Professional Documents
Culture Documents
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
Mustang 2066/2076/2086
Service Manual
Mustang 2066
Mustang 2076
Mustang 2086
SKID-STEER LOADERS
with Tier3 Yanmar Engine
SERVICE MANUAL
Addendum
PART #917292
Revision A - 10/08
INTRODUCTION
With correct maintenance and proper use, Gehl and Mustang skid-steer loaders will give
years of dependable service. This service manual is intended to be a guide in the assembly
and disassembly, installation and removal, adjustment and testing, troubleshooting and
replacement of components that together make up the Mustang 2066/76/86 family of
skid-steer loaders.
In many of the procedures found within, the installation steps are the exact opposite of the
removal steps and vice versa, and therefore, the opposite procedure is not written. Instead, a
note to reverse the procedure will be stated. This reduces redundancy and excessive pages in
the manual. In cases though, where the assembly and disassembly or removal and
installation procedures differ and additional steps or safety concerns are paramount, the
entire reverse procedure will be written out to include the new information.
The Table of Contents and Index can be used to make the procedure you need to find an
easier process. Also, there are black tabs extending off the pages highlighting the chapters
for those who prefer to thumb through the manual. Many schematics, photographs, and lineart drawings are used to help perform the necessary repairs, tests or adjustments that the
Mustang 2066/76/86 kid-steer loaders need to keep them in good running condition.
If you have any additional questions, please contact your authorized Gehl or Mustang dealer
or call the Gehl Service Department for assistance.
IMPORTANT
For maximum engine life, when shutting the engine down, allow the engine
to idle, without load, for five minutes. This will allow engine components
that operate at high temperatures to cool slightly before the engine itself is
shut down.
TABLE OF CONTENTS
TABLE OF CONTENTS
Specifications
Page 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Tire Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Buckets and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety
Page 2-1
Lubrication
Page 3-1
Mainframe
Page 4-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Rollover and Falling Object - Protective Structure Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Engine Access Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control Cover Components - Hand and Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Control Cover Components - Dual Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
PRINTED IN USA
917292/AP1008
TABLE OF CONTENTS
Control Cover Components - T-Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Control Cover Components - T-Bar/Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
ROPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
All-Tach Hitch Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Control Cover, Floor Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Rear Grille and Engine Cover Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Controls
Page 6-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lift and Tilt Components - Hand/Foot Control Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lift and Tilt Components - Dual Joystick and T-Bar/Joystick Control Models . . . . . . . . . . . . . . . . . . . . . . . 6-4
Lift and Tilt Components - T-Bar Control Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Drive Control Components - Hand/Foot Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Drive Control Components - Dual Joystick Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Drive Control Components - T-Bar and T-Bar/Joystick Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Lift/Tilt Control Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Electrical Hand Throttle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Electrical Foot Throttle Removal and Installation - Dual Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Electrical Foot Throttle Assembly - T-Bar, T-Bar/Joystick and Dual Joystick Controls . . . . . . . . . . . . . . . . 6-14
Hydrostatic System
Page 7-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Single-Speed Components - Dual Joystick Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Single-Speed Components - Hand/Foot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
2066/76 Two-Speed Components - Dual Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Two-Speed Components - Hand/Foot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Hydraulic/Hydrostatic Schematic - Dual Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Hydraulic/Hydrostatic Schematic - Hand/Foot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
ii
PRINTED IN USA
TABLE OF CONTENTS
Hydraulic System
Page 8-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Standard Auxiliary Hydraulics - Dual Joystick, H/F and T-Bar/Joystick Controls . . . . . . . . . . . . . . . . . . . . 8-5
Standard Auxiliary Hydraulics - T-Bar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
High-Flow Auxiliary Hydraulics - Dual Joystick, H/F and T-Bar/Joystick Controls . . . . . . . . . . . . . . . . . . 8-7
High-Flow Auxiliary Hydraulics - T-Bar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Lift Arm Hydraulics Components - 2066/76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Lift Arm Hydraulics Components - 2086 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Lift Arm Hydraulics Components - 56/6640. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
High-Flow Lift Arm Hydraulics Option - Dual Joystick, Hand/Foot, T-Bar/Joystick . . . . . . . . . . . . . . . . . 8-12
Pressure Tests, Standard-Flow and High-Flow Auxiliary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Manifold Valve Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Control Valve Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Main Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Control Valve Components - Standard-Flow and High-Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Electrical System
Page 9-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Description of Operation - Right and Left Instrument Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Chassis Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
ROPS Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Engine Electrical Components - 2066/76/86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
High-Flow and Two-Speed Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Power Distribution Panel Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Fuse Box Panel Test and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Interlock Control Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Interlock Control Module Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Two-Speed, Ride Control and Float Module Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Two-Speed, Ride Control and Float Module Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Electrical Standard Auxiliary Hydraulic Flow System Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Electrical High-Flow Auxiliary Hydraulic Flow System Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Engine Throttle Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Pilot Oil Solenoid Valve Test and Operation - Dual Joystick and Hand/Foot . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Solenoid Lock Valves Test and Operation - T-Bar Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Electrical Schematics - ROPS, Chassis, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
PRINTED IN USA
iii
917292/AP1008
TABLE OF CONTENTS
Engine
Page 10-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Engine Components - Yanmar 4TNV98 - 2066/76/86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Air Cleaner and Exhaust Components - 2066 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Air Cleaner and Exhaust Components - 56/6640 and 2076/86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Radiator Cooler Components - 2066/76/86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Radiator Cooler Components - 56/6640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Remote Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Air Cleaner Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Battery and Battery Tray Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Exhaust Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Fan Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Radiator Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Fan Shroud and Cooler Mount Plates Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Engine Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Engine Diagnostic Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Index
917292/AP1008
iv
PRINTED IN USA
SPECIFICATIONS
2066
2076/5640
2086/6640
Make of Engine
Yanmar
Yanmar
Yanmar
Model
4TNV98-ZNMS
4TNV98T-ZNMS
4TNV98T-ZNMS
Fuel
Diesel
Diesel
Displacement
202 in (3,31 L)
202 in (3,31 L)
202 in (3,31 L)
Horsepower - Net
Peak Torque
Operating Weight
Shipping Weight
Diesel
Fuel Tank
Chaincase (each)
Hydraulic Reservoir
Engine Coolant
Battery
Starter
Alternator
14-Volt DC, 95 A
Hydraulic System
14 x 17.5 - 14-ply
Bucket Description
Capacity (Heaped)
Dirt/Construction
15 cubic feet
Dirt/Construction
19 cubic feet
Dirt/Construction
Utility
27 cubic feet
Utility/Snow
Snow
14 cubic feet
Pallet Fork
NA
NA
*Operating load rated with a 70.0" inch (1778 mm) 2066/2076 dirt and construction bucket in accordance with SAE J818.
PRINTED IN USA
1-1
917292/AP1008
SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS
Dimensional Specifications
2066/2076/5640 (EU)
2086/6640 (EU)
in.
mm
in.
mm
164.5
4178
164.3
4173
123.1
3127
123.2
3129
80.5
2045
81.2
2062
134.1
3406
138.8
3526
40
41
Dump height
91.1
2314
91.6
32.0
813
36.0
Rollback at ground
24.1
26.6
94.5
94.5
Seat-to-ground height
40.2
1021
40.6
Wheelbase - nominal
43.2
1097
48.4
1229
66.3
1684
66.3
1684
69.8
1773
69.1
1755
7.6
193
7.6
Departure angle
83
99.1
2327
914
1031
193
83
2517
104.3
84.0
2134
86.3
2192
49.3
1252
52.2
1326
21
2649
21
917292/AP1008
1-2
PRINTED IN USA
SAFETY
Signal Words
General Information
WARNING
CAUTION
CAUTION indicates a potentially
hazardous situation which, if not avoided,
may result in minor or moderate injury. May
also alert against unsafe practices.
917292/AP1008
SAFETY
DANGER
SAFETY
Loader Stability - A skid-steer loaders stability is
determined by its wheel base and tread width. The
following elements can affect stability: terrain, engine
speed, load being carried or dumped, and sudden control
movements. DISREGARDING ANY OF THESE
FACTORS CAN CAUSE THE LOADER TO TIP,
POSSIBLY RESULTING IN DEATH OR SERIOUS
INJURY. Therefore, ALWAYS have the operator
restraint bar lowered and wear the seat belt. Operate the
controls only from the operators seat. Operate the
controls smoothly and gradually at an appropriate
engine speed that matches the operating conditions.
2-2
PRINTED IN USA
SAFETY
Lift Arm Support Device
Fig. 2-1
Fig. 2-3
PRINTED IN USA
2-3
917292/AP1008
SAFETY
WARNING
SAFETY
Lift Arm Support Device Disengagement
WARNING
NEVER leave the operators compartment to
disengage the lift arm support device with the
engine running.
To return the lift arm support device to its storage
position, proceed as follows:
1. Raise the lift arm completely.
2. Turn the keyswitch to the OFF position to stop the
engine, remove the key and take it with you.
Fig. 2-4
Fig. 2-5
Fig. 2-6
WARNING
BEFORE testing the machine, ALWAYS clear
people from the area.
3. Before leaving the operators compartment, check
to be sure the lift arm is being held in the raised
position by the solenoid valve (See NOTE).
NOTE: With the keyswitch OFF, and the solenoid
valve functioning properly, the lift arm will not move
when the lift control is moved forward. If the valve does
NOT hold the lift arm, do NOT leave the operators
compartment. Instead, have someone store the support
device for you. Then, contact your Gehl or Mustang
dealer to determine the reason why the lift arm lowers
while the keyswitch is in the OFF position.
4. To store lift arm support device, lift it up and inside
the lift arm. Insert lock pin through the hole in the
lift arm and through the support device.
ROPS Raising
For service, the ROPS can be unbolted and tilted back.
Gas-charged springs help tilt it back. A self-actuating
lock mechanism engages to lock the ROPS in a
rolled-back position.
1. The lift arm should be lowered or locked in the
raised position as per the Lift Arm Support Device
Engagement procedure in this chapter.
2. Turn the keyswitch to the OFF position to stop the
engine. Remove the key and take it with you.
3. Leave the operators compartment.
917292/AP1008
2-4
PRINTED IN USA
SAFETY
Fig. 2-7
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
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
PRINTED IN USA
2-5
917292/AP1008
SAFETY
WARNING
SAFETY
Relieving Hydraulic Pressure
Lift and Tilt
Auxiliary Hydraulics
Auxiliary Hydraulics
Auxiliary Hydraulics
Fig. 2-12 On Dual T-Bar models, lift and tilt functions are
controlled with the right control handle. The
auxiliary hydraulics are controlled with the left
foot on the auxiliary pedal assembly.
917292/AP1008
2-6
PRINTED IN USA
SAFETY
Loader Raising Procedure
The following procedure is used to raise the skid-steer
loader so that all four tires are off the ground.
WARNING
BEFORE servicing the machine, exercise the
Mandatory Safety Shutdown Procedure
described in this chapter.
Stand Placement Location
WARNING
PRINTED IN USA
2-7
917292/AP1008
SAFETY
SAFETY
NOTES
917292/AP1008
2-8
PRINTED IN USA
LUBRICATION
General Information
WARNING
Fig. 3-1
Fig. 3-2
Hydraulic System
Reservoir
Fig. 3-3
Chaincases
PRINTED IN USA
Grease
Fittings
Crankcase Oil
(Diesel Engine)
3-1
917292/AP1008
LUBRICATION
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.
Fig. 3-4
Fig. 3-5
Fig. 3-6
Crankcase Oil
The Yanmar diesel engine crankcase has a capacity of
11.8 qts. (11,2 L). The chart below lists recommended
oil viscosity for the Cummins engine.
Engine oil should be changed and filter element replaced
every 250 hours of service. A remote engine oil drain
can be found behind right rear tire. Refer to engine
operators manual (see NOTE) for details on changing
oil and to Oil Filter Removal and Oil Filter
Installation procedures in Engine chapter.
NOTE: Refer to engine operators manual for
additional information on oil change intervals,
including a 50-hour initial oil change interval.
Ambient Temperature
Viscosity
SAE 10 or 10W-30
SAE 15W-40
917292/AP1008
3-2
PRINTED IN USA
LUBRICATION
Chaincases
Each chaincase requires 9 U.S. qts (8,5 L) of any high
grade motor oil. This quantity of oil should be
maintained at all times. The oil in both chaincases
should be drained and refilled every 500 hours of
operation or annually, whichever occurs first.
3. Remove both oil fill and oil level check plugs. Figs.
3-10, 3-11
Fig. 3-8
Fig. 3-9
PRINTED IN USA
917292/AP1008
LUBRICATION
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
Fig. 3-12 Location of the left chaincase oil fill plug. Right
side same
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:
917292/AP1008
3-4
PRINTED IN USA
MAINFRAME
Introduction
Gehl 5640E/6640E and Mustang 2066/76/86 skid-steer
loaders have a welded steel chassis. Maintenance,
service and repair may be performed through standard
access panels.
22
15
26
35
10
35
35
35
11
9
9
9
33
34
28
33
34
13
28
9
9
35
24
25
13
16
25
34
35
34
30
36
23
35
6
39
2
4
29
30
37
14
2
39
17
32
19
12
18
1 NUT/HEX WHIZLOCK
2 NUT/LOCK NYLON INSERT
3 NUT/LOCK
4 ISOLATOR/ROPS
5 SPRING/TORSION
6 BUSHING
7 TAG/RIP CORD
8 RING
9 NUT/SPIRALOCK
10 COVER/BOOK BOX
11 HINGE/PIANO
12 WINDOW/REAR
13 CHANNEL/WIRE HARNESS
14 PIN
15 WINDOW/SKYLIGHT
16 GROMMET/HOLE PLUG
17 SPRING/GAS ASSIST
18 WEATHERSTRIP/WINDOW
19 RIPCORD/WEATHERSTRIP
20 SUPPORT/ROPS
21 SPACER/TUBE
22 ROPS/FOPS
23 HEADLINER/MOLDED
24 COVER/WIRE
25 PLUG/HOLE
26 PLUG/RUBBER
27 SCREW/SEM
28 WASHER/FLAT
29 SCREW/CAP
30 SCREW/CAP
31 SCREW/CAP
32 SCREW/CAP
33 SCREW/CAP
34 BOLT/CARRIAGE
35 SCREW/MACHINE
36 SCREW/MACHINE
37 WASHER/FLAT
38 WASHER/FLAT
39 WASHER/FLAT
40 PIN/COTTER
38
1
40
21
31
20
5
3
Fig. 4-1
PRINTED IN USA
4-1
917292/AP1008
MAINFRAME
27
MAINFRAME
Engine Access Cover - Removal and
Installation
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:
Welded Tab
Fig. 4-3
Fig. 4-4
Fig. 4-5
Removal Procedure
1. Open engine access cover until gas spring is
completely extended.
2. Disconnect the gas spring from engine access cover
by removing gas spring clip at access cover end of
gas spring, then pull gas spring off ball stud on
access cover. Fig. 4-2
3. Remove two capscrews, spacers and washers on
ROPS bolts securing access cover to frame. Fig. 4-3
4. Turn both ROPS bolts out until flush with welded
tab, remove engine cover. Figs. 4-4, 4-5
Installation Procedure - Follow all warnings first,
then reverse the removal steps.
