUNT/AIR CLEANER
19 MUFFLER
20 BOLT/CARRIAGE
21 BOLT/CARRIAGE
22 NUT/HEX

Fig. 10-2 Exploded view of the naturally-aspirated engine air cleaner and exhaust components

917292/AP1008

10-4

PRINTED IN USA

ENGINE
Air Cleaner and Exhaust Components - 56/6640 and 2076/86 Models
14
2

19
8

11

ATTACH TO
TURBO OUTLET
28

9
13

12

20
17
17

26

16
GASKET SUPPLIED WITH
ENGINE
24
25
ATTACH TO
23
TURBO INLET

10

18
4

27

15

22

10

1 SCREW/CAP
2 SCREW/CAP
3 CLAMP/MUFFLER
4 NUT/SPIRALOCK
5 CLAMP
6 CLAMP/AIR CLEANER
7 ELBOW 90
8 ELEMENT/ PRIMARY
9 ELEMENT/SECONDARY
10 CLAMP/T-BOLT

11 ASSY/AIR CLEANER
12 CLAMP/HOSE
13 VALVE/VACUATOR
14 END CAP/AIR CLEANER
15 ELBOW/MOLDED
16 OUTLET/EXHAUST
17 COUPLER/FLEX
18 MOUNT/AIR CLEANER
19 MUFFLER
20 GASKET/EXHAUST

21 TUBE/INTAKE
22 HOSE/AIR INTAKE
23 ADAPTER/FILTER
24 CLAMP/T-BOLT
25 INDICATOR/RESTRICTION
26 BOLT/CARRIAGE
27 SCREW/CAP
28 SCREW/CAP

Fig. 10-3 Exploded view of the turbocharged engine air cleaner and exhaust components

PRINTED IN USA

10-5

917292/AP1008

ENGINE

21

ENGINE
Radiator Cooler Components - 2066/76/86 Models
3

7
19
4

TO COOLER
OUTLET

17

16

12

TO FILTER
RETURN
3

23

1
3
13
20
TO COOLER
INLET
14

3
2

1
3
15

18

21

10
14

22
1

22
11

COOLER OUTLET

1.37
.77
TO ENGINE
WATER OUTLET

SHROUD AND FAN WITH


RELATION TO ENGINE

TO ENGINE
WATER INLET

.35

COOLER INLET
ASSEMBLED VIEW

.87

1 CLAMP/HOSE
2 NUT/HEX
3 SCREW/FLANGE
4 CAP/RADIATOR
5 PAD/COOLER
6 HOSE/FUEL
7 SEAL/BULB
8 BOTTLE/OVERFLOW

9 EXCHANGER/HEAT
10 FAN
11 HOSE/RADIATOR
12 HOSE/RADIATOR
13 SPACER/FAN
14 PLATE/MOUNT
15 ASSY/FAN SHROUD
16 HOSE/INLET

ENGINE

TO RESERVOIR
RETURN

17 HOSE/OUTLET
18 SEAL/BULB
19 COVER/COOLER
20 WASHER/SPACER
21 COVER/SHROUD
22 BOLT/CARRIAGE
23 SCREW/CAP

Fig. 10-4 Exploded view of the radiator cooler components

917292/AP1008

10-6

PRINTED IN USA

ENGINE
Radiator Cooler Components - 56/6640 Models
COOLER
OUTLET
TO ENGINE
WATER OUTLET
TO ENGINE
WATER INLET
TO RESERVOIR
RETURN
COOLER
INLET

ASSEMBLED VIEW

TO COOLER 9
OUTLET
7

15
14

6
3

21

11

TO RETURN
FILTER
23

17

1
3

12

18
20
2

13

22
19

1 CLAMP/HOSE
2 NUT/HEX WHIZLOCK
3 SCREW/FLANGE WHIZLOCK
4 CAP/RADIATOR
5 PAD/COOLER
6 HOSE/FUEL
7 SEAL/BULB
8 BOTTLE/OVERFLOW

1
TO COOLER 3
INLET
10
13

9 EXCHANGER/HEAT
10 HOSE/RAD/LOWER
11 HOSE/RAD/UPPER
12 SPACER/FAN
13 PLATE/COOLER MOUNT
14 HOSE/INLET/COOLER
15 HOSE/OUTLET/COOLER
16 SEAL/BULB

16

17 SHROUD/FAN
18 WASHER/SPACER
19 FAN
20 COVER/SHROUD/LOWER
21 INSULATION/SHROUD
22 BOLT/CARRIAGE
23 SCREW/CAP

Fig. 10-5 Exploded view of the radiator cooler components

PRINTED IN USA

10-7

917292/AP1008

ENGINE
SECTION NOTES

917292/AP1008

10-8

PRINTED IN USA

ENGINE
Remote Oil Filter Element Removal and
Installation
The remote engine oil filter, left of the radiator cooler, is
attached low to the left side of the engine compartment.

