Manual de Servicio Mustang 2066, 2076, 2086

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 MUSTANG MANUFACTU MANUFACTURING RING CO., INC. INC. PRINT PRINTED ED IN USA  Alll Ri gh  Al ghts ts Re Rese se rv ed ed..

    6     8     0     2     /     l     6    a     7    u     0    n     2    a     /     6    M     6     0    e    c     2    i    g    v    r    n    e    a     S     t    s    u     M Form No. 917152

Mus ust tan ang g 2066 Mustang 2076 Mustang 2086

SKID-STEER LOADERS  with Tier3 Yanmar 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 contactyour 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

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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

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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

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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

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SPECIFICATIONS

SPECIFICATIONS 2066

2076/5640

Make of Engine

Yanmar

Yanmar

Model

4TNV98-ZNMS

4TNV98T-ZNMS

4TNV98T-ZNMS

Fuel

Diesel

Diesel

Diesel

3

2086/6640

Yanmar  

3

3

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)

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.

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SPECIFICATIONS

Dimensional Specifications

2066/2076/5640 (EU)

 1

2086/6640 (EU)

 1

in.

mm

in.

mm

A

Overall operation height - fully raised

164.5

4178

164.3

4173

B

Height to hinge pin - fully raised

123.1

3127

123.2

3129

C

Overall height - top of ROPS

80.5

2045

81.2

2062

D

Overall length - bucket down

134.1

3406

138.8

3526

E

Dump angle @ full height

F

Dump height

91.1

2314

91.6

2327

G

Dump reach - bucket (full height)

32.0

813

36.0

914

J

Rollback at ground

24.1°

26.6°

M

Rollback angle at full height

94.5°

94.5°

O

Seat-to-ground height

40.2

1021

40.6

1031

P

Wheelbase - nominal

43.2

1097

48.4

1229

Q

Overall width - less bucket

66.3

1684

66.3

1684

R 

Overall bucket width

69.8

1773

69.1

1755

S

Ground clearance to chassis (between wheels)

7.6

193

7.6

193

U

Maximum back grading angle

V

Overall length (less bucket)

W

Departure angle

X

Clearance circle - front (with bucket)

84.0

2134

86.3

2192

Y

Clearance circle - front (less bucket)

49.3

1252

52.2

1326

40°

41°

83° 99.1

83° 2517

104.3

21°

2649 21°

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

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PRINTED IN USA

SAFETY Signal Words

DANGER “ D AN G ER ” i n di c at e s a n i m mi n en t ly 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.

“ W AR N IN G ” i n di c a te s a p o te n ti a ll y 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 operator’s license.

CAUTION “ CA UT IO N” i nd ic a te s a p ot e nt ia ll y 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, butonly  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 operator’s safety when designing its machinery and guards exposed moving parts for the operator’s protection. However, some areas cannot be guarded or shielded in order to assure proper operation. Furthermore, the Operator’s 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 45º to avoid spilling electrolyte. 2-1

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SAFETY Loader Stability   - A skid-steer loader’s stability is determined by its wheel base and tread width. The following elements can affect stability: terrain, engine speed, load being carriedor 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 operator’s 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 weightof 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 Operator’s 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 - DONOTraiseorloweraloaded  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

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SAFETY Lift Arm Support Device

WARNING BEFORE leaving the operator’s 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 operator’s 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 operator’s compartmentand 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 operator’s compartment.

Pull ring out of welded post

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SAFETY Lift Arm Support Device Disengagement 

WARNING NEVER leave the operator’s 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 operator’s 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 operator’s 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 operator’s compartment. 917292/AP1008

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PRINTED IN USA

SAFETY

WARNING DO NOT leave the operator’s 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 lockingmechanism

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.

Lower the ROPS until it contacts the chassis

Fig. 2-7

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

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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

5. Turn the keyswitch to the OFF position.

On Hand/Foot models, the lift and tilt functions are controlled with the foot pedals on the floorof  the ROPS. The auxiliary hydraulics are controlled in the right control handle. 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

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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. 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. Tie Down Support

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

Fig. 2-13

WARNING

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.

Fig. 2-14

4. Slowly lower the loader so that its weight rests on the jack stands (or blocks).

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.

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SAFETY NOTES 

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LUBRICATION General Information

2

WARNING 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.

1

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)

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

1

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 32°F (0°C) use SAE

Grade* 10 or 10W-30  Above 32°F (0°C) use SAE

Grade* 15W-40 *Service Classification: API CF-4/CG-4 Capacity: 11.8 Quarts (11,2 L)

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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.

3

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.

1

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 dipsticktube(3) on leftsideof 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 oilshould 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 operator’s 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 operator’s manual for  additional information on oil change intervals, including a 50-hour initial oil change interval.  Ambient Temperature

Viscosity

Below 32°F (0°C)

SAE 10 or 10W-30

 Above 32°F (0°C)

SAE 15W-40

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

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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. Change Chaincase Oil

1. Remove drain plug on chaincase and drain the oil. Fig. 3-10

2. Reinstall the drain plug. 3. Remove both oil fill and oil level check plugs.  Figs. Fig. 3-7

Location of engine oil dipstick 

3-10, 3-11

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

Fig. 3-9

Location of engine oil fill

Location of the hydraulic filter indicator  underneath the muffler 

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3-3

Fig. 3-10

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

Fig. 3-11

Location of the anti-freeze drain cock located at the bottom left on the radiator/cooler  917292/AP1008

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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

Fig. 3-13

Grease fitting locations

Fig. 3-14

Grease fitting locations

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

 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

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.

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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

27

22 15 26

35

10

35

35 35

9

9 33 34

9

9

11

9

28

33

34

13

28 9 9 35

24

25

13

16

9

25 34

35

34

30

36 23

4

8

35

7

6 39 2 4

29 30

37

14

2 39

17

32

6

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

     E      M      A      R      F      N      I      A      M

MAINFRAME Engine Access Cover - Removal and  Installation

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

 It is recommended that this service procedure be performed by a certified Gehl or Mustang dealer mechanic.  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

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 ROPSbolts 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.

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

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

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

     E      M      A      R      F      N      I      A      M

REAR VIEW 

23 SEE NOTE 2 22

4

20

29 8 3 12

16

17

11 9

29 8

27

29

18

12

12

12

30

27

SEE NOTE 3 19

30

7

31

5

13

29 1 SEE NOTE 1

5

2

SEE NOTE 2 15

5

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

4

22

31 8 3 16 17

29

31

31

18

7

12

NOTE 3 21

32

5

12 29

9

8

12 32

11

33

13

31 20

1

5

2

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

4

6

7 7

8

11 12

14

5 3

1 9 10

2

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 SPACE SPACER R 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

6

10

10 12 4

13 8

15 8 2

9 15 15 7

14 15

15

3

9

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 SUPPO SUPPORT RT 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

8

9 8

16 16

7 15 16 16

17

13

14 11

4

3 18

Fig. 4-10

9

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

5

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:

 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.

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.

Fig. 4-13

Gas spring attached to ROPS, one on each side

2. Disconnect negative (-) battery cable from battery. 3. Disconnect instrument panel wiring harness connector at harness bulkhead attached to chassis  bracket.  Fig. 4-12 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 weightof 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. 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

917292/AP1008

4-10

ROPS lock mechanism

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

5

8

11

2

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 20 21 22

FITTING/GREASE SCREW/CAP SCREW/CAP 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

9

NOTES : 1) USE LOCTITE 242 4

2) TORQUE TO 100 FT-LB

5

17 NOTES 1 & 2

11

2

Fig. 4-15

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

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:

 Raise lift arm; engage lift arm support device.  Shut off the engine.

Fig. 4-16

Location of three screws securing ROPS filler 

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

sides, remove three screws screws 1. On both left and right sides, 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

Remo move ve th thee tw two o pa pane nels ls (r (rig ight ht an and d le left ft)) on bo both th si side dess 2.   Re of the control cover area by releasing their swell latches.  Fig. 4-17 three screws with their spacers spacers at front of  3. Remove three sound pad and carefully remove the sound pad, up and over the control handles.  Fig. 4-18

Fig. 4-17

Remove eig eight ht scr screws ews sec securi uring ng fro front nt two boo boott 4. Remove flanges to the control cover.  Fig. 4-19

Location of swell latches securing Location securing the left side  panel in the foot area of o f the ROPS, right side is the same

5. Remove two screws that secure the control cover to the welded welded fram framee tab tab.. Remo Remove ve two screws screws tha thatt 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

917292/AP1008

4-12

Location Locati on of one of thr three ee screws screws sec securi uring ng the sound pad to the contro controll cover 

PRINTED IN USA

MAINFRAME NOTES Boot Flange

Control Cover 

     E      M      A      R      F      N      I      A      M

front ont bo boot ot fl flan ange gess se secu cure re the ru rubbe bberr bo boot otss to Fig. 4-19   The fr thee co th cont ntrol rol co cove ver. r. Th Ther eree ar aree fo four ur sc scre rews ws to remove the boot flange.