Gas Spring
Fig. 4-2
917292/AP1008
4-2
PRINTED IN USA
MAINFRAME
Chassis Components - 2066/76/86 Models
14
SEE NOTE 3
MAINFRAME
NOTES:
1. APPLY HI-TACK GASKET ADHESIVE
2. APPLY OIL-RESISTANT RTV
3. APPY PIPE THREAD SEALANT
REAR VIEW
23
SEE NOTE 2
22
20
29
8
3
12
16
17
11
9
29
8
27
29
18
12
12
12
30
27
30
31
13
29
SEE NOTE 3 19
1 SEE NOTE 1
SEE NOTE 2 15
21
6
(1 PER SIDE)
2
15 SEE NOTE 2
10
34
24
30
28
32
34
25
10
19 SEE NOTE 3
33
26
33
26
33
33
26
1 GASKET
2 SCREW/HEX
3 RESERVOIR CAP
4 BREATHER
5 PLUG
6 PLUG
7 PLUG
8 NUT/SPIRALOCK
9 STRAINER/FUEL
Fig. 4-6
10 WASHER/SEAL
11 SIGHT PORT
12 NUT/SPIRALOCK
13 FUEL SENSOR
14 PLUG/HS
15 CHAINCASE COVER
16 SEAT COVER RIGHT
17 CROSSMEMBER
18 SEAT COVER LEFT
26
19 PLUG/PIPE SOCKET
20 RESERVOIR COVER
21 WELDMENT/CHASSIS
22 ROPS FILLER
23 ROPS FILLER
24 COVER/TOEPLATE
25 BELLYPAN
26 SCREW/CAP
27 SCREW/CAP
28 SCREW/CAP
29 SCREW/CAP
30 SCREW/MACHINE
31 SCREW/MACHINE
32 SCREW/CAP TFS
33 WASHER/LOCK
34 WASHER/FLAT
PRINTED IN USA
4-3
917292/AP1008
MAINFRAME
Chassis Components - 56/6640 Models
25
NOTE 2
24
22
31
8
3
16
17
11
9
31
8
29
31
18
12
12
32
29
32
12
33
13
31 20
NOTE 3 21
NOTE 1
NOTE 2 15
19
5
23
6
(1 PER SIDE)
2
15 NOTE 2
10
36
26
32
30
34
36
27
10
21 NOTE 3
35
28
35
28
35
35
28
28
NOTES:
1. APPLY HI-TACK GASKET ADHESIVE
2. APPLY OIL-RESISTANT RTV
3. APPY PIPE THREAD SEALANT
14
NOTE 3
REAR VIEW
1 GASKET/FUEL SENDER
2 SCREW/HEX
3 CAP/RESERVOIR
4 BREATHER/RESERVOIR
5 PLUG
6 PLUG
7 PLUG
8 NUT/SPIRALOCK
9 STRAINER/FUEL FILL
Fig. 4-7
10 WASHER/SEAL
11 SIGHT PORT/OIL
12 NUT/SPIRALOCK
13 FUEL SENSOR/VDO
14 PLUG/SCREW
15 CHAINCASE COVER
16 COVER/UNDER SEAT
17 PLATE/CROSS
18 COVER/UNDER SEAT
19 FENDER/LEFT
20 FENDER/RIGHT
21 PLUG/PIPE
22 RESERVOIR COVER
23 CHASSIS
24 ROPS FILLER
25 ROPS FILLER
26 COVER/TOEPLATE
27 BELLYPAN
28 SCREW/CAP
29 SCREW/CAP
30 SCREW/CAP
31 SCREW/CAP
32 SCREW/MACHINE
33 SCREW/MACHINE
34 SCREW/CAP
35 WASHER/LOCK
36 WASHER/FLAT
917292/AP1008
4-4
PRINTED IN USA
MAINFRAME
Control Cover Components - Hand and Foot
1 SUPPORT/BOOT BEZEL
2 SPACER
3 COVER/BOOT
4 COVER/PUMP
5 COVER/PANEL LEFT
6 COVER/PANEL RIGHT
7 LATCH/SWELL
8 STRIP/FOAM
9 PAD/INTERIOR SOUND
10 PLUG/HARNESS
11 CONTROL COVER
12 SCREW/MACHINE
13 SCREW/CAP TFS
14 SCREW/TAPPING TF
15 SCREW/TORX
13
7
7
11
12
14
5
3
1
9
10
8
15
Fig. 4-8
PRINTED IN USA
4-5
917292/AP1008
MAINFRAME
Control Cover Components - Dual Joystick
1 SPACER
2 WELDMENT/CONTROL COVER
3 PLATE/FLOOR FOOT
4 PLATE/FLOOR SUPPORT
5 SUBFLOOR/FRONT SUPPORT
6 COVER/PUMP
7 COVER/PANEL LEFT
8 LATCH/SWELL
9 STRIP/FOAM
10 WELDMENT/FOOT SUPPORT
11 PAD/INTERIOR SOUND
12 COVER/PANEL RIGHT
13 HARNESS/THROTTLE
14 SCREW/MACHINE
15 SCREW/THREAD FORMING
16 SCREW/TORX HEAD
15
15
15
15
15
10
10
12
4
13
8
15
8
2
9
15
15
7
14
15
15
11
5
1
16
14
Fig. 4-9
917292/AP1008
4-6
PRINTED IN USA
MAINFRAME
Control Cover Components - T-Bar - 56/6640 Models
1 COVER/CONTROLS
2 SUPPORT/BOOT BEZEL
3 SPACER
4 COVER/BOOT
5 PLATE/FLOOR SUPPORT
6 COVER/PUMP
7 COVER/PANEL LEFT
8 LATCH/SWELL
9 STRIP/FOAM
10 FOOT SUPPORT
11 PAD/INTERIOR SOUND
12 COVER/PANEL RIGHT
13 FRONT FLOOR
14 SUBFLOOR/FRONT SUPPORT
15 SCREW/MACHINE
16 SCREW/CAP
17 SCREW/TAPPING
18 SCREW/TORX DRIVE
16
16
16
16
16
6
10
10
12
5
9
8
16
16
7
15
16
16
17
13
14
11
4
3
18
Fig. 4-10
2
15
PRINTED IN USA
4-7
917292/AP1008
MAINFRAME
Control Cover Components - T-Bar/ Joystick - 56/6640 Models
1 CONTROL COVER
2 SUPPORT/BOOT BEZEL
3 SPACER
4 COVER/BOOT
5 PLATE/FLOOR FOOT PILOT
6 PLATE/FLOOR SUPPORT
7 SUBFLOOR/FRONT SUPPORT
8 COVER/PUMP
9 COVER/PANEL LEFT
10 LATCH/SWELL
11 STRIP/FOAM
12 FOOT SUPPORT
13 PAD/INTERIOR SOUND
14 COVER/PANEL RIGHT
15 SCREW/MACHINE
16 SCREW/CAP
17 SCREW/TAPPING
18 SCREW/TORX DRIVE
16
16
16
16
16
8
12
12
14
6
10
11
10
16
1
16
9
15
16
17
7
13
4
3
18
Fig. 4-11
11
2
15
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:
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.
Cotter Pin
Pin
917292/AP1008
4-10
PRINTED IN USA
MAINFRAME
All-Tach Hitch Components - 2066/76/86 Models
15
6
18
22
20
3
9
16
14
13
12
1
21
7
17
10
19
4
11
1 WASHER/FLAT
2 PIN/SPRING
3 NUT/LOCK
4 SPRING
5 ADAPTOR/ROD
6 SPRING
7 LINK/LATCH LEFT
8 LINK/LATCH RIGHT
9 PLATE/LATCH LINK
10 ADAPTOR/PUSH ROD
11 PIN/LATCH
12 WASHER/BEVEL
13 RING/RETAINING
14 SPACER
15 HANDLE
16 FAST-A-TACH
17 SCREW/CAP
18 GRIPS
19 FITTING/GREASE
20 SCREW/CAP
21 SCREW/CAP
22 WASHER/FLAT
7
LEFT
20
22
6
21
19
13
16
NOTE 1
3
15
8
RIGHT
14
NOTES 1 & 2
18
1
19
10
NOTES :
17 NOTES 1 & 2
11
1 WASHER/FLAT
2 PIN/SPRING
3 NUT/LOCK
4 SPRING
5 ROD/PUSH
6 SPRING
7 LINK/LATCH
8 LINK/LATCH
9 PLATE/LATCH LINK
10 ADAPTOR/ROD
11 PIN/LATCH
12 ALL-TACH
13 HANDLE
14 WASHER/BEVEL
15 RING/RETAINING
16 SPACER
17 SCREW/CAP
18 GRIPS
19 FITTING/GREASE
20 SCREW/CAP
21 SCREW/CAP
22 WASHER/FLAT
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:
917292/AP1008
4-12
PRINTED IN USA
MAINFRAME
NOTES
Boot Flange
MAINFRAME
Control Cover
Fig. 4-19 The front boot flanges secure the rubber boots to
the control cover. There are four screws to
remove the boot flange.
Control Cover
PRINTED IN USA
4-13
917292/AP1008
MAINFRAME
Crossmember Removal and Installation
Pivot Tube
Removal Procedure
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:
4-14
PRINTED IN USA
MAINFRAME
5. Remove six locking capscrews securing the
crossmember to the chassis. Fig. 4-27
6. With an assistants help, carefully lift the
crossmember out of the chassis.
Installation Procedure - Follow all warnings first,
then reverse the removal steps.
Manifold
PRINTED IN USA
4-15
917292/AP1008
MAINFRAME
Rear Grille Removal and Installation
The rear grille is bolted onto the chassis and can be
removed to perform work on the cooler system, engine,
engine fan and shrouds.
Removal Procedure
1. Open the engine access cover and swing the rear
grille fully open.
2. Disconnect the rear grille electric lights at the
connector. Fig. 4-28
3. Remove lock pin from its storage position and set it
to keep rear grille from closing. Fig. 4-29
4. Remove one capscrew, washer, and locknut that
fasten the grille to the chassis. Fig. 4-30
917292/AP1008
4-16
PRINTED IN USA
MAINFRAME
Rear Grille and Engine Cover Components - 2066/76/86
38
28
44
38
20
32
36
13
40
4
38
1
5
14
31
14
42
21
40
43
27
11
36
24
39
11
30
16
35
6
40
25
10
34
8
9
2
41
36
3
41
5
15
22
STORE STOP PIN
IN LOWER PIVOT
37
12
15
41
33
29
29
39
11
18
38
19
38
19
38
17
38
38
23
FASTEN TO SIDE
PANELS OF ROPS
38
23
1 NUT/HEX WHIZLOCK
2 NUT/HEX
3 NUT/HEX
4 NUT/LOCK
5 NUT/LOCK
6 SPRING/COMPRESS
7 STUD/BALL
8 WASHER/FLAT
9 MOUNT/LATCH
10 ASSY/LATCH ROD
11 BUMPER
Fig. 4-32
23 SEAL/EDGE
24 ROD/HANDLE
25 LATCH/REAR DOOR
26 SEAL/BULB
27 TORSION BAR
28 TUBE/EXHAUST
29 SEAL/FOAM
30 SEAL/BULB
31 GAS SPRING
32 COVER/ENGINE
33 REAR GRILLE
12 BUSHING
13 BRACKET
14 CLIP/GAS SPRING
15 NUT/SPIRALOCK
16 BRACKET
17 COVER LEFT
18 COVER RIGHT
19 SEAL/BULB
20 HANDLE/GRAB
21 SCREEN
22 PIN/LOCK
34 PIN/COTTER
35 SCREW/CAP
36 BOLT/CARRIAGE
37 BOLT/CARRIAGE
38 SCREW/MACHINE
39 NUT/JAM
40 WASHER/FLAT
41 WASHER/FLAT
42 WASHER/LOCK
43 NUT/HEX
44 SCREW/CAP
PRINTED IN USA
4-17
917292/AP1008
MAINFRAME
Rear Grille and Engine Cover Components - 56/6640
48
41
7
19
25
39
13
41
5
14
39
28
14
20
46
29
36
41
42
43
47
17
4
11
33
30
FASTEN TO
SIDE PANEL
OF ROPS
4
18
18
34
41 41
38
5
32
27
6
32
22
41
23
8
32
24
10
44
45
37
9
31
40
5
35
18
3
21
15
12
45
22
15
21
45
40
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
917292/AP1008
4-18
PRINTED IN USA
CONTROLS
Introduction
This chapter covers removal, installation, assembly, and
adjustment procedures for standard and optional control
equipment on Gehl 5640E/6640E and Mustang
2066/76/86 skid-steer loaders.
Equipment Identification
Because there are a variety of options available for
2066/76/86 models, it is IMPORTANT to properly
identify equipment BEFORE beginning service
procedures. Illustrations and photographs are provided
with procedures to aid in servicing this equipment.
Hand/Foot Controls
On loaders with Hand/Foot controls, left and right
drive control handles operate independently of each
other. Pushed forward together moves the loader
forward, but push either one further forward than the
other and the loader turns. Separate foot pedals control
lift and tilt functions of lift arm and bucket. Engine
speed is controlled with hand throttle dial located in the
right instrument panel. A yellow rocker switch in the
right control handle controls standard auxiliary
hydraulics in tandem with a lock-on (red) button switch.
On high-flow models, a rocker switch in the right
instrument panel activates high-flow hydraulics.
T-Bar Controls
On skid-steer loaders with T-Bar controls, the left
T-Bar operates the wheel drives and pumps for both
sides of the skid-steer loader. The right T-Bar controls
the lift and tilt functions of the lift arm and bucket.
Engine speed is controlled with a foot throttle pedal and
dial in the right instrument panel. Standard-flow
auxiliary hydraulics is controlled by a foot pedal. On
high-flow models, a rocker switch in the right
instrument panel activates the high-flow hydraulics.
Float Control
The float control on skid-steer loaders is controlled by a
momentary button switch in the right control handle and
lights a panel light.
PRINTED IN USA
6-1
917292/AP1008
CONTROLS
T-Bar/Joystick Controls
On skid-steer loaders with T-Bar/Joystick controls,
the right joystick handle controls the lift and tilt
functions of the lift arm and bucket and the left T-Bar
operates the wheel drives for both sides of the skid-steer
loader. Engine speed is controlled with a foot throttle
pedal and dial in the right instrument panel. A yellow
rocker switch in the right control handle controls
standard auxiliary hydraulics in tandem with a lock-on
(red) button switch. On high-flow models, a rocker
switch in the right instrument panel activates the
high-flow hydraulics.
CONTROLS
Hand/Foot Controls
4, 11
1, 7, 10
4, 11
2, 3, 6, 8, 9
1, 7, 10
1, 6, 8, 9
5
3
1 - Drive Control
2 - Lift Control
3 - Tilt Control
4 - Hand Throttle
5 - Foot Throttle
6 - Standard Auxiliary Hydraulics Control
T-Bar/Joystick Controls
T-Bar Controls
4, 11
6
1, 7, 8, 10
4, 11
5
1, 3, 4
2, 3, 8, 9
2, 3, 6, 8, 9
917292/AP1008
6-2
PRINTED IN USA
CONTROLS
Lift and Tilt Components - Hand/Foot Control Models
15
12
11
10
15
13
E
17
B
17
10
14
A
C
16
4
1
4
REAR OF
MACHINE
1
F
9
6
B
A
C
D
7
1
2
9
E
4
5
4
1
8
P PORT
T PORT
PORT 1A
PORT 2A
1 FITTING/STRAIGHT
2 TEE/FEMALE RUN
3 PEDAL/FOOT
4 PLUG/O-RING
5 VALVE/FOOT
6 PLATE/FLOOR FOOT PILOT
Fig. 6-1
PORT 2B
PORT 1B
7 PLATE/FLOOR SUPPORT
8 SUBFLOOR/FRONT SUPPORT
9 TUBE/PILOT
10 HOSE/PRESSURE
11 HOSE/PRESSURE
12 HOSE/PRESSURE
13 HOSE/PRESSURE
14 HOSE/PRESSURE
15 ORIFICE/CHECK VALVE
16 SCREW/CAP TF
17 SCREW/CAP
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
NO. 4 PORT
18
TO JOYSTICK PORT P
TO JOYSTICK PORT T
26
17
12
PORTS T & P
PORTS
1,2,3 & 4
6
11
25
25
16
14
23
5
TO
PO JO
RT YST
2 IC
27
23
TO
PO JO
RT YST
1 IC
20
TO JOYSTICK
PORT 3
TO JOYSTICK
PORT 4
22
1
21
19
1
15
1 FITTING/STRAIGHT
2 BUSHING/PIVOT
3 PIN/TILT CONSOLE
4 MOUNT/TOWER
5 HANDLE/RATCHET
6 ADAPTER/QD/HD
7 ADAPTER/QD/HD
8 FLANGE/BOOT/JOYSTICK
9 FLANGE/BOOT/JOYSTICK
Fig. 6-2
10 BOOT/JOYSTICK
11 STAND/DRV/JOYSTICK
12 JOYSTICK/KAWASAKI
13 BOOT/JOYSTICK
14 COVER/CONSOLE
15 HOSE/LP
16 HOSE/LP
17 HOSE/LP
18 GRIP/AUX/ELEC
19 HOSE/LP
20 HOSE/LP
21 NUT/LOCK
22 SCREW/CAP
23 BOLT/CARRIAGE
24 SCREW/TORX TF
25 SCREW/MACHINE TF
26 SCREW/CAP TFS
27 WASHER/FLAT
Exploded view of Dual Joystick and T-Bar/Joystick lift and tilt components
917292/AP1008
6-4
PRINTED IN USA
CONTROLS
Lift and Tilt Components - T-Bar Control Models
23
10
11
14
24
24
15
22
18
25
1
16
9
21
7
22
7
21
6
12
13
19
25
3
24
20
17
NOTE 3
NOTES:
NOTE 1 & 2
1 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
PRINTED IN USA
6-5
917292/AP1008
CONTROLS
Drive Control Components - Hand/Foot Models
1 WASHER/FLAT
2 NUT/HEX LOCK
3 PIN/ROLL
4 ROD END/FEMALE
5 ROD END/FEMALE
6 SPACER
7 SHAFT/PIVOT
8 BUSHING/PIVOT
9 BRACKET/PIVOT
10 ROD
11 ARM/ASSEMBLY
12 ROD END
13 NUT/SPIRALOCK
14 NUT/SPIRALOCK
15 DEVICE/CENTER
16 PLUG 4-PIN
17 WEDGE 4-PIN
18 NUT/LOCK
19 BOOT/T-BAR
20 ARM/PUMP
21 PILOT H-F/LEFT
22 PILOT H-F/RIGHT
23 BOOT/H-F PILOT
24 ASSEMBLY/PIVOT
25 STUD/ROD
26 ROD/THREADED
27 ROD/THREADED
28 PIVOT TUBE
29 BOOT/H-F PILOT
30 GRIP/AUXILIARY
31 GRIP
32 NUT/HEX LOCK
33 SCREW/CAP
34 SCREW/CAP
35 SCREW/CAP
36 SCREW/CAP
37 SCREW/CAP
38 SCREW/CAP
39 BOLT/CARRIAGE
40 NUT/JAM
41 WASHER/FLAT
42 WASHER/FLAT
43 NUT/HEX
32
2
25
11
9
30
40
20
1
8
40
18
39
39
23
37
20
40
40
32
35
13
7
13
28
27
20
19
35
18
8
31
18
14
33
43
18
22
26
39
40
18
41
36
42
12
43
24
13
34
8
43
11
43
29
15
12
40
13
38
3
18
40
5
32
41
19
38
39
42
15
36
21
13
10
18
5
13
12 38
40
SEE NOTES 16
1&2
13
36
42
38
18
42
36
17 SEE NOTE 3
10
13
40
12
NOTES:
Fig. 6-4
Deutsch DTM04-12P
CLR
Circuit
Function
RED
Vehicle
Power
Power
1 12
BLK
Vehicle
Ground
Ground
2 11
GRY
Prop Coil
Return
Current
Feedback
3 10
YEL
Prop Coil
PWM Output
Coil #1
Current
SW3
Switch #3
BRN
PUR
Prop Coil
PWM Output
Coil #2
Current
SW2
Switch #2
GRN/
BRN
PNK
Switch
Common
Switch
Common
Pin
Function
Pin
Pin
Number Function
Constant
Active
Circuit
Function
Constant
Output
CLR
_
_
BLU
917292/AP1008
6-6
PRINTED IN USA
CONTROLS
Drive Control Components - Dual Joystick Models
4
TO JOYSTICK
PORT #4
TO JOYSTICK
PORT #1
TO JOYSTICK
PORT #2
23
4
23
18
4
TO JOYSTICK
PORT #T
22
TO JOYSTICK
PORT #3
20
27
18
13
TO JOYSTICK
PORT #P
21
13
15
17
29
5
11
10
14
28
30
30
16
7
26
3
26
8
8
2
1
24
19
1 FITTING/TEE
2 FITTING/90
3 BUSHING/PIVOT
4 FITTING/90
5 JOYSTICK/DRIVE
6 VALVE/SOLENOID
7 PIN/TILT CONSOLE
8 TOWER MOUNT
9 HANDLE/RATCHET
10 ADAPTER
11 ADAPTER
12 FLANGE/BOOT
13 FLANGE/BOOT
14 JOYSTICK STAND
15 BOOT/JOYSTICK LEFT
16 COVER/CONSOLE
17 BOOT/JOYSTICK
18 HOSE/LOW PRESSURE
19 HOSE/PRESSURE
20 TUBE/JOYSTICK
21 HOSE/PRESSURE
22 HOSE/PRESSURE
23 HOSE/PRESSURE
24 NUT/HEX WHIZLOCK
25 SCREW/CAP
26 BOLT/CARRIAGE
27 SCREW/THREAD CUTTING
28 SCREW/MACHINE
29 SCREW/TAP/R
30 WASHER/FLAT
2
20
Fig. 6-5
PRINTED IN USA
6-7
917292/AP1008
CONTROLS
Drive Control Components - T-Bar and T-Bar/Joystick Models - 56/6640
7
28
5
2
36
1
5
22
22
24
27
31
20
10
36
20
20
13
36
36
20
25
28
34
39
31
35
34
37
16
11
26
17
39
23
2
1
36
21
14
10
20
36
13
13
12
20
32
37
39
39
11
38
32
29
20
36
33
30
28
38
32
NOTE 3
13
15
19
34
12
8
3
18
Fig. 6-6
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
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
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:
Fig. 6-7
Fig. 6-8
Fig. 6-9
917292/AP1008
6-10
PRINTED IN USA
CONTROLS
R e moval Pr oc e dur e - D ual Jo ys t i ck an d
T-Bar/Joystick Controls
WARNING
Control Valve
Manifold
PRINTED IN USA
6-11
917292/AP1008
CONTROLS
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:
6-12
PRINTED IN USA
CONTROLS
Electrical Foot Throttle Removal and
Installation - Dual Joystick Controls
Gehl 5640E/6640E and Mustang 2066/76/86 dual
joystick control units have an electric foot throttle
located
above
the
right
foot
rest
for
increasing/decreasing the engine's speed.