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:

q Shut off the engine and allow to cool.


(For detailed instructions, refer to the Safety
chapter of this manual.)

Fig. 10-6 Remote engine oil filter access point on the left
side of the radiator cooler

Removal Procedure
1. Open the engine access cover and rear grille. Lock
the grille open with the latch pin on the grille's lower
pivot area. Figs. 10-6, 10-7
2. On left side of engine compartment find the oil filter
element. Fig. 10-7
3. Clean area around oil filter element.
4. Place a suitable container beneath the oil drain
weldment to catch any leaking oil. Fig. 10-8
5. Turning counterclockwise, loosen oil filter element
with a filter wrench.
Fig. 10-7 Location of rear grille latch

6. Turn filter element by hand until it is free of oil filter


head.
Installation Procedure

2. Apply a thin film of oil to seal on filter element


before installing.
3. Hand tighten filter element, turning it clockwise,
until gasket contacts filter mating surface, then turn
element another 3/4 turn to seat gasket.
4. If old oil has been removed also, fill crankcase with
9.5 qts. (9,0 L) of oil. (See Lubrication chapter.)
Oil Drain Weldment

5. Start engine and check for leaks near oil filter. Shut
off engine, recheck oil level, and fill as needed.

Fig. 10-8 Top view looking at the remote oil filter

PRINTED IN USA

10-9

917292/AP1008

ENGINE

1. Clean oil filter mating surface of any debris before


installing new element.

ENGINE
Air Cleaner Assembly Removal and
Installation
Removal Procedure
Air Cleaner Clamp

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:
Shut off engine. Engine components
may be extremely hot, particularly
engine muffler and exhaust pipes.
Serious injury can occur touching hot
components.

Fig. 10-9 View of air cleaner assembly from rear of


skid-steer loader

(For detailed instructions, refer to the Safety


chapter of this manual.)
1. Open the engine access cover and rear grille.
2. Clean area around the hose connections.
3. Loosen hose clamp securing the 90 elbow to air
filter assembly. Pull elbow with air intake hose off
end of air filter. Cover air cleaner hose opening to
prevent contamination. Fig. 10-10
4. Release the air cleaner clamp to release the air
cleaner canister. Fig. 10-9
5. Remove two capscrews and locknuts on filter clamp
attached to filter bracket. Fig. 10-11
Installation Procedure - Follow all warnings first,
then reverse the removal steps.

Fig. 10-10 Location of hose clamp to loosen at the front of


the air cleaner

Fig. 10-11 Unbolt two capscrews and locknuts securing air


cleaner clamp to the chassis

917292/AP1008

10-10

PRINTED IN USA

ENGINE
Battery and Battery Tray Removal and
Installation
Removal Procedure
Negative Battery Cable

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:

q Tilt back ROPS/FOPS until lock engages.


q Shut off the engine.
(For detailed instructions, refer to the Safety
chapter of this manual.)

Fig. 10-12 Disconnect the negative battery cable first, then,


disconnect the positive battery cable

WARNING
Review the following safety considerations
before working on or around the battery:

q Keep sparks and flames away from


battery. Gas given off by the batterys
electrolyte solution is extremely
explosive.

q Avoid contact with battery electrolyte;


wash off any electrolyte immediately.

q Wear safety glasses when working near


battery.

q Do not tip battery more than 45 to avoid

Fig. 10-13 Location of the battery holddown angle

spilling electrolyte solution.

r To avoid injury from spark or short circuit,

1. Disconnect and remove the negative (-) and then


disconnect the positive (+) battery cable from the
battery. Fig. 10-12
2. Remove two locknuts from the battery rods and the
hold down battery angle. Fig. 10-13
3. Lift the battery forward and out of chassis.
4. Remove two capscrews on carriage bolts and a nut
on the rear corner of the battery tray, securing the
battery tray to the chassis. Fig. 10-14
Fig. 10-14 Location of two capscrews securing the battery
tray to the chassis

PRINTED IN USA

Installation Procedure - Follow all warnings first,


then reverse the removal steps.

