Gehl 1640E Mustang 2012 Skid Steer Loader Service Manual 917400 08.2009 - PDF DOWNLOAD

Gehl 1640E Mustang 2012

Form No. 917400 Revision A 08/09

Service Manual

SKID-STEER LOADERS

INTRODUCTION With correct maintenance and proper use, the Gehl 1640E and Mustang 2012 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 Gehl 1640E and Mustang 2012 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.

Many schematics, photographs, and line art drawings are used to help perform the necessary repairs, tests, or adjustments that the skid-steer loader needs to keep it 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.

GEHL 1640E / MUSTANG 2012

TABLE OF CONTENTS

TABLE OF CONTENTS Specifications

Page

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety

Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Arm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Arm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ROPS – Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ROPS – Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Lubrication

Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Grease Fitting Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cooling System Drain Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Mainframe

Page

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Mainframe (Chassis), Rear Grille and Engine Cover Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine Access Cover - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ROPS/FOPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Seat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Seat Slide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ROPS/FOPS Rear Window Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Restraint Bar Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 PRINTED IN USA

1

TABLE OF CONTENTS

GEHL 1640E / MUSTANG 2012

All-Tach® Hitch Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Restraint Bar Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 All-Tach® Hitch Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Lift Arm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Lift Arm Bushing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Lift Arm Stop Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Floor Cover/Step Cover/Kickplate Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Fuel Sensor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Wheel Drives

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Wheel Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Axle Housing Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Drive Chain Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Axle and Wheel Bearing Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Controls

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Control Locations - T-Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Wheel Drive, Foot Throttle and Lift Tilt Components - Illustration - Later Models . . . . . . . . . . . . . . . . . . . . . . . 44 Wheel Drive, Foot Throttle and Lift Tilt Components - Parts Listing - Later Models . . . . . . . . . . . . . . . . . . . . . 45 Wheel Drive, Foot Throttle and Lift Tilt Components - Illustration - Earlier Models . . . . . . . . . . . . . . . . . . . . . . 46 Wheel Drive, Foot Throttle and Lift Tilt Components - Parts Listing - Earlier Models . . . . . . . . . . . . . . . . . . . . 47 Control Handle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Control Handle Position Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 T-Bar Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Backup Alarm Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Pivot Tube Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Pump Control Arm Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Lift/Tilt Controls Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Lift/Tilt Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Auxiliary Hydraulics Cable Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Auxiliary Hydraulics Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Engine and Hand Throttle Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Hand Throttle, Foot Throttle Pedal and Throttle Cables/Throttle Rod Removal and Installation . . . . . . . . . . . . . 59 Hand Throttle Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Foot Throttle Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2

PRINTED IN USA

GEHL 1640E / MUSTANG 2012 Hydrostatic System

TABLE OF CONTENTS Page

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Hydrostatic Components - Standard Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Hydrostatic Components - Drive Motor with Brake Release Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Hydrostatic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Charge Pressure Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Hydrostatic Pump Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Hydrostatic Pump Removal / Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Hydrostatic Pump Drive Coupling Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Drive Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Hydrostatic/Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76, 77

Hydraulic System

Page

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Hydraulics - Non-Self Level and Self Level Valve Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Hydraulics - Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Hydraulics - Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Pressure Tests, Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Tilt Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Self-Leveling Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Lift Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Solenoid Valve Test - Tilt, Lift, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Tilt Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Lift Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Tilt Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Lift/Tilt Cylinder Disassembly / Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Gear Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Self-Leveling Valve Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Self-Leveling Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Safety Lock Valves - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Lift, Tilt and Brake Solenoid Valves - Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Main Control Valve Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Control Valve Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Main Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Control Valve Spool Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

PRINTED IN USA

3

TABLE OF CONTENTS Electrical System

GEHL 1640E / MUSTANG 2012 Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Description of Operation - Right and Left Instrument Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Electrical Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Electrical Battery Disconnect Switch Components (EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Electrical Battery Disconnect Switch Components (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Electrical ROPS/FOPS Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Relay Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Relay Test - Fuel Pull, Starter, Safety Lock and Auxiliary Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Glow Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Seat Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Restraint Bar Switch Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Engine Disconnect Switch - Remote Battery Terminal Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 118 Restraint Bar Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Front and Rear Work Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Electrical Lights Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Dome Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Lift and Tilt Solenoid Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Brake Solenoid Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Auxiliary Neutral Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124, 125

Engine

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Engine Components and Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Air Cleaner and Exhaust Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Radiator/Cooler Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Air Cleaner Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Air Filter Element Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Battery and Battery Tray Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Exhaust Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Fan Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Radiator/ Oil Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Fan Shroud and Support Brackets Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Fan Shroud Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Fan Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Engine Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

INDEX

4

Page 147

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

SPECIFICATIONS

SPECIFICATIONS Model Engine Make Engine Model Fuel Displacement Horsepower - Net Peak Torque Rated Operating Capacity Operating Weight Shipping Weight

1640E / 2012 Yanmar 3TNV82A-BPMS Diesel 81.2 CID (1,33 L) 23.9 hp (17,8 kW) 68 lbf-ft. (86 N•m) 850 lbs. (386 kg) 2980 lbs. (1352 kg) 2820 lbs. (1279 kg)

Capacities Engine Oil Fuel Tank Chaincase (each) Hydraulic Reservoir Engine Coolant

Capacities 5.8 US qts. (5,5 L) 7.7 US gal. (29,1 L) 6.0 US qts. (5,7 L) 7.2 US gal. (27,2 L) 8.0 US qts. (7,57 L)

Electrical System Battery Starter Alternator

Electrical 12-V DC, Group 24, 675 CCA, 115 Reserve 12-V DC (1,7 kW) 40 A

Hydraulic System Hydraulic System Pressures Standard Auxiliary Flow Rate Travel Speed (with standard tire)

Hydraulic System 2255 PSI (156 bar) 10.1 gal/min (38,2 L/min) 0 to 5.5 mph (0 to 9,0 km/h)

Tire Options 5.70 x 12 Heavy-Duty 4-Ply 23 x 8.50-12 Heavy-Duty 6-Ply

Tire Options Description NHS Trac Loader Chevron NHS Heavy-Duty 2000

Buckets and Capacities Width - Description 36 inches (914 mm) - Dirt/Construction 44 inches (1118 mm) - Dirt/Construction 48 inches (1219 mm) - Utility/Snow 15.75-19.68-24 inches (400-500-610 mm) Pallet

Capacity (Heaped) 5.3 cubic feet ; 0,15 cubic meters 7.4 cubic feet ; 0,21 cubic meters 9.8 cubic feet ; 0,28 cubic meters Not Applicable

*Operating capacity rated with a 5.70 tires, 5.3 cubic foot (0.15 m3) dirt/construction bucket in accordance with SAE J818, SAE J732 and ISO 14397-1.

PRINTED IN USA

917400/AP0809

1

SPECIFICATIONS

GEHL 1640E / MUSTANG 2012

M

E

A

G B F

C W O

I D

P

S

X

V

Z

Y

1640E and 20121

Dimensional Specifications A B C D E F G I M O P Q R S V W X Y Z

Q

R

Overall operation height - fully raised Height to hinge pin - fully raised Overall height - top of ROPS Overall length - bucket down Dump angle @ full height Dump height Dump reach - bucket (full height) Rollback at ground Rollback angle @ full height Seat-to-ground height Wheelbase - nominal Overall width - less bucket Overall bucket width Ground clearance to chassis (between wheels) Overall length (less bucket) Departure angle Clearance circle - front (with bucket) Clearance circle - front (less bucket) Clearance circle - rear

in.

124.7 96 74.7 101.4 72.3 14.8

34.6 30.5 35.8 36.0/44.0 6.0 75 58 32.8 43.2

mm 3167 2438 1897 2576 45.9º 1836 376 23.4º 100.3º 879 775 909 914/1118 152 1905 30.1º 1473 833 1097

1 - w/5.3 cu.-ft. bkt./7.4 cu.-ft. bkt., and 5.7 x 12 tires

2

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

SAFETY Signal Words

DANGER “DANGER” indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

General Information The above safety alert symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! It stresses an attitude of “safety awareness” and can be found throughout this service manual and on decals on the machine.

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

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

Both Gehl and Mustang Company ALWAYS consider the operator’s safety when designing machinery and guards exposed moving parts for the operator’s protection. However, some areas cannot be guarded or shielded in order to assure proper operation. The Operator’s Manual and the decals on the machine warn of additional hazards and should be read and observed closely.

These topics in the Safety chapter of the service manual include procedures, which, when followed, will allow safe performance of service procedures: Mandatory Safety Shutdown Procedure, Lift Arm Support Device, Roll-Over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS) Lock Mechanism, Loader Raising and Lowering Procedures, and Relieving Hydraulic Pressure.

PRINTED IN USA

WARNING “WARNING” indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

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

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

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

Damaged or Worn-out Parts - For safe operation, replace damaged or worn-out parts with genuine Gehl/ Mustang service parts, before operating this equipment.

Attachments - Gehl and Mustang loaders are designed and intended to be used only with Gehl/Mustang Company attachments or approved referral attachments.

The Company cannot be responsible for operator safety if the loader is used with a non-approved attachment.

Battery Safety - To avoid injury from a spark or short circuit, disconnect the negative battery cable before servicing any part of the electrical system. Do not tip the battery more than 45º.

917400/AP0809

3

SAFETY

GEHL 1640E / MUSTANG 2012

Loader Stability - A skid-steer loader’s stability is determined by its wheelbase and tread width. The following elements can affect stability: terrain, 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 operator’s seat. Operate the controls smoothly and gradually at an appropriate engine speed that matches the operating conditions.

DO NOT exceed the rated operating capacity of the machine. For additional stability when operating on inclines or ramps, ALWAYS travel with the heavier end of the loader toward the top of the incline.

ALWAYS look to the rear before backing up.

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

Keyswitch - NEVER attempt to bypass the keyswitch to start the engine. Use the jump-starting procedure detailed in the Service chapter of the Operator’s Manual.

Hydraulic Fluid Leaks - NEVER use hands to search for hydraulic fluid leaks.

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

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

ALWAYS wear safety glasses when searching for hydraulic leaks or when working near batteries.

Loaded Bucket/Fork - DO NOT raise or drop a loaded bucket or fork suddenly. Abrupt movements under load can cause serious loader instability.

NEVER push the lift control into the “float” position with the bucket or attachment loaded or raised, because this will cause the lift arm to lower rapidly.

strength to support the weight of the loader and the load.

DO NOT smoke or have any spark-producing equipment in the area while filling the fuel tank or while working on the fuel or hydraulic systems.

Exhaust Gases - Exhaust fumes can kill. DO NOT operate this machine in an enclosed area unless there is adequate ventilation.

Engine - NEVER use ether or starting fluid.

People - NEVER carry riders. DO NOT allow others to ride on the machine or attachment, because they could fall or cause an accident.

BE SURE all persons are away from the machine and warn others in the area before starting the engine.

ALWAYS face the machine and use handholds and steps when getting on and off. DO NOT jump off machine.

Wear appropriate ear protection for prolonged exposure to excessive noise.

ALWAYS perform a daily inspection of the machine before using it. Look for damage, loose or missing parts, leaks, etc.

Remove trash and debris from the machine and engine compartment each day to minimize risk of fire.