Swell Latch
Removal Procedure
Throttle
Panel Cover
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:
Mechanical
Stop
PRINTED IN USA
6-13
917292/AP1008
CONTROLS
CONTROLS
Electrical Foot Throttle Assembly - T-Bar, T-Bar/Joystick and Dual Joystick Controls
12
16
15
18
13
6
19
1
7
14
7
16
15
17
11
10
14
17
19
4
1
5
2
21
9
2
3
20
8 BRACKET/THROTTLE
9 THROTTLE BRACKET
10 PEDAL/THROTTLE
11 ROD/THREADED
12 SENSOR/THROTTLE
13 THROTTLE LINK
14 NUT/HEX WHIZLOCK
Fig. 6-18 Exploded view of the auxiliary hydraulics controls for T-Bar, T-Bar/Joystick and Dual Joystick control models
917292/AP1008
6-14
PRINTED IN USA
HYDROSTATIC SYSTEM
Introduction
This chapter covers troubleshooting, testing, removal,
installation, and adjustment procedures for the
hydrostatic system components on Gehl 5640E/6640E
and Mustang 2066/76/86 skid-steer loaders.
HYDROSTATIC
NOTES
PRINTED IN USA
7-1
917292/AP1008
HYDROSTATIC SYSTEM
Hydrostatic System - Single-Speed Components - Dual Joystick Controls
BRAKE -08 ORB (N,P)
46
23
1
11
10
20
16
22
16
25
28
6
40
30
G
31
H
44
15
16
38
12
G
21
13
41
17
N
19
34
18
14
43
P
24
H
16
33
36
Q
7
N
C
37
2
27
45
9
Q
D
K
35
8
41
26
16
29
15
44
1 FITTING/STRAIGHT
2 FITTING/TEE
3 FITTING/45
4 FITTING/TEE
5 CAP/37 FLARE
6 FITTING/TEE
7 CAP/37 FLARE
8 FITTING/TEE
9 FITTING/STRAIGHT
10 FITTING/45
11 FITTING/90
12 HOSE/PRESSURE
Fig. 7-1
45
39
25 HOSE/CHARGE INLET
26 TUBE/BRAKE
27 TUBE/BRAKE
28 HOSE/PRESSURE
29 FITTING/STRAIGHT
30 HOSE/PRESSURE
31 HOSE/PRESSURE
32 HOSE/PRESSURE
33 FITTING/90
34 FITTING/90
35 TUBE/BRAKE
36 HOSE/PRESSURE
13 SWITCH/TEMP
14 NUT/SPIRALOCK
15 WASHER/FLAT
16 FITTING/STRAIGHT
17 SCREW/CAP
18 VALVE/SOLENOID
19 TUBE/DRAIN MOTOR
20 HOSE/PRESSURE
21 MANIFOLD/RETURN
22 PUMP/TANDEM
23 TUBE/CHARGE
24 TUBE/DRAIN MOTOR
37 HOSE/DRAIN
38 MOTOR/ONE SPEED
39 MOTOR/ONE SPEED
40 HOSE/PRESSURE
41 FITTING/STRAIGHT
42 SCREW/CAP
43 SCREW/CAP
44 SCREW/CAP
45 CLAMP/HOSE
46 WASHER/FLAT
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)
13
11
21
19
47
29
1
A
31
12
14
33
E
1
CONNECT TO INLET ON "3" OR
"5" BANK MANIFOLD VALVE
21
F
22
36
50
28
37
20
A
23
21
G
5
44
6
16
34
J
35
27
17
46
L
8
26
24
49
25
P
10
30
32
18
21
51
41
2
45
39
C
21
10
43
D
51
K
9
46
42
50
40
20
K
38
1 FITTING/90
2 FITTING/TEE
3 FITTING/45
4 FITTING/90
5 CAP/37 FLARE
6 FITTING/45
7 FITTING/TEE
8 CAP/37 FLARE
9 FITTING/TEE
10 FITTING/STRAIGHT
11 ADAPTER/90
12 FITTING/TEE
13 FITTING/90
Fig. 7-2
27 MANIFOLD/RETURN
28 PUMP/TANDEM
29 TUBE/TANDEM PUMP
30 HOSE/PRESSURE
31 HOSE/PRESSURE
32 TUBE/DRAIN MOTOR
33 HOSE/PRESSURE
34 HOSE/PRESSURE
35 HOSE/PRESSURE
36 HOSE/CHARGE
37 HOSE/CHARGE INLET
38 TUBE/BRAKE LEFT
39 TUBE/BRAKE RIGHT
14 TUBE/CHARGE
15 PLUG
16 HOSE/PRESSURE
17 SWITCH/TEMP
18 NUT/SPIRALOCK
19 WASHER/FLAT
20 WASHER/FLAT
21 FITTING/STRAIGHT
22 HOSE/PRESSURE
23 SCREW/CAP
24 VALVE/SOLENOID
25 TUBE/DRAIN MOTOR
26 HOSE/PRESSURE
40 FITTING/STRAIGHT
41 FITTING/90
42 TUBE/BRAKE
43 HOSE/DRAIN
44 MOTOR/ONE SPEED
45 MOTOR/ONE SPEED
46 FITTING/STRAIGHT
47 FITTING/TEE
48 SCREW/CAP
49 SCREW/CAP
50 SCREW/CAP
51 CLAMP/HOSE
Exploded view of the t-bar, t-bar/joystick and hand/foot hydrostatic single-speed system
PRINTED IN USA
7-3
917292/AP1008
HYDROSTATIC SYSTEM
Hydrostatic System - Two-Speed Components - Dual Joystick Controls
BRAKE -08 ORB (N,P)
50
25
13
12
E
22
18
8
24
18
36
37
48
31
17
18
G
26
19
7
23
11
34
44
14
Q
45
P
21
20
47
16
42
15
45
29
10
30
H
18
49
40
P
C
L
N
39
33
27
10
18
43
49
28
41
N
11
48
32
35
17
D
45
1 FITTING/STRAIGHT
2 FITTING/TEE
3 FITTING/STRAIGHT
4 FITTING/45
5 FITTING/TEE
6 FITTING/90
7 CAP/37 FLARE
8 FITTING/TEE
9 CAP/37 FLARE
10 FITTING/TEE
11 FITTING/STRAIGHT
12 FITTING/45
13 FITTING/90
Fig. 7-3
27 MOTOR/TWO-SPEED
28 TUBE/TWO-SPEED
29 TUBE/TWO-SPEED
30 TUBE/MOTOR DRAIN
31 HOSE/CHARGE INLET
32 TUBE/BRAKE
33 TUBE/BRAKE
34 HOSE/PRESSURE
35 FITTING/STRAIGHT
36 HOSE/PRESSURE
37 HOSE/PRESSURE
38 HOSE/PRESSURE
39 FITTING/90
14 HOSE/PRESSURE
15 SWITCH/TEMP
16 NUT/SPIRALOCK
17 WASHER/FLAT
18 FITTING/STRAIGHT
19 SCREW/CAP
20 MANIFOLD/VALVE
21 TUBE/MOTOR DRAIN
22 HOSE/PRESSURE
23 MANIFOLD/RETURN
24 PUMP/TANDEM
25 TUBE/CHARGE
26 MOTOR/TWO-SPEED
40 TUBE/CASE DRAIN
41 TUBE/BRAKE
42 HOSE/PRESSURE
43 HOSE/DRAIN
44 HOSE/PRESSURE
45 FITTING/STRAIGHT
46 SCREW/CAP
47 SCREW/CAP
48 SCREW/CAP
49 CLAMP/HOSE
50 WASHER/FLAT
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)
1
A
30
20
50
15
22
46
14
12 16
13
K
47
E
1
8
48
48
22
C
F
D
G
29
53
38
21
7
24
22
28
32
17
23
11
49
27
25
19
4
18
42
J
49
31
26
35
10
52
H
36
22
33
N
54
40
22
43
45
10
34
49
Fig. 7-4
11
53
41
39
1 FITTING/90
2 FITTING/TEE
3 FITTING/STRAIGHT
4 FITTING/45
5 FITTING/90
6 CAP/37 FLARE
7 FITTING/45
8 FITTING/TEE
9 CAP/37 FLARE
10 FITTING/TEE
11 FITTING/STRAIGHT
12 ADAPTER/90
13 FITTING/TEE
14 FITTING/90
54
M
O
21
15 TUBE/CHARGE
16 PLUG
17 HOSE/PRESSURE
18 SWITCH/TEMP
19 NUT/SPIRALOCK
20 WASHER/FLAT
21 WASHER/FLAT
22 FITTING/STRAIGHT
23 HOSE/PRESSURE
24 SCREW/CAP
25 MANIFOLD/VALVE
26 TUBE/DRAIN MOTOR
27 HOSE/PRESSURE
28 MANIFOLD/RETURN
44
29 PUMP/TANDEM
30 TUBE/TANDEM PUMP
31 HOSE/PRESSURE
32 MOTOR/TWO-SPEED
33 MOTOR/TWO-SPEED
34 TUBE/TWO-SPEED
35 TUBE/TWO-SPEED
36 TUBE/DRAIN MOTOR
37 HOSE/CHARGE
38 HOSE/CHARGE INLET
39 TUBE/BRAKE
40 TUBE/BRAKE
41 FITTING/STRAIGHT
42 FITTING/90
43 TUBE/CASE DRAIN
44 TUBE/BRAKE
45 HOSE/DRAIN
46 HOSE/PRESSURE
47 HOSE/PRESSURE
48 HOSE/PRESSURE
49 FITTING/STRAIGHT
50 FITTING/TEE
51 SCREW/CAP
52 SCREW/CAP
53 SCREW/CAP
54 CLAMP/HOSE
Exploded view of the t-bar, t-bar/joystick and hand/foot hydrostatic two-speed system
PRINTED IN USA
7-5
917292/AP1008
HYDROSTATIC SYSTEM
Troubleshooting Guide
The following troubleshooting guide lists potential
hydrostatic system problems, as well as possible causes
and remedies, for Gehl 5640E/6640E and Mustang
2066/76/86 skid-steer loaders.
IMPORTANT
DO NOT attempt to service or repair major
hydrostatic system components, such as the
hydrostatic pumps or drive motors, unless
authorized to do so by your Gehl or Mustang
dealer. Any unauthorized repair will void the
warranty.
Problem
Possible Cause
Remedy
Check switches.
917292/AP1008
7-6
PRINTED IN USA
HYDROSTATIC SYSTEM
Problem
Possible Cause
Remedy
Neutral is difficult to
maintain.
Troubleshoot engine.
Sluggish response to
acceleration.
Hydrostatic drive is
overheating.
PRINTED IN USA
7-7
917292/AP1008
HYDROSTATIC SYSTEM
Problem
Possible Cause
Remedy
Hydrostatic (drive)
system is noisy.
Relief valves on engine-end hydrostatic pump Switch valves with those on front hydrostatic
pump. Problem should switch to the left side.
malfunctioning.
Replace defective relief valve.
917292/AP1008
7-8
PRINTED IN USA
HYDROSTATIC SYSTEM
Problem
Possible Cause
Remedy
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.
PRINTED IN USA
7-9
917292/AP1008
917292/AP1008
7-10
TILT CYLINDERS
AUXILIARY HYD
COUPLERS
OPTIONAL HYD
ALL-TACH
TRAVEL
JOYSTICK
LIFT/TILT
JOYSTICK
LEFT
DRIVE
MOTOR
RIGHT
DRIVE
MOTOR
STANDARD
HYDRAULIC
PUMP
OPTIONAL
HIGH FLOW
HYDRAULIC
PUMP
AC
HYDRAGLIDE
MANIFOLD
G2
X2
JOYSTICK PILOT
SUPPLY SOLENOID
X1
HYD
ALL-TACH
VALVE
MB B G
MA A
PILOT SUPPLY
SOLENOID VALVE
MANIFOLD
MG
B MB
G1A MA
X1
SHOWN WITH
OPTIONAL
TWO-SPEED
SOLENOID
VALVE
X2
BRAKE
SOLENOID
VALVE
P1
P2
HYDROSTATIC
PUMP
LIFT
TILT
STD
AUX
LIFT CYLINDERS
RESERVOIR
HEAT
EXCHANGER
FILTER
ASSEMBLY
WITH BYPASS
HYDROSTATIC SYSTEM
Hydraulic/Hydrostatic Schematic - Dual Joysticks
Tier3 Yanmar Engine
PRINTED IN USA
HYDROSTATIC SYSTEM
TILT
FOOT
PEDAL
LIFT
FOOT
PEDAL
RIGHT
DRIVE
MOTOR
LEFT
DRIVE
MOTOR
OPTIONAL
HIGH FLOW
HYDRAULIC
PUMP
STANDARD
HYDRAULIC
PUMP
HYDROGLIDE
MANIFOLD
AC
PILOT SUPPLY
SOLENOID VALVE
MANIFOLD
SHOWN WITH
OPTIONAL
TWO SPEED
SOLENOID VALVE
HYDRAULIC
ALL-TACH
VALVE
A B
STD AUX
LIFT
TILT
SELF
LEVEL
VALVE
HYDROSTATIC
PUMP
BRAKE
SOLENOID
VALVE
RESERVOIR
LIFT CYLINDERS
FILTER
WITH
HEAT
EXCHA
917292/AP1008
7-11
PRINTED IN USA
CASE DRAIN
OPTIONAL HYD
ALL-TACH
TILT CYLINDERS
AUXILIAR HYD
COUPLERS
Hydraulic/Hydrostatic Schematic
Hand/Foot with Foot Valves
Tier3 Yanmar Engine
HYDROSTATIC SYSTEM
NOTES
917292/AP1008
7-12
PRINTED IN USA
HYDRAULIC SYSTEM
IMPORTANT
Problem
Possible Cause
Remedy
Drive is disconnected.
PRINTED IN USA
8-1
917292/AP1008
HYDRAULICS
HYDRAULIC SYSTEM
Troubleshooting Guide
Problem
Possible Cause
Remedy
Standard-flow auxiliary
hydraulics function slowly.
917292/AP1008
8-2
PRINTED IN USA
HYDRAULIC SYSTEM
Troubleshooting Guide
Problem
Possible Cause
Remedy
Lift Arm doesnt maintain raised Oil leaking past lift cylinder seals (internal
position with lift control in
or external).
NEUTRAL.
Bucket drifts downward with tilt Oil leaking past tilt cylinder seals (external
control in NEUTRAL.
or internal).
PRINTED IN USA
Linkage misadjusted.
8-3
917292/AP1008
HYDRAULICS
HYDRAULIC SYSTEM
Troubleshooting Guide
Problem
Possible Cause
Remedy
No downward pressure on
the bucket.
Standard auxiliary or
high-flow auxiliary functions
slowly.
Standard-flow auxiliary
hydraulics do not function.
917292/AP1008
8-4
PRINTED IN USA
HYDRAULIC SYSTEM
Standard Auxiliary Hydraulics - Dual Joystick, Hand/Foot and T-Bar/Joystick
60
12 13
34
12
NOTE 3
NOTE 4
5
NOTE 2
39
H
42
64
19
9
39
30
43
49
J
NOTE 1
L
48
17
REPLACEMENT
FILTER 074830
45
X
44
20
50
46
3 65
41
12
T
32
14
13
21
12
20
23
21
26
25
NOTE
1) CONNECT TO ROD END OF LIFT CYLINDER.
2) CONNECT TO BASE END OF LIFT CYLINDER.
3) CONNECT TO ROD END OF TILT CYLINDER.
4) CONNECT TO BASE END OF TILT CYLINDER.