10-11

917292/AP1008

ENGINE

disconnect negative (-) battery cable


before servicing electrical system.

ENGINE
Starter Removal and Installation

Removal Procedure

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:

q Raise lift arm; engage lift arm support


device.

q Shut off the engine.

Fig. 10-15 Disconnect wires at the starter solenoid

q Roll ROPS back until lock engages.


(For detailed instructions, refer to the Safety
chapter of this manual.)
1. Disconnect and remove the negative (-) battery
cable from the battery. Fig. 10-12
2. Remove the nut that secures the positive (+) battery
cables and one smaller wire to the starter solenoid.
Fig. 10-15
3. Remove the two capscrews securing the starter to
the engine. Fig. 10-16
4. Remove the starter from the engine.

Starter

Installation Procedure - Follow all warnings first,


then reverse the removal steps.
Fig. 10-16 Location of one of two capscrews securing the
starter/solenoid to the engine

917292/AP1008

10-12

PRINTED IN USA

ENGINE
Exhaust Assembly Removal and
Installation
Removal Procedure

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:

q Lower the lift arm completely.


q Tilt back ROPS/FOPS until lock engages.
q Shut off the engine.

Fig. 10-17 Location of muffler in the engine compartment

(For detailed instructions, refer to the Safety


chapter of this manual.)

WARNING
Shut off engine. Engine components
may be extremely hot, particularly engine
muffler and exhaust pipes. Serious injury can
occur touching hot components.
1. Open engine access cover and lock open the rear
grille.
2. Loosen muffler clamp securing muffler to flex
coupler. Fig. 10-18

Flex Coupler

Fig. 10-18 Location of muffler clamp securing muffler to


flex coupler

3. Inside the right riser, remove two top capscrews and


loosen two bottom capscrews securing the muffler
to the right riser. Fig. 10-19
4. Lift muffler up and pull the bottom capscrews out of
the larger hole openings and remove the muffler.

*Tighten the mounting hardware only after checking


alignment of exhaust assembly so tailpipe is centered in
opening on engine cover when closed.

Fig. 10-19 Four capscrew securing the muffler to the right


riser. Remove the top two capscrews and loosen
the bottom two capscrews to remove the muffler.

PRINTED IN USA

10-13

917292/AP1008

ENGINE

Installation Procedure - Follow all warnings first,


then reverse the removal steps.*

ENGINE
Fan Belt Adjustment
Adjustment Procedure

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:

q Shut off the engine.

Fan Belt

(For detailed instructions, refer to the Safety


chapter of this manual.)
1. Open the engine access cover and lock open the rear
grille.

Fig. 10-20 Location of alternator in front of the fan shroud


and engine fan blade

2. Test fan belt tension by pushing on the belt midway


between the alternator and the engine crankshaft
pulley. The belt should deflect about " (13 mm)
under a load of 20 lbs. (90 N). If adjustment is
needed, follow steps below. Figs. 10-20, 10-21
3. Loosen two bolts on alternator - one at low pivot
area and one on top in slide bracket. Also, loosen the
bolt where the bracket attaches to the engine. Figs.
10-21, 10-22
4. Rotate the alternator in a clockwise direction
(viewed from engine end) until correct belt tension
is achieved.
5. Retighten bolts.
Fig. 10-21 Location to push on the belt. Also, the bolt on
alternator bracket attached to the engine

Fig. 10-22 Location of two capscrews to loosen prior to


adjustment of the fan belt

917292/AP1008

10-14

PRINTED IN USA

ENGINE
Radiator Cooler Removal and Installation
The radiator cooler is mounted on a shroud located just
behind the engine.
Removal Procedure

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:

q Shut off the engine.


(For detailed instructions, refer to the Safety
chapter of this manual.)

Fig. 10-23 Location the upper radiator hose at top center of


the radiator cooler

1. Drain the oil from the hydraulic reservoir per the


procedure in the Lubrication chapter.
2. Drain the engine coolant from the radiator per the
procedure in the Lubrication chapter.