New operators MUST operate loader in an open area away from bystanders. Practice with controls until the loader can be operated safely and efficiently.

Mandatory Safety Shutdown Procedure BEFORE cleaning, adjusting, lubricating or servicing the unit or leaving it unattended: 1. Move drive control handle(s) to the neutral position.

2. Lower the lift arm and attachment completely. If the lift arm must be left in the “raised” position, BE SURE to properly engage the lift arm support device.

3. Move the throttle to the low idle position, shut off the engine and remove the key.

4. Before exiting, move the lift/tilt control(s) to verify that controls do not cause movement of the lift arm or hitch.

Only after these precautions can you be sure it is safe to proceed. Failure to follow the above procedure could lead to death or serious injury.

DO NOT drive too close to an excavation or ditch. BE SURE that the surrounding ground has adequate 4

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

SAFETY

Lift Arm Support Device

4. Place the lift arm support device on the left cylinder rod.

WARNING BEFORE leaving operator’s compartment to work on the loader with the lift arm raised, ALWAYS engage the lift arm support device.

Turn the keyswitch to OFF, remove the key and take it with you.

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

BE SURE to engage the lift arm support device whenever the lift arm is raised. When the device is not being used, secure it to the anchor on the underside of the lift arm using the slide latch and retainer provided.

The lift arm support device is a safety device which must be kept in proper operating condition at all times.

The following procedures outline the correct way to engage and disengage the lift arm support device.

5. Return to the operator’s compartment and restart the engine.

6. Slowly lower the lift arm until the support device contacts the top end of the lift cylinder.

7. Be sure the support device is secure against the cylinder end. Then, stop the loader engine, remove the key and leave the operator’s compartment.

Lift Arm Support Device Disengagement

Lift Arm Support Device Engagement

WARNING

1. Raise the lift arm fully.

2. Turn keyswitch to OFF position to stop engine.

3. Remove the lift arm support device from its storage location.

NEVER leave the operator’s compartment to disengage the lift arm support device with the engine running.

To return the lift arm support device to its storage position, proceed as follows: 1. Raise the lift arm completely.

2. Turn the keyswitch to the OFF position to stop the engine, remove the key and take it with you.

Slide Latch

WARNING BEFORE testing the machine, ALWAYS clear people from the area.

3. Before leaving the operator’s compartment, check to be sure the lift arm is being held in the raised position by the solenoid valve (See NOTE).

PRINTED IN USA

917400/AP0809

5

SAFETY

GEHL 1640E / MUSTANG 2012

NOTE: With the keyswitch OFF, and the solenoid valve functioning properly, the lift arm will not move when the lift control is moved forward. If the valve does not hold the lift arm, DO NOT leave the operator’s compartment. Instead, have someone store the support device for you. Then, contact your Gehl/Mustang dealer to determine the reason why the lift arm lowers while the keyswitch is in the OFF position.

4. Remove one capscrew and washer on each side of the ROPS forward stantions.

4. To store the lift arm support device, remove it from the lift cylinder rod and return it to its storage location. Secure the support device under the lift arm with the slide latch.

5. Lift ROPS up and tilt it back until the self-actuating lock mechanism engages. The lock mechanism locks the ROPS in a rolled-back position.

Slide Latch

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 rolledback position.

1. The lift arm should be lowered or locked in the raised position as per the “Lift Arm Support Device Engagement” procedure in this chapter.

2. Turn the keyswitch to the OFF position to stop the engine. Remove the key and take it with you.

3. Leave the operator’s compartment.

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.

WARNING DO NOT leave the operator’s compartment with the engine running. Before leaving the loader, shut off the engine according to the “Mandatory Safety Shutdown Procedure” described in this chapter.

6

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

SAFETY

ROPS – Lowering 1. Apply upward force on the ROPS and push the lock mechanism handle toward the back of the loader.

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.

2. Lower the ROPS until it contacts the chassis.

4. Reinstall the two capscrews and flat washers that secure the ROPS front uprights to the chassis.

PRINTED IN USA

917400/AP0809

7

SAFETY

GEHL 1640E / MUSTANG 2012 result from improperly raising or blocking the skid-steer loader.

Relieving Hydraulic Pressure The following procedure should be used to relieve pressure in the hydraulic system before performing service procedures on hydraulic system components.

1. Completely lower the bucket or attachment.

2. Turn the keyswitch to the “OFF” position to shut off engine.

3. With the operator in the seat and the restraint bar lowered, turn the keyswitch to the “ON” position, but DO NOT start the engine.

4. Move the lift, tilt and auxiliary hydraulics controls through several cycles.

1. To raise and block the skid-steer loader, obtain four jack stands (or blocks) of sufficient strength to support the loader. A reinforced pallet may also be used.

2. Using a jack or hoist capable of raising the fullyequipped loader, lift the loader until the tires are off the ground.

3. Place the reinforced pallet, jack stands (or blocks) under the flat part of the loader chassis. Place them parallel with, but not touching, the tires.

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

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

Auxiliary Hydraulics

Lift and Tilt

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.

Loader Lowering Procedure When the service procedures are complete, the skidsteer loader can be taken down from the “raised” position. To lower the loader onto its tires: 1. Using a jack or hoist, raise the loader until its weight no longer rests on the reinforced pallet, jack stands (or blocks).

2. Carefully remove the reinforced pallet, jack stands (or blocks) under the loader.

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

WARNING DO NOT rely on a jack or hoist to maintain the “raised” position without additional blocking and supports. Serious personal injury could 8

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

LUBRICATION

General Information

Hydraulic Oil Reservoir The oil reservoir for hydraulic and hydrostatic systems has a capacity of 7.2 U.S. gallons (27,2 liters). A visual oil level indicator is located on the left riser for convenient maintenance of the hydraulic oil level.

WARNING NEVER service this unit when any part of the machine is in motion. ALWAYS BE SURE to exercise the “Mandatory Safety Shutdown Procedure” (see Safety chapter) BEFORE servicing this equipment.

Routine lubrication is an important factor in preventing excessive part wear and premature failures. Loader and engine operation depend on using correct grade, highquality lubricating oils. This chapter and the chart below list locations, temperature ranges and types of recommended lubricants to be used when servicing this machine. In addition, refer to the engine manual for specific grades and ratings as specified by the engine manufacturer.

IMPORTANT

Visual Hydraulic Oil Level Indicator

The hydraulic oil reservoir should be drained and filled after every 500 hours of operation or annually (whichever occurs first).

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

Hydraulic System Reservoir Use Petro-Canada Premium HVI60, or equivalent that contains anti-rust, anti-foam, and anti-oxidation additives and conforms to ISO VG46.

Capacity: 7.2 Gallons (27,2 L)

PRINTED IN USA

Hydraulic Oil Drain

Chaincases

Grease Fittings

Crankcase Oil

Use hydraulic system oil or SAE grade 15W-40 motor oil.

Capacity (each side): 6.0 Quarts (5,7 L)

Use lithium-based grease

Below 32°F (0°C) use SAE Grade* 10 or 10W-30 Above 32°F (0°C) use SAE Grade* 15W-40 *Service Classification: API - CI-4/SL Capacity (w/ filter change): 5.8 Quarts (5,5 L)

917400/AP0809

9

LUBRICATION

GEHL 1640E / MUSTANG 2012

Use Petro-Canada Premium HVI60 hydraulic oil (or ISO VG46 equivalent) that contains anti-rust, anti-foam and anti-oxidation additives. Hydraulic oil filter element should be replaced after every 250 hours of operation or annually (whichever occurs first). For details, refer to “Hydraulic Oil Filter Element Replacement” procedure in the Hydraulics System chapter.

Crankcase Oil The Yanmar three-cylinder diesel engine crankcase has a capacity of 5.8 U.S. quarts (5,5 liters). The chart below lists recommended oil viscosity for the Yanmar engine.

Engine Oil Dipstick

Engine Oil Fill Hydraulic Filter Location

Hydraulic Oil Fill Cap

Ambient Temperature

Viscosity

Below 32°F (0°C)

SAE 10 or 10W-30

Above 32°F (0°C)

SAE 15W-40

Service classification: API - CI-4/SL

Engine oil should be changed and filter element replaced every 500 hours of service. Access to the engine oil filter and drain plug is from underneath the skid-steer, through the rear belly pan.

Engine Oil Drain

10

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

LUBRICATION

The engine oil filter is located on the left side of the engine. This view is taken from underneath the engine and looking up through the belly pan.

Engine Oil Filter Location

Chaincases Each chaincase requires six quarts (5,7 L) of motor oil.

This quantity of oil should be maintained at all times.

The oil in both chaincases should be drained and refilled every 500 hours of operation or annually, whichever occurs first.

Change Chaincase Oil 1. Remove drain plug on chaincase and drain the oil.

Chaincase Drain Plugs

A side view of the engine oil filter location.

Engine Oil Filter Location

IMPORTANT Always dispose of waste lubricating oil according to local regulations or take to a recycling center for disposal; do not pour onto the ground or down the drain.

2. Reinstall the drain plug.

Refer to engine operator’s manual (see NOTE) for details on changing oil, and to “Oil Filter Removal” and “Oil Filter Installation” procedures in Engine chapter of this manual.

3. Remove the oil fill plug.

Chaincase Fill Plug

NOTE: Refer to engine operator’s manual for additional information on oil change including the 50-hour initial oil change.

intervals,

4. Add six quarts (5,7 L) of motor oil through the fill plug.

5. Reinstall the fill plug.

PRINTED IN USA

917400/AP0809

11

LUBRICATION

GEHL 1640E / MUSTANG 2012

Grease Fitting Locations Use lithium-based grease on all grease fittings.

Grease every 10 hours of operation (or daily) 1. Grease All-Tach® hitch attachment pivots.

2. Grease tilt cylinder pivots.

3. Grease lift cylinder pivots.

12

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

LUBRICATION

Cooling System Drain Procedure

Hydraulic Oil Cooler Plug/Cap Procedure

Gehl 1640E and Mustang 2012 model skid-steer loaders use a hydraulic oil cooler/radiator design to help keep the hydraulic oil and engine coolant from overheating.

Many procedures in this Service Manual require partially or fully draining the radiator/cooler to perform the procedures.

1. On the cooler side, unscrew the 90º fitting from the top right cooler tube and plug/cap the tube and the 90º fitting.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine and allow it to cool.

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

Radiator Drain Procedure 1. Place a catch pan with a capacity of at least 10-gallons (37,9 L) behind and underneath the chassis, below the drain cock or plug.

2. On the cooler side, unscrew the bottom right cooler tube from the straight fitting in the cooler port and plug/cap the tube and the straight fitting.

NOTE: A design change replaced the drain cock with a plug.

2. Open the drain cock or unscrew the plug at the lower center bottom of the radiator cooler to drain the anti-freeze.

Anti-freeze Drain Cock

Note: Plugging or capping the two tubes in steps 1 and 2 will help prevent hydraulic oil from spilling onto the floor of the chassis if removal of the radiator/cooler is required.