5) RELIEF SETTING 3000PSI 25PSI
16
24
52
54
67
55
16
53
37
40
R
58
R
W
36
15
33
S
68
13
35
57
29
61 12
15
63
S
J
12 15
56
17
28
18
59
12
C
A
69
62
51
58
9
27
11
2
2
47
22
66
31
8
7
20
2
2
38
10
1 FITTING/STRAIGHT
2 FITTING/STRAIGHT
3 ELBOW/FITTING 90
4 WASHER/FLAT
5 NUT/HEX
6 SCREW/CAP
7 FITTING/90
8 FITTING/STRAIGHT
9 FITTING/STRAIGHT
10 FITTING/TEE
11 SCREW/CAP
12 PLATE/TWIN COVER
13 CLAMP/TUBE
14 CAP/37 FLARE
15 CLAMP/TUBE
16 CLAMP/HOSE
17 FITTING/90
Fig. 8-1
18 FITTING/90
19 ASSY/FILTER
20, 21 NUT/SPIRALOCK
22 VALVE/SELF LEVEL
23 PUMP/GEAR SINGLE
24 HYDRAGLIDE
25 ACCUMULATOR
26 PLATE/SPACER
27 FITTING/TEE
28 TUBE/TILT
29 TUBE/TILT
30 TUBE/TILT
31 SPACER
32 TUBE/AUXILIARY
33 TUBE/AUXILIARY
34 TUBE/FILTER
35 TUBE/HYDRAGLIDE
36 TUBE/HYDRAGLIDE
37 VALVE/CONTROL
38 3-BANK/VALVE
39 TUBE/TILT
40 TUBE/LIFT
41 TUBE/LIFT
42 TUBE/LIFT
43 TUBE/LIFT
44 TUBE/AUX FEED
45 TUBE/AUX RETURN
46 TUBE/CASE DRAIN
47 PORT/TEST
48 CLAMP/ACCUM
49 ACCUMULATOR
50 TUBE/ACCUM
51 TUBE/SUCTION
52 FITTING/45
53 HOSE/PRESSURE
54 FITTING/90
55 HOSE/DRAIN
56 HOSE/PRESSURE
57 BRACKET/HARNESS
58 CLAMP/T-BOLT
59 SCREW/CAP
60 SCREW/CAP
61 SCREW/CAP
62 BOLT/CARRIAGE
63 SCREW/CAP
64 SCREW/MACHINE
65 SCREW/CAP
66 BOLT/CARRIAGE
67 BOLT/CARRIAGE
68 WASHER/LOCK
69 CLAMP/HOSE
Exploded view of the standard auxiliary hydraulics for dual joystick, hand/foot and t-bar/joystick controls
PRINTED IN USA
8-5
917292/AP1008
HYDRAULICS
HYDRAULIC SYSTEM
Standard Auxiliary Hydraulics - T-Bar Controls
10
47
3
9
41
1
29
52
24 21
54
28 51
17
24
16
20
20
4
46
18
23
4
45
27
23
20
TO HYDRAULIC TANK
43
18
33
42
TO HYDRAULIC TANK
32
15
44
14
6
34
48
50
38
26
12
12
5
6
12
10
39
25
37
30
31
19
9
11
3
22
10
40
40
13
10
19
13
3
2
56
55
49
57
53
36
55
35
NOTES:
1 CONNECT TO ROD END OF LIFT CYLINDER.
2 CONNECT TO BASE END OF LIFT CYLINDER.
3 CONNECT TO ROD END OF TILT CYLINDER.
4 CONNECT TO BASE END OF TILT CYLINDER.
5. RELIEF SETTING 3000PSI 25PSI.
ASSEMBLED VIEW
1 ELBOW/FITTING 90
2 WASHER/FLAT
3 NUT/HEX
4 FITTING/90
5 FITTING/STRAIGHT
6 FITTING/STRAIGHT
7 FITTING/TEE
8 SCREW/CAP
9 PLATE/TWIN COVER
10 CLAMP/TUBE
11 CAP/37 FLARE
12 CLAMP/TUBE
13 CLAMP/HOSE
14 FITTING/90
15 PLUG
Fig. 8-2
16 FILTER ASSEMBLY
17 NUT/SPIRALOCK
18 NUT/SPIRALOCK
19 NUT/SPIRALOCK
20 STRAP
21 VALVE/SELF LEVEL
22 PUMP/GEAR SINGLE
23 VALVE/SOLENOID
24 FITTING/TEE
25 TUBE/TILT
26 TUBE/TILT
27 TUBE/TILT
28 BRKT/SOLENOID LIFT
29 SPACER
30 TUBE/AUXILIARY
31 TUBE/AUXILIARY
32 TUBE/LIFT
33 TUBE/LIFT
34 TUBE/SUCTION
35 FITTING/45
36 HOSE/PRESSURE
37 HOSE/PRESSURE
38 BRACKET/HARNESS
39 VALVE/CONTROL
40 CLAMP/T-BOLT
41 TUBE/TILT
42 TUBE/LIFT
43 TUBE/TILT
44 TUBE/LIFT
45 TUBE/FILTER
46 SCREW/CAP
47 SCREW/CAP
48 SCREW/CAP
49 BOLT/CARRIAGE
50 SCREW/CAP
51 SCREW/CAP
52 SCREW/MACHINE
53 SCREW/CAP
54 BOLT/CARRIAGE
55 WASHER/LOCK
56 CAP/TUBE
57 CLAMP/HOSE
917292/AP1008
8-6
PRINTED IN USA
HYDRAULIC SYSTEM
High-Flow Auxiliary Hydraulics - Dual Joystick, Hand/Foot and T-Bar/Joystick
66
12
P
13
42
54
46
48
20
T
53
REPLACEMENT
FILTER 074830
18
N
CC
50
47
DD
55
EE
51
FF
GG
3
62
13 16
18
X DD
Y
FF
19
65
13
EE
CC BB
21
P
59
49
70
NOTE 4
31
32
13
45
5
NOTE 1
33
66
13 14
NOTE 2
NOTE 3
42
37
13
BB
43
X
29
AA
44
71
13
38
63
30
16 67
69
56
14
39
16
V
74
Z
V
B
Z
F
GG
AA
35 36
64
21
27
13
13
5
14
22
17
57
24
15
26
22
25
NOTES:
73
60
17
61
68
40
75
64
28
72
11
23
34
52
6
8
2
7
3
2
21
2
41
10
1 FITTING/STRAIGHT
2 FITTING/STRAIGHT
3 ELBOW/FITTING 90
4 WASHER/FLAT
5 NUT/HEX
6 SCREW/CAP
7 FITTING/90
8 FITTING/STRAIGHT
9 FITTING/STRAIGHT
10 FITTING/TEE
11 SCREW/CAP
12 CLAMP/TUBE
13 PLATE/TWIN COVER
14 CLAMP/TUBE
15 CAP/37 FLARE
16 CLAMP/TUBE
17 CLAMP/HOSE
Fig. 8-3
18, 19 FITTING/90
20 FILTER ASSEMBLY
21, 22 NUT/SPIRALOCK
23 VALVE/SELF LEVEL
24 HYDRAGLIDE
25 ACCUMULATOR
26 PLATE/SPACER
27 PUMP/GEAR DOUBLE
28 FITTING/TEE
29, 30, 31 TUBE/TILT
32, 33 TUBE/HIGH-FLOW
34 SPACER
35, 36 TUBE/AUXILIARY
37 TUBE/FILTER
38 TUBE/HYDRAGLIDE
39 TUBE/HYDRAGLIDE
40 VALVE/CONTROL
41 5-BANK/VALVE
42 TUBE/TILT
43, 44 TUBE/LIFT
45, 46 TUBE/LIFT
47 TUBE/FEED
48 TUBE/RETURN
49 TUBE/AUX FEED
50 TUBE/AUX RETURN
51 TUBE/CASE DRAIN
52 PORT/TEST
53 CLAMP/ACCUM
54 ACCUMULATOR
55 TUBE/ACCUM
56 TUBE/SUCTION
57 FITTING/45
58 HOSE/PRESSURE
59 HOSE/PRESSURE
60 FITTING/90
61 HOSE/DRAIN
62 HOSE/PRESSURE
63 BRACKET/HARNESS
64 CLAMP/T-BOLT
65 SCREW/CAP
66 SCREW/CAP
67 SCREW/CAP
68 BOLT/CARRIAGE
69 SCREW/CAP
70 SCREW/MACHINE
71 SCREW/CAP
72 BOLT/CARRIAGE
73 BOLT/CARRIAGE
74 WASHER/LOCK
75 CLAMP/HOSE
Exploded view of the high-flow auxiliary hydraulics for dual joystick, hand/foot and t-bar/joystick controls
PRINTED IN USA
8-7
917292/AP1008
HYDRAULIC SYSTEM
High-Flow Auxiliary Hydraulics - T-Bar Controls
13
58
58
12
12
1
35
3
50 12
63
28 25
65
34 62
21
11
28
20
24
12
24
6
57
22
26
6
31
33
32
26
24
56
52
22
39
51
TO HYDRAULIC TANK
38
53
19
8
8
17
41
59
TO HYDRAULIC TANK
61
55
54
10
1
40
5
12
47
30
15
15
1
7
67 18
15
44
8
29
46
36
37
13
23
12
14
4
45
18
23
16
49
3
68
66
16
13
12
49
27
48
13
12
60
69
64
43
66
42
NOTES:
1 CONNECT TO ROD END OF LIFT CYLINDER.
2 CONNECT TO BASE END OF LIFT CYLINDER.
3 CONNECT TO ROD END OF TILT CYLINDER.
4 CONNECT TO BASE END OF TILT CYLINDER.
5. STANDARD FLOW RELIEF SETTING 3000PSI 25PSI.
6. HIGH FLOW RELIEF SETTING 2900PSI 25PSI.
1 FITTING/STRAIGHT
2 ELBOW/FITTING 90
3 WASHER/FLAT
4 NUT/HEX
5 SCREW/CAP
6 FITTING/90
7, 8 FITTING/STRAIGHT
9 FITTING/TEE
10 SCREW/CAP
11 CLAMP/TUBE
12 PLATE/TWIN COVER
13 CLAMP/TUBE
14 CAP/37 FLARE
15 CLAMP/TUBE
16 CLAMP/HOSE
17 FITTING/90
Fig. 8-4
18 PLUG/O-RING
19 FITTING/90
20 FILTER ASSEMBLY
21 NUT/SPIRALOCK
22 NUT/SPIRALOCK
23 NUT/SPIRALOCK
24 STRAP
25 VALVE/SELF LEVEL
26 VALVE/SOLENOID
27 PUMP/GEAR DOUBLE
28 FITTING/TEE
29, 30, 31 TUBE/TILT
32 TUBE/HIGH-FLOW
33 TUBE/HIGH-FLOW
34 BRACKET/SOLENOID
35 SPACER
36, 37 TUBE/AUXILIARY
38, 39 TUBE/LIFT
40 TUBE/FEED
41 TUBE/SUCTION
42 FITTING/45
43 HOSE/PRESSURE
44 VALVE/CONTROL
45 HOSE/PRESSURE
46 HOSE/PRESSURE
47 BRACKET/HARNESS
48 VALVE/PROPORTION
49 CLAMP/T-BOLT
50 TUBE/TILT
51 TUBE/LIFT
52 TUBE/TILT SOLENOID
53 TUBE/LIFT
ASSEMBLED VIEW
54 TUBE/RETURN
55 TUBE/CASE DRAIN
56 TUBE/FILTER
57, 58, 59 SCREW/CAP
60 BOLT/CARRIAGE
61, 62 SCREW/CAP
63 SCREW/MACHINE
64 SCREW/CAP
65 BOLT/CARRIAGE
66 WASHER/LOCK
67 TEST PORT
68 CAP/TUBE
69 CLAMP/HOSE
917292/AP1008
8-8
PRINTED IN USA
HYDRAULIC SYSTEM
Lift Arm Hydraulics Components - 2066/76 Models
28
28
32
16
33
TO TOP OF HYDRAULIC RESERVOIR
4
8
7
9
21
34
13
32
10
10
18
27
14
17
35
8
1
2
18
24
18
5
1
23
PRESSURE
25
18
18
5
18
29
33
11
13
16
15
5
21
PRESSURE
26
3
22
4
32
34
17
12
5
29
4
19 34
32
HYDRAULICS
20
34
20
31
22
19
30
31
29
5
29
31
30
31
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
PRINTED IN USA
8-9
917292/AP1008
HYDRAULIC SYSTEM
Lift Arm Hydraulics Components - 2086 Models
32
33
28
15
28
4
7
34
21
17
12
1
32
27
13
16
35
8
20
5
17
24
17
20
5
PRESSURE
23
1
25
17
12
33
14
15
1
5
29
17
17
10
32
PRESSURE
21
26
3
22
19
34
3
5
16
11
32
29
18 34
34
19
31
22
18
30
31
29
5
29
31
30
31
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
917292/AP1008
8-10
PRINTED IN USA
HYDRAULIC SYSTEM
Lift Arm Hydraulics Components - 56/6640 Models
39
10
34
32
22
33
32
3
33
7
35
29
2
17
34
16
6
18
23
3
4
41
27
26
1
37
16
30
28
26
38
11
17
39
19
12
40
22
31
37
14
36
20
34
36
5
13
29
38
35
24
23
15
8
13
11
24
34
3
8
20
40
GREASE TAPER
OF PINS
35
12
NOTES:
35
25
21
21
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
PRINTED IN USA
8-11
917292/AP1008
HYDRAULIC SYSTEM
High-Flow Lift Arm Hydraulics Option - Dual Joystick, Hand/Foot, T-Bar/Joystick
10
12
3
9
1
4
REFERENCE HARDWARE FROM
HYDRAULIC GROUP
11
13
15
1 FITTING/STRAIGHT
2 CLAMP/TUBE
3 CLAMP/TUBE
4 PLATE/TWIN COVER
5 HOSE/PRESSURE
6 COUPLER/MALE
7 COUPLER/FEMALE
8 COUPLER/MALE
9 HOSE/PRESSURE
10 TIE/DUAL CLAMP
11 TUBE/HIGH-FLOW UPPER
12 TUBE/HIGH-FLOW LOWER
13 TUBE/HIGH-FLOW CASE DRAIN
14 PLATE/COUPLING
15 SCREW/CAP
14
6
Fig. 8-8
917292/AP1008
8-12
PRINTED IN USA
HYDRAULIC SYSTEM
Pressure Tests, Standard-Flow and
High-Flow Auxiliary
The control valve on the skid loader controls lift and tilt
functions of the lift arm, standard and high-flow
auxiliary hydraulics. It is located on the right side of the
chassis. The relief valve(s) inside the control valve can
be tested at the lift arm couplers.
Test Procedure
WARNING
Fig. 8-9
Fig. 8-10 System pressure test location on the right lift arm
for high-flow hydraulic couplers
PRINTED IN USA
8-13
917292/AP1008
HYDRAULICS
HYDRAULIC SYSTEM
WARNING
BEFORE continuing this service procedure,
perform the following SAFETY procedures:
Fig. 8-13 View of the adjuster screw beneath the cap on the
relief valve
917292/AP1008
8-14
PRINTED IN USA
HYDRAULIC SYSTEM
Hydraulic Oil Filter Element Replacement
Gehl 5640E/6640E and Mustang 2066/76/86 skid-steer
loaders have one hydraulic oil filter. The hydraulic oil
filter needs to be replaced when the restriction indicator
shows red.
NOTE: When reading the restriction indicator, run the
engine at HIGH idle with the hydraulic oil temperature
at 70F (21C) or warmer.
Replacement Procedure
WARNING
Muffler
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
HYDRAULICS
HYDRAULIC SYSTEM
Injected fluid MUST be surgically removed by a
doctor familiar with this type of injury or
gangrene may result.
NOTES
WARNING
ALWAYS wear safety glasses when
checking for hydraulic fluid leaks.
Escaping fluid under pressure can be
invisible and can cause permanent eyesight
damage if safety glasses are not worn.
8. ALWAYS check for hydraulic fluid leaks after
assembling components of the hydraulic system.
917292/AP1008
8-16
PRINTED IN USA
HYDRAULIC SYSTEM
Control Valve Removal and Installation
2
11
Removal Procedure
7
9
WARNING
4
10
8
6
Port #1
Port #9
Port #2
Ports #4
Port #3
PRINTED IN USA
8-17
917292/AP1008
HYDRAULICS
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
Port #4
Installation Procedure
1. Secure the control valve to the welded bracket with
four locking capscrews. If straight or 90 fittings are
not in the control valve, install them at this time.
2. Ports 10 and 11: Connect four hoses to straight
fittings on the control valve, two hoses in front and
two more in the rear.
3. Port 9 (high-flow only): Connect the pressure hose
to the 90 fitting on the control valve, other end
connects to gear pump.
Ports #10
Port #6
3
2
11
7
9
917292/AP1008
4
10
8
6
8-18
PRINTED IN USA
HYDRAULIC SYSTEM
9. Port 3: Connect the hydraulic filter tube to the
straight fitting on control valve.
10. Ports 1 and 2 (high-flow only): Connect the
high-flow tubes at the straight fittings on the control
valve.
Ports #7
Ports #8
WARNING
Ports #11
1
2
11
7
9
4
10
8
6
PRINTED IN USA
8-19
917292/AP1008
HYDRAULICS
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:
8-20
PRINTED IN USA
HYDRAULIC SYSTEM
Control Valve Disassembly and Assembly
The main control valve is a mono-block designed
control valve with spools.
Disassembly Procedure
1. Remove the main control valve per the procedure in
this chapter and place valve on a flat surface that can
retain or collect any hydraulic oil runoff.
2. To access the spools, use an Allen wrench to loosen
two hex socket capscrews, one on each side of the
spool cap. Fig. 8-30
Spool Cap
3. Pull spool cap off the spool and retain the o-ring.
Fig. 8-31
4. Grab the spring assembly on the end of the spool and
pull the spool out of the control valve and retain all
o-rings. Fig. 8-32
5. Repeat steps 1-4 for all spools needing removal
from the control valve.
6. To remove port relief valves from the control valve,
use a wrench to loosen the valve from the
mono-block control valve. Fig. 8-33
HYDRAULICS
Spool
Spring Assy
8-21
917292/AP1008
HYDRAULIC SYSTEM
Main Relief Valve Removal and Installation
An anti-cavitation relief valve is integrated within the
standard-flow control valve, two anti-cavitation relief
valves are integrated within the high-flow control valve.