Control Cover 

Fig. 4-20

The control control cover removed from the skid-steer  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 wi th th thee co cont ntro roll ha hand ndle less to fac facil ilit itat atee wo work rk on th thee 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:

 Raise lift arm; engage lift arm support device.

Disconne onnect ct whe wheel el dri drive ve cont controlrods rolrods at piv pivot ot tub tubee Fig. 4-21   Disc on hand/foot, t-bar and t-bar/joystick units

 Shut off the engine.  Tilt back ROPS/FOPS until lock engages. (For detailed instructions, refer to the Safety  the  Safety  chapter of this manual.) control cover per the procedure procedure found found 1. Remove the control in this chapter.

2.   H a n d / F o o t , T - B a r a n d T - B a r / J o y s t i c k : 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.. Dis arms Discon connect nect bot both h con contro troll rod rodss at the piv pivot ot tub tube. e. Fig. 4-21

Fig. 4-22

Location of two two hose lines at front of the control valve joined to the right dual joystick control handle

Fig. 4-23

Location of two hose lines Location lines at rear of the control control valve joined to the right dual joystick control handle

3. Dual Joysticks: 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

Disconnect four hose b.   Left Control Handle:   Disconnect line li ness at th thee to top p of th thee hy hydr dros osta tati ticc pu pump mp,, an and d tw two o more hoses, one on each side of the hydrostatic  pump.  Fig. 4-25 contaminati ination, on, ALWAY ALWAYS S clean NOTE:   To prevent contam the area around the hydraulic fittings before disconnecting any hydraulic plug, hose or tube.

NOTE:   To aid in the correct reassembly of the hydraul hyd raulic ic hose hoses, s, mark the hos hoses es to be remo removed ved BEFORE removal in step 3. Disconnec nectt any ele electr ctrica icall con connec nector torss att attach ached ed to the 4. Discon control handles.  Fig. 4-26 917292/AP1008

4-14

PRINTED IN USA

MAINFRAME 5. Remove six locking capscrews securing the crossmember to the chassis.  Fig. 4-27 6.   With an assistant’s 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

4-15

Three capscrews securing crossmember on left side, right side same

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 thepin keeps therear grillefrom closing.

Fig. 4-30

Location of hardware fastening the rear grille to the chassis

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. Installation Procedure - Reverse the removal steps

Handle Rod

Fig. 4-28

Location of the rear grille lights connector 

917292/AP1008

Fig. 4-31

4-16

Location of hardware securing the rear grille latch assembly to the rear grille

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

7

13

40 4 38 1 5

14

31

7

14

42

21 40

43

27

4

11

36

24

39 11

5

30

16

35 6 40 25

10

34

8

2 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

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

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

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

1

14

39

28 14

7

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

44

8

45

2

24

10

37

9

31 40 5

35

18

3 21

2

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.

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.

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

     S      L      O      R      T      N      O      C

CONTROLS

Hand/Foot Controls

Dual Joystick Controls

4, 11

1, 7, 10

4, 11

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

1, 6, 8, 9

5 3

2

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

5

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

15

10

13

E 17 B

3

F

17

10 14

 A  C

D

16

5

4

1

5

5

4 REAR OF MACHINE

1 F

9

6

B  A  C D

7

1 2

1

9 E 4

5 4 1 8

P PORT T PORT PORT 1A 

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 2A 

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

7

PORTS 1,2,3 & 4

6

11

25

25

16 14

23 5 27

T    O   P  O   J  O   R  T    Y    S   I  C   2   T    K   

23 2

T    O   P  O   J  O   R  T    Y    S   I  C   1   T    K   

20

4

3

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

5

7 21

6 12 13

19

25

2

3 24

5

20

17

4

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

8

5

40

3 25

11

9

30

1

20

1 8

40 18

39

39 23

37 20

6

40

40

13

4

32

5

7 13

28

27 19

20 35

18

8

31

18

14

33

43 18

22

26

39

40

18

12

13

5

34

43

29 15

12

3 1

18

8

40

13

38

5

41

36 42

1

43

24

40

43

11

5

32

41

19 38 42

39

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:

5

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

35

CLR

  Circuit Function

Deutsch DTM04-12P Pin Function

Pin Pin Number Function

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

Constant  Active

Constant Output

CLR _ _ BLU

4

9

SW3

Switch #3

BRN

PUR

Prop Coil PWM Output

Coil #2 Current

5

8

SW2

Switch #2

GRN/ BRN

PNK 

Switch Common

Switch Common

6

7

_

_

_

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

9

30 16 7

26 3

26

8 8 2 1

24 19

6

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 1

3

36

5

22

22

24

27

31

3

20

10

36 20

20

13

36

36

20

25

28

34

3

39

31 35

3

34

37

17

16

11

26

39

23

2 1

36

21

14

5

4

3

10

3

1

20 36

13 12

20

32

37

39 39

11

3

38

32

29

5

20

13

7

36

33 30

28

38 32

NOTE 3

5

6

5

13

15

19

34

12 8 3

18

Fig. 6-6

1) ROUTE ELECTRICAL WIRES BEFORE INSTALLING TERMINALS INTO CONNECTORS

9

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

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:

 Raise lift arm; engage lift arm support device.  Shut off the engine.  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 mo v al P r oc e du r e - D u al J o ys t ic k a n d T-Bar/Joystick Controls

WARNING

Control Valve

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

Manifold

 Raise lift arm; engage lift arm support device.  Shut off the engine.  Tilt back ROPS/FOPS until lock engages. 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

(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

     S      L      O      R      T      N      O      C

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:

 Shut off the engine.

Fig. 6-12

An Allen wrench is used to loosen the set screw on the hand throttle control knob

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

(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.

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 

Fig. 6-15

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

Location of two swell latches securing the right  panel cover to the side of the chassis

 Raise lift arm; engage lift arm support device.  Shut off the engine. (For detailed instructions, refer to the Safety  chapter of this manual.) 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

     S      L      O      R      T      N      O      C

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

12 16

6

8

15

18

4

13

6 19 1 7 14 7

16 15 17

11 10 14

17 19 4

1 5 2

21 9 2

5

3 20

1 ASSY/ BALL JOINT 2 WASHER/FLAT 3 PIN/ROLL 4 NUT/LOCK 5 BUSHING/PIVOT 6 NUT/SPIRALOCK™ 7 SPRING

Fig. 6-18

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

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 manufacturer’s service manual.

NOTES

     C      I      T      A      T      S      O      R      D      Y      H

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 23

L  A 

B

46

1

4

11

10

E

20

16

22 16

25

28 6

40

30 G 31 H 44

D

15 16 38

C

3

12

G 21

13

41

5

17

DRAIN CONNECTION FOR DUAL JOYSTICK  E

N 19

P 9

B

34

14 43

L

P 24

H 16

33

36

Q

7 N

C D

18

37 2

27 45

9 Q K 

35 8

41 26

16 29

39

Fig. 7-1

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

15 44

K 

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

45

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

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

L

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

D

21

F

36

50

7

C

22

28

37

20  A 

G

5

G

44

6

23

21

16

34 J

H

35

27 17

46

L 8

N

E

B

4

26

24

3

49

M

25 P

F

10

P

H

30

32

18

21

2

J

51

M

N

Q

41

45 C 21

D

39

Q 10

43

K  46

51 9 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

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

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

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 

F

5

50

25

B

13

1

12

E 22

18 24

8 18

36

G

C 48

H

37

31

D

17 18

G

23

11

26

J

19 7

34

44

14

Q 45

DRAIN CONNECT FOR DUAL JOYSTICK  E F

P 21

B

6

4

20 47

16

42

15

M

J

45

29

Q

M

10

30

H

49

L N

18

40 P

L

C

39 3

2

27

18

9

33

10 43

49

K 

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

K 

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

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°

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

15

22

46

B

14

20

50

12 16

13 K 

47

E

1

48

8 48

22

C F D

G 29

53

38

21 22

28

G

32

7

24 6

17

23

11

49

R

9

Q

H J

K 

E

B

27

25

5

19 4

18

L

42

J

F

P

49

31

26

R

35

P

3

10

52

H 36

22

O N

33 N

C

54

L

Q

2

40

22

43

45

10

34 49 O

M

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 44

21

D

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

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, don’t 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 manufacturer’s 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 manufacturer’s 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 Control s 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 Control s 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 manufacturer’s 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  manufacturer’s service manual.

Excessive leakage in engine-end hydrostatic pump.

Refer to the pump manufacturer’s manual for  service procedures. Repair or replace rear  pump as needed.

Servo controller malfunctioning.

Refer to the pump manufacturer’s manual for  service procedures. Repair or replace rear  pump as needed.

Relief valves on engine-end hydrostatic pump malfunctioning.

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

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 manufacturer’s manual for  service procedures. Repair or replace rear  pump as needed.

Right side doesn’t drive in either direction. Left side operates normally.

Right side doesn’t drive in one direction.