Fan Shroud

3. Open the engine access cover and lock open the rear
grille.
4. Disconnect the hose clamps on two radiator hoses
and the fittings on two hydraulic oil hoses from the
inlets and outlets of the radiator cooler. Figs. 10-23
- 10-26

Fig. 10-24 Location the lower radiator hose at bottom left of


the radiator cooler - access the hose clamp at a
cut-out in the fan shroud weldment

NOTE: Be sure to plug or cap the openings on the oil


cooler and its disconnected hydraulic and coolant hoses
to prevent contaminants from entering the hydraulic and
coolant system.
5. Remove remote radiator overflow line at the top of
the radiator. Fig. 10-27

Installation Procedure - Follow all warnings first,


then reverse the removal steps.*
*ALWAYS check for hydraulic fluid leaks after
reassembling any components of the hydraulic system.

Fig. 10-25 Location one engine hydraulic hose at bottom


right of radiator cooler

PRINTED IN USA

10-15

917292/AP1008

ENGINE

6. Remove five flange screws securing the cooler to


the shroud. Figs. 10-28, 10-29

ENGINE

WARNING
NEVER use your hands to search for
hydraulic fluid leaks. Use a piece of
paper or cardboard. Escaping fluid
under pressure can be invisible and penetrate the skin causing serious injury. If any
fluid is injected into your skin, see a doctor at
once. Injected fluid MUST be surgically removed by a doctor familiar with this type of
injury or gangrene may result.
ALWAYS wear safety glasses when
checking for hydraulic fluid leaks.
Escaping fluid under pressure can be
invisible and cause permanent eyesight
damage if safety glasses are not worn.

Fig. 10-27 View of the radiator cooler overflow line


connected to the overflow bottle

ALWAYS check for hydraulic fluid leaks after


reassembling any components of the hydraulic system.

Fig. 10-28 Location of the top flange screw securing the


cooler to the shroud, other side same

Fig. 10-26 Location of one hydraulic oil hose at top right of


the cooler

917292/AP1008

Fig. 10-29 Location the bottom flange screw securing the


cooler to the shroud, other side same

10-16

PRINTED IN USA

ENGINE
Fan Shroud and Cooler Mount Plates
Removal and Installation
Removal Procedure

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:

q Shut off the engine.

Overflow Bottle

(For detailed instructions, refer to the Safety


chapter of this manual.)

Fig. 10-30 Location of one of five flange screws securing


the shroud assembly to the cooler mount plates,
other side same

WARNING
DO NOT attempt to service any part of
radiator cooler system until engine has been
allowed to cool down. Serious injury may
result from high temperature of oil and water
or high pressure.
1. Remove the hydraulic reservoir drain plug and drain
the hydraulic oil into a suitable container. Refer to
the procedure in the Lubrication chapter.

Fig. 10-31 Location of one of five flange screws securing


the shroud assembly to the cooler mount plates,
other side same

NOTE: If the hydraulic hoses are plugged after


disconnecting to prevent leakage, it should not be
necessary to drain the hydraulic reservoir. Hoses should
be plugged after disconnecting to prevent contaminants
from entering the hydraulic system.
2. Remove the radiator cooler per the procedure in this
chapter.

4. Remove the fan shroud assembly.


5. Unbolt two carriage bolts securing the cooler
mounting plates to the floor of the chassis, one on
each side of the skid-steer loader. Fig. 10-32
6. Remove both of the cooler mounting plates.
Installation Procedure - Follow all warnings first,
then reverse the removal steps.*
Fig. 10-32 Location of two carriage bolts securing the
cooler mount plates to the floor of the chassis,
other side same
PRINTED IN USA

* BE SURE and uncap/unplug the hydraulic hoses prior


to reconnecting them to the oil cooler.

10-17

917292/AP1008

ENGINE

3. Remove five flange screws securing the shroud


assembly to cooler mounting plates that are secured
to the floor of the chassis. Figs. 10-30, 10-31

ENGINE
Engine Removal and Installation
The following procedure allows removal of diesel
engine without removing hydrostatic pump assembly.
Some hydraulic hoses need disconnecting in this
procedure, and if they cannot be capped/plugged to
prevent fluid loss, the hydraulic reservoir should be
drained BEFORE disconnecting hydraulic hoses.