A relief valve(s) activates when oil pressures inside the
control valve reach unacceptable levels; to relieve that
pressure and prevent damage to valve and hydraulic
system.
Removal Procedure
WARNING
917292/AP1008
8-22
PRINTED IN USA
HYDRAULIC SYSTEM
Control Valve Components - Standard-Flow and High-Flow
7
1
4
8
1 KIT/PLUG
2 KIT/CHECK VALVE
3 CONTROL/REAR
4 KIT/PLUG
5 VALVE/RELIEF
6 CONTROL/ANTERIOR
7 VALVE/PORT RELIEF
8 VALVE/PORT RELIEF
9 VALVE/RELIEF
10 KIT/CHECK VALVE
7
1
HYDRAULICS
4
8
10
6
9
8-23
917292/AP1008
HYDRAULIC SYSTEM
HYDRAULICS
NOTES
917292/AP1008
8-24
PRINTED IN USA
ELECTRICAL SYSTEM
Introduction
Description of Operation - Right and Left
Instrument Panels
Right Instrument Panel
Hourmeter
Fuel Level
Gauge
Engine
Coolant
Temperature
Gauge
q Battery
Engine Oil
Pressure
Battery
Pre-Heat Indicator
Lamp
Light
Switch
High-Flow
Auxiliary
Switch
On
starts.
Off
Key
Switch
Start
Engine
Speed
Control
Knob
Fig. 9-1
PRINTED IN USA
9-1
917292/AP1008
ELECTRICAL
ELECTRICAL SYSTEM
Left Instrument Panel
The left instrument panel for Gehl 5640E/6640E and
Mustang 2066/76/86 skid-steer loaders holds the
manual parking brake switch, indicator lights and the
accessory plug. Optional switches and HVAC controls
are also on this panel.
1. Two-speed Indicator Lamp - it lights when
skid-steer loaders two-speed HIGH range is
engaged.
2. Parking Brake Indicator Lamp - it lights when
skid-steer loader's parking brake is engaged.
3. Hydraglide Ride Control Indicator Lamp - it
lights when loaders (optional) ride control is
engaged.
4. Fan Switch - controls the (optional) fan on heater
and/or air conditioning package.
5. HVAC Switch - controls the (optional) selection of
heat or air conditioning.
6. 12-VDC Power Outlet - a plug-in outlet with rubber
boot used for external electrical connections.
7. Parking Brake Switch - used to apply the parking
brake.
Engine Malfunction
High-Speed
Control (Optional)
Ride Control
(Optional)
Parking Brake
Float Indicator
Parking Brake
Switch
Switch (Optional)
HVAC Selector
Switch (Optional)
12-VDC Power
Outlet
Fig. 9-2
917292/AP1008
9-2
ELECTRICAL SYSTEM
Troubleshooting Guide
Problem
Possible Cause
Remedy
Faulty keyswitch
Replace keyswitch.
Battery faulty
Fuse blown
Replace fuse.
Replace relay.
Faulty buzzer
Replace fuse.
Faulty sender
Replace fuse.
Faulty alternator
Faulty hourmeter
Replace hourmeter.
PRINTED IN USA
9-3
ELECTRICAL
917292/AP1008
ELECTRICAL SYSTEM
Troubleshooting Guide
Problem
Possible Cause
Remedy
Seat or restraint bar switch malfunctioning or Operator is in the seat with the restraint bar
down. Replace switches as needed.
not activated
Poor connections to starter relay in
instrument panel
Battery terminals or cables loose or corroded Clean battery terminals and cables and
tighten them.
917292/AP1008
Battery terminals or cables loose or corroded Clean battery terminals and cables and
tighten them, replace cables as needed.
Battery or alternator defective
9-4
PRINTED IN USA
ELECTRICAL SYSTEM
Chassis Electrical Components
3
10
GREEN/PURPLE
STARTER
34
WHITE
STARTER
30
34
12
29
19
PINK/BLACK
GRID HEATER
29
30
14
18
RED
GRID HEATER
18
GRAY
DETAIL
A
GREEN
LEFT JOYSTICK
44
HYD ALLTACH
28
25
17
27
FRONT OF
MACHINE
RIGHT JOYSTICK
6
11
24
BLUE/BLACK
PILOT SOLENOID (1)
PINK/BROWN
HIGH FLOW-REVERSE SOLENOID (2)
GREEN/GRAY
HIGH FLOW-FORWARD SOLENOID (3)
YELLOW/GRAY
LOW FLOW-REVERSE SOLENOID (4)
PINK/GRAY
LOW FLOW-FORWARD SOLENOID (5)
8
1
22
WHITE
START
SOLENOID
37
41
40
GRAY PLUG TO
THE OUTSIDE OF
THE MACHINE
23
7
33
GREEN PLUG TO
THE INSIDE OF
THE MACHINE
33
22
31
36
43
36
15
43
16
17
33
35
PURPLE/BLACK
TWO-SPEED
SOLENOID
YELLOW/BLACK
R/C-FLOAT
13
16
PURPLE/BLACK
TWO-SPEED
SOLENOID
1
2
32
13
35
16
20
45
21
BROWN/BLACK
R/C-FLOAT
6
LEFT JOYSTICK
28
TO REAR
DOOR
HARNESS
13 16
13
26
39
13
8
8
37
TO FUEL PUMP
9
26
38
SERVICE PARTS:
26
FUSE/ATM/5 AMP
FUSE/ATM/7.5 AMP
FUSE/ATM/10 AMP
FUSE/ATM/15 AMP
FUSE/ATM/20 AMP
FUSE/ATM/25 AMP
FUSE/ATM/30 AMP
FUSE/MAXI/60 AMP
184633
184632
184631
184630
184629
184628
184627
195073
ELECTRICAL
16
OIL TEMP
SWITCH
POWER TAP
RELAY/20 AMP/MICRO
183733
RELAY/ISO/SPST/30 AMP 195076
RELAY/ISO/SPST/50 AMP 195075
COVER/FUSE/4 WAY
COVER/FUSE/2 WAY
DIODE
1 TIE/WIRE
2 CLAMP/HOSE
3 NUT/HEX WHIZLOCK
4 NUT/SERRATED LOCK
5 NUT/HEX WHIZLOCK
6 NUT/HEX
7 CLAMP/TUBE
8 TIE/NYLON
9 CLAMP/HOSE
10 ANGLE/BATTERY
11 CLAMP/TUBE
Fig. 9-3
194554
194633
187347
12 BATTERY
13 NUT/SPIRALOCK
14 NUT/SPIRALOCK
15 CLAMP/TUBE
16 NUT/SERRATED FL
17 MODULE/2-SPEED
18 CLIP/CONDUIT
19 BRACKET/BATTERY
20 BRACKET/MATING
21 RELAY 20AMP
22 HARNESS/CHASSIS
23 BRACKET/HARNESS
24 PLATE/ELECTRICAL
25 CABLE/POSITIVE
26 SOLENOID
27 COVER/FUSE
28 COVER/FUSE
29 ROD/BATTERY
30 COVER/ELECTRICAL
31 SCREW/TAPPING
32 SCREW/CAP
33 NUT/HEX
34 BOLT/CARRIAGE
35 SCREW/CAP TF
36 WASHER/FLAT
37 NUT/HEX
38 NUT/HEX
39 NUT/HEX
40 COVER/HARNESS
41 COVER/HOLDDOWN
43 WASHER/FLAT
44 FOAM/COVER
45 FOAM/COVER
PRINTED IN USA
9-5
917292/AP1008
ELECTRICAL SYSTEM
ROPS Electrical Components
TO RADIO
OPTION
TO RIGHT
WORK LIGHT
TO DOME LIGHT
17
17
TO STROBE
LIGHT OPTION
17
TO LEFT WORK LIGHT
TO RESTRAINT BAR
22
14
20
TO SEAT
SWITCH
TO SEAT
PAN GROUND
26
11
12
5
6
12
7
13
12
23
KEYED
POWER
10
16
HIGH FLOW
TO FLASHER
OPTION
15
22
8
18
9
BROWN - START
RED 05 - BAT
GREEN - BAT
RED - ACC 2
THROTTLE
25
24
24
NOTE:
TORQUE KNOB SET
SCREW TO 20-30 in-lb.
TO DOOR
SWITCH
20
20
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
917292/AP1008
9-6
PRINTED IN USA
ELECTRICAL SYSTEM
Engine Electrical Components - Mustang 2066/76/86 Models
20
13
15
13
11
21
22
18
12
6
4
9
10
14
20
ELECTRICAL
19
19
16
17
1 NUT/LOCK
2 CLAMP/TUBE
3 CLAMP/TUBE
4 LOOM/CABLE
5 BRACKET/HARNESS
6 CABLE/POSITIVE
7 CABLE/NEGATIVE
8 HARNESS/ENGINE
Fig. 9-5
9 CLAMP/TUBE
10 CLAMP/TUBE
11 P-CLAMP
12 WIRE/ALTERNATOR
13 SENDER/TEMP
14 SCREW/CAP
15 SCREW/CAP
16 WASHER/LOCK
20
17 SCREW/CAP
18 NUT/HEX
19 SCREW/CAP
20 SCREW/CAP
21 NUT/HEX
22 SCREW/CAP
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)
EXTEND ICON TO BE ON
RIGHT HAND SIDE OF
SWITCH WHEN INSTALLED
1 NUT/SERRATED
2 MODULE/HIGH-FLOW
3 SWITCH/HIGH-FLOW
Two-Speed Control
1 BULB/LAMP
2 NUT/SERRATED
3 MODULE/TWO-SPEED SHIFT
Fig. 9-6
917292/AP1008
9-8
PRINTED IN USA
ELECTRICAL SYSTEM
NOTES
PRINTED IN USA
9-9
917292/AP1008
ELECTRICAL SYSTEM
Power Distribution Panel Test and
Operation
Gehl 5640E/6640E and Mustang 2066/76/86 skid-steer
loaders utilize a power distribution panel in the
electrical system to maximize the efficiency of engine,
hydraulic, power and electrical operations. This panel is
attached on the left riser, just behind the battery.
Power Distribution Panel Fuse Test (Figs. 9-7 - 9-10)
The following procedure can be used to test the fuses
found inside the power distribution panel.
Fig. 9-7
WARNING
Test Points
Vehicle Power
Engine Starter
Grid Heater
Fig. 9-8
ECU
Keyswitch
Power
Diode
917292/AP1008
Fig. 9-9
9-10
PRINTED IN USA
ELECTRICAL SYSTEM
#86. The relay should actuate. There should
be continuity between terminal #30 and
terminal #87.
u
3. Replace any fuse that did not have power at each test
point. Replace any relay that does not have
continuity between powered terminals.
Fuses
Power Relays
Relays
PRINTED IN USA
9-11
917292/AP1008
ELECTRICAL
WARNING
Fig. 9-11 View of inside the fuse box panel located near
the left knee of the operator inside the ROPS
(shown with cover off)
ELECTRICAL SYSTEM
Fuse Box Panel Relay Test (Figs. 9-11 and 9-12)
There are three power relays inside the fuse box panel
that supply power to the fuses for individual circuits.
The cover has a decal that identifies the fuses. These
relays can be tested as:
1. Turning the keyswitch to the ON position should
produce an audible "click" from each relay closing.
2. To test each relay individually, pull one relay out of
the panel at a time, listening for the audible "click"
of the relay opening.
3. Plug the relay back into the panel and listen for the
audible "click" of the relay re-closing.
4. Replace any relay where there is no discernible
"clicking" sound heard at keyed power or opening
(removing) of the relay.
u
#85
#86
Load
Live Power
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:
rear grille.
(For detailed instructions, refer to the Safety
chapter of this manual.)
1. Using a volt/ohm multimeter or a test lamp, confirm
the following conditions with the wiring connected.
u
9-12
ELECTRICAL SYSTEM
u
WARNING
OIL PSI SW IN
AUTO-GLOW TIME IN
HYD TEMP SW IN
ENG TEMP SW IN
DOOR SW IN
SEAT SW IN
PARK BRAKE SW IN
+12VDC IN
GREEN LED
DIAGNOSTIC
INDICATORS (15)
ALARM BUZZER
OUTPUT CONNECTOR
6 PIN DEUTSCH
DT15-06
INPUT CONNECTOR
12 PIN DEUTSCH
DT15-12PA
MATING CONNECTOR:
DEUTSCH PNB DT06-06S
MATING CONNECTOR:
DEUTSCH PNB DT06-12S
9-13
917292/AP1008
ELECTRICAL
917292/AP1008
9-14
X
OFF
ON
OFF
ON
Pin No.
1.1
2.1
2.5
2.6
2.2
2.3
2.4
1.4
1.9
1.3
1.5
1.6
1.7
1.8
1.10
OFF
ON
ON
LED Title
+12VDC (IN)
Brake Sol (OUT)
Fuel Sol (OUT)
Start Relay (OUT)
Hyd Relay (OUT)
Seat Belt Lt (OUT)
Park Brake Lt (OUT)
Restraint Bar Sw (IN)
Door Sw (IN)
Seat Sw (IN)
Park Brake Sw (IN)
Hyd Temp Sw (IN)
Engine Temp Sw (IN)
Oil PSI Sw (IN)
Auto-Glow Time (IN)
ON
SAFETY RELAYS
DISABLE
OFF
ON
SAFETY RELAYS
DISABLE
ON
OFF
AFTER
1 SEC
ON
ON
ON
ON
ON
ON
ON
AUTO-GLOW TIME
ON
ON
ON
AT POWER ON
ON
Pin No.
Function
ON
LED State
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
OFF
9
11
12
ID
L
RE
AY
AM
ON
OFF
OFF
OFF
OFF
ON
OFF
OFF
ON FOR
5 SEC
OFF
AFTER
30 SEC
OFF
AFTER
30 SEC
ON
ON
ON
ON
T
FE
OFF
ON
NO
M
AR )
AL und
N
o
E
W S
)
L
O
AS
SA
RM irp T D arm
1
N
S
LE
P
ID
#
O
LA Ch
ID
M
U Al
O
RE
Y
A
E
A
H
O
t
t
N
E
S
N
LA
LT n
TL
AK
LE
E en
AK
LE
O
RE
BE ite
EL
BR
IN it
BR
K
SO
LS
TB
RT
AT term NG term
R
D
E
E
A
A
D
Y
E In
S (In
ST
H
PA
FU
SE
(
HY
SO
LE
ON
10
n)
n)
n)
s)
)
io
tio H itio
Po
)
di ITC nd ITCH dit
wn
n
F
T W
o
n
)
F
o W Co W o T )
H D
nt
PU LO
S
O
S
C
S
C r
se
P p RE SI C PU en E IN -G
in WIT Ba CH in W p
e
r
R
)
M
T
r
S
t
P
N
p
I w
I
m E m U l
O
E
S
o
or
W CP
at AR train SWel S MP r Te ERT r Te ESS Oi CH r O TIMAUT
at
H er
E n
R w
B s
V ve
IT oo OW G
TE e
PO VD
ic
2 D Ind
ITC Op INT Re RAK Pa VER Ov E O O IL P Lo SWh D
L
C
N
D
D
I
1
O ith R it
-G UR USE
SE
SW ith RA ith K B ith O ith IN ith
VD ith
UN ED
TU
AT N w EST N w AR N w YD N w NG N w OW N w OON w UTON D OT
12N w ROo L
E
O
L (O
D (O
E (O
R (O
A (O
P (O
H (O
S (O
+O
G (N
N
N
(
INPUTS (12 Pin Connector #1.X)
t
ea
ELECTRICAL SYSTEM
Interlock Control Module Truth Table
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:
12
PIN DESCRIPTIONS:
1. BLK GROUND
2. TAN FLOAT LAMP
3. GRY RIDE CONTROL TOGGLE
4. PNK FLOAT SWITCH
5. RED +12VDC
6. WHT LOW/HIGH GEAR TOGGLE
7. BLU RIDE CONTROL LAMP
8. BRN RIDE CONTROL SOLENOID
(5 AMP OUTPUT)
9. YEL FLOAT/RIDE SOLENOID
(10 AMP OUTPUT)
10. OPERATOR PRESENCE INPUT
11. ORG HIGH GEAR LAMP
12. PUR HIGH GEAR SOLENOID
(5 AMP OUTPUT)
MATING CONNECTOR:
DEUTSCH PNB DT06-12S
12 PIN DEUTSCH
PN DT15-12PA
Fig. 9-19 Illustration of the two-speed, ride control and float module
PRINTED IN USA
9-15
917292/AP1008
ELECTRICAL
FLOAT/RIDE SOL
+12 VDC
FLOAT SW
LO/HI GEAR SW
SEAT SW
RIDE CTRL SW
GREEN LED
DIAGNOSTIC
INDICATORS (8)
9-16
Operator Taking
Seat
Operator Leaving
Seat
Float No Effect
Float Hold ON
Activate Float
Ride Control
No Effect
(hold
for
5 sec)
Toggle Ride
Control ON
Toggle Ride
Control OFF
Toggle High
Gear OFF
Low
Tog /Hig
gle h G
Sw ear
itch
Rid
To e C
g
gle ontro
Sw l
itch
Toggle High
Gear ON
Flo
Sw at Mo
itch m
en
tar
y
ACTION
Se
(Re at Sta
la
y O te
utp
ut)
At Power Up
Flo
So at/R
le
no ide C
id
on
tro
l
0
Prev
State
0
(after
.25 S
delay)
Prev
State
0
(after
.25 S
delay)
0
(after
.25 S
delay)
Rid
Sole e Co
no ntro
id
l
917292/AP1008
Hig
Sole h Ge
no ar
id
0
Co
n
tro
l La
mp
0
0
(after
.25 S
delay)
Prev
State
Rid
e
Hig
h
Ge
ar
Lam
p
0
Flo
at
Lam
p
0
COMMENTS
ELECTRICAL SYSTEM
Two-Speed, Ride Control and Float Module Truth Table
Fig. 9-20 Truth table for the two-speed, ride control and float module
PRINTED IN USA
ELECTRICAL SYSTEM
The High Gear Sol LED should toggle
ON (light) and OFF with alternate pushes of
button.
u
Standard Flow
Troubleshooting Test
1. Check the auxiliary control fuse in the fuse box
panel.