Servo controller malfunctioning. Refer to pump manufacturer’s 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 doesn’t 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 manufacturer’s service manual.

Excessive leakage in gear-end hydrostatic pump.

Refer to pump manufacturer’s 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 manufacturer’s 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 doesn’t 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 manufacturer’s manual for  service procedures. Repair or replace front pump as needed.

Servo controller malfunctioning. Refer to pump manufacturer’s manual for  service procedures. Repair or replace front pump as needed.

PRINTED IN USA

7-9

917292/AP1008

HYDROSTATIC SYSTEM      S       S       Y      A      L      P      B      Y      R      M      B      E      E      H      T      S       I      T      L      I      S       F      A      W      T      A      E      H

Hydraulic/Hydrostatic Schematic - Dual Joysticks Tier3 Yanmar Engine

     R      E      G       N      A      H      C       X      E

     R      I      O       V      R      E      S       E      R

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     T      L      I      T

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        1         P

        2         P

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     R      T

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     E      V      L      A      V      L      E      V      E      L      F      L      E      S 

     H      T      D      I      L      E      I      D      W      A      E      O       N      N      P      N      E      W      I      O       S  -       E      V      L      L      O        O      T      H      P      W      O       A      S      O       T      S       V

     T

     H      C       A      T      E      V      D      L  -      L      Y      L      A      H      A      V

     B

     D      I      T      O       O      N      L      I      E      P      L        K      O      S       C      Y      I      T      L      S       Y      P      P      O      U       J      S 

     2      X

     1      X

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     G 

     E      D      D      I      L      L      G      O       A      I      F      R      N      D      Y      A      H      M

     2      G 

     S 

     C       L      W      I      L      A      O      L      U       N      F      A      O       H      R      P      I      T      D      M        P      G      I      Y      U       O       H      H      P

     C       D      I      R      L      A      U       D      A      P      N      R      D      M      A      T      Y      U       S       H      P

     R      T      E      O       H      V      I      T      G      I      R      O       R      D      M

     R      E      O        T      V      I      T       F      R      E      D      O      L      M

     4

2

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917292/AP1008

     R      E      L      P      U       O       C       N      I      A      R      D      E      S       A      C 

     H      T      O       R      X      E      R

     S       T      R      O       P      E      R      U       S       S       E      R      P      H      G       I      H .  . .  . .      B       A

     T

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     G       N      I      T      A      R      E      P      O  -       E      G       U       A      G .   . .  . .  .      A      M

     A      E      R      U       S      S        E      R      P

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     B      E      R      U       S      S        E      R      P

     2

     D      E      E      L      B      R      I      A .  . .  . . .  .      R

     R      O       E      R      )        F      U       E      T      R      T      S       C        S       I      O       I      E      F      U       R      R      P      C      P      O       E      R       L      E      R      I        O       T      H      U      S       C       R      S        T      E      E      Y      N      R      R      R      A      I      O       O       P .      L      I      2      X      C .       F  . .      E      B      G       U       2      (        1  -      A      X       G  -       1      X      G 

     T      R      O       P      N      O       I      T      C       U       S       T      S       O       O       B .  . .  . .  . .      S 

     3 

     1

     K      C       L      I      E      T      V      S       A      Y      O       R      T      J 

     K      C       T      L      I      T      I      T        /       S      Y      T      F      O       I      L      J 

     Y      E      K      T      R      O       P      G       V      0       2      A

     C       A

     G       N      I      T      A      R      E      P

     O  -       G       E      E      G       R        U       U      A      S      S        G .       E  . .      R  . . .      P      G       M

     E      R      U       S       S       E      R      P      L      O       R      T      N      O       C .   . .  . .  . .      Y

     T      R      O       P      E      G       U       A      G 

     S       R      E      D      N      I      L      Y      C       T      L      I      T      D      Y      H      L      A      H      N      C       A      O      I       T       T      P      L      L      O       A

7-10

     P

     D      Y      H      S       Y      R      R      E      A      L      I      L      I      P       X      U      U      O       A      C 

PRINTED IN USA

HYDROSTATIC SYSTEM

A       O      L L      P      -        T I            O           A T       C      N      H      A      L      H      Y      D     

 C      A            O      UX        U      L I      P      I                A      E L      R      R       S      H      Y      D     

T I           L T            C      Y           I L N           D      E      R       S     

H       O      Y      P      D      T            C      OI        O      N       U      A L      P                H      E L           R       GI        S      H      F       OL            W     

 C      A       S      E      D      R      A      I N          

P      F      L I      E       O           D       O      F T           A      T      L     

P      F      T I           E       O           D       O      T L      A      T      L     

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

M      D      E L                F       O      I R      V      T       OT            E      R     

M      D      R            GI             O      I R      V            OT            E      T H      R      P      H       S       U      Y      T A           M      D      N           D      P      A R       U      A           R D      I C L                

P      H      H       O       U      Y       GI       M      D           P T           H       OI            P      R A           N       U      F L           L       O      A L       CI            W          

M      H      A      Y      N      D R            O      FI             O       G      L D           L I           D      E     

A       C     

 G     

V      A      H      A      L      Y           - L       D      V L      E      T A           R       C       UA            H      I L            C     

A     

 S      T       O      S       O      W      P      H       O            O      L E           I T      N       S      O      W      N      N       O      P E           E           A      W      D I      D      L      T I           V      H      A      L V           E     

B     

T     

M       S      P           A       O       OI L            N      L E           I F           N      T       O      O       S U            L D        P        I           D      P      V      L      A      Y      L V           E     

D      A      B     

 C      V      L E                 SE       A      V                E      F L      V L      E      L      L I           F      T     

V       S      B      A       O      R      A      L V           L E           K      E      N      E       O           D I     

T I           L T          

 S      T D           A       U      X     

P      H       U      Y      M      D      P       OR             S           A T           I C T           

T          

H       S      M       GI             OH            A      H      W      I N           F      N       C      L O            W       O      W      I      N      T      T       S      H      R      E       O       C       O      L      T      P T           V       OI             OI            L      N      N      A V           A      E      L      L I      F           T       C      Y      L I           N      D      E      R       S     

R      E       S      E      R      V       O      I R          

E       H      X      E       C       A      H       T      A     

PRINTED IN USA

7-11

W      F                I T L      TI  H           E           R     

917292/AP1008

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, don’t 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 manufacturer’s service manual. Hydraulic components related to the drive system are covered in the Hydrostatic System  chapter.

IMPORTANT DO NOT attempt to service or repair major  hydraulic system components, such as the gear pump, unless authorized to do so by y ou r G eh l o r M us ta ng d ea le r. A ny unauthorized repair will void the warranty.

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

     S      C      I      L      U      A      R      D      Y      H

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 doesn’t 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 Arm will not lower or raise.

Bucket drifts downward with tilt control in NEUTRAL.

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

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.

Oil leaking past tilt cylinder seals (external or internal).

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

     S      C      I      L      U      A      R      D      Y      H

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

F

34

12 NOTE 3 NOTE 4 5

NOTE 2 39 H

42

K 

64 19

9 39

30

43 49

J

NOTE 1

M

L 48

17

REPLACEMENT FILTER 074830

F

G

45

 Y 

E

U

 X D 44

50

B

 A 

 W 

46

E

D

T

3 65

Q

N P

41

G

P

12

T 58

32

14

13

21

12

20

23

5

1

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

5

24

52

54

4

67

55 16 53

37

40

R

S

 W 

36

15

33

S

R

13

35

57

61 12

15

63

5 29

68

J

 V 

K 

12 15

M

56

B

17

28

L

C

18 59 12

U

N  X

H

 V 

 Y 

Q

C  A 

20

69

62

51

58

9 27

11

2 2

47

6

22

66 31

2

8 7 20 2

8

2 38

10

9

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

     S      C      I      L      U      A      R      D      Y      H

HYDRAULIC SYSTEM Standard Auxiliary Hydraulics - T-Bar Controls 10

47

9

4

3 9

41

1 29

24

54

52

21 28 51

2

17

3

24

16

6

4

20

20 4 46

18 23

7

4 45

27 23

20

TO HYDRAULIC TANK 

43

18

33

42 TO HYDRAULIC TANK 

32

4

15

44

14

6 34 48 50 8

38

26

9

12

12 5 6

12

39 25

37

30

31

10 3

10

19 9

1

11 3

22

9

9

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 47 48 49 50 51 52 53 54 55 56 57

SCREW/CAP SCREW/CAP SCREW/CAP BOLT/CARRIAGE SCREW/CAP SCREW/CAP SCREW/MACHINE SCREW/CAP BOLT/CARRIAGE WASHER/LOCK CAP/TUBE 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

S

5

42 46

48

54

R

20

9

U

M

T 53

REPLACEMENT FILTER 074830

18

N L

K 

D

C

CC

J

50

47

DD

55

B

EE

59

 Y 

5

51 K 

FF

L

D

H

62

J

GG 3

T

S

13 16

U

E

 A 

18

 X DD

FF

19 65 13

EE

 Y 

F

E

CC BB

21

P

H

G

49 G

70 NOTE 4

31

32

C

13

45

5 NOTE 1 33

 A 

66

13 14 NOTE 2 NOTE 3 42

M

37

13

BB

43

 X 29

69

30

 AA 

44

13 38

63

71

16 67

56

14

39

16

W 

 V  74

Z  V 

 W 

B

Z

F GG

N

 AA 

35 36

64

R

21

27

13

13 5

5

14

22 17

57

1

24

15

26

4

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.