Fuel Separator
Fuel Line

Removal Procedure
Return Fuel Line

WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:

Fig. 10-33 Location of the fuel separator petcock and the


return fuel line petcock

q Raise lift arm; engage lift arm support


device.

q Shut off the engine.


(For detailed instructions, refer to the Safety
chapter of this manual.)

Fuel Pump

1. Drain the hydraulic oil reservoir (as required) and


the engine oil.
2. Remove engine access covers per the procedure in
the Mainframe chapter.
3. Remove rear grille per the procedure in the
Mainframe chapter.
NOTE: The following step is not required, but it is
recommended.
4. Remove the ROPS per the procedure found in the
Mainframe chapter.

Fig. 10-34 View of fuel pump with its electrical connector


and the forward fuel line disconnected prior to
removal of the engine from the chassis

5. Remove the battery and battery tray per the


procedure in this chapter.
6. Remove the air cleaner assembly per the procedure
in this chapter.

WARNING
DO NOT PROCEED with the following steps
unless engine has completely cooled and is
safe to touch.
Starter

7. Remove exhaust assembly per the procedure in this


chapter.

Fig. 10-35 Disconnect the white wire on the starter solenoid

8. Remove oil cooler per the procedure in this chapter.

917292/AP1008

10-18

PRINTED IN USA

ENGINE
9. Remove fan shroud and cooler mounting plates per
the procedure in this chapter.
10. Turn fuel return line petcock (small red petcock) to
its OFF position and disconnect line from the
engine. Fig. 10-33
11. Turn fuel separator petcock to its OFF position. Fig.
10-33
12. Disconnect the fuel line in front of the fuel pump
and unplug the electrical connector on the fuel
pump. Fig. 10-34

Fig. 10-36 View of hydraulic hoses attached at the


hydrostatic and gear pump. Remove the hoses at
their fittings prior to removing the engine from
the chassis.

NOTE: The following step includes disconnection of


hydraulic hoses. If hoses cannot be capped/plugged to
prevent fluid loss, the hydraulic reservoir should be
drained BEFORE disconnecting hoses. Refer to the
Hydraulic System chapter for the procedure.
NOTE: ALWAYS clean area around hydraulic fittings
BEFORE disconnecting any hydraulic hose or tube.
13. Disconnect the following:
a. Remote Oil Drain hose Fig. 10-40
b. Small White Wire on the Starter Fig. 10-35
c. Ground Cable from Engine to Chassis Fig.
10-37
d. Positive Battery Cable from Engine
e. Grid Heater Electrical Connector Fig. 10-38
f. Unplug Engine Harness Fig. 10-39

Fig. 10-37 View of the engine ground cable attached to the


engine

g. Unbolt Remote Oil Filter from Plate Fig. 10-41


14. Disconnect all hydraulic hoses at the hydrostatic
pump and the gear pump from their fittings. Fig.
10-36

Battery

16. Remove one carriage bolt, lock nut (80 ft-lbs) (109
Nm) and two washer on four engine mounts. Fig.
10-42
17. With hoist attached to engine, lift slightly and pull
engine rearward. Continue pulling engine rearward
until pump is free from drive coupling. Then remove
engine from chassis.
Installation Procedure - Follow all warnings first,
then reverse the removal steps.*
Fig. 10-38 Location of the red wire grid heater electrical
connector that needs disconnecting prior to
removing the engine from the chassis
PRINTED IN USA

* Bleed the electric fuel pump. Also check engine oil and
hydraulic oil levels prior to starting the skid-steer loader.

10-19

917292/AP1008

ENGINE

15. Attach lift hooks to engine located on front and rear


of head cylinder. Fig. 10-43

ENGINE

Fig. 10-39 Unplug the engine harness at this location

Fig. 10-42 View of one of four engine mounts

Fig. 10-40 Location of the remote oil drain hose on the


bottom of the left riser

Fig. 10-43 Lift hooks on lift eyes on the engine are ready to
pull the engine out of the skid-steer loader

Fig. 10-41 View of three nuts securing the remote oil filter
to the left side of the chassis