3. Close the drain cock or screw the plug back into the radiator cooler when finished draining.

PRINTED IN USA

917400/AP0809

13

LUBRICATION

GEHL 1640E / MUSTANG 2012 CHAPTER NOTES

14

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

MAINFRAME

Introduction

sprockets. Oil is used inside these cases to ensure the chains always receive proper lubrication.

Gehl 1640E and Mustang 2012 model skid-steer loaders have a welded steel chassis. Maintenance, service and repair may be performed through standard access panels.

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

Two side chaincases provide mounting for the drive motors and for the front and rear axles. The side cases also serve as sealed housings for the drive chains and

Mainframe (Chassis), Rear Grille and Engine Cover Components 15

17 14

22

31

23

43

3 19

18

12

16

26

6

14

30

21

2

11 42

25 42 28

44

20

21

9

32

23 39

22

38

36 5 37

32 7

32

24

35

10

41

29

4

34

8

1

2

13 45

NOTE: SHOULDER BOLT THREADS INTO ROPS PIN. 27 40

PRINTED IN USA

917400/AP0809

1 BOLT/SHOULDER 2 BUSHING/OILITE 3 NUT/HEX LOCK 4 SCREW/CAP WHIZLOCK 5 HANDLE/ THROTTLE 6 SPRING/COMPRESSION 7 WASHER/BELLEVILLE 8 CAP/HYD. RESERVOIR 9 BREATHER/HYD. RESERVOIR 10 PLUG 11 BUMPER 12 BUSHING 13 SIGHT PORT/OIL LEVEL 14 NUT/SPIRALOCK 15 CLIP/RETAINING 16 PIN/LOCK 17 ASSY/LATCH ROD 18 LATCH 19 LATCH/REAR DOOR 20 GRILLE/REAR 21 PIN/DOOR/LOWER 22 STUD/BALL 23 NUT/HEX SERRATED LOCK 24 NUT/HEX CENTERLOCK 25 CHASSIS 26 COVER/ENGINE 27 COVER/HYD. RESERVOIR 28 SENSOR/FUEL 29 BELLYPAN/REAR 30 TIE/ZIP WITH CLIP 31 GAS SPRING/RESTRAINT BAR 32 SEAL/BULB 33 COVER/CHAINCASE 34 BELLYPAN/FRONT 35 WASHER/FRICTION 36 GRIP/THROTTLE 37 BOLT/CARRIAGE 38 BOLT/CARRIAGE 49 BOLT/CARRIAGE 40 SCREW/MACHINE 41 SCREW/TAPPING 42 NUT/HEX JAM 43 WASHER/FLAT 44 NUT/SPIRALOCK 45 CAP/FUEL FILL

15

MAINFRAME

GEHL 1640E / MUSTANG 2012

Engine Access Cover - Removal and Installation

Installation Procedure - Follow all warnings first, then reverse the removal steps.

NOTES

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine.

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

Removal Procedure 1. Open the engine access cover until the gas spring is completely extended.

2. Disconnect the gas spring from the engine access cover by removing the gas spring clip at the access cover end of the gas spring, and then pulling the gas spring off the ball stud on the access cover.

3. Holding up the engine cover, remove two shoulder bolts securing the access cover to the ROPS/FOPS assembly and remove the engine cover.

16

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

MAINFRAME

Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS

16

17 22

14

29

27

10

6

9

28

8

24 14 35

34 2

21 21 34

20 15

2 3

19 1

3

2

26

18

2

26 18

36

30

12

7

36 23

31

1 TETHER/MANUAL 2 WASHER/FLAT 3 MOUNTING/ISOLATOR 4 NUT/HEX LOCK 5 NUT/HEX LOCK 6 CLAMP/TUBE 7 SPRING/TORSION 8 NUT/HEX LOCK 9 TAG/RIP CORD 10 RING 11 PIN 12 ROPS SUPPORT 13 SPACER/TUBE

PRINTED IN USA

30

32

13 37

38

11

5 12

4

14 INSERT/INTERNALLY THREADED 15 HOLDER/MANUAL 16 ROPS/FOPS 17 SCREW/SEMS 18 NUT/HEX CENTERLOCK 19 NUT/TINNERMAN FLAT 20 NUT/SPECIAL 21 WINDOW 22 TOP WINDOW/ROPS 23 GAS SPRING/ ROPS 24 TOP HARNESS COVER 25 FOAM/SOUND SUPPRESSION 26 WASHER/FLAT

917400/AP0809

27 STRIP/LOCKING 28 REAR WINDOW/ROPS 29 SEAL/WINDOW 30 SCREW/CAP 31 SCREW/CAP 32 SCREW/CAP 33 BOLT/CARRIAGE 34 SCREW/CAP 35 SCREW/MACHINE 36 WASHER/FLAT 37 WASHER/FLAT 38 PIN/COTTER

17

MAINFRAME

GEHL 1640E / MUSTANG 2012

ROPS/FOPS Removal and Installation

1. Remove one capscrew and flat washer securing each gas spring to the ROPS/FOPS.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine.

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

Removal Procedure 1. Remove the engine access cover per the procedure in this chapter.

2. Disconnect the negative (-) battery cable at the battery, or, if equipped, turn the electrical disconnect switch to OFF.

2. Disconnect the ROPS/FOPS lock mechanism from the chassis by removing the capscrew, washer, spacer and locknut.

3. Disconnect two harness connectors at the harness bulkhead attached at the rear of the ROPS/FOPS.

3. On each side, carefully remove the capscrew securing the ROPS/FOPS pivot pin to the frame.

Harness Connectors

4. Raise the ROPS/FOPS per the procedure in the Safety chapter of this manual.

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

WARNING The hoist MUST BE situated precisely above the ROPS/FOPS 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.

18

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

MAINFRAME

4. Using a punch, force the pivot pin outward until the ROPS/FOPS is released from the pin.

Seat Removal and Installation

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

Removal Procedure 5. Lift the ROPS/FOPS off the loader.

1. Remove four nuts from the studs attaching the seat to the seat pan underneath the ROPS/FOPS.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

2. Release the lock mechanism and lower the ROPS/ FOPS. 3. Disconnect seat switch from the wiring harness.

4. Lift the seat from the seat pan.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

PRINTED IN USA

917400/AP0809

19

MAINFRAME

GEHL 1640E / MUSTANG 2012

Seat Slide Replacement

2. With an assistant outside the ROPS/FOPS to catch the window, push window outward.

Replacement Procedure 1. Remove the seat per the procedure in this chapter.

2. Remove the four screws attaching the seat slides to the seat.

2 of 4 Slide Screws Shown

3. Slowly pull weatherstrip away from window frame.

Weatherstrip

3. Replace with new slides using the existing screws.

ROPS/FOPS Rear Window Removal and Installation

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine.

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

Removal Procedure 1. Grab and pull emergency exit tag until the ripcord pulls free of rubber seal.

20

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

MAINFRAME

Installation Procedure 1. Recommended but not required: Mix a solution of 10% liquid dish soap and 90% water in a spray bottle.

6. Use the pigtail hook tool to “pull down” weatherstrip seal on the outside of the ROPS/FOPS to secure the window.

NOTE: To install the rear window, obtain two insert tools from your glass dealer.

Pigtail Hook

L-Hook

7. On the inside of the ROPS/FOPS, install the ripcord in the ripcord lip, starting at top of weatherstrip. Be sure to have emergency exit tag slipped over the ripcord before performing this step.

2. Apply soap solution to window, weatherstrip and metal frame surfaces.

3. Start at top of window frame and install weatherstrip with the ripcord lip facing inside the ROPS/ FOPS and the glass lip facing out.

8. Using L-hook tool, secure the ripcord in the ripcord lip by “pulling down” the lip over the cord.

9. Test the window for security and mating of all seals.

4. From inside the ROPS/FOPS, spray soap solution between glass window and inside edge of rear window.

5. Use L-hook tool between glass and weatherstrip and work it underneath the glass. Lift the glass lip up over the weatherstrip.

PRINTED IN USA

917400/AP0809

21

MAINFRAME

GEHL 1640E / MUSTANG 2012

Restraint Bar Components

16

2

13

5

12 5

10

2

1

18

1 3 10

20 18

4

14 15

22

16 6 18

21

7 18

8

10

1 SCREW/SHOULDER 2 BUSHING 3 NUT/HEX LOCK 4 BUMPER 5 SPACER/TUBE 6 SWITCH/PROXIMITY 7 MAGNET/SWITCH ACTUATOR 8 STUD/BALL 9 NUT/SERRATED LOCK 10 NUT/SPIRALOCK 11 BAR/RESTRAINT

19

19

17

9

11

20

4

8

12 MOUNT/RESTRAINT BAR/LH 13 MOUNT/RESTRAINT BAR/RH 14 GAS SPRING/RESTRAINT BAR 15 MOUNT/GAS SPRING 16 BOLT/CARRIAGE 17 BOLT/CARRIAGE 18 WASHER/FLAT 19 NUT/HEX MACHINE 20 WASHER/EXTERNAL LOCK 21 SCREW/MACHINE

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

MAINFRAME

All-Tach® Hitch Components

3.28 .06

NOTE 1 20

7

14 2

10

8

NOTE 1 19

11 17

5

NOTE 1 12

15 4

16

18

6 13

16 1 NOTE 2 9

NOTES: 1. APPLY LOCTITE™ 242 TO PART NOS. 310-32678, 650488, AND 651364.

3

2. SPRING PIN TO EXTEND EQUAL DISTANCE ON EACH SIDE OF ADAPTOR ROD, BUT NOT BEYOND FACE PLATE OF WELDMENT.

1 PIN/SPRING 2 NUT/HEX LOCK 3 NUT/HEX LOCK 4 SPRING/COMPRESSION 5 PIN 6 ADAPTOR/ROD 7 SPRING/COMPRESSION 8 ADAPTOR/PUSH ROD 9 PIN 10 HANDLE/HITCH

PRINTED IN USA

11 2-PIN ALL-TACH 12 WASHER/SPECIAL 13 WASHER/FLAT 14 WASHER/FLAT 15 GRIP 16 ZERK/GREASE 17 SCREW/CAP 18 SCREW/CAP 19 SCREW/CAP 20 SCREW/CAP

917400/AP0809

23

MAINFRAME

GEHL 1640E / MUSTANG 2012

Restraint Bar Removal and Installation Removal Procedure

3. Through the instrument panel openings, remove two locknuts on carriage bolts securing the restraint bar to the ROPS/FOPS.

1. Remove two machine screws on the instrument panel covers on both sides of the ROPS/FOPS. A cover on both sides can be removed too.

Right Side Panel

4. Pop the gas spring off its ball stud with a flat-tip screwdriver.

Left Side Panel

5. Remove the restraint bar assembly from the ROPS/ FOPS. 2. Unplug the restraint bar switch red wire from the ROPS/FOPS wire harness.

NOTE: For restraint bar switch removal, refer to the Electrical chapter.

Installation Procedure - Reverse the removal steps.

24

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

MAINFRAME

All-Tach® Hitch Removal and Installation

Lift Arm Removal and Installation

Removal Procedure

Removal Procedure

1. Lower the lift arm and slightly extend the two tilt cylinders.

1. Lower the lift arm.

NOTE: Support the hitch with suitable hoisting

3. Remove the hitch per the procedure in this chapter.

2. Remove the bucket or attachment from the loader.

equipment before performing the next step.