75

64

6) HIGH FLOW RELIEF SETTING 2900PSI   25PSI.

9

40

9

2

28

72

11

2 52

6 8

2 7

3 2

23

34

21 2

10

41

8 9

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 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75

FITTING/90° HOSE/DRAIN HOSE/PRESSURE BRACKET/HARNESS CLAMP/T-BOLT SCREW/CAP SCREW/CAP SCREW/CAP BOLT/CARRIAGE SCREW/CAP SCREW/MACHINE SCREW/CAP BOLT/CARRIAGE BOLT/CARRIAGE WASHER/LOCK 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

3

12

1

4

35

34 62

12

50

63

28 25

65

2

21

4

11

28

12 4

20

8

6

24

24 6

57

22 26

9

6 31

33 32

26

24

56

52

22

39

51 TO HYDRAULIC TANK 

38

6

53

19

8 8

17

41

2

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

4

13

23 12

14 4

45 18

37

2

1

1

36

23

16

4

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 8

34 13

32

10 10

18

1

8

27 14 17

35

4

6

8 1 18

24

2 18

5

5 1

23

PRESSURE 25

18

18 5

18 29

33

1

11

13

16

15

5

PRESSURE

5

21

7

26 3

32

34

22

3

POSITION GREASE ZERKS TOWARDS CHASSIS

4

17

12 5 29

20

4 19 34 34 20

31 30

32

     S      C      I      L      U      A      R      D      Y      H

22 19

31 29 5

POSITION GREASE ZERKS TOWARDS CHASSIS

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

9

28

15

TO TOP OF HYDRAULIC RESERVOIR 8

28

4 7

34

8

21 12

32 16

2

17 1

8

27

6

13

35

4

8 20

1

5 17

24

17

20

5 PRESSURE 23

1 25

17

12

33

14 15

1 5 29

17

17

10

5

32

PRESSURE

5

21 26

3 22

POSITION GREASE ZERKS TOWARDS CHASSIS

19

4

34

3 5

7

16 11 32

29

18 34

4

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 HYDRAUL IC SYSTEM Lift Arm Hydraulics Hydraulics Component Components s - 56/6640 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

1

16

23

6

18 3

4 41

6

27

5

26

1 37 16

5

30 28

26

38

6

6

11

1

5

17

39

19 12 40

14

36 5

34

5

36 13

29

5

38

7

3

35

24

23

15 8

22

31

37

20

1

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

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

5

10

12 3

3

9 1

2

4 REFERENCE HARDWARE FROM HYDRAULIC GROUP

4

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

7

Fig. 8-8

8

Exploded view of the high-flow lift arm hydraulic system

917292/AP1008

8-12

PRINTED IN USA

HYDRAULIC HYDRAUL IC SYSTEM Pressure Tests, Standard-Flow and  High-Flow Auxiliary  The control valve on the skid loader controls lift and tilt func fu ncti tion onss of th thee li lift ft ar arm, m, st stan anda dard rd an and d hi high gh-f -flo low w 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

 Shut off the engine.  Relieve hydraulic system pressure. (For detailed instructions, instructions, refer to the the Safety   Safety  chapter of this manual.) preventt conta contaminati mination, on, ALWAY ALWAYS S clean NOTE:   To preven the area around the hydraulic fittings before disconnecting any hydraulic plug, hose or tube. What yo you’ u’ll ll ne need ed:: an as assi sist stan antt an and d a mi mini nimu mum m 50 5000 00 1.   What PSI (345 bar) pressure gauge.

Fig. 8-10

System pre System pressu ssure re tes testt loc locati ation on on the rig right ht lif liftt arm for high-flow hydraulic couplers

pressure reading test at the auxiliary auxiliary 2. Perform the pressure 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

Installl the pre pressu ssure re gauge in the end of the male 3. Instal coupler and activate the auxiliary hydraulic (or turn Figs. s. 8-9 8-9,, 8-1 8-10 0 on hig high-f h-flow low)) to pre pressu ssurizethe rizethe lin line. e. Fig engine should should be running running at HIG HIGH H 4. For this test, engine IDLE. assistant observe observe the pressure pressure reading on the 5. Have assistant gauge. gau ge. The pre pressu ssure re rea readin ding g on you yourr resp respect ective ive 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). thee pr press essur uree rea readi ding ng is NOT NOT be betw tween een the 6. If th abovemen abov emention tioned ed pres pressure sures, s, adju adjust st pres pressure sure as follows: PRINTED IN USA

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HYDRAULIC SYSTEM

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

 Shut off the engine.  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

Fig. 8-11

Standard flow relief valve location at the bottom rear of the control valve

Fig. 8-12

An additional high-flow relief valve location at the top rear of the control valve

Fig. 8-13

Viewof the adjuster screw beneaththe cap onthe relief valve

b. With a flat-edge screwdriver, turn the adjuster  screw IN to increase pressure or OUT to decrease pressure.  Fig. 8-13 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, thereis NO CHANGE in the  pr es su re re ad in g, th is in di ca te s a de fe ct iv e 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.

917292/AP1008

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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 70°F (21°C) or warmer. Replacement Procedure

Fig. 8-14

WARNING

Location of hydraulic reservoir drain plug  behind the right rear tire

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

 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 3. Reinstall the drain plug. 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

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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

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PRINTED IN USA

HYDRAULIC SYSTEM Control Valve Removal and Installation

3

5

1

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

Fig. 8-17

 Raise lift arm; engage lift arm support device.

Control valve port reference numbers (high-flow valve shown)

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

Port #1 Port #9

1. If necessary (see following NOTE), drain oil from hydraulic reservoir. For this procedure refer to “Hydraulic Reservoir” in the  Lubrication chapter.

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. 3.   Port 3: Disconnect the hydraulic filter tube from the straight fitting on control valve.

Port #3

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

6. Port 6:   Disconnect the pressure hose from the straight fitting on the control valve, other end connects to gear pump.

Location of port 3 at rear of control valve

PRINTED IN USA

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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.

Ports #10

Port #6

Fig. 8-21

3. Port 9 (high-flow only): Connect the pressure hose to the 90° fitting on the control valve, other end connects to gear pump.

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

5

1

4 10

8 6

Fig. 8-22

8-18

Control valve port reference numbers (high-flow valve shown)

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 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.

Ports #11

Fig. 8-24

Location of port 11 on the control valve

3

5

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

8-19

Control valve port reference numbers(high-flow valve shown)

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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:

 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

Fig. 8-28

View of 3-bank standard-flowmanifold valve on inside right of the chassis

Fig. 8-29

Location of two locking capscrews securing the manifold valve to the right side of the chassis wall

 Shut off the engine.  Relieve hydraulic system pressure.  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.

NOTE:   A f t e r r e m o v i n g a n d / o r r e p l a c i n g a n y 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.

917292/AP1008

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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

3. Pull spool cap off the spool and retain the o-ring. Fig. 8-30

View of a hex socket capscrew, 1 of 2, used to securing the spool cap to the control valve

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 Assembly Procedure - Reverse the disassembly steps.

Fig. 8-31

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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

8-21

A wrench can be used to remove a port relief  valve from the control valve body

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

Fig. 8-34

Use a wrench to remove the relief valve(s) from the control valve

Fig. 8-35

Location of o-rings on the relief valve

 Shut off the engine.  Relieve hydraulic system pressure.  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 en ch , l oo se n a nd r e mo ve t he 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

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PRINTED IN USA

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

7 1

8

2

6

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

5

3

7 1

High-Flow Control Valve

8

2

3

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4 8

5

10

6 9

Fig. 8-36

Exploded view of the main control valve components

PRINTED IN USA

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HYDRAULIC SYSTEM NOTES 

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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 2066/76/86skid-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

 Fasten Seat Belt (momentary and buzzer will sound for five seconds)

 Engine malfunction lamp on left panel (two Engine Air Filter  Restriction Engine Coolant Temperature Hydraulic Oil Restriction

seconds)

Fasten Seat Belt

   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

Hydraulic Oil Temperature

Pre-Heat Indicator  Lamp

Light Switch High-Flow Auxiliary Switch

2. The keyswitch can then be turned to the “START”  position.

 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

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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 loader’s 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 loader’s (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

®

High-Speed Control (Optional)

8. Power Fast-A-Tach /Power All-Tach    used to actuate the (optional) Power Fast-A-Tach ®/Power  All-Tach ® .

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 displays flash codes.

   engine

warning light also

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 Distribution fuse failed

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

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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  not activated down. Replace switches as needed. 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 doesn’t 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