917292/AP1008

10-20

PRINTED IN USA

ENGINE
Yanmar 4TNV98-ZNMS Engine ECU Fault Codes

PRINTED IN USA

10-21

917292/AP1008

ENGINE
Yanmar 4TNV98-ZNMS Engine ECU Fault Codes

917292/AP1008

10-22

PRINTED IN USA

ENGINE
Yanmar 4TNV98-ZNMS Engine ECU Fault Codes

PRINTED IN USA

10-23

917292/AP1008

ENGINE

NOTES

917292/AP1008

10-24

PRINTED IN USA

INDEX

A
Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Air Cleaner and Exhaust Components - 2066 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Air Cleaner and Exhaust Components - 56/6640 and 2076/2086 . . . . . . . . . . . . . . . . . . 10-5
Air Cleaner Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
All-Tach Hitch Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

B
Battery and Battery Tray Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-11

C
Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Chassis Components . . . . . . . . . . . . .
Chassis Electrical Components . . . . . . . .
Control Cover Components - Hand and Foot .
Control Cover Components - T-Bar . . . . . .

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4-3,4-4
. . 9-5
4-5,4-6
. . 4-7

Control Cover Components - T-Bar/Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8


Control Cover/Floor Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Control Handle Actuation Buttons - Two-Speed, Ride Control and Float Module . . . . . . . . 9-21
Control Valve Components - Standard-Flow and High-Flow . . . . . . . . . . . . . . . . . . . . 8-23
Control Valve Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Controls Chapter
Drive Control Components - Dual Joystick Models. . . . . . . . . . . . . . . . . . . . . 6-7

Electrical Foot Throttle Removal and Installation - Dual Joystick Controls . . . . . . . 6-13
Electrical Hand Throttle Removal and Installation . . . . . . . . . . . . . . . . . . . . 6-12
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lift and Tilt Components - Dual Joystick and T-Bar/Joystick Control Models . . . . . . 6-4
Lift and Tilt Components - Hand/Foot Control Models. . . . . . . . . . . . . . . . . . . 6-3
Lift and Tilt Components - T-Bar Control Models . . . . . . . . . . . . . . . . . . . . . 6-5
Lift/Tilt Control Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Cooling System Drain Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

D
Description of Operation - Right and Left Instrument Panels . .
Dimensional Specifications . . . . . . . . . . . . . . . . . . . .
Drive Control Components - Hand/Foot . . . . . . . . . . . . .
Drive Control Components - T-Bar and T-Bar/Joystick Models.
PRINTED IN USA

Index-1

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. . 9-1
. . 1-2
6-6,6-7
. . 6-8

917292/AP1008

INDEX

Drive Control Components - Hand/Foot Models . . . . . . . . . . . . . . . . . . . . . . 6-6


Drive Control Components - T-Bar and T-Bar/Joystick Models . . . . . . . . . . . . . . 6-8
Electrical Foot Throttle Assembly - T-Bar, T-Bar/Joystick and Dual Joystick Controls . 6-14

INDEX

E
Electrical Foot Throttle Assembly - T-Bar, T-Bar/Joystick and Dual Joystick Controls . . . . . . 6-14
Electrical Foot Throttle Removal and Installation - Dual Joystick Controls . . . . . . . . . . . . 6-13
Electrical Hand Throttle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Electrical System Chapter
Chassis Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Control Handle Actuation Buttons - Two-Speed, Ride Control and Float Module . . . . 9-21
Description of Operation - Right and Left Instrument Panels. . . . . . . . . . . . . . . . 9-1
Electrical High-Flow Auxiliary Hydraulic Flow System Test and Operation . . . . . . . 9-19
Electrical Standard Auxiliary Hydraulic Flow System Test and Operation . . . . . . . . 9-17
Engine Electrical Components - 2066/76/86 . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Engine Throttle Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Fuse Box Panel Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
High-Flow and Two-Speed Electrical Components . . . . . . . . . . . . . . . . . . . . . 9-8
Interlock Control Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Interlock Control Module Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Pilot Oil Solenoid Valve Test and Operation - Dual Joystick and Hand/Foot. . . . . . . 9-20
Power Distribution Panel Test and Operation . . . . . . . . . . . . . . . . . . . . . . . 9-10
ROPS Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Schematics - ROPS, Chassis and Engine. . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Solenoid Lock Valves Test and Operation - T-Bar Only . . . . . . . . . . . . . . . . . 9-20
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Two-Speed, Ride Control and Float Module Test . . . . . . . . . . . . . . . . . . . . . 9-15
Two-Speed, Ride Control and Float Module Truth Table . . . . . . . . . . . . . . . . . 9-16
Electrically-controlled High-Flow Auxiliary Hydraulic Flow System Test and Operation . . . . 9-19
Electrically-controlled Standard Auxiliary Hydraulic Flow System Test and Operation. . . . . . 9-17
Engine Access Cover - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Engine Chapter
Air Cleaner and Exhaust Components - 2066 . . . . . . . . . . . . . . . . . . . . . . . 10-4
Air Cleaner and Exhaust Components - 56/6640 and 2076/86 . . . . . . . . . . . . . . 10-5
Air Cleaner Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . 10-10
Battery and Battery Tray Removal and Installation . . . . . . . . . . . . . . . . . . . 10-11
Engine Components - Yanmar 4TNV98 - 2066/76/86. . . . . . . . . . . . . . . . . . . 10-3
Engine Diagnostic Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Exhaust Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 10-13
Fan Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Fan Shroud and Cooler Mount Plates Removal and Installation . . . . . . . . . . . . . 10-17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Radiator Cooler Components - 2066/76/86 . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Radiator Cooler Components - 56/6640 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Radiator Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Remote Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . 10-9
Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
917292/AP1008