2. Remove two capscrews and locknuts securing the lower tilt cylinder pivot pins. While supporting the tilt cylinders, drive the pins out of their mounts.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: Shut off the engine.

Relieve hydraulic system pressure.

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

4. Attach a suitable hoist to the lift arm.

5. Remove two locknuts and capscrews securing the lift cylinder pivot pins to the lift arm.

3. Remove two capscrews and locknuts securing the hitch to the lowest pivot pins on the lift arm, and drive the pins out of their mounts.

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

6. While supporting the lift cylinder, remove the lift cylinder pins from the lift arm.

7. Repeat steps 4 and 5 for other side of the lift arm.

Installation Procedure - Reverse the removal steps.

NOTE: Always clean around hydraulic fittings before disconnecting any hydraulic line. When removing hydraulic lines, cap or plug the ends to prevent contaminating the hydraulic system.

NOTE: To help in the correct reassembly of the hydraulic hoses and tubes, mark them prior to disassembly with an oil-resistant chalk or marker or other suitable marking material.

PRINTED IN USA

917400/AP0809

25

MAINFRAME

GEHL 1640E / MUSTANG 2012

Lift Arm Components 12 15 5

15

12

1

13

3

6

10

5

13 9 16

18

11

13

4

13 7 18 8 16 17

14 NOTE 1 NOTES:

13

1 2 3 4 5 6 7 8 9

26

NUT/HEX LOCK SHIM ARM/LIFT STANDOFF PIN/LIFT ARM PLATE/KNEECAP RH PLATE/KNEECAP LH PLATE/COVER/HYD TUBES AUXILIARY CAP

1. APPLY LOCTITE™ 242

2 NOTE 2

2. ADDITIONAL SHIMS MAY BE USED TO INSURE CONTACT BETWEEN SHIMS AND CHASSIS STOP BLOCKS.

10 11 12 13 14 15 16 17 18

LOCK/LIFT ARM LATCH/SLAM ZERK/GREASE SCREW/TAPPING THREAD CUTTING SCREW/CAP SCREW/CAP SCREW/TAPPING THREAD CUTTING WASHER/LOCK WASHER/FLAT

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

MAINFRAME

8. Disconnect four upper and lower tilt cylinder hoses from the tilt cylinder.

Upper Tilt Cylinder Hoses

11. Underneath the hydraulic tubes cover plate, remove the hose clamp and locknut securing the tilt cylinder hoses to the front of the lift arm.

12. Remove three self-tapping screws securing the auxiliary cap plate to the lift arm at the quick couplers.

Lower Tilt Cylinder Hoses

13. Disconnect two hydraulic hoses from their 90° fittings on two flat-faced quick couplers located on the left knee of the lift arm.

9. Remove both tilt cylinders from the lift arm per the procedure in the Hydraulics System chapter.

10. Remove four self-tapping screws securing the step to the hydraulic tubes cover plate and remove the plate.

14. Remove both flat-faced couplers, 90° fittings and hardware from the lift arm.

15. Using a suitable hoist, raise lift arm to gain access to the hydraulic hoses and the lift tube fittings.

PRINTED IN USA

917400/AP0809

27

MAINFRAME

GEHL 1640E / MUSTANG 2012

16. On the right lift arm, disconnect two tilt cylinder hydraulic hoses, one from the tilt solenoid and one from the chassis riser.

Tilt Solenoid

20. If replacing the lift arm, carefully pull the four hydraulic hoses inside the lift arm rearward out of the lift arm.

Installation Procedure - Reverse the removal steps.

NOTE: After removing/replacing any components of the lift and tilt system, ALWAYS prime hydraulic system by operating the lift arm attachment (NO LOAD) slowly up and down for several cycles. Check system for hydraulic oil leaks following guidelines in the Safety chapter. Fill the hydraulic reservoir until fluid becomes visible in the hydraulic oil level sight gauge on the inside of the left lift arm riser.

NOTE: Refer to the lift arm bushing installation 17. On the left liftarm remove two auxiliary hydraulic hoses from the chassis riser.

procedure in replacement.

this

chapter

if

bushings

require

18. Remove two capscrews and locknuts securing the lift arm pivot pins to the chassis. Drive the lift arm pivot pins out of the chassis.

19. Remove the lift arm assembly from the loader with a suitable hoist.

28

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

MAINFRAME

Lift Arm Bushing Replacement

Lift Arm Stop Installation and Adjustment Installation/Adjustment Procedure

NOTE: Lift arm stops should be shimmed as needed

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

to ensure a gap of no more than 1/8" (3 mm) between the stops and the lift arm when the lift arm is fully lowered.

1. Lower lift arm and measure gaps between stops and chassis.

Replacement Procedure 1. Remove the lift arm from the loader per the procedure in this chapter.

2. Use a punch to drive out the four upper lift arm bushings, two on each side of the lift arm.

NOTE: Applying heat to the upper lift arm bushings will release the adhesive and simplify removal.

3. Clean inside the opening to provide a smooth surface for installation of the new bushings.

4. If replacing the spring bushing in each lower lift arm, use a punch to drive them out of the lift arm.

5. Install new spring bushings by pressing them into place or using a rubber mallet to drive them into the lift arm.

6. Reinstall the lift arm on the loader per the procedure in this chapter.

NOTE: It will be necessary to add one shim for every 1/8" (3 mm) gap.

2. Raise lift arm and engage the lift arm support device.

3. Remove two capscrews on each stack of shims.

4. Install shim(s) and secure with capscrews. Use Loctite® 242 or equivalent retaining compound.

5. Start engine and lower lift arm. Verify gaps and repeat procedure as needed.

PRINTED IN USA

917400/AP0809

29

MAINFRAME

GEHL 1640E / MUSTANG 2012

Floor Cover/Step Cover/Kickplate Removal and Installation

2. On the floor cover, remove the five thread-forming screws securing the cover to the control mount and kickplate.

The floor cover, step cover and kickplate may be removed for access to handle assemblies, control linkages and connections to control rods, cables and hoses.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm, engage lift arm support device.

Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

3. EU Only Skid-Steer Loaders: At this time, carefully pull the sound pad up and out of the machine.

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

4. Remove the floor cover from the skid-steer loader.

Removal Procedure

5. On the kickplate, remove four thread-forming screws securing the kickplate to the crossmember and remove the kickplate.

1. On the step cover, remove two thread-forming screws securing the cover to the kickplate and remove the step cover.

Installation Procedure - Reverse the removal steps.

30

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

MAINFRAME

Crossmember Removal and Installation The crossmember can be removed as a complete unit with the control handles to facilitate work on the hydraulic/hydrostatic tandem pump found beneath it or to perform work on the control handles.

3. Underneath the crossmember, locate the two wheel drive control rods that connect the pivot tube to the top of the hydrostatic pump at the pump control arms. Disconnect control rods at the pivot tube.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

4. Disconnect the electrical connector in the left control handle at the end of the wire (if so equipped).

1. Remove the floor cover, step cover and kickplate per the procedure in this chapter.

2. At the main control valve, disconnect the lift and tilt control rods at the control valve. Remove the spring clip on the yoke to release each control rod.

5. Remove the four carriage securing the crossmember to the chassis on each side.

PRINTED IN USA

917400/AP0809

31

MAINFRAME

GEHL 1640E / MUSTANG 2012

6. Carefully lift the crossmember out of the chassis.

Installation Procedure 1. Clean old gasket adhesive off fuel tank.

2. Install new gasket using Form-A-Gasket #7651211 (or equivalent) to seal sensor opening on fuel tank.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

Fuel Sensor Removal and Installation Removal Procedure

3. With the float to the rear of the fuel tank, install the sensor in the fuel tank.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Shut off the engine.

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

1. Drain fuel tank into a clean approved container.

Drain fuel below the sensor mounting (½ full).

2. Disconnect the two wires from the sensor.

3. Remove the five screws securing the sensor, then remove the sensor and gasket from the tank.

4. Install new gasket using Form-A-Gasket #7651211 (or equivalent) to the five screws.

Form-A-Gasket On Screws and Gasket

32

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

MAINFRAME

5. Install the five screws through the sensor into the fuel tank. DO NOT OVERTIGHTEN. 6. Attach #25 (brown) wire to center stud with a nut, and #0 (black) wire to ground stud with the fifth screw.

Rear Grille Latch Removal and Installation Removal Procedure 1. Open the rear grille and lock open with the lock pin.

Rear Grille Removal and Installation The rear grille is bolted onto the chassis and can be removed to perform work on the cooling system, engine, engine fan and shrouds.

Removal Procedure 1. Open the engine access cover and swing the rear grille fully open.

2. Disconnect the tail lights wire harness and free the harness from the rear grille.

2. Pull out the two carriage bolts, washers and bushing and remove the latch assembly.

3. Support the rear grille with a suitable hoist.

4. Remove two cotter pins on two grille pins fastening the grille to the chassis.

Installation Procedure - Reverse the removal steps.

Installation Procedure - Reverse the removal steps.

PRINTED IN USA

917400/AP0809

33

MAINFRAME

GEHL 1640E / MUSTANG 2012 CHAPTER NOTES

34

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

WHEEL DRIVES

Introduction

drive motors are directly connected to chaincases. Each motor drives one set of wheels on each side of the loader through a chain and sprocket system.

This chapter covers removal, installation, assembly and adjustment procedures for wheel drive system components on Gehl 1640E and Mustang 2012 model skid-steer loaders. Wheel drive components covered in this chapter are shown below.

Service procedures related to the hydrostatic pump and drive motors can be found in the Hydrostatic System chapter.

Gehl 1640E and Mustang 2012 model skid-steer loaders are equipped with a hydrostatic pump assembly coupled to the diesel engine, providing hydrostatic power to the two fixed-displacement hydrostatic drive motors. The

Wheel Drive Components

18 6 15 16 4 20

O FR

21

NT

3 17

1

18 8

15

2

17

16

19 5

3

11 10

7

EXPLODED VIEW RIGHT HAND SIDE 13

9

12

1 2 3 4 5 6 7 8

BOLT/HUB CONE/BEARING CUP/BEARING SEAL/AXLE THRUST WASHER NUT WHEEL BOLT NUT/HEX LOCK ROLLER CHAIN ASSY

PRINTED IN USA

9 10 11 12 13 14 15 16 17 18 19

ROLLER CHAIN ASSY SPROCKET SHAFT W/SPROCKET/LONG SHAFT W/SPROCKET/SHORT AXLE HUB AXLE HUB HUB O-RING O-RING WASHER/ SPECIAL SCREW/CAP

917400/AP0809

35

WHEEL DRIVES

GEHL 1640E / MUSTANG 2012 spreader bar, push the axles outward in their slots to tighten the chain.

Drive Chain Adjustment Skid-steer loader drive chain tension should be checked every 250 hours of operation.

Adjustment Procedure

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

Axle Nut

Shut off the engine.

Raise and securely block the loader so all four tires are off the ground.