2. Check the diode and micro-relay in the power
distribution panel. Fig. 9-9
3. Check connections at the control handle and coils.
4. Be sure that the interlock control module is
outputting a signal for the hydraulic solenoid safety
relay.
u
9-17
917292/AP1008
ELECTRICAL
High Flow
ELECTRICAL SYSTEM
u
917292/AP1008
9-18
PRINTED IN USA
ELECTRICAL SYSTEM
Electrically-controlled High-Flow Auxiliary
Hydraulic Flow System Test and
Operation
The high-flow auxiliary hydraulics flow is controlled by
a rocker switch located beneath the light switch in the
right instrument panel and a high-flow module located
in the engine compartment on the left riser tower, below
the two-speed ride control and float module. The rocker
switch contains an integrated circuit that controls the
signal to a proportional solenoid valve (5-bank) (Fig.
9-22) located on the right chaincase beneath and to the
right of the operators seat. Figs. 9-26, 9-28, 9-29
Fig. 9-28 Location of the high-flow auxiliary hydraulics
control rocker switch in the right instrument
panel
Troubleshooting Test
1. There are indicators on the high-flow module to aid
in diagnosis. Have an assistant actuate the rocker
switch and monitor the indicators on the module.
This will provide direction on what to troubleshoot.
2. Check the auxiliary control fuse in the fuse box
panel.
3. Check the electrical connections at the 5-bank
proportional solenoid valve.
4. Be sure that the module is outputting a signal for the
hydraulic solenoid safety relay.
u
PRINTED IN USA
9-19
917292/AP1008
ELECTRICAL SYSTEM
Engine Throttle Test and Operation
The engine speed is controlled by an electronic rotary
throttle (Fig. 9-30). The throttle is located on the right
instrument panel. Dual Joystick and T-Bar controls
models have a second throttle located near the
operators right foot. If there are problems with the
throttle, the engines ECU will supply an error message
on the left instrument panel. See the Engine chapter for
error code identification.
Fig. 9-31 Location of the solenoid lock valves for the lift
and tilt functions of the T-Bar control skid-steer
loader
917292/AP1008
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
PRINTED IN USA
9-21
917292/AP1008
ELECTRICAL SYSTEM
84 RD-14
39
44
43
TO WIPER/WASHER/
DOOR SWITCH
0 BK-14
43 0R-14
0 BK-14
AB C
RIGHT CONSOLE
ASSEMBLY
43 OR-14
0 BK-14
60 OR-14
61 GN-16
84 RD-14
0 BK-16
43 OR-14
LEFT CONSOLE
ASSEMBLY
0 BK-16
84 RD-14
43 OR-14
0 BK-16
59 RD-14
52 WH-16
FLOOD LAMP
LEFT
FRONT
6 WORK
LIGHT
RIGHT
FRONT
WORK
LIGHT
DOME
LIGHT
0 BK-16
0 BK-16
0 BK-16
HOURMETER
34 YL-16
15 BR-16
34
0 BK-14
52 WH-16
36
52 WH-16
53 RD-16
18
SAFETY
INTERLOCK
CONTROL
MODULE
0 BK-16
6
5
4
3
2
1
52 WH-16
TO EU
LIGHTS
24 BU-16
53 RD-14
0 BK-14
40 GY-16
30
27
53 RD-16
15 BR-16
19 WH-16
53 RD-16
14 PU-16
31 OR-16
53 RD-16
29
34 YL-16
32 GN-16
53 RD-16
28
4 BU-16
87 TN-16
1
3
2
4
11 RD-14
48 WH-14
11C43 OR-14
INSERTION SIDE
RED
48 WH-14
89 RD-14 A
110 WH-14 B
0 BK-14
33
33A
40 GY-16
53 RD-16
23 OR-16
POWER ALL
TACH SWITCH PARK BRAKE
(OPT)
SWITCH
30 PU-16
8
3
12
A 9
2
B
54 RD-16
43 OR-14
43 OR-14
0 BK-12
53 RD-16
87 TN-16
53 RD-16
53 RD-16
31
GLOW
HYD
TEMP
13
11 RD-14
0 BK-16
A B 23
0 BK-16
53 RD-16
32
OIL
BATT
PSI
ENG HYD
TEMP FILTER
0 BK-14
0 BK-14
0 BK-14
0 BK-14
53 RD-16
SEAT
BELT
AIR
FILTER
FLOAT
SHUTDOWN
RIDE
WARNING CONTROL CONTROL
53 RD-16
37 GN-16 15
ROPS
GROUND
20
53 RD-16
24 BU-16
22 GN-16
53 RD-16
67 PK-16
53 RD-16
14
S
(I)
ENG TEMP
37
53 RD-16
15 BR-16
53 RD-16
53 RD-16
16
23 OR-16
25 BR-16
38
0 BK-16
40 GY-16
17
S
(I)
FUEL
35
53 RD-16
0 BK-16
53 RD-16
0 BK-14
37 GN-16
15 BR-16
29 YL-16
36 BU-14
54 RD-14
0 BK-16
10 WH-16
17 GN-16
30 PU-16
40 GY-16
0 BK-14
0 BK-14
33 PK-16
43 OR-14
40 GY-16
19
1
2
3
4
5
6
7
8
9
10
11
12
22
RESTRAINT
BAR
SWITCH
11B
21
DGN
RED ORGWHT
SEAT
SWITCH
5
6
42 GN-14
11 RD-14
126 GN-16
123 TN-16
124 YL-16
125 PK-16
62 RD-14
25
LIGHT SW
1 7
10 3
41
48 WH-14
122 PU-16
A B CD E
20 BR ST OFF
ON
ST
2 RD BAT
26
43 OR-14
42 GN-14
54 RD-14
20 BR-16
02 RD-14
61 GN-16
04 DBL-16
14 PUR-16
19 WHT-16
22 DGN-16
23 ORG-16
24 DBL-16
25 BRN-16
31 ORG-16
32 DGN-16
34 YL-14
40 GRY-16
87 TAN-16
21
10 WH-16
A B CD E F
ROPS 5 PIN
CONNECTION
1 2 3 4 5 6 7 8 9 101112 1
24
109 BK-16
69 WH-16
70 RD-14
21
5 RD IGN
60 OR-16
53 RD-14
125 PK-16
59 RD-14
62 RD-14
84 RD-14
54 RD-14
123 TN-16
122 PU-16
124 YL-16
126 GN-16
67 PK-16
0 BK-14
56 RD-12
11
55 WH-12
11 RD-12
0 BK-12
56 RD-12
89 RD-14
110 WH-14
AB
0 BK-12
10 WH-16
54 RD-14
ACCESSORY PLUG
05 RD-14
17 GN-16
54 RD-14
55 WH-12
0 BK-12
IGNITION SW
54 RD-14
17 GN-16
A
B
67 PK-16
17 GN-16
10 WH-16
AC/HEAT POWER
56 RD-12
55 WH-12
0 BK-12
11 RD-12
33 PK-16
29 YL-16
36 BU-14
50 WH-14
[ OPT. ]
24 BU-16
87 TN-16
4 BU-16
40 GY-16
32 GN-16
34 YL-16
31 OR-16
14 PU-16
19 WH-16
23 ORG-16
22 GN-16
25 BR-16
FLASHER
1 2 3 4 5 6 7 8 9 101112 2
12 PIN GRAY
KEYED CONNECTION
PLUG
05 RD-16
69 WH-16
70 RD-16
36 BU-14
42 GN-14
43 OR-14
33 PK-16
50 WH-16
109 BK-16
20 BR-14
29 YL-16
02 RD-14
33 PK-16
29 YL-16
36 BU-14
50 WH-14
05 RD-16
20 BR-14
02 RD-14
42 GN-14
43 OR-14
109 BK-16
69 WH-16
70 RD-14
12 PIN GRAY
NON-KEYED CONNECTION
RECEPTACLE
1 2 3 4 5 6 7 8 9 101112 3
12 PIN GRAY
KEYED CONNECTION
PLUG
917292/AP1008
9-22
PRINTED IN USA
ELECTRICAL SYSTEM
A B C D E F G H J
104 16-GY
31 OR-14
106 PU-16
ELECTRICAL SCHEMATIC
4TNV98 ENGINE
K L
M N P R S T
U V W X
103 BR-16
94 RD-14
105 YL-16
101 GN-16
115 BU-16
114 GY-16
22 GN-16
99 OR-16
69 WH-16
14 PU-16
98 TN-16
102 OR-16
96 PK-16
34 YL-16
111 PU-16
111 GY-16
14 PU-16
ENGINE
OIL PRES
SWITCH
TO CHASSIS
101 GN-16
96 PK-16
104 16-GY
94 RD-14
106 PU-16
103 BR-16
RACK POSITION/ACTUATOR
1 2 3 4 5 6
1 2
SPEED
SENSOR
1 2 3 4 5 6
69 WH-16
114 GY-16
115 BU-16
105 YL-16
COLD START
COIL
99 OR-16
EGR VALVE
34 YL-16
98 TN-16
TO STARTER
SEE CHASSIS
SCHEMATIC
22 GN-16
102 OR-16
69 WH-16
31 OR-14
ENGINE
TEMP
SENDER
B+
9-23
1 2
PRINTED IN USA
ENGINE
TEMP
SENDER
(ECU)
ALTERNATOR
917292/AP1008
WIRE #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
COLOR
BLACK
RED
RED
BLUE
BLUE
RED
ORANGE
RED
ORANGE
NA
WHITE
RED
RED
RED
PURPLE
BROWN
RED
GREEN
YELLOW
WHITE
BROWN
GREEN
GREEN
ORANGE
BLUE
BROWN
WHITE
GRAY
GRAY
YELLOW
PURPLE
ORANGE
GREEN
PINK
YELLOW
BLUE
BLUE
GREEN
PURPLE
YELLOW
GRAY
YELLOW
GREEN
ORANGE
PINK
WIRE #
FUNCTION
45
GROUND
BATT POWER DIRECT
46
BATT POWER FUSED
47
GLOW COIL
48
GLOW CONTROL LAMP
49
IGN SW/PWR RELAY
50
51
HORN BUTTON/RELAY
PWR RELAY/CIRCUIT BREAKERS
52
53
HORN RELAY/HORN
NA
54
SEAT SW
55
LIGHTS POWER(KEYED)
56
IGN (KEYED) PWR
57
CHASSIS POWER (KEYED)
58
59
OIL PRESSURE SW
60
SEAT BELT LAMP
ROPS POWER (KEYED)
61
62
RESTRAINT BAR SW
63
SAFETY RELAY/ALTERNATOR
AIR FILTER RESTRICTION SW
64
65
IGN SW/START RELAY #1
66
START RELAY/SAFETY RELAY
67
ENG TEMP SENDER
68
2 SPEED LAMP
RIDE CONTROL LAMP
69
70
FUEL SENDER
2 SP SW/CONTROL MODULE
71
RIDE CONT SW/MODULE
72
ENG TEMP SENDER/GLOW MODULE73
74
INTERLOCK MOD/ RELAY 1 & 2
75
BRAKE SW/INTERLOCK MOD
76
ENG TEMP SW
77
HYD FILTER SW
CONTROL MOD/START RELAY
78
79
ALTERNATOR/HOUR METER
HYD SOLENOIDS
80
PARK BRAKE SOLENOID
81
82
PARK BRAKE LITE
83
CONTROL MOD/2 SP SOL.
CONTROL MOD/RIDE CONT SOL. 84
HYD TEMP SW
85
START SIGNAL TO GLOW MOD
86
87
REAR WORK LTS.
88
HEAD LTS & TAIL LTS
GLOW MODULE
S
COLOR
YELLOW
PURPLE
WHITE
WHITE
GREEN
WHITE
RED
WHITE
RED
RED
WHITE
RED
BROWN
YELLOW
RED
ORANGE
GREEN
RED
WHITE
BLACK
BLUE
PURPLE
PINK
TAN
WHITE
RED
BLACK
BLUE
ORANGE
BLUE
TAN
ORANGE
GRAY
GRAY
PINK
YELLOW
RED
WHITE
TAN
RED
PINK
BROWN
TAN
GRAY
WHITE
WIRE #
FUNCTION
89
PULL COIL TIMER
90
PULL COIL TIMER
91
PULL COIL RELAY/FUEL SOL
92
LIGHT SW/FLASHER
93
BACK UP ALARM
94
FLASHER/CONNECTOR
FUEL SOL (HOLD)
95
DOOR SWITCH/SAFETY MOD
96
GAUGE POWER
97
INTERLOCK POWER
98
99
AC/HEAT POWER
ACCESSORY POWER
100
101
FAN CLUTCH
102
GLOW RELAY SIGNAL
WIPER/WASH POWER
103
104
RADIO POWER
105
RADIO MEMORY
ALL TACH POWER (SWITCH)
106
107
ALL TACH POWER
GLOW RELAY GRND TO ECM
108
INJ PUMP RELAY GRND TO ECM 109
LIFT PUMP RELAY GRND TO ECM 110
STOP/SHUTDOWN INDICATOR - ECM
111
WARN/COLD INDICATOR - ECM 112
114
THROTTLE SENSOR GRND
THROTTLE SENSOR POWER
115
116
THROTTLE SENSOR SIGNAL
THROTTLE SWITCH SIGNAL
117
118
THROTTLE SWITCH POWER
SOLENOID LOCK POWER
119
INJ PUMP POWER
120
121
HORN POWER
122
LIFT PUMP POWER
123
POWER TO LIFT PUMP
RIDE/2 SPEED MODULE POWER
124
125
BACK UP ALARM POWER
GLOW PLUG POWER
126
127
START SOL
FAN CLUTCH POWER
128
DOME/STROBE POWER
129
FLOAT SW/CONT MOD
130
CONT MOD/RIDE CONT SOL
131
FLOAT LAMP
132
133
EXTRA START FUEL SOL
134
SAFETY RELAY/STARTER
917292/AP1008
AUXILIARY CONTROL POWER
AUXILIARY COIL POWER - LF FORWARD
AUXILIARY COIL POWER - LF REVERSE
AUXILIARY COIL FEEDBACK
AUXILIARY COIL POWER - HF FORWARD
AUXILIARY COIL POWER - HF REVERSE
AUXILIARY HF SWITCH POWER
FORWARD SIG FROM SWITCH TO HF MODULE
REVERSE SIG FROM SWITCH TO HF MODULE
POWER IND HF FORWARD
POWERE IND HF REVERSE
AUX COIL FEEDBACK HF FORWARD
AUX COIL FEEDBACK HF REVERSE
RIGHT TURN SIGNAL
LEFT TURN SIGNAL
FRONT POSITION LIGHT
ROAD LTS/LOW BEAM
LIGHTS POWER 2 (KEYED)
FLASHER/TURN SIG. POWER
RH TURN SIG./FLASHER
LH TURN SIG./FLASHER
TURN SIGNAL SW PWR
GREEN
YELLOW
ORANGE
RED
PINK
YELLOW
GRAY
PINK
GREEN
PURPLE
TAN
YELLOW
PINK
GREEN
BRN
GRY
YELLOW
TAN
GRAY
GRN
ORANGE
PINK
FUNCTION
SEAT AIR COMPRESSOR PWR
REAR WIPER/WASH PWR
REAR WIPER SW PWR
REAR WASHER SW PWR
FRT WIPER PWR
FRT WASHER SW PWR
STROBE SWITCH PWR
ROAD LTS/HI BEAM
FRONT WORKLIGHTS
LICENSE PLT LIGHT
ROADLIGHTS SW PWR
TAILLIGHTS SW PWR
STOP LIGHT
POSITION LIGHT SW PWR
FLASHER POWER TO RELAY
COLOR
YELLOW
PURPLE
YELLOW
ORANGE
TAN
GRAY
PINK
BLUE
BROWN
PUR
YELLOW
PINK
RED
ORANGE
BROWN
WIRE #
FUNCTION
ALL-TACH POWER (LOCKING)
135
GLOW MODULE POWER
136
ELECTRIC AUXILIARY POWER
137
138
START RELAY GRND TO ECU
ECU POWER RELAY GRND TO ECU 139
ECU/EGR POWER - KEYED
140
FUEL RACK RELAY GRND TO ECU 141
FUEL RACK POWER - KEYED
142
GLOW RELAY CONTROL TO ECU 143
ALTERNATOR SPEED OUTPUT
144
145
COLD START COIL TO ECU
RACK POS SENSOR TO ECU
146
FUEL RACK COIL GRND TO ECU 147
148
ENG TEMP SENSOR TO ECU
149
EGR1 TO ECU
EGR2 TO ECU
150
151
EGR3 TO ECU
152
EGR4 TO ECU
THROTTLE SENSOR (2) GRND
153
THROTTLE SENSOR (2) POWER
THROTTLE SENSOR (2) SIGNAL
ALL-TACH POWER UNLOCK
COLD START SWITCH
AUX INTERLOCK TO START
COLOR
RED
RED
RED
PURPLE
GREEN
RED
YELLOW
PINK
PINK
TAN
ORANGE
BLUE
GREEN
ORANGE
BROWN
GRAY
YELLOW
PURPLE
WHITE
RED
BLACK
WHITE
TAN
PURPLE
ELECTRICAL SYSTEM
Electrical Schematics - Wire Number and Color Legend - Tier3 Yanmar Engine
9-24
PRINTED IN USA
TO FLASHERS
LEFT TOWER
14
50A WHT-14
DCB A
00 BLK-14
49A DGN-14
43 ORG-14
42 DGN-14
21C DGN-16
RIDE CONT/
2 SPEED
1211109 8 7 6 5 4 3 2 1
10
40
TO FLASHERS
RIGHT TOWER
50B WHT-14
1211109 8 7 6 5 4 3 2 1
CHASSIS
CONNECTION
3
1 2
57 NEUTRAL
58 START
1
21D DGN-16
21B DGN-16
38 PUR-16
23 ORG-14
35A4 DBL-16
39 YEL-16
86 BRN-16
24 DBL-14
26 WHT-16
79 PNK-16
85 PNK-16
27 GRY-16
87 TAN-14
OH BLK-18
38
REAR
WORK
LIGHT
REAR
WORK
LIGHT
125 RED/WHT-18
12
12
CAN
12
TERMINATOR 12A
12
17
FORWARD HORN
BACKUP
50 ALARM
SWITCH
BACKUP
ALARM
51 SWITCH
86 BRN-16
OA2 BLK-16
38 PUR-16
OA3 BLK-16
52
LEFT CONTROL
HANDLE SWITCHES
0S BLK-12
55 WHT-12
56 RED-12
11 RED-12
E D CB A
4
CHASSIS
CONNECTION
654321
TAIL
LIGHT
DIAGNOSTIC
CONNECTOR
11
FUSE PANEL
53
74 DB 14
55 WT 12
80 YL 14
60 OG 14
56 RD 12
1
2
1
2
1
2
3
4
30
28
49 DGN-14
49A DGN-14
A
B
49 GN-14
0 BK-14
CHASSIS
CONNECTION
2
A
BB
1 2 3 4 5 6 7 8 9 101112
86+
87
30
85-
30
0B6 BK 16
76B OG 14
0B1 BK 16
20 BR 14
0V BLK-16
16
FUEL
SENDER
O2C RD 10
05A RD 14
O2D RD 10
05C RD 14
0 BK-16
32 GN-16
0D BLK-16
25 BRN-14
HYD TEMP
SWITCH
43
HYD FILTER
RESTRICT
SWITCH
39
40 GRY-14
HIGH FLOW
9
1 2 3 4 5 6 7 8 9 101112
BACKUP
ALARM
80 YL-14
49 DGN-14
A
B
FLOAT
CONTROL
SOLENOID
2 SPEED
SOLENOID
79B PNK-16
76 ORG-14
O6 ORG-14
26 WHT-16
0E BLK-16
08 ORG-16
CHASSIS
CONNECTION
1
1 2 3 4 5 6 7 8 9 101112
PUMP
FUEL
O8 OG 16
HORN
06 OG 14
ALLTACH
85-
RADIO
86+
ACCESS
20
SOL LOCK
20
HORN
20
87
ACCESS
30
30
62 WT 14
7.5
7.5
53 RD 14
20 WIPE/WASH
20
78 GY 16
FUEL
PUMP
20
116C RD-14
AU
CONTROL
87
85-
87
85-
30
86+
30
86+
87
85-
30
86+
RIDE/2SP
RIDE
CONTROL
SOLENOID
41
B A
1
2
HIGH FLOW
SOL-REVERSE
19 WH-16
27
31
44
1
2
HIGH FLOW
SOL-FORWARD
7
AIR FILTER
RESTRICT
SWITCH (OPT)
1
2
1
2
GROUND STUD
LEFT SIDE TOWER
GROUND STUD
LEFT SIDE TOWER
39A YEL-16
OA5 BLK-16
42
1
2
RIDE
CONTROL
SOLENOID
36B DBL-14
0A6 BLK-16
39B YEL-16
OA1 BLK-16
121 DGN-14
128 GRY-16
0L BLK-14
1
2
JOYSTICK
SUPPLY SOL
36A DBL-14
OA4 BLK-18
BRAKE
SOLENOID
1
2
PILOT
PRESSURE
SOLENOID
02I RD-10
02H RD-10
02G RD-10
13 RD 14
59 RD 14
76A OG 14
79C PK 16
11 RD 12
02H RD 10
POWER
0B2 BK 16
02G RD 10
POWER
0B5 BK 16
02I RD 10
POWER
0B4 BK 16
35A1 DBL-16
0M BLK-16
120 PNK-14
127 BRN-16
20
LIGHTS
20
O2B RD 10
29
32
30
02 RED-14
117 PNK-16
119A GRY-14
118 YEL-16
119B GRY-14
TO POWER
DISTRIBUTION
PANEL
1
2
1
2
35B DBL-16
85 PNK-16
27 GRY-16
116 RD-16
116 RD-16
45
37
STARTER
46
STD FLOW
SOL-FORWARD
85
+
86
25
87
35
35C BL-16
87
30
AC
BATTERY
82 WH-14
36
A
KEY
ECU
POWER
POWER
POWER
GRID
+86
26
ENGINE
HEATER
(GRID)
30
87
GLOW SOL.