Index-2

PRINTED IN USA

INDEX
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Engine Components - Yanmar 4TNV98 - 2066/76/86 . . . . . . . . . . . . . . . . . . . . . . . 10-3
Engine Diagnostic Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Engine Electrical Components - 2066/76/86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Engine Throttle Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Exhaust Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

F
Fan Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Fan Shroud and Cooler Mount Plates Removal and Installation. . . . . . . . . . . . . . . . . . 10-17
Fuse Box Panel Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Fuse Box Panel Relay Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Fuse Box Panel Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

G
Grease Fitting Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

H
High-Flow and Two-Speed Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
High-Flow Auxiliary Hydraulics - Dual Joystick, Hand/Foot and T-Bar/Joystick Controls . . . . . 8-7
High-Flow Auxiliary Hydraulics - T-Bar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
High-Flow Lift Arm Hydraulics Option - Dual Joystick, Hand/Foot, T-Bar/Joystick . . . . . . . 8-12
Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic System Chapter
Control Valve Components - Standard-Flow and High-Flow . . . . . . . . . . . . . . . 8-23
Control Valve Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
High-Flow Auxiliary Hydraulics - Dual Joystick, H/F and T-Bar/Joystick Controls. . . . 8-7
High-Flow Auxiliary Hydraulics - T-Bar Controls . . . . . . . . . . . . . . . . . . . . . 8-8
High-Flow Lift Arm Hydraulics Option - Dual Joystick, H/F, T-Bar/Joystick . . . . . . 8-12
Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Lift Arm Hydraulics Components - 2066/76 . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Lift Arm Hydraulics Components - 2086 . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Lift Arm Hydraulics Components - 56/6640 . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Main Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 8-22
Manifold Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Pressure Tests, Standard-Flow and High-Flow Auxiliary . . . . . . . . . . . . . . . . . 8-13
Standard Auxiliary Hydraulics - Dual Joystick, H/F and T-Bar/Joystick Controls. . . . . 8-5
Standard Auxiliary Hydraulics - T-Bar Controls . . . . . . . . . . . . . . . . . . . . . . 8-6
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
PRINTED IN USA

Index-3

917292/AP1008

INDEX
Hydrostatic System - 2066/76 Two-Speed Components - Dual Joystick Controls. . . . . . . . . . 7-4
Hydrostatic System - Single Speed Components - Dual Joystick Controls . . . . . . . . . . . . . 7-2
Hydrostatic System - Single Speed Components - Hand/Foot Controls . . . . . . . . . . . . . . . 7-3
Hydrostatic System - Two-Speed Components - Hand/Foot Controls . . . . . . . . . . . . . . . . 7-5
Hydrostatic System Chapter
2066/76 Two-Speed Components - Dual Joystick Controls . . . . . . . . . . . . . . . . 7-4
Hydraulic/Hydrostatic Schematic - Dual Joystick Controls . . . . . . . . . . . . . . . . 7-10
Hydraulic/Hydrostatic Schematic - Hand/Foot Controls. . . . . . . . . . . . . . . . . . 7-11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Single-Speed Components - Dual Joystick Controls . . . . . . . . . . . . . . . . . . . . 7-2
Single-Speed Components - Hand/Foot Controls . . . . . . . . . . . . . . . . . . . . . . 7-3
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Two-Speed Components - Hand/Foot Controls . . . . . . . . . . . . . . . . . . . . . . . 7-5