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

1. Remove the wheels and tires on the side of the loader to be serviced.

2. Remove six self-tapping screws on the chaincase access cover (between tires) to access the drive chain.

6. After the proper chain tension is obtained, retighten the locknuts on the axle. Axle housing locknuts should be torqued to 280 ft.-lbs. (380 N•m).

NOTE: The drive chain must have a minimum of 1/2" (13 mm) deflection; overtightening causes premature drive chain and sprocket wear.

7. Scrape off the old oil-resistant RTV and reapply new RTV. Reinstall the access cover.

Chaincase Access Cover Screws

Fill Plug

3. Drain the oil from the chaincase. See the procedure in the Lubrication chapter.

4. Correct chain deflection is ½" @ 20 lbs. force (13 mm @ 89 N) - halfway between the sprockets.

5. To adjust chain tension, loosen the six locknuts on two axles on one side of the loader. Using a

8. Remove the fill plug on the chaincase access cover.

9. Refill the chaincase oil until the oil is up to the fill plug.

10. Reinstall the wheels and tires. Axle nut torque is: 100 ft.-lbs. (136 N•m) to press the bearings into place. Loosen the nut, then retighten to 30 ft.-lbs.

(41 N•m).

11. Repeat the adjustment procedure for the other side.

36

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

WHEEL DRIVES

Axle Housing Assembly Removal and Installation

5. Remove a large cotter pin on a slotted axle nut on the axle hub.

Axle Nut

Removal Procedure

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

Axle Hub Cotter Pin

Shut off the engine.

Raise and securely block the loader so all four tires are off the ground.

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

1. Remove the wheels and tires on the side of loader being serviced.

6. With a wrench, remove the slotted axle nut and the special washer beneath it.

7. Pull the axle hub off the axle assembly.

2. Drain the oil from the chaincase. See the procedure in the Lubrication chapter.

3. Remove six self-tapping screws on the chaincase access cover (between tires) to access the drive chain.

4. Remove the six locknuts attaching the axle housing to the chassis.

8. Pull the axle housing away from the chassis.

NOTE: It may be necessary to carefully insert a pry bar or chisel between the chassis and axle housing to loosen the axles.

PRINTED IN USA

917400/AP0809

37

WHEEL DRIVES

GEHL 1640E / MUSTANG 2012

Installation Procedure 1. Apply oil-resistant RTV sealant (or equivalent) between the axle housing and the chassis.

2. Align the holes in the axle housing with the studs in the chassis and push the axle housing into place.

5. Place the special washer on the axle and secure it to the axle with the slotted axle nut. Axle nut torque is: 100 ft.-lbs. (136 N•m) to press the bearings into place. Loosen the nut, then retighten to 30 ft.-lbs.

(41 N•m).

6. Reinstall and secure the large cotter pin through a hole in the end of the axle and through the slotted axle nut.

3. Install the six locknuts securing the axle housing to the chassis (hand tighten at this point).

4. Place the axle hub onto the axle.

7. Adjust the drive chains per the procedure in this chapter.

8. Reinstall the chaincase access cover using oilresistant RTV sealant (or equivalent) between the cover and the chaincase.

9. Refill the chaincase oil until the oil is up to the fill plug.

10. Reinstall the wheels and tires. Wheel nut torque is: 180 ft.-lbs. (244 N•m).

38

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

WHEEL DRIVES

Drive Chain Removal and Installation

5. Supporting the axle with a suitable hoist, pull the axle housing out of the chaincase to allow the axle housing sprocket to drop inside the chaincase.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Shut off the engine.

Raise and securely block the loader so all four tires are off the ground.

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

1. Remove the wheels and tires on the side of the loader being serviced.

2. Drain the oil from the chaincase. See the procedure in the Lubrication chapter.

6. Slip the drive chain off the axle housing sprocket.

Then, slip the drive chain off the drive motorsprocket.

3. Remove the six tapping screws on the chaincase access cover to gain access to the drive chain.

4. For each drive chain: Loosen the six locknuts on axle assembly attached to the chain. Slide the axle assembly in its slots to loosen the chain tension.

Drive Motor Sprocket

7. Remove the drive chain from the chaincase.

Installation Procedure - Follow the Removal Procedure warnings first, then:

NOTE: When installing the left and right side drive chains, install the inside chain first.

1. Wrap the chain around sprocket of the axle.

2. Wrap the chain around the drive motor sprocket.

3. Adjust the drive chain to the proper tension per the procedure in this chapter.

4. Install the chaincase access covers using oil-resistant RTV sealant (or equivalent) between the covers and chaincase. Refill the chaincase oil until the oil is up to the fill plug.

5. Reinstall the wheels and tires. Wheel nut torque is: 180 ft.-lbs. (244 N•m).

PRINTED IN USA

917400/AP0809

39

WHEEL DRIVES

GEHL 1640E / MUSTANG 2012

Axle and Wheel Bearing Disassembly and Assembly

2. Install the double-lip axle seal in the axle housing.

Use suitable drivers or a press to countersink all components until they bottom out.

Disassembly Procedure 1. Remove the axle housing assembly per the procedure in this chapter.

Axle Seal

2. Remove the outer bearing cone from the axle shaft.

3. Remove the axle shaft from the chassis per the procedure in this chapter.

4. Remove the inner bearing cone from the axle shaft.

5. Remove the axle seal and outer bearing cup from the axle housing assembly.

6. Turn housing assembly over and remove the inner bearing cup from the axle housing assembly.

Assembly Procedure

NOTE: Pack the tapered bearing cones with synthetic grease before assembling.

3. Turn the axle housing over and press an additional bearing cup into the other side of the axle housing with a force of 6000 lbf. (26,7 kN) using a bearing press.

Bearing Cup

1. Install the bearing cup in the axle housing with a force of 6000 lbf. (26,7 kN) using a bearing press.

Bearing Cups

40

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

WHEEL DRIVES

4. Place the axle shaft on a flat surface with the shaft in a vertical position. Press the bearing cone onto the axle shaft with a suitable driver or a press at a force of 6000 lbf. (26,7 kN). Note the orientation of the first bearing cone.

Bearing Cone

PRINTED IN USA

917400/AP0809

41

WHEEL DRIVES

GEHL 1640E / MUSTANG 2012

CHAPTER NOTES

42

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

CONTROLS

Introduction

provided with procedures to aid in servicing this equipment.

This chapter covers the removal, installation, assembly, and adjustment procedures for standard and optional controls on Gehl 1640E and Mustang 2012 model skidsteer loaders.

Equipment Identification Because there are a variety of options available for Gehl 1640E and Mustang 2012 models, it is necessary to properly identify the controls before beginning the service procedures. Illustrations and photographs are

T-Bar Controls On skid-steer loaders with “T-Bar Controls,” the left TBar operates the drive wheels 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 by the hand and/or foot throttles.

Standard-flow auxiliary hydraulics is controlled by a foot pedal.

Control Locations - T-Bar

6

3 4 5 2 1 1 - Drive Control 2 - Lift/Tilt Control

PRINTED IN USA

3 - Horn Button Switch (EU Models) 4 - Auxiliary Hydraulics

917400/AP0809

5 - Foot Throttle 6 - Hand Throttle Handle

43

CONTROLS

GEHL 1640E / MUSTANG 2012

Wheel Drive, Foot Throttle and Lift Tilt Components - Illustration - Later Models

Right

51 48 23

75

67

56

55

45 66 73

34

34

48 46

35

71 70

75

57 28

25

64 73

69

67

1

61 5

28

39

10

5

11

12

9

61

6

9 53

69

10

36

11 70

1

29

43

26

70 64

70

16

30

41

14

2

TO FOOT THROTTLE IN ENGINE GROUP

42

66 60

62

70

26

13 4

29

26

58

47

30

40 7 59

63 18

70

3 44

65

68 74

27

52

Left

73 20

24 72

22

54

15

53

21 17

8

34

19 19

8 66

49 24 64

19

35

32 33

65

68 74

1

15

17 38

17

69

B

20 72 73

24

61

19 24

5

17

10

A

28

11

27

11

10 54

21

B

37

61 72

17

36

72

A

31

5

1

17

21 64

37

69 72

50

65

15 24

44

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

CONTROLS

Wheel Drive, Foot Throttle and Lift Tilt Components - Parts Listing - Later Models

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

BEARING/FLANGE MOUNT SCREW/SHOULDER BUSHING/SUPER OILITE BUSHING/OILITE BUSHING/OILITE FLANGED JOINT/BALL ASSEMBLY/ BALL JOINT WASHER/FLAT NUT/HEX LOCKING NUT/LOCK NUT/LOCK NUT/LOCK NUT/LOCK SPACER PIN/ROLL END/ROD END/ROD NUT/LOCK NYLON INSERT BEARING ROD END/ELASTOMERIC NUT/SPIRALOCK HANDLE ASSEMBLY/LEFT GRIP HANDLE ASSEMBLY/RIGHT GRIP NUT/HEX TOP LOCK SWITCH/DX YOKE/CLEVIS RETAINER/PUMP ARM HN LF CLOC PIN/CLEVIS PIN/CLIP/ RUE PIVOT SHAFT/PIVOT ASSEMBLY/PIVOT TUBE PLATE/CROSS/CONTROLS BRACKET/CONTROL ARM STOP/T-BAR ROD ROD

PRINTED IN USA

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75

KICKPLATE MOUNT/CONTROL FLOOR PEDAL/THROTTLE COVER/STEP PEDAL/AUXILIARY ROD/CONTROL/LIFT ROD/CONTROL/LIFT CABLE YOKE/CLEVIS ARM/ASSEMBLY ASSEMBLY/PIVOT LINKAGE SLEEVE/ CONTROL VALVE ARM/ASSEMBLY PIVOT/CONTROL ARM/PUMP BONNET/AUXILIARY SWITCH CABLE END VALVE PIN CABLE/LIFT SCREW/CAP WHIZLOCK SPRING BUSHING SCREW/CAP SCREW/CAP SCREW/CAP SCREW/CAP BOLT/CARRIAGE BOLT/CARRIAGE SCREW/CAP BOLT/CARRIAGE SCREW/ CAP HEX HEAD TAPPING SCREW/CAP SOCKET HEAD NUT/JAM HEX NUT/JAM HEX WASHER/LOCK NUT/HEX

917400/AP0809

45

CONTROLS

GEHL 1640E / MUSTANG 2012

Wheel Drive, Foot Throttle and Lift Tilt Components - Illustration - Earlier Models

Right

54 50 23

74

67 47 66 72

33

33

50 74

48

34

70

27

64 72

69

67

1

60 5

27

38

10

5

11

12

6

9 56

69

10

35

9

60 11

70

1

28

42

25

70 64

70

16

29

40

14

2

TO FOOT THROTTLE IN ENGINE GROUP

41

66

59

62

70

25

13 4

28

61

25

46

49

29

39

45 7

63

58 18

52

70

44

3 43

Left

65

68 73

26

55

72 20

24 71

22

57

15

56

21 17

8

33

19 19

8 66

51 24 64

19

34

31 32

65

68 73

1

15

17 37

17 B

20 71 72

24

69 60

19 24

5

17

10

A

27

11

26

11

10 57

21

B

36

60 71

17

35

71

A

30

5

1

17

21 64

36

69 71

53

65

15 24

46

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

CONTROLS

Wheel Drive, Foot Throttle and Lift Tilt Components - Parts Listing - Earlier Models