RELAY
-85
20
34
+
86
AU CONTROL
RELAY
START
CB A
FOOT THROTTLE
47
ECU 6
1B 1D 1F 1H 1K 1M 2B 2D 2F 2H 2K 2M 3B 3D 3F 3H 3K 3M 4B 4D 4F 4H 4K 4M
1A 1C 1E 1G 1J 1L 2A 2C 2E 2G 2J 2L 3A 3C 3E 3G 3J 3L 4A 4C 4E 4G 4J 4L
TO BATTERY
POSITIVE
TERMINAL
3A3B3C3D3E3F3G
1A1B1C1D1E1F1G1H1J1K1L1M2A2B2C2D2E2F2G2H2J2K2L2M
3H3J3K3L3M4A4B4C4D4E4F4G4H4J4K4L4M
21A DGN-16
92 PUR-18
97 PNK-16
0T BLK-16
02 RD-8
02D RED-10
02C RED-10
02B RED-10
PANEL 18,19,20,21,55,56
HEAT
85
54
POWER DISTRIBUTION
ACESSORY
KEY POWER RT
13B RED-14
A
0 BLK-14
B
12
11
10
9
8 48
7
6
5 RIGHT
4 JOYSTICK
3
2
1
START SOL.
RELAY
30
- 85
OK BK
+86
FUEL RACK
RELAY
18
35A2 BL-14
79A PNK-16
118 YEL-16
117 PNK-16
119 GRY-16
0P BLK-16
116 RED-16
STD FLOW
SOL-REVERSE
79A PNK-16
116 RED-16
0P BLK-16
119 GRY-16
117 PNK-16
118 YEL-16
30
87
56 AC PWR
35G BL-16
02 RD-14
2A RED-14
55 HEATER PWR
94B RED-16
27 GRY-16
85 PNK-16
35B DBL-16
ENGINE
GROUND
+
86
85
93 DGN-18
ECU RELAY
87
19
A
B
ACESSORY
KEY POWER LT
13B RED-14
0N BK-14
96 PNK-16
05B RD 14
95 YEL-16
21D DG 16
START SAFETY
33 PK 14
60 ORG-14
62 WHT-14
53 RED-14
84 RED-14
54 RED-14
59 RED-14
67 PNK-18
125 PNK-14
123 TAN-14
122 PUR-14
124 YEL-14
126 DGN-14
94C RED-16
0B3 BK 16
25
BACK
10 ALARM
GAUGES
126 DGN-14
124 YEL-14
122 PUR-14
123 TAN-14
125 PNK-14
35A DBL-16
01 BLK-16
116A RED-14
120 PNK-14
127 BRN-16
121 DGN-14
128 GRY-16
60
10 AC/HEAT
10
84 RD 14
DOME
STROBE
10
54 RD 14
INTERLOCK
01 BLK-16
127 BRN-16
128 GRY-16
123 TAN-14
124 YEL-14
122 PUR-14
116 RED-14
35A DBL-16
125 PNK-14
120 PNK-14
126 DGN-14
121 DGN-14
05F RED-14
82 10-WHT
10
10
25
60
60
60
60
74 DB 14
02 RD-10
02 RD-10
4 DBL-18
94D RED-18
30
69A WHT-18
85-
49
ENGINE
CONNECTION
A B CD E F GH J K L MNP R S T U V W
132 PNK-18
0J BLK-16
14A PUR-18
102 ORG-18
86+
105 YEL-18
67 PNK-18
50 WHT-14
29 YEL-14
20 BRN-14
33 PNK-14
42 DGN-14
43 ORG-14
05 RED-14
02 RED-14
36 DBL-14
71 BLK-18
70 RED-14
69 WHT-14
02 RED-14
29 YEL-14
20 BRN-14
71 BLK-18
50 WHT-14
33 PNK-14
43 ORG-14
42 DGN-14
36 DBL-14
70 RED-14
69 WHT-14
05 RED-14
132 PNK-18
0F BK-16
102 ORG-18
105 YEL-18
87
81 RED-8
81 RD-8
70B RED-16
69C WHT-16
109 BLK-18
14A PUR-18
103 BRN-18
104 GRY-18
106 PUR-18
56 RED-12
0S BLK-12
11 RED-12
55 WHT-12
SHIELD DRAIN
GROUND
23 ORG-14
24 DBL-14
87 TAN-14
OH BLK-18
79 PNK-16
85 PNK-16
27 GRY-16
39 YEL-16
35A4 DBL-16
86 BRN-16
38 PUR-16
26 WHT-16
REAR DOOR,LIGHTS,
BACKUP ALARM
TAIL
LIGHT
00 BK-14
49 DGN-14
43 ORG-14
42 DGN-14
130 BLK-16
05D RED-16
0G BLK-16
C1 RED-18
0G BLK-16
130 BLK-16
C1 RED-18
05D RED-16
111 GRY-18
111 PUR-18
92 PUR-18
114 GRY-16
97 PNK-16
106 PUR-18
101 DGN-16
100 DBL-18
114 GRY-16
99 ORG-16
98 TAN-18
111 PUR-18
60 ORG-14
53 RED-14
125 PNK-14
59 RED-14
62 WHT-14
84 RED-14
54 RED-14
123 TAN-14
122 PUR-14
124 YEL-14
126 DGN-14
67 PNK-18
23 ORG-14
24 DBL-14
87 TAN-14
4 DBL-18
14B PUR-16
22 DGN-14
31 ORG-14
34 YEL-14
19 WHT-16
32 DGN-14
40 GRY-14
25 BRN-14
4 DBL-18
14B PUR-16
19 WHT-16
22 DGN-14
23 ORG-14
24 DBL-14
25 BRN-14
31 ORG-14
32 DGN-14
34 YEL-14
40 GRY-14
87 TAN-14
05E RED-18
21 DGN-18
02A RD-14
0 BK-0
103 BRN-18
109 BLK-18
34 YEL-14
31 ORG-14
22 DGN-14
104 GRY-18
31 ORG-14
106 PUR-18
95 YEL-18
93 DGN-18
71 BLK-18
100 DBL-18
109 BLK-18
70A RED-18
C1 BLK-18
C1 RED-18
0 BLK-16
94A RED-16
104 GRY-18
69A WHT-18
70A RED-18
67 PNK-18
71 BLK-18
4 DBL-18
21 DGN-18
132 PNK-18
C1 RED-18
94A RED-16
94D RED-18
05E RED-18
0J BLK-16
C1 BLK-18
0 BLK-16
14 PUR-18
94 RED-14
69B WHT-14
102 ORG-18
104 GRY-18
106 PUR-18
103 BRN-18
105 YEL-18
101 DGN-16
100 DBL-18
114 GRY-16
99 ORG-16
98 TAN-18
111 PUR-18T
111 GRY-18T
96 PNK-16
9-25
103 BRN-18
94 RED-14
105 YEL-18
101 DGN-16
100 DBL-18
114 GRY-16
22 DGN-14
99 ORG-16
69B WHT-14
14 PUR-18
98 TAN-18
102 ORG-18
96 PNK-16
34 YEL-14
111 PUR-18T
111 GRY-18T
98 TAN-18
99 ORG-16
101 DGN-16
917292/AP1008
111 GRY-18
92 PUR-18
97 PNK-16
95 YEL-18
93 DGN-18
35A3 DB 16
SOL LOCK PILOT
29 YL 14
ELECTRICAL SYSTEM
PRINTED IN USA
ENGINE
Introduction
Troubleshooting Guide
The following troubleshooting guide lists potential
engine problems, as well as possible causes and
remedies, for Gehl 5640E/6640E and Mustang
2066/76/86 skid-steer loaders.
When a problem occurs, dont overlook simple causes.
A malfunction could be caused by something as simple
as an empty fuel tank. After a mechanical failure has
been corrected, be sure to locate the cause of the
problem. For further troubleshooting information, refer
to the engine manufacturers manual.
IMPORTANT
DO NOT attempt to service or repair major
engine components unless authorized to do
so
by
your
Gehl
or
Mustang
dealer/distributor. Any unauthorized repair
will void the warranty.
Problem
Possible Cause
Remedy
PRINTED IN USA
10-1
917292/AP1008
ENGINE
ENGINE
Problem
Possible Cause
Remedy
Troubleshoot/replace
Wiring to and from ignition, seat switch, Check wiring for poor connections or
broken leads and repair wiring or
restraint bar switch, etc. loose or
connection.
disconnected
Engine overheats.
917292/AP1008
Engine overloaded
Exhaust restricted
Add coolant.
10-2
PRINTED IN USA
ENGINE
Engine Components - Yanmar 4TNV98 - Mustang 2066/76/86 Models
5
42
40
46
57
39
30
43
50
16
42
23
24
58
10
13
1
35
44
4
16
28
29
37
26
47
18
27
22
17
25
41
48
20
52 NOTE
1&5
14
38
15
NOTE 2
11
21
NOTES
25
14
7
28
55
NOTE
1&4
12
33
11
31
51
45
NOTE 2
NOTE 6
54
41
49
53
9
8
NOTE
1&3
NOTE
1&5
7
7
NOTE
1&3
19
49
27
34
32
30
34
3
3
36
37
2
34
26
TO FUEL
RETURN
56
59
34
15
25
FUEL
SUPPLY
28
41
34
1 FITTING/STRAIGHT
2 NUT/LOCK
3 NUT/LOCK
4 FITTING/STRAIGHT
5 NUT/SPIRALOCK
6 WASHER/HARD
7 WASHER/SNUBBING
8 ISOLATOR
9 HOUSING/FLYWHEEL
10 CLAMP/TUBE
11 NUT/SPIRALOCK
12 FITTING/90
13 PUMP/FUEL
14 ISOLATOR
15 VALVE/SHUT OFF
56
16 ENGINE
17 COUPLER
18 FILTER/FUEL
19 MOUNT/ENGINE
20 ENGINE MOUNT
21 ENGINE MOUNT
22 MATING FILTER
23 BRACKET/ALT.
24 SPACER/ALT.
25 HOSE/FUEL
26 HOSE/FUEL
27 HOSE/FUEL
28 HOSE/FUEL
29 SPACER/ALT.
30 MOUNT/FILTER
31 ADAPTER/FILTER
32 ALTERNATOR
33 CLAMP/HOSE
34 CLAMP/HOSE
35 FILTER/OIL
36 STARTER
37 SEPARATOR/FUEL
38 BELT/ALT. FAN
39 HOSE/FILTER
40 HOSE/FILTER
41 HOSE OIL DRAIN
42 ASSY/DIPSTICK
43 BRACKET/DIPSTICK
44 WASHER/FLAT
45 SCREW/SET
46 SCREW/CAP
47 SCREW/CAP
48 SCREW/CAP
49 BOLT/CARRIAGE
50 SCREW/CAP
51 SCREW/CAP
52 SCREW/CAP
53 SCREW/CAP
54 SCREW/CAP
55 SCREW/CAP
56 NUT/HEX
57 SCREW/CAP
58 SCREW/CAP
59 SCREW/CAP
Fig. 10-1 Exploded view of the Yanmar 4TNV98 naturally-aspirated and turbocharged engine
PRINTED IN USA
10-3
917292/AP1008
ENGINE
Air Cleaner and Exhaust Components - 2066 Models
12
4
5
19
14
12
15
2
12
21
20
13
1
GASKET PROVIDED
WITH ENGINE
1
18
3.84
2.68
9
17
22
1 NUT/HEX
2 SCREW/CAP
3 CLAMP/MUFFLER
4 CLAMP/AIR CLEANER
5 ELBOW/90
6 ELEMENT/PRIMARY
7 ELEMENT/SECONDARY
8 COUPLING/HOSE
16
11
9 CLAMP/T BOLT
10 ASSY/AIR CLEANER
11 CLAMP/T-BOLT
12 CLAMP/HOSE
13 VALVE/VACUATOR
14 END CAP/AIR CLEANER
15 INDICATOR/RESTRICTION
16 HOSE/MOLDED
17 COUPLER/FLEX
18 MOUNT/AIR CLEANER
19 MUFFLER
20 BOLT/CARRIAGE
21 BOLT/CARRIAGE
22 NUT/HEX
Fig. 10-2 Exploded view of the naturally-aspirated engine air cleaner and exhaust components
917292/AP1008
10-4
PRINTED IN USA
ENGINE
Air Cleaner and Exhaust Components - 56/6640 and 2076/86 Models
14
2
19
8
11
ATTACH TO
TURBO OUTLET
28
9
13
12
20
17
17
26
16
GASKET SUPPLIED WITH
ENGINE
24
25
ATTACH TO
23
TURBO INLET
10
18
4
27
15
22
10
1 SCREW/CAP
2 SCREW/CAP
3 CLAMP/MUFFLER
4 NUT/SPIRALOCK
5 CLAMP
6 CLAMP/AIR CLEANER
7 ELBOW 90
8 ELEMENT/ PRIMARY
9 ELEMENT/SECONDARY
10 CLAMP/T-BOLT
11 ASSY/AIR CLEANER
12 CLAMP/HOSE
13 VALVE/VACUATOR
14 END CAP/AIR CLEANER
15 ELBOW/MOLDED
16 OUTLET/EXHAUST
17 COUPLER/FLEX
18 MOUNT/AIR CLEANER
19 MUFFLER
20 GASKET/EXHAUST
21 TUBE/INTAKE
22 HOSE/AIR INTAKE
23 ADAPTER/FILTER
24 CLAMP/T-BOLT
25 INDICATOR/RESTRICTION
26 BOLT/CARRIAGE
27 SCREW/CAP
28 SCREW/CAP
Fig. 10-3 Exploded view of the turbocharged engine air cleaner and exhaust components
PRINTED IN USA
10-5
917292/AP1008
ENGINE
21
ENGINE
Radiator Cooler Components - 2066/76/86 Models
3
7
19
4
TO COOLER
OUTLET
17
16
12
TO FILTER
RETURN
3
23
1
3
13
20
TO COOLER
INLET
14
3
2
1
3
15
18
21
10
14
22
1
22
11
COOLER OUTLET
1.37
.77
TO ENGINE
WATER OUTLET
TO ENGINE
WATER INLET
.35
COOLER INLET
ASSEMBLED VIEW
.87
1 CLAMP/HOSE
2 NUT/HEX
3 SCREW/FLANGE
4 CAP/RADIATOR
5 PAD/COOLER
6 HOSE/FUEL
7 SEAL/BULB
8 BOTTLE/OVERFLOW
9 EXCHANGER/HEAT
10 FAN
11 HOSE/RADIATOR
12 HOSE/RADIATOR
13 SPACER/FAN
14 PLATE/MOUNT
15 ASSY/FAN SHROUD
16 HOSE/INLET
ENGINE
TO RESERVOIR
RETURN
17 HOSE/OUTLET
18 SEAL/BULB
19 COVER/COOLER
20 WASHER/SPACER
21 COVER/SHROUD
22 BOLT/CARRIAGE
23 SCREW/CAP
917292/AP1008
10-6
PRINTED IN USA
ENGINE
Radiator Cooler Components - 56/6640 Models
COOLER
OUTLET
TO ENGINE
WATER OUTLET
TO ENGINE
WATER INLET
TO RESERVOIR
RETURN
COOLER
INLET
ASSEMBLED VIEW
TO COOLER 9
OUTLET
7
15
14
6
3
21
11
TO RETURN
FILTER
23
17
1
3
12
18
20
2
13
22
19
1 CLAMP/HOSE
2 NUT/HEX WHIZLOCK
3 SCREW/FLANGE WHIZLOCK
4 CAP/RADIATOR
5 PAD/COOLER
6 HOSE/FUEL
7 SEAL/BULB
8 BOTTLE/OVERFLOW
1
TO COOLER 3
INLET
10
13
9 EXCHANGER/HEAT
10 HOSE/RAD/LOWER
11 HOSE/RAD/UPPER
12 SPACER/FAN
13 PLATE/COOLER MOUNT
14 HOSE/INLET/COOLER
15 HOSE/OUTLET/COOLER
16 SEAL/BULB
16
17 SHROUD/FAN
18 WASHER/SPACER
19 FAN
20 COVER/SHROUD/LOWER
21 INSULATION/SHROUD
22 BOLT/CARRIAGE
23 SCREW/CAP
PRINTED IN USA
10-7
917292/AP1008
ENGINE
SECTION NOTES
917292/AP1008
10-8
PRINTED IN USA
ENGINE
Remote Oil Filter Element Removal and
Installation
The remote engine oil filter, left of the radiator cooler, is
attached low to the left side of the engine compartment.