5

10 GREEN/PURPLE STARTER

34

 WHITE STARTER

30

34

12

29

19 PINK/BLACK  GRID HEATER 29 30 14 18

18

RED GRID HEATER

ELECT. PANEL DETAIL VIEWS DETAIL

GRAY 

B

DETAIL  A 

GREEN

LEFT JOYSTICK  44

HYD ALLTACH 28

6

25

17

27

FRONT OF MACHINE RIGHT JOYSTICK  6

8

1

11

24

BLUE/BLACK  PILOT SOLENOID (1)

 A 

B

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

8

 WHITE START SOLENOID

37 41 40

GRAY PLUG TO THE OUTSIDE OF THE MACHINE 23

4

7 33

GREEN PLUG TO THE INSIDE OF THE MACHINE

33

31

36 36

15

43

16 17

22

43 33

4

35

13

6

4

16

PURPLE/BLACK  TWO-SPEED SOLENOID

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

9

1

2 32

8

13

35

16

1 8

20 45

21

BROWN/BLACK  R/C-FLOAT

6 LEFT JOYSTICK 

28

TO REAR DOOR HARNESS

6 16 13 16

13

26

39

13

6

8 8

8

6

8

8

37

8

4

TO FUEL PUMP

9 26

26

38

6

1

8

SERVICE PARTS:

8

FUSE/ATM/5 AMP FUSE/ATM/7 .5 AMP FUSE/ATM/1 0 AMP FUSE/ATM/1 5 AMP FUSE/ATM/2 0 AMP FUSE/ATM/2 5 AMP FUSE/ATM/3 0 AMP FUSE/MAXI/ 60 AMP

184633 184632 184631 184630 184629 184628 184627 195073

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OIL TEMP SWITCH POWER TAP

RELAY/20 AMP/M ICRO 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

3

1

1

20

TO SEAT SWITCH TO SEAT PAN GROUND

26

11

4

12

6

12

5

5 7 13

12

6

23

KEYED POWER

7

10 16 HIGH FLOW  15

TO FLASHER OPTION

22 8

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

24

2

25

TO DOOR SWITCH

24

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

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 ROPS’s electrical components

917292/AP1008

9-6

PRINTED IN USA

ELECTRICAL SYSTEM Engine Electrical Components - Mustang 2066/76/86 Models 20 13

13

15

11

21

22 18 12 6

4 9

10 14

1

20

8

2

2

3

19

5

     L      A      C      I      R      T      C      E      L      E

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

7

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)

2

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

1

3

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

2

1

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

3

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 PanelFuse Test (Figs. 9-7  9-10)

The following procedure can be used to test the fuses found inside the power distribution panel.

WARNING

Fig. 9-7

Location of the power distribution panel on the left riser (behind the battery)

BEFORE beginning this service procedure, perform the following SAFETY procedure: Test Points

 Shut off the engine.  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. 

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 

The relay may be tested by removing it and taking it to a work bench. Apply a groundto 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. 

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 operator’s 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 maximizethe 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.

Fig. 9-11

WARNING

View of inside the fuse box panel located near  the left knee of the operator inside the ROPS (shown with cover off)

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

 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 boxpanel 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

     L      A      C      I      R      T      C      E      L      E

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. 

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.

WARNING

Fig. 9-14

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

The engine's ECU provides both the control current and ground for the solenoid:

 Shut off the engine.  Raise engine cover and lock open the rear grille. (For detailed instructions, refer to the Safety  chapter of this manual.)



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.

1. Using a volt/ohm multimeter or a test lamp, confirm the followingconditions with the wiringconnected. 

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

Illustration of the solenoid

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 

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 locatedinside the left instrument panel. Fig. 9-15

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

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

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. 

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. 

Location of the interlock control module inside the left instrument control panel

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 eachinput andoutput. 

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.

GREEN LED DIAGNOSTIC INDICATORS (15)

    N     I      C      D     V      2     1     +

    T     U       O      L      O       S      E     K     A     R     B

    T     U       O      L      O      S       L     E     U      F

    T     U       O      Y     A     L     E     R     T     R     A     T      S 

    T     U       O      Y     A     L     E     R     D     Y     H

    T     U       O      T     L     T     L     E     B     T     A     E      S 

    T     U       O      T     L     E     K     A     R     B     K     R     A     P

    N     I     W      S      R     A     B     T     N     I     A     R     T       S     E     R

    N     I     W      S      R      O       O      D

    N     I     W       S     T     A     E      S 

    N     I     W      S      E     K     A     R     B     K     R     A     P

    N     I     W      S      P     M     E     T     D     Y     H

    N     I     W      S      P     M     E     T

    N     I     W      S      I       S     P     L     I      G       O      N     E

    N     I     E     M     I     T     W      O     L       G  -        O     T      U      A

 ALARM BUZZER OUTPUT CONNECTOR 6 PIN DEUTSCH DT15-06

Fig. 9-16

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

Illustration of the interlock control module

PRINTED IN USA

9-13

917292/AP1008

     L      A      C      I      R      T      C      E      L      E

ELECTRICAL SYSTEM Interlock Control Module Truth Table

   )      d      M    n     R     u     A     o    L     A    S      m      N     a      W   r    l     A     O      S     t   n     D     E     T     T     e     U    t    i     H      O      S      m    )    r     N     E     p     e    r    t   n    i   h      N    I    G    I     L    (     C      M     A      N    t     R     E    n     N     A    L     e    t     R    i     A     E     T      m     T    L    r     E     e    t     N     B     I    n    I     T    (     L     A     1     E     A     S      #     N     Y     R     A    L     E     E     T     R     N     T     I     R     A        D    I    O     T     S      )     X .      N      2     6      E    L     #     P     O     r     S      M     A    L     o     L     t     E     U      N       F     c     O     e      E     n     5      K     n     A     R     o      B     2      C      K      #     R     n     Y     A     P     A     P     i     P    L      M     E     A     R     6        4    L      (     Y     T     T    L      S     E     E     T      F     B     D     U      T    I    O     A     S     A     P     S     E      N     D    I    O     S     T     U      E    L      O        3      O      N     S     E    L     E     S     O     S     A     E    L     D     E     Y     R     H     E      2     K     A     R     B     D     Y     H

    s       f      f     r     n     n     d     w      f      f     s        f    w      f     n      O      e       m     e     o       s     u      r     m     t     m     i     d      D     r      O      o     r      O      a      e      T     n     o      i     D     s       r     n     t     t     a      r     e      t     a      r     t     l     e        S      l    w     n     e     l       t     o     o      t    w     n      f     n     n     e     u     A     e      l    u       i     o     w     l     g     i       A    w     a       e     l     t     e       b       o       h     h     m     P    w      e      s     e     w     n     t     t     n     o       S      o      S      o      R     s     y     c   ,     s     i     r     m     r     i     l     a       l  ,       o       p       p       n     a       n     m     g      t     D     i     n     e      l     s     G         e      P     e      P     "     A     a     l     n     s      o     m     s     o     m     a      i     r     d     t     l     N     o      e      h     e     u     u     t     e     u     t     e      d     t     l     i      S      n     t     D   -     i     a     t    v     D     F     o      S     v     o     S     n     A     t    u     u      t     t      t     o     t     o     i     i        v     o      o     i     i     W     I     m     "     e        h     r     t    u      r     h     m    u      n     r     m     n     n     r     m     n      O        o      e     e     o        e     c     t     d      l     t     d     e     r     A     l     U       U       a      n     p      o      S     l     M     n     e     e       k     k     M     n     k     M     e         e       d       l     e      s      i     a      r     i     e      s      t     n     k     t     I     n     t     l     a      o     t     i     e     n     a     a       a       r     a       A    w     o      n     d      o     r     e       S     o     r     t     r     e      t     a     r     r        g       S     I     B     a      m     n     n     e     n     d      S     B       t     c     B     n     B     d      n     B     e     p      r     e       n     A     n     t     t     r     l     I     n     n     i     l     d      n     k     t     a      r     a     r     k     d      k     a      t     e      s      i     e     d      d     e     r     r     d       d       a     h     i    u      u       l     g         e       e       e       a       a           s      a      s     a     a      h     e      n     n    u     u     n     o     u     n     o      o     y      o      e     S     e     g      h     t     o      o      I     n    w     r     n     P     L     n     P     L      S     i     L      C      I     P     E     a     D     F     a      S      F     a      S      S     H     L      S      1     a     P     I     N      O 

    N      O 

    N      O 

    R      O      C      F     E     N     S       O     5 

    N      O 

    N      O 

    1

    F     F      O 

Fig. 9-17

    F     F      O 

    F     F      O 

    N      O 

    N      O 

    N      O 

    N      O 

    F     F      O 

    F     F      O 

    F     F      O 

    N      O 

    R      O      C      F     E     N     S       O      5 

    N      O 

    F     F      O 

    F     F      O 

    F     F      O 

    N      O      F     F      O 

    E     L     B     A     T     H     T     U      R     T     E     L     U      D      O      M     L      O      R     T     N      O       C      K      C       O     L      R     E     T     N     I