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

BEARING/FLANGE MOUNT SCREW/SHOULDER BUSHING/SUPER OILITE BUSHING/OILITE BUSHING/OILITE FLANGED JOINT/BALL JOINT/BALL WASHER/FLAT NUT/SERRATED LOCK NUT/HEX LOCK NUT/HEX LOCK NUT/HEX LOCK NUT/HEX LOCK SPACER PIN/ROLL ROD END/FEMALE ROD END/FEMALE NUT/HEX LOCK BEARING/BRONZE ROD END/ELASTOMERIC NUT/SPIRALOCK™ STEERING ARM/LEFT STEERING ARM/RIGHT NUT/HEX TOP LOCK YOKE/CLEVIS RETAINER/PUMP ARM NUT/CENTERLOCK PIN/CLEVIS PIN/CLIP RUE PIVOT SHAFT/PIVOT TUBE/PIVOT TUBE PLATE/CROSSMEMBER CONTROLS BRACKET/CONTROL ARM STOP/T-BAR ROD ROD

PRINTED IN USA

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74

KICKPLATE MOUNT/CONTROL FLOOR PEDAL/THROTTLE COVER/STEP PEDAL/AUXILIARY MOUNT/SOLENOID LINKAGE/AUXILIARY CABLE/AUXILIARY CONTROL ROD CONTROL /LIFT ROD CONTROL/LIFT CABLE/FOOT THROTTLE YOKE/CLEVIS ARM/ASSEMBLY SWITCH/NEUTRAL CENTERING PIVOT ASSEMBLY LINKAGE SLEEVE/CONTROL VALVE ARM/ASSEMBLY PIVOT/CONTROL ARM/PUMP SCREW/CAP WHIZLOCK SPRING BUSHING SCREW/TAPPING SCREW/CAP SCREW/CAP SCREW/CAP SCREW/CAP BOLT/CARRIAGE BOLT/CARRIAGE SCREW/CAP BOLT/CARRIAGE SCREW/TAPPING NUT/HEX JAM NUT/HEX JAM WASHER/LOCK NUT/HEX

917400/AP0809

47

CONTROLS

GEHL 1640E / MUSTANG 2012

Control Handle Removal and Installation

IMPORTANT Note the wire terminal connections in the electrical connector for reassembling the control handle if replacing the handle’s electrical cable.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

3. Remove the locknuts to disconnect the studded rod end(s) on the control rod(s) from the control handle assemblies on the handle(s) being removed.

Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

Removal Procedure 1. Remove the control cover per the procedure in the Mainframe chapter.

Left

2. Disconnect the electrical connector in the left control handle from the wiring harness (if so equipped).

Horn Button Wiring in Control Handle

Left

Horn Button Connection Location

48

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

CONTROLS bracket on the pivot assembly is oriented 90° to the chassis.

Right Left

4. Remove two capscrews, washers and locknuts on the elastomeric rod ends attaching the control handle assembly to the chassis crossmember. Remove the handle assembly.

Installation Procedure: Follow all warnings first, then reverse the removal steps (see NOTE below).

2. Right control handle vertical orientation: Change the lift control rod length attached to the bottom of the pivot assembly.

Right

NOTE: When the control handle is installed, and if the control rod(s) are adjusted correctly, the control handle shafts are vertically straight, up and down. If changes are needed, refer to the “Control Handle Position Adjustment” procedure in this chapter.

Control Handle Position Adjustment Control handles are adjusted two ways for proper operation: a vertically straight appearance and the handle orientation.

Adjustment Procedure

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

3. Right control handle orientation: Change the tilt control rod length attached to the handle above the pivot assembly. Adjust the tilt rod length until it is oriented 90° to the chassis. BE SURE the adjustment allows for the full actuation of the control valve in both directions of handle operation.

Tilt Control Rod

Raise lift arm; engage lift arm support device.

Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

1. Left control handle: Adjust the two control rod lengths connected at the pivot assembly, so the PRINTED IN USA

917400/AP0809

49

CONTROLS

GEHL 1640E / MUSTANG 2012

T-Bar Control Handle Assembly

3. Place top half of pivot and three washers on control handle, then slide handle through pivot.

Assembly Procedure The left T-Bar control handle operates the drive functions for the left and right sides of the skid-steer loader. There is also a button switch for the horn in the grip assembly.

The right T-Bar control handle operates the lift and tilt functions of the skid-steer loader.

NOTE: The left T-Bar is identical to the right T-Bar except that a different lower pivot is used on each.

1. Attach elastomeric rod ends to sides of pivot with capscrews, washers and locknuts.

Elastomeric Rod Ends

4. Place T-Bar stop between washers: Left T-Bar: Secure to pivot with capscrew and locknut.

Capscrew

2. Press or drive two bronze bearings into holes on pivot. Use a bearing driver, if available.

Left T-Bar: Press pivot assembly on the bottom of the control handle and secure with a roll pin.

50

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

CONTROLS

Right T-Bar: Secure with studded rod end, placed in recessed area, and jam nut. Install spacers above and below the lift control rod end and secure in control handle with a capscrew.

Backup Alarm Components

10 11

10

8 9

2

3

5

6 1

7

4 1 2 3 4 5 6

CLAMP/INSULATED HOSE NUT/LOCK NUT/LOCK NUT/LOCK SWITCH/BACKUP ALARM ALARM/BACKUP

PRINTED IN USA

7 8 9 10 11

4

TRIGGER/BACKUP ALARM SWITCH/MOUNT/BACKUP ALARM SCREW/CAP BOLT/CARRIAGE BOLT/CARRIAGE

917400/AP0809

51

CONTROLS

GEHL 1640E / MUSTANG 2012

Pivot Tube Removal and Installation

3. Disconnect two hydrostatic pump arm control rods from the pivot tube arms.

Pivot tube exploded views are good references for the pivot tube’s removal and installation procedures. Refer to these views for locations of components in the assemblies.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Shut off the engine.

4. Remove the four lock nuts and carriage bolts securing the control pivot to the crossmember.

Tilt back ROPS/FOPS until lock engages.

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

1. Remove the floor cover/step cover/kickplate per the procedure in the Mainframe chapter.

2. At the left control handle pivot assembly, disconnect two control rods from the pivot tube arms.

5. Remove the control pivot tube assembly from the crossmember.

6. Disassemble the pivot tube assembly on a workbench to replace parts as needed. Refer to the exploded views for the correct positioning of the pivot tube parts.

NOTE: If the skid-steer loader is equipped with a backup alarm, remove the two carriage bolts and locknuts securing the alarm switch bracket mount to the pivot tube. Set them aside.

NOTE: It’s recommended that good notes be taken to aid in reassembly. If necessary, mark the holes on the levers.

52

Installation Procedure: Follow all warnings first, then reverse the removal steps.

1. Attach all the control rods and centering devices to the appropriate levers on the pivot tube assembly.

2. Install the floor cover/step cover/kickplate per the procedure in the Mainframe chapter.

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

CONTROLS

Pump Control Arm Assembly Removal and Installation

3. Slide the control arm assembly off the hydrostatic pump shaft.

Removal Procedure

Installation Procedure: Follow all warnings first, then reverse the removal steps.* * If the control rods’ lengths were not altered and the rod ends slip right in, or if only a very slight adjustment is made to fit the rod end in the control arm assembly, no adjustment should be necessary.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Lift/Tilt Controls Removal and Installation

Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

1. Remove the locknut and capscrew on each elastomeric rod end attached to the two pump control arm assemblies.

Pump Control Arms

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

Removal Procedure 1. Remove the floor cover/step cover/kickplate per the procedure in the Mainframe chapter.

2. On the right control handle, remove the lift control rod and the tilt control rod clevis yoke pins at the main control valve.

2. Remove the two capscrew and lock washers that clamp the two parts of the pump control arm assembly to the hydrostatic pump shaft.

PRINTED IN USA

917400/AP0809

53

CONTROLS

GEHL 1640E / MUSTANG 2012

3. Disconnect the electrical connector in the left control handle at the end of the wire (if so equipped).

Locknuts

4. Disconnect the two drive control rods on the left control handle pivot at the pivot tube arm assemblies.

6. Pull the left and right control handle assemblies forward and out of the chassis.

Installation Procedure: Follow all warnings first, then reverse the removal steps.

Lift/Tilt Control Adjustment

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

5. Remove the two carriage bolts and locknuts securing each control arm bracket to the front of the crossmember.

Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

Adjustment Procedure

Carriage Bolts

The lift and tilt control rod lengths can be adjusted to obtain proper position of the T-Bar. Refer to “Control Handle Position Adjustment” procedure in this chapter.

The “Self-leveling Valve Adjustment” procedure in the Hydraulic System chapter is also related to the correct operation of the lift and tilt controls. Refer to this procedure as needed.

54

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

CONTROLS

Auxiliary Hydraulics Cable Removal and Installation

2. Loosen the large jam nut on the auxiliary control cable.

Refer to the exploded views as a reference in identifying the parts and components.

With Spool Electric Lock

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

With Pedal Electric Lock

1. At the main control valve, disconnect the electrical connector (if so equipped) on the auxiliary hydraulics spool.

With Spool Electric Lock

3. Unscrew the cable end from the bonnet.

PRINTED IN USA

917400/AP0809

55

CONTROLS

GEHL 1640E / MUSTANG 2012

4. Remove the two (spool lock) or four (pedal lock) socket-head capscrews securing the bonnet to the main control valve.

6. Disconnect the ball joint and hex nut on the auxiliary cable from the auxiliary pedal assembly.

With Pedal Electric Lock

With Spool Electric Lock

7. Loosen the large jam nut securing the cable to the control mount and slide the auxiliary linkage off the auxiliary whisker switch.

With Pedal Electric Lock With Pedal Electric Lock

Whisker Switch

5. Remove the pin securing the auxiliary cable to the control valve, and remove the cable.

With Spool Electric Lock

8. Remove the cable. If replacing the cable, remove the ball joints, hex nuts and jam nuts from the old cable.

Installation Procedure: Follow all warnings first, then reverse the removal steps.* * For cable adjustment, refer to the “Auxiliary Hydraulics Cable Adjustment” procedure in this chapter.

56

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

CONTROLS

Auxiliary Hydraulics Cable Adjustment

5. Disconnect the ball joint on the cable from the auxiliary pedal assembly by removing the hex nut.

Adjustment Procedure The auxiliary hydraulics cable should be adjusted so that the hydraulic control valve is engaged when the foot pedal is depressed. Refer to the exploded views for identifying the parts and components.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Shut off the engine.

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

1. Sit in the seat, pull the restraint bar down and turn the key to the “ON” or “ACCESSORY” position (DO NOT START ENGINE) to release the electrical detent on the auxiliary hydraulics valve spool (if so equipped).