I
Interlock Control Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Interlock Control Module Truth Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

L
Lift and Tilt Components - Dual Joystick and T-Bar/Joystick Control Models . . . . . . . . . . . 6-4
Lift and Tilt Components - Hand/Foot Control Models . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lift and Tilt Components - T-Bar Control Models . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Lift Arm Hydraulics Components - 2066/2076 Models . . . . . . . . . . . . . . . . . . . . . . . 8-9
Lift Arm Hydraulics Components - 2086 Models . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Lift Arm Hydraulics Components - 56/6640 Models . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Lift/Tilt Control Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Liftarm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Liftarm Support Device Disengagement . .
Liftarm Support Device Engagement . . . .
Loader Lowering Procedure . . . . . . . . .
Loader Raising Procedure . . . . . . . . . .
Lubrication Chapter
Chaincases . . . . . . . . . . . . .
Cooling System Drain Procedures .
Crankcase Oil . . . . . . . . . . .
General Information . . . . . . . .
Grease Fitting Locations . . . . . .
Hydraulic Oil Reservoir . . . . . .

917292/AP1008

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3-3
3-4
3-2
3-1
3-4
3-2

Index-4

PRINTED IN USA

INDEX

M
Main Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Mainframe Chapter
All-Tach Hitch Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3,4-4
Control Cover Components - Dual Joystick . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Control Cover Components - Hand and Foot . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Control Cover Components - T-Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Control Cover Components - T-Bar/Joystick . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Control Cover, Floor Cover Removal and Installation. . . . . . . . . . . . . . . . . . . 4-12
Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Engine Access Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Rear Grille and Engine Cover Components . . . . . . . . . . . . . . . . . . . . . 4-17,4-18
Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Rollover and Falling Object - Protective Structure Components . . . . . . . . . . . . . . 4-1
ROPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Mandatory Safety Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Manifold Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

P
Pilot Oil Solenoid Valve Test and Operation - Dual Joystick and Hand/Foot . . . . . . . . . . . 9-20
Power Distribution Panel Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Power Distribution Panel Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Pressure Tests, Standard-Flow and High-Flow Auxiliary . . . . . . . . . . . . . . . . . . . . . . 8-13

R
Radiator Cooler Components - 2066/76/86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Radiator Cooler Components - 56/6640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Radiator Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Rear Grille and Engine Cover Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17,4-18
Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Remote Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Rollover and Falling Object - Protective Structure Components . . . . . . . . . . . . . . . . . . . 4-1
ROPS Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
ROPS Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
ROPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
ROPS, Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

PRINTED IN USA

Index-5

917292/AP1008

INDEX

S
Safety Chapter
Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Liftarm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Liftarm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Liftarm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
ROPS, Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
ROPS, Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Schematics
Electrical Schematics - ROPS, Chassis and Engine . . . . . . . . . . . . . . . . . . . . 9-22
Hydraulic/Hydrostatic Schematic - Dual Joystick Controls . . . . . . . . . . . . . . . . 7-10
Hydraulic/Hydrostatic Schematic - Hand/Foot Controls. . . . . . . . . . . . . . . . . . 7-11
Solenoid Lock Valves Test and Operation - T-Bar Only . . . . . . . . . . . . . . . . . . . . . . 9-20
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Standard Auxiliary Hydraulics - Dual Joystick, Hand/Foot and T-Bar/Joystick Controls . . . . . . 8-5
Standard Auxiliary Hydraulics - T-Bar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

T
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-i
Two-Speed, Ride Control and Float Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Two-Speed, Ride Control and Float Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Two-Speed, Ride Control and Float Module Truth Table . . . . . . . . . . . . . . . . . . . . . . 9-16

917292/AP1008

Index-6

PRINTED IN USA

Gehl Company, 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 USA
www.gehl.com
www.mustangmfg.com

917292/AP1008

2008 MUSTANG MANUFACTURING COMPANY, INC.


All Rights Reserved.

PRINTED IN USA

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