    N      O 

    N      O 

    e     t      a      N     N     N     N     N     N     N     N     N     N     N     N     N     N     N     t      S       O      O      O      O      O      O      O      O      O      O      O      O      O      O      O      D     E     L

    N      O      N      O      F     F      O 

    N      O      F     F      O 

    N      O      N      O 

    F     F      O 

    N      O 

     C      F     R     F     E     T     E      O     F     S      A     1

    N      O 

    F     F      O 

    X

X

    X

X

X

X

X

X

X

X

X

X

X

    N      O 

    N      O 

    N      O 

    N      O 

    N      O 

    N      O 

    N      O 

    N      O 

    N      O 

    N      O 

    N      O 

    N      O 

    N      O 

    N      O      R     E     W      O      P     T     A

    P     M     E     T     R      G      E     N     V     I      O      N     D     R     Y     A     H     W

    E     M     I     T     W      O     L       G  -       O     T      U      A

    P     M     L     E     I     T      O      F     F     F     R     F     N     F     F     E     N     W     N     E      O     E      O      E      O      E      O      V      O       K     K     K     K     W      O      D     D     A     I     D     A     I     D     A     I     L     W     A     I     E      O      E      O      R     E      O     R     E      O      R     E     O      R     E      O        N     B      S      B      S      B      S      N     N     N     D     B     S     I     D     N     N     A     A     A     A     T     I     E     E     K     E     K     E     E     K     E     L      G      U       G     I     T     U      K     E     L     L     R     E     L     L     R     L     L     R     L     N     H     N     S      H     R     E      O     A     E       A     E     O      A     E      O      E      S      E     P      S      A     P     R      S     P     R      O      S      P     R     S      P     R      S 

     S      Y     A     L     E     R     Y     T     E     F     A      S 

     S      Y     A     L     E     R     E     Y     T     L     E     B     A     F      S     A     I       S      D

 .     o      N     n     i     P

    n     o     i     t      c      n    u      F

    N      O          F     R     C     E     F     R     C     E     F     E     T     S      F     E     T     S      F     0       O     F      0        O       A     3      A     3 

    1

    D     E    )     S     U      W     T     O    L     O     T      N     G     U       P      2     D     O      N     T     E    I    E     1     S     U     U     A     T      M    I     T    G     O    )   n    )   n      N    I      N      W     e     R     o    i     O     p     U     1    t    i     T     U    L     D     O     1     P      d     G    r      n      N      N    I     H     o     o     O     O     o     T     H    (     C    )   n    C     T     D     U    I    I     C     T     S    I    h      W     o    t     A     P    i      0     t    i     S    l    i      W     w     S   i     E     1      d     O     R    n     R      N     U     H     o     w     S     O     O    (     S     o     T     O    )   n    C    I    C    L     E     p     R      W    h     o     P    t     D    i      m    t    i     S    L      9    I   i     w     P     e      d     T     O    n      M    r      N     E    e     o        O      W    (      )     v     C     T     R     X .     O     E     O    L     1     p      V    h    )    s    t      m    i     O     o      8      e     P     w     #     E     T      W     r     F     S    r      N      N    I     F     e     o      O     G     v     O     P    (     t      M      N     O      n     E     c    i     E     T    h     e     )   n     H    t     R    i     w     E     n     7     S      V    w     w    l     C     n     T     o    I     e      N     O    n     D      W     O    (     o       a    r     S     Y     P     D     a     E     H      C     H     B    h     K     n    t    t    i     C     A     T    I    n    i     P     6      w     i     R    )    t     a     B      W    r      N    t     a      2     S     K    s     O     e     R     1    (      (     e     S     R     A     A     R     P      S       n    i   r     B    h    t     T    i     o      N     w     T    t    I     U      5      a     A     P    r      N     R     e     T     O    (     N     I     S     p     E     O     R     H    h     C    t    i     4     T    I    )     w    r     o      N     S    t      W     T     O    )    (    t   n     a     A     c    i     E      d     e    s    n    I     S     e    r      3      D     P     D     E    L      N     C     R     U     o     E     D      V      N      W    (     2     O     R     O     G     P    1    h    t    i     C      2     w     D      V      N     2    (     1    O     +

    s      s      s      s      c      c      c      c      i     i     i     i     l     e      l     e      l     e      e      l    u     r    u     r    u      r    u     r       a      a      a     a       a       a      a     r     r     a     r       d     s      d     s      r     s      d     s     d      y     n    y     n    y      n    y     n     o      H     o      e      H     o      o      H     i     H     i     i     t     t     t  ,     i     t     t  ,    ,    ,        c      s      c      s     c      r     a      s     c      s    u     n    u     n     e     u     n    u      n    u      o     u      o     u      o     u      o     F      F     e     t     p      e     F       F     t     d      e     t     d      t     d      e     n     r     n     r     O      n     r     n     r     a      l       a     e      a     t     a     t     a     t      a     t      e     t      t     o      a     t     a     t     e     t     l     l       S       n     S      n     S     b      n     b      n      S     b      a     d      a      t     a     d      l     e      t     a      d     a      a     d     a      t     t     s      s      n     i     s      s      s     n     i     s     n     b      s     n     i     n     a      D     I     n     a      A     I     n     a     D     n     a     D     I     I

    E     L     B     A     N     E

     S      Y     A     L     E     R     Y     T     E     F     A      S 

    E     L     B     A      S     I      D

     S      Y     A     L     E     R     E     Y     T     L     E     B     A     F      S     A     I       S      D

    t    u      p      t    u       O     /       t    u         S      p     n     E     T     I     e         )         )         )           )      )         )         )          A     i   v       )      )     T      C      C      C      C      C       C      C      C      C       S      t     c      D     D     D     D     D      )      )         D     D     D     D      )      )         )         )          A     V     V     V     V     V     V     V     V     V     D     D     D     D     D      2      2      2     D      f      2      2      2      2      2     D     N     N      2     N     N     N     N     E     o       (     1      (     1      (     L      1      (      1      (      1      (      1      G         G      1      (      1      (      1      (          G      G      G          (      (          (          (      H     H     H     H      G           e      H     H     H     H     H      (      (      C     I      p   y        G     I      G     I      G     I      G     I      G     I      W     W      G     I      G     I      G     I      G     I      W     W     W     W     T        O        O        O        O        O     H     H     H     H      S      T     H     H     H     H     H      O     L     L     L     L     L     L 

     O      N      G      A     I     D     o .      1     1     5      6      2      3      4     4      9      3      5      6      7      8      0   .  .  .  .  .  .  .  .  .  .  .  .  .  .     1     N     1      2      2      2      2      2      2     1     1     1     1     1     1     1  .     1     n     i     P

     )        )          N      )      N     I      )     I       T      (      )      )         (     N           (     I        )       )         )     T      U     w     N     N     T       I      (      (      I      S     T     U      O      w      e         )         U        S        (         T      )       U      O      t     r    w     p      )      i      O          )         S     m      w      S      (       (          (      O      )      O      U      T       )       N      t     L     a     I     T     I      I     B     N     N     e      p      m      (     N      (       O      U      y     y      L     I       k     e        w      (       l      (     t     e     k      t      (      (     a      a      l         l     n    w    w     a      m     T    w     l     o      l     e      l     e      r     a      i     o       S       r      C        S        S       e      D     o      R     e      B     B     r       I      G        r      S      B     T     e      e     l     t       t     R     t     k     a     n      S     i     V     e      S         k     i     s      o      t     T     r     d      a      r     t     k     l     a      r     o      d        g      P     o        2     e       e       a       l     a       a       e       a       i     e      y     t    y      S      P     R     D      S      P     n     t     D     1     r    u      S    u        E     H     E      O      A     L     +     B     F     H

Truth table for the interlock control module

917292/AP1008

9-14

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:

 Shut off the engine.  Raise engine cover and lock open the rear grille.

Fig. 9-18

(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 canbe done by observing the green diagnostic LED indicators on the module. 