2. Remove the floor cover/step cover/kickplate per the procedure in the Mainframe chapter.

6. Loosen the jam nut on the ball joint.

7. Twist the ball joint in to tighten or out to loosen the auxiliary hydraulics cable (most adjustments will require a tightening of the cable.)

8. Reinstall the ball joint and hex nut and secure it to the auxiliary hydraulics pedal assembly.

9. Retighten the jam nut snug against the ball joint to set the adjustment.

10. Check operation of auxiliary hydraulics cable by using an appropriate attachment.

3. Pivot the auxiliary hydraulics pedal assembly to the right and keep it depressed.

Auxiliary Pedal

4. Turn the key back to the “OFF” position.

PRINTED IN USA

917400/AP0809

57

CONTROLS

GEHL 1640E / MUSTANG 2012

Engine and Hand Throttle Components

5 51

28

34 32

46

56

56

43 29

29

55

39

36

47

8

37

1

22

26

57

52

59

12

38

54

42

45

15

32

27

33

45

4 40

2

45

41

35 44

14 49

54 58

16

40

45 6

23 1 39

43 31

1 2 4 5 6 8 12 14 15 16 22 23 26 27 28 29 31 32 33 34 35

58

BUSHING/OILITE FLANGED JOINT/BALL NUT/HEX LOCK NUT/HEX LOCK NUT/HEX LOCK SCREW/CAP WHIZLOCK NUT/SPIRALOCK ISOLATOR SCREW/SHOULDER PLATE/PUMP MOUNT PIVOT/THROTTLE HAND PIVOT/THROTTLE FOOT BRACE/ENGINE TOP ROD/THROTTLE ENGINE/YANMAR 3TNV82A YOKE/CLEVIS NUT/CENTERLOCK PIN/CLEVIS MOUNT/ENGINE BRACKET/ENGINE MOUNT/FRONT LINKAGE/THROTTLE

36 37 38 39 40 41 42 43 44 45 46 47 49 51 52 54 55 56 57 58 59

CABLE/THROTTLE PLATE/FLEXIBLE DRIVE SCREW/CAP WASHER/FLAT WASHER/PLATED WASHER/FLAT MOUNT/ENGINE BUSHING SCREW/CAP NUT/HEX SCREW/CAP SCREW/CAP BOLT/CARRIAGE WASHER/FLAT WASHER/FLAT WASHER/LOCK WASHER/LOCK PIN/COTTER SCREW/CAP SCREW/CAP SCREW/CAP

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

CONTROLS

Hand Throttle, Foot Throttle Pedal and Throttle Cables/Throttle Rod Removal and Installation

3. Loosen the large jam nut on the throttle cable bracket tab and slide out the foot throttle cable.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

1. Remove the floor cover/step cover/kickplate per the procedure in the Mainframe chapter.

4. Remove nut on the long capscrew securing the foot throttle pedal to the floor of the chassis and remove the capscrew and bushing. Remove the foot throttle pedal (if needed) at this time.

2. At the foot throttle pedal weldment, remove the clip pin, clevis spring pin from the cable yoke and the shoulder screw on the spring. Remove the cable yoke from the throttle cable.

Long Capscrew

5. Remove the clevis pin and cotter pin securing the hand throttle cable yoke to the hand throttle.

Cable Yoke

PRINTED IN USA

917400/AP0809

59

CONTROLS

GEHL 1640E / MUSTANG 2012

6. Remove three Belleville washers, one carriage bolt, friction washer and locknut on the hand throttle securing it to the chassis. Remove the hand throttle (if needed) at this time.

9. Remove both the foot and hand throttle cables from the skid-steer loader. If replacing one or both cables, remove the clevis yokes, hex nuts and jam nuts from the old cable.

10. Remove the hex nut on the ball joint attached to the throttle rod and slide the ball joint out of the pivot.

Friction Washer

Belleville Washers

7. At the junction point where the foot throttle cable and hand throttle cable meet, disconnect the clevis pins and cotter pins securing both cables to their respective pivots.

11. At the engine’s throttle linkage, disconnect the shoulder screw and locknut attaching the linkage to the engine, and remove the linkage and throttle rod from the skid-steer loader.

Foot Throttle Nut

8. Loosen the large jam nuts securing both throttle cables near the pivots and slide out cables.

Installation Procedure: Follow all warnings first, then reverse the removal steps.* * Perform “Throttle Adjustment” procedure in this chapter after the installation is complete.

Hand Throttle Nut

60

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

CONTROLS

Hand Throttle Tension Adjustment

Foot Throttle Adjustment

Hand throttle tension should be tight enough to maintain any desired engine RPM, but loose enough to allow easy operation. The hand throttle tension can be INCREASED or DECREASED.

A foot throttle is used to control the engine RPM to match increased power requirements. The foot throttle is coupled to the hand throttle through a throttle pivot assembly. The foot throttle is properly adjusted when pushing the hand throttle FULLY FORWARD causes the foot pedal to be pressed flush against the floor plate.

Adjustment Procedure

Adjustment Procedure

WARNING WARNING

BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Shut off the engine.

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

Tilt back ROPS/FOPS until lock engages.

NOTE: The three Belleville-type washers must be

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

installed properly to provide tension against the hand throttle.

1. With the hand throttle pulled back to an IDLE position, remove the clevis pin and cotter pin to disconnect the throttle yoke from the foot pedal.

Belleville Washers

1. To INCREASE TENSION tighten locknut securing hand throttle pivot assembly to chassis.

2. To DECREASE TENSION loosen locknut securing hand throttle pivot assembly to chassis.

2. Push down on the foot pedal until it is flush with the floor plate.

3. Push the hand throttle lever forward until it is at the high-idle position.

4. With the foot pedal down and the hand throttle pushed forward, readjust the foot throttle yoke to the pedal weldment and secure the adjustment with the jam nut, clevis pin and cotter pin.

PRINTED IN USA

917400/AP0809

61

CONTROLS

GEHL 1640E / MUSTANG 2012

CHAPTER NOTES

62

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDROSTATIC SYSTEM

Introduction

of the loader through a chain-and-sprocket system. The pumps and motors are controlled individually, allowing complete flexibility in forward, reverse, gradual, pivot and spin turns.

This chapter covers troubleshooting, testing, removal, installation, and adjustment procedures for the tandem pump system on Gehl 1640E and Mustang 2012 model skid-steer loaders.

For detailed information on pump and motor internal repairs, consult the Gehl-Mustang Service Department or the component manufacturer’s service manual.

Related hydraulic components are covered in the Hydraulic System chapter of this manual.

A hydrostatic pump assembly coupled to the engine provides power to two fixed-displacement hydrostatic drive motors. The motors drive the wheels on each side Hydrostatic Components - Standard Drive Motor

1

TUBE/BRAKE RELEASE

1

Hydrostatic Components - Drive Motor with Brake Release Valve

8 USE EXISTING HARDWARE TO INSTALL 10

7 3

6 2 3 9

4

1 CLAMP/HOSE 2 NUT/LOCK 3 FITTING/90º 4 HOSE/PRESSURE 5 HOSE/PRESSURE 6 TUBE/HANDLE 7 VALVE/BRAKE RELEASE 8 BRACKET/PUMP 9 DECAL 10 SCREW/CAP

1

5

USE EXISTING HARDWARE TO INSTALL

DECAL VIEW

1

LEFT INSIDE TOWER

PRINTED IN USA

917400/AP0809

63

HYDROSTATIC SYSTEM

GEHL 1640E / MUSTANG 2012

Hydrostatic Components 40

33

37

3 43

6

7

21 13

5

14 38

34

20 35

16

12

36

19

30

3

44

15

30 9

39

23

22

8 32 23

28

8

29

17

27

2

29

31 8

1 49

8

25

26

4

18

1

42 11

DRIVE MOTOR AND FITTING ORENTATION REFERENCE. 10

8 41

19

35

4

19

44

34

8

8

8

8

49 1 1

8

46 47

49

45

2 24

48

17

LEFT DRIVE MOTOR, RIGHT SIDE OF PUMP

RIGHT DRIVE MOTOR, LEFT SIDE OF PUMP 1

1 FITTING/STRAIGHT 11 WASHER/FLAT 2 FITTING/TEE 12 VALVE/SOLENOID 3 FITTING/90º 13 PLATE/SPACER 4 FITTING/90º 14 MANIFOLD/HYD. 5 CAP/37º FLARE 15 CLAMP/DUAL 6 CLAMP/TWIN TUBE 16 PLATE/CLAMP 7 FITTING/STRAIGHT 17 FITTING/90º 8 FITTING/90º 18 MOTOR/MS02 9 SWITCH/TEMP. 19 PUMP/REAR 10 O-RING 20 NUT/LOCK

64

4

49

1

21 NUT/LOCK 22 TUBE/DRAIN 23 TUBE/DRAIN 24 PLATE/PUMP 25 HOSE/PRESSURE 26 HOSE/PRESSURE 27 HOSE/PRESSURE 28 HOSE/PRESSURE 29 HOSE/PRESSURE 30 TUBE/DRAIN

917400/AP0809

31 TUBE/BRAKE 32 TUBE/BRAKE 33 TUBE/TANK 34 PUMP/FRONT 35 CROSS/TEE 36 TUBE/JUMP 37 PLATE/TWIN 38 SCREW/CAP 39 SCREW/CAP 40 SCREW/CAP

41 SCREW/CAP 42 SCREW/CAP 43 BOLT/CARRIAGE 44 WASHER/FLAT 45 SCREW/CAP 46 SCREW/CAP 47 WASHER/FLAT 48 WASHER/FLAT 49 FITTING/45º

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDROSTATIC SYSTEM

Charge Pressure Test and Adjustment Gehl 1640E and Mustang 2012 model skid-steer loaders have, as standard equipment, a charge pressure test port as part of the hydrostatic pump system. Before performing the following test, run the skid-steer loader to be sure the hydraulic oil is at normal operating temperature.

NOTE: This test requires a minimum of a 500 psi (34.5 bar) pressure gauge.

WARNING

Test Port Cap Removed

BEFORE beginning this service procedure, perform the following SAFETY procedures: Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

Test Procedure 1. Remove the step cover to access the test port.

2. Remove the metal cap from the test port located over the double gear pump.

3. Install the pressure gauge on the charge pressure test port.

4. Restart the engine and check the pressure reading on the gauge. The gauge should read 250 - 300 psi (17-21 bar).

5. If the pressure reading on the gauge is either lower or higher than specified, refer to the manufacturer’s service manual for the hydrostatic pump, and the charge pressure adjustment procedure that follows.

6. When finished, reinstall the metal cap to the test port.

Adjustment Procedure Add or remove shims on the charge pressure relief valve (next section) to adjust the charge pressure. Add shims to increase the charge pressure; remove shims to decrease the charge pressure.

Charge Pressure Test Port

PRINTED IN USA

917400/AP0809

65

HYDROSTATIC SYSTEM

GEHL 1640E / MUSTANG 2012

Hydrostatic Pump Relief Valves

Hydrostatic Pump Removal / Installation

Each hydrostatic pump is equipped with two highpressure relief valves, for a total of four hydrostatic pump relief valves in the hydrostatic drive system. The two front relief valves on the hydrostatic pump assembly control the front hydrostatic pump, which drives the left side of the skid loader. The two rear relief valves on the hydrostatic pump assembly control the rear hydrostatic pump, which drives the right side of the skid-steer loader. Refer to the manufacturer’s manual for service procedures.