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:
Fig. 10-6 Remote engine oil filter access point on the left
side of the radiator cooler
Removal Procedure
1. Open the engine access cover and rear grille. Lock
the grille open with the latch pin on the grille's lower
pivot area. Figs. 10-6, 10-7
2. On left side of engine compartment find the oil filter
element. Fig. 10-7
3. Clean area around oil filter element.
4. Place a suitable container beneath the oil drain
weldment to catch any leaking oil. Fig. 10-8
5. Turning counterclockwise, loosen oil filter element
with a filter wrench.
Fig. 10-7 Location of rear grille latch
5. Start engine and check for leaks near oil filter. Shut
off engine, recheck oil level, and fill as needed.
PRINTED IN USA
10-9
917292/AP1008
ENGINE
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.
917292/AP1008
10-10
PRINTED IN USA
ENGINE
Battery and Battery Tray Removal and
Installation
Removal Procedure
Negative Battery Cable
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:
WARNING
Review the following safety considerations
before working on or around the battery:
PRINTED IN USA
10-11
917292/AP1008
ENGINE
ENGINE
Starter Removal and Installation
Removal Procedure
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:
Starter
917292/AP1008
10-12
PRINTED IN USA
ENGINE
Exhaust Assembly Removal and
Installation
Removal Procedure
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:
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
PRINTED IN USA
10-13
917292/AP1008
ENGINE
ENGINE
Fan Belt Adjustment
Adjustment Procedure
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:
Fan Belt
917292/AP1008
10-14
PRINTED IN USA
ENGINE
Radiator Cooler Removal and Installation
The radiator cooler is mounted on a shroud located just
behind the engine.
Removal Procedure
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:
Fan Shroud
3. Open the engine access cover and lock open the rear
grille.
4. Disconnect the hose clamps on two radiator hoses
and the fittings on two hydraulic oil hoses from the
inlets and outlets of the radiator cooler. Figs. 10-23
- 10-26
PRINTED IN USA
10-15
917292/AP1008
ENGINE
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.
917292/AP1008
10-16
PRINTED IN USA
ENGINE
Fan Shroud and Cooler Mount Plates
Removal and Installation
Removal Procedure
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:
Overflow Bottle
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.
10-17
917292/AP1008
ENGINE
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:
Fuel Pump
WARNING
DO NOT PROCEED with the following steps
unless engine has completely cooled and is
safe to touch.
Starter
917292/AP1008
10-18
PRINTED IN USA
ENGINE
9. Remove fan shroud and cooler mounting plates per
the procedure in this chapter.
10. Turn fuel return line petcock (small red petcock) to
its OFF position and disconnect line from the
engine. Fig. 10-33
11. Turn fuel separator petcock to its OFF position. Fig.
10-33
12. Disconnect the fuel line in front of the fuel pump
and unplug the electrical connector on the fuel
pump. Fig. 10-34
Battery
16. Remove one carriage bolt, lock nut (80 ft-lbs) (109
Nm) and two washer on four engine mounts. Fig.
10-42
17. With hoist attached to engine, lift slightly and pull
engine rearward. Continue pulling engine rearward
until pump is free from drive coupling. Then remove
engine from chassis.
Installation Procedure - Follow all warnings first,
then reverse the removal steps.*
Fig. 10-38 Location of the red wire grid heater electrical
connector that needs disconnecting prior to
removing the engine from the chassis
PRINTED IN USA
* Bleed the electric fuel pump. Also check engine oil and
hydraulic oil levels prior to starting the skid-steer loader.
10-19
917292/AP1008
ENGINE
ENGINE
Fig. 10-43 Lift hooks on lift eyes on the engine are ready to
pull the engine out of the skid-steer loader
Fig. 10-41 View of three nuts securing the remote oil filter
to the left side of the chassis
917292/AP1008
10-20
PRINTED IN USA
ENGINE
Yanmar 4TNV98-ZNMS Engine ECU Fault Codes
PRINTED IN USA
10-21
917292/AP1008
ENGINE
Yanmar 4TNV98-ZNMS Engine ECU Fault Codes
917292/AP1008
10-22
PRINTED IN USA
ENGINE
Yanmar 4TNV98-ZNMS Engine ECU Fault Codes
PRINTED IN USA
10-23
917292/AP1008
ENGINE
NOTES
917292/AP1008
10-24
PRINTED IN USA
INDEX
A
Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Air Cleaner and Exhaust Components - 2066 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Air Cleaner and Exhaust Components - 56/6640 and 2076/2086 . . . . . . . . . . . . . . . . . . 10-5
Air Cleaner Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
All-Tach Hitch Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
B
Battery and Battery Tray Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-11
C
Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Chassis Components . . . . . . . . . . . . .
Chassis Electrical Components . . . . . . . .
Control Cover Components - Hand and Foot .
Control Cover Components - T-Bar . . . . . .
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4-3,4-4
. . 9-5
4-5,4-6
. . 4-7
Electrical Foot Throttle Removal and Installation - Dual Joystick Controls . . . . . . . 6-13
Electrical Hand Throttle Removal and Installation . . . . . . . . . . . . . . . . . . . . 6-12
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lift and Tilt Components - Dual Joystick and T-Bar/Joystick Control Models . . . . . . 6-4
Lift and Tilt Components - Hand/Foot Control Models. . . . . . . . . . . . . . . . . . . 6-3
Lift and Tilt Components - T-Bar Control Models . . . . . . . . . . . . . . . . . . . . . 6-5
Lift/Tilt Control Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Cooling System Drain Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
D
Description of Operation - Right and Left Instrument Panels . .
Dimensional Specifications . . . . . . . . . . . . . . . . . . . .
Drive Control Components - Hand/Foot . . . . . . . . . . . . .
Drive Control Components - T-Bar and T-Bar/Joystick Models.
PRINTED IN USA
Index-1
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. . 9-1
. . 1-2
6-6,6-7
. . 6-8
917292/AP1008
INDEX
INDEX
E
Electrical Foot Throttle Assembly - T-Bar, T-Bar/Joystick and Dual Joystick Controls . . . . . . 6-14
Electrical Foot Throttle Removal and Installation - Dual Joystick Controls . . . . . . . . . . . . 6-13
Electrical Hand Throttle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Electrical System Chapter
Chassis Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Control Handle Actuation Buttons - Two-Speed, Ride Control and Float Module . . . . 9-21
Description of Operation - Right and Left Instrument Panels. . . . . . . . . . . . . . . . 9-1
Electrical High-Flow Auxiliary Hydraulic Flow System Test and Operation . . . . . . . 9-19
Electrical Standard Auxiliary Hydraulic Flow System Test and Operation . . . . . . . . 9-17
Engine Electrical Components - 2066/76/86 . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Engine Throttle Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Fuse Box Panel Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
High-Flow and Two-Speed Electrical Components . . . . . . . . . . . . . . . . . . . . . 9-8
Interlock Control Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Interlock Control Module Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Pilot Oil Solenoid Valve Test and Operation - Dual Joystick and Hand/Foot. . . . . . . 9-20
Power Distribution Panel Test and Operation . . . . . . . . . . . . . . . . . . . . . . . 9-10
ROPS Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Schematics - ROPS, Chassis and Engine. . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Solenoid Lock Valves Test and Operation - T-Bar Only . . . . . . . . . . . . . . . . . 9-20
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Two-Speed, Ride Control and Float Module Test . . . . . . . . . . . . . . . . . . . . . 9-15
Two-Speed, Ride Control and Float Module Truth Table . . . . . . . . . . . . . . . . . 9-16
Electrically-controlled High-Flow Auxiliary Hydraulic Flow System Test and Operation . . . . 9-19
Electrically-controlled Standard Auxiliary Hydraulic Flow System Test and Operation. . . . . . 9-17
Engine Access Cover - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Engine Chapter
Air Cleaner and Exhaust Components - 2066 . . . . . . . . . . . . . . . . . . . . . . . 10-4
Air Cleaner and Exhaust Components - 56/6640 and 2076/86 . . . . . . . . . . . . . . 10-5
Air Cleaner Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . 10-10
Battery and Battery Tray Removal and Installation . . . . . . . . . . . . . . . . . . . 10-11
Engine Components - Yanmar 4TNV98 - 2066/76/86. . . . . . . . . . . . . . . . . . . 10-3
Engine Diagnostic Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Exhaust Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 10-13
Fan Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Fan Shroud and Cooler Mount Plates Removal and Installation . . . . . . . . . . . . . 10-17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Radiator Cooler Components - 2066/76/86 . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Radiator Cooler Components - 56/6640 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Radiator Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Remote Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . 10-9
Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
917292/AP1008
Index-2
PRINTED IN USA
INDEX
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Engine Components - Yanmar 4TNV98 - 2066/76/86 . . . . . . . . . . . . . . . . . . . . . . . 10-3
Engine Diagnostic Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Engine Electrical Components - 2066/76/86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Engine Throttle Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Exhaust Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
F
Fan Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Fan Shroud and Cooler Mount Plates Removal and Installation. . . . . . . . . . . . . . . . . . 10-17
Fuse Box Panel Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Fuse Box Panel Relay Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Fuse Box Panel Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
G
Grease Fitting Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
H
High-Flow and Two-Speed Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
High-Flow Auxiliary Hydraulics - Dual Joystick, Hand/Foot and T-Bar/Joystick Controls . . . . . 8-7
High-Flow Auxiliary Hydraulics - T-Bar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
High-Flow Lift Arm Hydraulics Option - Dual Joystick, Hand/Foot, T-Bar/Joystick . . . . . . . 8-12
Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic System Chapter
Control Valve Components - Standard-Flow and High-Flow . . . . . . . . . . . . . . . 8-23
Control Valve Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
High-Flow Auxiliary Hydraulics - Dual Joystick, H/F and T-Bar/Joystick Controls. . . . 8-7
High-Flow Auxiliary Hydraulics - T-Bar Controls . . . . . . . . . . . . . . . . . . . . . 8-8
High-Flow Lift Arm Hydraulics Option - Dual Joystick, H/F, T-Bar/Joystick . . . . . . 8-12
Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Lift Arm Hydraulics Components - 2066/76 . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Lift Arm Hydraulics Components - 2086 . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Lift Arm Hydraulics Components - 56/6640 . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Main Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 8-22
Manifold Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Pressure Tests, Standard-Flow and High-Flow Auxiliary . . . . . . . . . . . . . . . . . 8-13
Standard Auxiliary Hydraulics - Dual Joystick, H/F and T-Bar/Joystick Controls. . . . . 8-5
Standard Auxiliary Hydraulics - T-Bar Controls . . . . . . . . . . . . . . . . . . . . . . 8-6
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
PRINTED IN USA
Index-3
917292/AP1008
INDEX
Hydrostatic System - 2066/76 Two-Speed Components - Dual Joystick Controls. . . . . . . . . . 7-4
Hydrostatic System - Single Speed Components - Dual Joystick Controls . . . . . . . . . . . . . 7-2
Hydrostatic System - Single Speed Components - Hand/Foot Controls . . . . . . . . . . . . . . . 7-3
Hydrostatic System - Two-Speed Components - Hand/Foot Controls . . . . . . . . . . . . . . . . 7-5
Hydrostatic System Chapter
2066/76 Two-Speed Components - Dual Joystick Controls . . . . . . . . . . . . . . . . 7-4
Hydraulic/Hydrostatic Schematic - Dual Joystick Controls . . . . . . . . . . . . . . . . 7-10
Hydraulic/Hydrostatic Schematic - Hand/Foot Controls. . . . . . . . . . . . . . . . . . 7-11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Single-Speed Components - Dual Joystick Controls . . . . . . . . . . . . . . . . . . . . 7-2
Single-Speed Components - Hand/Foot Controls . . . . . . . . . . . . . . . . . . . . . . 7-3
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Two-Speed Components - Hand/Foot Controls . . . . . . . . . . . . . . . . . . . . . . . 7-5
I
Interlock Control Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Interlock Control Module Truth Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
L
Lift and Tilt Components - Dual Joystick and T-Bar/Joystick Control Models . . . . . . . . . . . 6-4
Lift and Tilt Components - Hand/Foot Control Models . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lift and Tilt Components - T-Bar Control Models . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Lift Arm Hydraulics Components - 2066/2076 Models . . . . . . . . . . . . . . . . . . . . . . . 8-9
Lift Arm Hydraulics Components - 2086 Models . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Lift Arm Hydraulics Components - 56/6640 Models . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Lift/Tilt Control Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Liftarm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Liftarm Support Device Disengagement . .
Liftarm Support Device Engagement . . . .
Loader Lowering Procedure . . . . . . . . .
Loader Raising Procedure . . . . . . . . . .
Lubrication Chapter
Chaincases . . . . . . . . . . . . .
Cooling System Drain Procedures .
Crankcase Oil . . . . . . . . . . .
General Information . . . . . . . .
Grease Fitting Locations . . . . . .
Hydraulic Oil Reservoir . . . . . .
917292/AP1008
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3-3
3-4
3-2
3-1
3-4
3-2
Index-4
PRINTED IN USA
INDEX
M
Main Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Mainframe Chapter
All-Tach Hitch Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3,4-4
Control Cover Components - Dual Joystick . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Control Cover Components - Hand and Foot . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Control Cover Components - T-Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Control Cover Components - T-Bar/Joystick . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Control Cover, Floor Cover Removal and Installation. . . . . . . . . . . . . . . . . . . 4-12
Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Engine Access Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Rear Grille and Engine Cover Components . . . . . . . . . . . . . . . . . . . . . 4-17,4-18
Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Rollover and Falling Object - Protective Structure Components . . . . . . . . . . . . . . 4-1
ROPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Mandatory Safety Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Manifold Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
P
Pilot Oil Solenoid Valve Test and Operation - Dual Joystick and Hand/Foot . . . . . . . . . . . 9-20
Power Distribution Panel Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Power Distribution Panel Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Pressure Tests, Standard-Flow and High-Flow Auxiliary . . . . . . . . . . . . . . . . . . . . . . 8-13
R
Radiator Cooler Components - 2066/76/86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Radiator Cooler Components - 56/6640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Radiator Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Rear Grille and Engine Cover Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17,4-18
Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Remote Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Rollover and Falling Object - Protective Structure Components . . . . . . . . . . . . . . . . . . . 4-1
ROPS Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
ROPS Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
ROPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
ROPS, Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
PRINTED IN USA
Index-5
917292/AP1008
INDEX
S
Safety Chapter
Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Liftarm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Liftarm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Liftarm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
ROPS, Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
ROPS, Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Schematics
Electrical Schematics - ROPS, Chassis and Engine . . . . . . . . . . . . . . . . . . . . 9-22
Hydraulic/Hydrostatic Schematic - Dual Joystick Controls . . . . . . . . . . . . . . . . 7-10
Hydraulic/Hydrostatic Schematic - Hand/Foot Controls. . . . . . . . . . . . . . . . . . 7-11
Solenoid Lock Valves Test and Operation - T-Bar Only . . . . . . . . . . . . . . . . . . . . . . 9-20
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Standard Auxiliary Hydraulics - Dual Joystick, Hand/Foot and T-Bar/Joystick Controls . . . . . . 8-5
Standard Auxiliary Hydraulics - T-Bar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
T
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-i
Two-Speed, Ride Control and Float Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Two-Speed, Ride Control and Float Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Two-Speed, Ride Control and Float Module Truth Table . . . . . . . . . . . . . . . . . . . . . . 9-16
917292/AP1008
Index-6
PRINTED IN USA
Gehl Company, 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 USA
www.gehl.com
www.mustangmfg.com
917292/AP1008
PRINTED IN USA