Location of the two-speed, ride control and float module inside the engine compartment

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

GREEN LED DIAGNOSTIC INDICATORS (8)

     W      S       T      A      E      S 

     W      S       L      R      T      C       E      D      I      R

     W      S       T      A      O       L      F

     W      S       R      A      E      G       I      H      /       O      L 

     C       D      V      2      1     +

     L      O       S       L      R      T      C       E      D      I      R

     L      O       S       E      D      I      R      /       T      A      O       L      F

1

6

12

7

     L      O       S       R      A      E      G       H      G       I      H

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

PIN DESCRIPTIONS:

Illustration of the two-speed, ride control and float module

PRINTED IN USA

9-15

917292/AP1008

     L      A      C      I      R      T      C      E      L      E

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

     S      T       N      E      M      M      O       C 

    p      m     a    L    t     a     o    l     F     p      m     a    L    r    a     e      G     h     g    i    H

    s      e     l      g       g       o      t     s     s       e     r      p   .    y      l     r     o      a      r     t     t     n     n       e      o     c      m     e      o      d      i     M     r

    s      e     l      g       g       o      t     s     s       e     r      p     y   .     r     a      r     t       n     a     e      e      g       m     h     o      i     g       M     h

     0 

     d    i    o    r    a     n     e    l    o     e      G     S     h     g    i    H      0 

     d    l    o    i    o    r    t     n     n     e    l    o     o      C     S     e      d    i    R    l    o    r    t     n     o      d    i    o      C     n     e     e    l    o      d    i    R    /     S    t     a     o    l     F    )    t     u     p    t     u      O     y     e     a    t    l    e     a    t     R     S    (    t     a     e     S

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    1

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    t .     c      e       f      f     e      s .      o      s        n     e     s      r     p      a      s      h     e      s     s       d     i      r     e      r     r       p      e    v    y       r     o      e      a      t     t     n     t     a      e      s      m     t       o      a     e      M      S 

X

     )       r      S     y      e     l      t      5      a      0      f     e      a       2      (    .     d 

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    e     v     t     e     a      r      t     P      S 

    1

   v     e     t      e      t     a      r     P      S 

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    r      S      )    y        e     a      t      5      l     e        0      f     a       2      (    .     d 

0 

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0 

0 

     )       d       l      r     o      c     e      o      f     h       s       (     5 

    h     c    t    i      w     S    e    l    o    r    l    g    t     n     g     o     o      C     T     e      d    i    R     h   t    i    r    a    c      w     S    e     e    l    g      G     h     g     g    i    H     o     T    /      w     o    L

     N      O        I      T      C       A

Fig. 9-20

    p      U      r     e     w     o      P     t     A

    h     g     i       H     N       e     l      O     g      r       g      a     e       o     T      G 

    h     g      F     i     H     F       e      O     l     g      r       g      a     e      o     T      G 

    e      N     d      i     R      O     l      o      e      r     l     g      t     g      n     o      o       T      C 

    F     e      F     d      i     R      O     l      o      e      r     l     g      t     g      n     o      o       T      C 

    l     o      r     t     t     n     c      o      e       f      C      f     e      E       d      o     i     R     N

    t     a      o      l     F     e      t     a     v     i     t     c      A

    N      O      d      l     o      H     t     a      o      l     F

    F     F      O      t     a      o      l     F     e      l     g       g       o     T 

    t     c      e       f      f     E     o      N     t     a      o      l     F

    g       n     i    v     a      e     L      r     o      t     a     r      t     e      a      p      e       O      S 

    g       n     i     k     a      T     r     o     t      a      r     e      t       p      a     e       O      S 

Truth table for the two-speed, ride control and float module

917292/AP1008

9-16

PRINTED IN USA

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

Fig. 9-21



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.

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

High Flow

Fig. 9-22   Location of the standard flow coils and high-flow coils on the 5-bank proportional solenoid valve

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 operator’s seat. 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. 

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

     L      A      C      I      R      T      C      E      L      E

ELECTRICAL SYSTEM 



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 operator’s 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 operator’s 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 ( ).

Fig. 9-24

View of voltmeter pins probing the wires going intopin 1 and pin 2 ofthe connectors onthe coils

917292/AP1008

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. 9-27

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 operator’s 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. 

Fig. 9-29

Location of the high-flow auxiliary hydraulics high-flow module

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

Fig. 9-30

Location of the electronic rotary throttle on the right instrument panel

PRINTED IN USA



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 operator’s 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 ( ).

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 operator’s right foot. If there are problems with the throttle, the engine’s 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 solenoidsare 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 

Fig. 9-32

Location of the pilot oil solenoid coil on the 5-bank proportional solenoid valve

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 operator’s 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. 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

ELECTRICAL - ROPS SCHEMATIC

FLOOD LAMP

LEFT FRONT 6  WORK  LIGHT

RADIO CONNECTION STROBE LIGHT (OPT) 40 123

6

RIGHT FRONT  WORK  LIGHT

DOME LIGHT 39

44

43

     4      1  -      4      D      1       R      K      4      B      8       0 

43 0R-14 0 BK-14

TO WIPER/WASHER/ DOOR SWITCH  A B C

84 RD-14 43 OR-14

LEFT CONSOLE  ASSEMBLY 

     4      1       R      O       3       4

     6       1       K      B

     6       1       K      B

     0 

     0 

     4     6      4      1  -     1  -      1      R     N     D       O     G        R        0     1        4      6     6        8    

RIGHT CONSOLE  ASSEMBLY 

     4     4      1  -     1      R     K       O     B        3     0          4

0 BK-16

     4     6       1  -      1       D     H      R     W      9     2      5      5 

0 BK-16 0 BK-16 0 BK-16 HOURMETER 15 BR-16

34 YL-16

0 BK-14

34

52 WH-16

36

53 RD-16      6       1       H      W      2      5 

18 19 33 PK-16 37 GN-16 15 BR-16 29 YL-16 36 BU-14

6 5 4 3 2 1

SAFETY  INTERLOCK  CONTROL MODULE

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

43 OR-14

54 RD-14 0 BK-16 10 WH-16 17 GN-16 30 PU-16 40 GY-16 52 WH-16

     4     4      1  -     1       K     K      B     B

0 BK-16 53 RD-16

     4      1       K      B

     0     0    

     6       1       K      B

     0 

53 RD-16 16 23 OR-16

P      A      R           

53 RD-16 37 GN-16 15 K

B      R      A      K            E

 C       O           N      L F           O      R T       O      A T      L          

53 RD-16 24 BU-16

13

     4      1       K      B      0 

ROPS GROUND

53 RD-16

TO EU LIGHTS  A B 23

14

22 GN-16

0 BK-16 53 RD-16

     4     4     4      1  -     1  -     1       K     K     K      B     B     B      0     0        0    

67 PK-16 53 RD-16

S (I) ENG TEMP 37

53 RD-16

15 BR-16

53 RD-16

17

25 BR-16

38

     0 

     6       1       Y      G       0       4

40 GY-16

W      S      A      UH            R           N      D T      I N           O       G      W       TW           N       O       C            S-         ON        R      P      E           I D           E      R T      D       O      E      L     

S (I) FUEL 35

53 RD-16

20 0 BK-16      2      1       K      B      0 

53 RD-16 87 TN-16

53 RD-16 23 OR-16 24 BU-16

POWER ALL TACH SWITCH PARK BRAKE (OPT) SWITCH 89 RD-14  A  8 30 PU-16 3 110 WH-14 B 12  A  9 2 B 54 RD-16

     4     6       1  -      1       D     K      R     B      1     0       1

53 RD-16      4      1       K      B      0 

     6       1       Y      G       0       4

53 RD-16      4      4      1  -      1       R      R      O       O       3       3       4      4

     4      1       D      R

53 RD-16

F      I L       S          A     B E          E               L      ET       A      R I      R      T     T     

32 31 30

     4      1       H

     W      8       4

33A 

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

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

    H       G      E T      M     Y      L           P     D       OW      

27

     3       5 

40 GY-16 87 TN-16 1 3 2 4

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

0 BK-14

33

    E     P      O      E T      M     N      S     I      P      G     I     L      F      I L               H      A B      T E          Y           R     D      T T     

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

8

2

7

FLASHER

     6      6       1  -      1       N     H      G      W      7     0       1     1

[ OPT. ]      4      6      6     4        1  -      1     1  -      1       K     L  -     U      H      P     Y     B     W      3      9     6      0       3      2     3      5 

 AC/HEAT POWER  A  B

55 WH-12 0 BK-12

 ACCESSORY PLUG

 A B

11 0 BK-14

4

POWER ALL TACH

05 RD-14

 A B C D E

21      6       1       N      G       7      1

     2      2      2      1  -      1      1      2        H      D  -     1      D      W      R     K  -     R      5       B     6       5      1      1     0      5 

IGNITION SW 

54 RD-14

0 BK-12      2      2      2     1      1  -   -     2     1       D     H     1  -     D      R     W     K     R      6      5     B        1      5      5     0        1  

56 RD-12

     4     4      1  -     1       D     H      R     W      9     0       8     1        1

67 PK-16

     6     4        1  -     1        N     D      G     R        7     4      1     5 

21

     6     4        1  -     1        H     D      W     R      0     4        1     5 

20 BR-16      4      1       D      R      4      5 

02 RD-14 61 GN-16

5 RD IGN 20 BR ST OFF ON ST 2 RD BAT

     6       6        6         6     1          6      6     6        6         6        6      1   -      1     6       1      1  -     1  -      6      1  -     1  -     1      1   -     1  -   -     G    -     1       U     N        U  -       Y     N      L  -     R     U      H     R     N     R      B     T      G      G          Y      O      P        W      O      G     B        B      4     7     4     0     2        4     1     4     9     3      2     5       2     8       4     3      3     3        1        1     2     2     2

26            6         6       6     6      6         6      6     6      6      6      6      1  -      1  -      1  -     1  -     1  -      1  -      1  -     1  -      1  -     4     1  -     1       T      Y     N      L      H      L     N     G      N     1  -     R      N     G      B      B     R      R     R      G     L      U       A        G     T        D     B      D     P      W     G     R      Y        O      D      4     4      9     D     O      4     5     1        4     0     7        0      1      1     2     3      2     2     3      2     3     4      2     2      3         8 

     4      4      1  -      1      R      N       O       G       3       4      2      4

10 WH-16      4         6     6        4     4     4     6     6        6          6     1        6     4      1  -   -     1  -     1  -      1  -     1  -      1  -     1  -     1  -     1  -      1  -     1       U     L        D     D     N      R     D     K      P     D      D      T     P     Y     N     K      P      R     R     R      O     R        5     R          2     4     4     3     2        4     G     7        9      0     3       5     2      6      2      2      2      6        5      6     8         5     1        1     1     2         6       1      1

5

ROPS 5 PIN CONNECTION

1 2 3 4 5 6 7 8 9 101112 1

 A B CD E F 24

     6      6     4        1  -      1     1        K      H  -     D      B      R      9      W        0      9     0      1      6     7  

1 2 3 4 5 6 7 8 9 101112 2

12 PIN GRAY  KEYED CONNECTION PLUG

12 PIN GRAY  NON-KEYED CONNECTION RECEPTACLE

       6      4     4      4      6      6     4      6     6        4     4     1      1     1      1  -      4     1      1     1      1  -     1      1  -     1  -     D  -      R  -     D  -      N      1  -     K  -      H  -     D         R      B     R      G      R     B      W     R      K     L  -     U     H      P     Y     B     W     5      0     2      O          2      9      9     0       3     9        6     0        0         2     0      4      3     0            3     2        3     5          4     1      6     7

       4        6     6         6      4     4     4     6      6     6      6     4        1      1  -     1  -      1  -      1  -     1  -     1  -     1  -      1  -     1  -     1  -      1      K     R      L  -     D         R     K      H     B      D     H      D     U     N        P        W      B      Y     R      R     W      R     B     G     O      9        3     3         0     0        0      9     2      5     9        0      6     2         2      0         4     3      5     1        2      0     6         7     3     4

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     

104 16-GY  31 OR-14 106 PU-16

ELECTRICAL SCHEMATIC 4TNV98 ENGINE

D      E      F       G      H       J      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

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

1      2       3     

RACK POSITION/ACTUATOR

4     

101 GN-16 96 PK-16

1     

 

2     

SPEED SENSOR

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

 5       6     

1      2       3     

EGR VALVE

4       5     

105 YL-16

 6     

99 OR-16

COLD START COIL

A     

34 YL-16 98 TN-16

 3      1       O      R      - 1       4     

 6     1      9      0      W     2      H      O        R      1 -       6     - 1        6     

2      2       G      N      - 1        6      1      2     

PRINTED IN USA

 S       S       O T       C      E           H      E       S      E       C      T      M      H      A      A      A      R T           T            S S            E R       C I      I S                

ENGINE TEMP SENDER (ECU)

9-23

ENGINE TEMP SENDER

W      B      +     L     

 ALTERNATOR

917292/AP1008

ENGINE

Introduction 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.

ordered from the Gehl Manufacturing Company.

Company

or

Mustang

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.

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.

When a problem occurs, don’t 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 manufacturer’s 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 y ou r 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 - (27°C))

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.

PRINTED IN USA

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.

10-1

917292/AP1008

     E      N      I      G      N      E

ENGINE Problem

Possible Cause

Starter will not crank engine

Battery terminals or cables corroded or  Clean battery terminals and cables and loose secure them tightly.

Engine overheats.

917292/AP1008

Remedy

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 doesn’t start, troubleshoot circuit. Replace faulty switch as needed.

Wiring to and from ignition, seat switch, restraint bar switch, etc. loose or  disconnected

Check wiring for poor connections or  broken leads and repair wiring or  connection.

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

29

28

37

26

47

6

18 27

22 17

25

41

48

20

52

14

NOTE 1& 5

38 21 14

NOTES

15 NOTE 2

11

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

25

7 28

55 NOTE 1&4

12

33

11

31

1 4

51 45

49

53

9 8

41 NOTE 6

6

54

7

NOTE 2

NOTE 1& 3

NOTE 1& 5

7 7 NOTE 1&3

8

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

Fig. 10-1

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

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

5

12

4 5

19

6

14

12

15 2 12 21

20

13

7

1 GASKET PROVIDED  WITH ENGINE 1

18

8

3.84

3

2.68 9

17

16 11

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

Fig. 10-2

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

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

2

17

11

 ATTACH TO TURBO OUTLET 28

3

6

7

9 13

12

20

17

26

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

1

10

18 4

27

4

15 5

10

22

21

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

Fig. 10-3

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

Exploded view of the turbocharged engine air cleaner and exhaust components

PRINTED IN USA

10-5

917292/AP1008

     E      N      I      G      N      E

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

7 19 4

TO COOLER OUTLET

6

9

17

1

16

12

3

TO FILTER RETURN 3

8

23

1 3 13 20 TO COOLER INLET 14

3 2

1

1 3 15

2

18

21

5

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 

TO RESERVOIR RETURN

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

Fig. 10-4

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

.87

     E      N      I      G      N      E

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

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

1

6 3

21

11

1

4

8

TO RETURN FILTER 23

17

9

3

12

3

1

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

Fig. 10-5

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

5

16

1

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

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 theenginecompartment.

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

 Shut off the engine and allow to cool. Fig. 10-6

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

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

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

Location of rear grille latch

Installation Procedure

1. Clean oil filter mating surface of any debris before installing new element. 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

Fig. 10-8

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

Top view looking at the remote oil filter 

PRINTED IN USA

10-9

917292/AP1008

     E      N      I      G      N      E

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

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

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

 Tilt back ROPS/FOPS until lock engages.  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:

 Keep sparks and flames away from battery. Gas given off by the battery’s electrolyte solution is extremely explosive.  Avoid contact with battery electrolyte; wash off any electrolyte immediately.  Wear safety glasses when working near  battery.  Do not tip battery more than 45  to avoid spilling electrolyte solution.

Fig. 10-13  Location of the battery holddown angle

 To avoid injury from spark or short circuit, disconnect negative (-) battery cable before servicing electrical system. 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.

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ENGINE Starter Removal and Installation

Removal Procedure

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

 Raise lift arm; engage lift arm support device.  Shut off the engine.

Fig. 10-15  Disconnect wires at the starter solenoid

 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

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ENGINE Exhaust Assembly Removal and  Installation Removal Procedure

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

 Lower the lift arm completely.  Tilt back ROPS/FOPS until lock engages.  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. Installation Procedure - Follow all warnings first, then reverse the removal steps.*

*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 thebottomtwo capscrewsto removethe muffler.

PRINTED IN USA

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ENGINE Fan Belt Adjustment  Adjustment Procedure

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

 Shut off the engine. (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 ½" (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

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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:

 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 

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

 10-26

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 6. Remove five flange screws securing the cooler to the shroud.  Figs. 10-28, 10-29 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 

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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 

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Fig. 10-29  Location the bottom flange screw securing the cooler to the shroud, other side same

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

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

 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. 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 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.

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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 

 Raise lift arm; engage lift arm support device.  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 thewhite wire on thestarter solenoid

8. Remove oilcooler per theprocedure in this chapter.

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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 OilFilterfrom Plate Fig. 10-41 14.   Disconnect all hydraulic hoses at the hydrostatic  pump and the gear pump from their fittings.  Fig. 10-36

15.  Attach lift hooks to engine located on front and rear  of head cylinder.  Fig. 10-43

Battery

16. Remove one carriage bolt, lock nut (80 ft-lbs) (109  N•m) 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 oiland hydraulic oillevelsprior to starting theskid-steer loader.

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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

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ENGINE Yanmar 4TNV98-ZNMS Engine ECU Fault Codes

PRINTED IN USA

10-21

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ENGINE Yanmar 4TNV98-ZNMS Engine ECU Fault Codes

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ENGINE Yanmar 4TNV98-ZNMS Engine ECU Fault Codes

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10-23

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ENGINE

NOTES

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3,4-4 Chassis Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Control Cover Components - Hand and Foot. . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 5,4-6 Control Cover Components - T-Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 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 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 . . . . . . . . . . . . . . . . . . . . 9-1 Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -2 Drive Control Components - Hand/Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 6,6-7 Drive Control Components - T-Bar and T-Bar/Joystick Models. . . . . . . . . . . . . . . . . . . 6-8 PRINTED IN USA

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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

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INDEX Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-1 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

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Liftarm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -7 Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -7 Lubrication Chapter  Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -3 Cooling System Drain Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -1 Grease Fitting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -4 Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -2

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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 . . . . . . . . . . . . . . . . . . . . . 4-1 7,4-18 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 0

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-7 Radiator Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Rear Grille and Engine Cover Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 7,4-18 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

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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

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