Relief Valve Location

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

Removal Procedure 1. Drain the oil from the hydraulic reservoir per the procedure in the Lubrication chapter.

2. Remove the floor cover/step cover/kickplate per the procedure in the Mainframe chapter.

3. Remove the crossmember per the procedure in the Mainframe chapter.

4. Disconnect two hydraulic pressure hoses at the gear pump.

Relief Valve Location

Note: Mark the hoses, tubes and fittings for reassembly, and cap or plug them after they are disconnected to prevent contaminants from entering the hydraulic system.

66

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDROSTATIC SYSTEM

5. Label and disconnect all the hydraulic hoses connected to the hydrostatic pump.

6. Position a hoist above the hydrostatic pump.

Attach lifting straps around the pump and raise the hoist to remove slack from the strap/hook. The hoist should now support the weight of the pump.

7. Remove the two capscrews securing the hydrostatic pump to the flywheel housing and two capscrews securing the pump support plate to the flywheel housing.

PRINTED IN USA

917400/AP0809

67

HYDROSTATIC SYSTEM

GEHL 1640E / MUSTANG 2012

8. Shift the hydrostatic pump forward to disengage the splined shaft drive of the pump.

2. Remove the six capscrews securing the flywheel housing to the engine.

Splined Shaft Drive

9. Lift and maneuver the hydrostatic pump out of the skid-steer loader.

3. Remove the eight capscrews attaching the flexible coupling plate to the engine.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

Hydrostatic Pump Drive Coupling Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm, engage lift arm support device.

Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

Installation Procedure - Follow all warnings first, then reverse the removal steps.* * Regrease the tooth spline of the flexible drive coupling plate before reinstalling the hydrostatic pump.

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

1. Remove the hydrostatic pump per the procedure in this chapter.

68

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDROSTATIC SYSTEM

Drive Motor Removal and Installation

5. Disconnect all hydraulic hoses and tubes on each drive motor.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

Raise and securely block the loader so all four tires are off the ground.

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

Removal Procedure 1. Underneath the skid-steer loader, remove four capscrews securing the front belly pan and then remove the belly pan from the chassis.

6. Remove six socket-head capscrews and washers attaching the drive motor to the chaincase. Remove the drive motor with a suitable hoist.

2. Remove drive chains per the procedure in the Wheel Drives chapter.

3. If necessary, drain oil from hydraulic reservoir per the procedure in the Hydraulic System chapter.

NOTE: If the hydraulic hoses and tubes are plugged after removal to prevent oil leakage, it should not be necessary to drain the hydraulic reservoir. Hydraulic hoses and tubes should be plugged to prevent contaminants from entering the hydraulic system.

4. BEFORE disconnecting hydraulic hoses and tubes from the drive motor, mark each hose/tube and the port where it attaches to the drive motor (so that hoses/tubes can be correctly re-attached during installation).

PRINTED IN USA

917400/AP0809

69

HYDROSTATIC SYSTEM

GEHL 1640E / MUSTANG 2012

Installation Procedure - Follow all warnings first, then reverse the removal steps.

NOTE: Scrape off old gasket material and apply new sealant to mating surface of the drive motor before reassembly to the chassis.

CHAPTER NOTES

70

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDROSTATIC SYSTEM

Troubleshooting Guide The troubleshooting guide lists potential hydrostatic system problems, as well as possible causes and remedies.

If you cannot locate a particular hydrostatic system problem in this chart, consult the troubleshooting chart in the Hydraulic System chapter.

Problem No response from the hydrostatic drive or the lift/tilt systems

When a problem occurs, don’t overlook simple causes.

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

Possible Cause

Remedy

Hydraulic oil viscosity too high

Allow longer warm-up or replace oil with the proper viscosity oil.

Hydraulic oil supply too low

Check for low oil level in reservoir. Add oil as needed.

Hydrostatic pump drive disconnected Drive coupling failure.

Check for broken or worn pump drive coupling and replace, as needed.

Parking brake engaged.

Disengage parking brake.

Hydraulic oil supply too low

Check for low oil level in reservoir. Add oil if necessary.

Control rod linkage disconnected

Check linkage connection at control levers and neutral centering mechanisms. Reconnect linkage.

Low or no charge pressure

See hydrostatic pump manual.

Hydrostatic pump relief valves malfunctioning

Inspect and clean the relief valves.

Replace them as needed.

Drive wheels do not turn in proper direction for T-Bar movement

High pressure hydraulic hoses between hydrostatic pump and drive motors connected incorrectly

Reconnect hoses to proper ports on the drive motors. Refer to schematic and figures in the Hydrostatic System chapter.

Lift/tilt controls fail to respond

Hydraulic oil viscosity too high

Allow longer warm-up or replace with the proper viscosity oil.

Hydraulic oil level low

Check oil level in reservoir. If oil is low, check for an external leak. Repair and add oil.

Solenoid valve(s) malfunctioning

Check electrical connections to lift/tilt solenoids and repair.

Restraint bar or seat switch malfunction

Check switches.

Traction drive will not operate in either direction

PRINTED IN USA

917400/AP0809

71

HYDROSTATIC SYSTEM

Problem Neutral difficult to maintain

Sluggish acceleration

Hydrostatic drive overheating

72

GEHL 1640E / MUSTANG 2012

Possible Cause

Remedy

Rod ends loose on centering mechanism or servo rod

Check and tighten or replace components.

Neutral centering mechanism(s) out of adjustment

Adjust neutral centering mechanism(s).

See Controls chapter for procedure.

Clamping bolt loose

Tighten clamp bolt.

Hydrostatic pump out of adjustment

See hydrostatic pump manual.

Air in the hydraulic system

Cycle the lift and tilt cylinders to maximum stroke and maintain pressure for a short time to clear air from system.

Check hydraulic oil reservoir; fill as needed.

Hydraulic oil supply too low

Check hydraulic oil reservoir. Add oil, if necessary.

Low hydrostatic system charge pressure

See hydrostatic pump manual.

Drive motor(s) or hydrostatic pump(s) have internal damage or leakage

Refer to component manufacturer’s service manual.

Engine not responding under load

Troubleshoot engine.

Automatic parking brake partially engaged

Units with brake release valve, cycle the valve to release the parking brake pressure. Other units without brake release valve, contact your dealer.

Drive system overloaded continuously

Improve efficiency of operation.

Lift and tilt system overloaded continuously

Improve efficiency of operation.

Drive motor(s) or hydrostatic pump(s) have internal damage or leakage

Refer to component manufacturer’s service manual.

Oil cooler plugged with debris

Clean oil cooler fins.

Loader being operated in a high temperature area with no air circulation

Reduce duty cycle and improve air circulation.

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

Problem Hydrostatic (drive) system noisy

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

Right side doesn’t drive in one direction

PRINTED IN USA

HYDROSTATIC SYSTEM

Possible Cause

Remedy

Hydraulic oil viscosity too high

Allow longer warm-up or replace oil with the proper viscosity oil.

Drive motor(s) or hydrostatic pump(s) have internal damage or leakage

Refer to component manufacturer’s service manual.

Air in hydraulic system.

Cycle lift and tilt cylinders to maximum stroke and maintain pressure for a short time to clear air from system.

Check oil level in reservoir; fill as needed.

Excessive internal leakage in right drive motor

Repair or replace as needed. Refer to motor manufacturer’s service manual.

Excessive leakage in engine-end hydrostatic pump

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

Servo controller malfunctioning

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

Relief valves on engine-end hydrostatic pump malfunctioning

Switch valves with those on front hydrostatic pump. See “Hydrostatic Pump Relief Valves” information in this chapter; problem should switch to the left side. Replace defective relief valve.

Control rod linkage to engine-end hydrostatic servo is disconnected

Reattach control rod linkage.

Relief valve on engine-end hydrostatic pump malfunctioning

Switch one relief valve with the other relief valve on rear pump; problem should switch to reverse direction.

Clean or replace the faulty valve as needed.

Engine-end hydrostatic pump malfunctioning

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

Servo controller malfunctioning

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

917400/AP0809

73

HYDROSTATIC SYSTEM

Problem

Possible Cause

Remedy

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

Excessive internal leakage in left drive motor

Repair or replace as needed. Refer to motor manufacturer’s service manual.

Excessive leakage in gear-end hydrostatic pump

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

Relief valves on gear-end hydrostatic pump malfunctioning

Switch valves with those on rear hydrostatic pump. See “Hydrostatic Pump Relief Valves” information in this chapter; problem should switch to the right side. Replace defective relief valve as needed.

Servo controller malfunctioning

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

Control rod linkage to gear-end hydrostatic servo disconnected

Reattach control rod linkage.

Relief valve on gear-end hydrostatic pump malfunctioning

Switch relief valve with other relief valve on front pump; problem should switch to the reverse direction. Clean or replace the faulty valve as needed.

Gear-end hydrostatic pump malfunctioning

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

Servo controller malfunctioning

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

Left side doesn’t drive in one direction

74

GEHL 1640E / MUSTANG 2012

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDROSTATIC SYSTEM

THIS PAGE INTENTIONALLY LEFT BLANK

PRINTED IN USA

917400/AP0809

75

HYDROSTATIC SYSTEM

GEHL 1640E / MUSTANG 2012

Hydrostatic/Hydraulic Schematic 25 HP 2500 LOW IDLE: 1500 RPM HIGH IDLE: 2500 RPM

TEST PORT

.98 CID .98 CID SAUER DANFOSS LPV 1.53

L1

L2

P 1750 PSI P

T

3046

3046

B

TILT

A PORT B

OPTIONAL BRAKE RELEASE

PORT A SAUER DANFOSS LPV 1.53

L1

L2

B

LIFT

A

B

AUX 3046

A

3046

T

PORT B

PORT A

76

R

R

L

15.6 CID

CID 15.6

L

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDROSTATIC SYSTEM

Hydrostatic/Hydraulic Schematic

P 1750 PSI T STANDARD FLOW NON SELF LEVEL

B

TILT

A

TILT B

LIFT

A LIFT

B

AUX

A

A EATON SELF-LEVEL VALVE W/ RELIEF UNLOAD SPOOL)

B

C

T

D

TILT

LIFT

OPTIONAL SELF LEVEL

PRINTED IN USA

917400/AP0809

77

HYDROSTATIC SYSTEM

GEHL 1640E / MUSTANG 2012 CHAPTER NOTES

78

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

Introduction

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

This chapter covers troubleshooting, testing, removal, installation and adjustment procedures for hydraulic system components on Gehl 1640E and Mustang 2012 model skid-steer loaders. Primary hydraulic system components in this chapter are shown below and on following pages.

Power for the lift arm functions and auxiliary hydraulics is provided by a gear pump attached to the front of the tandem pumps.

Models include a standard-flow auxiliary hydraulics system with two hydraulic couplers on the left lift arm for attachment hookup.

When a problem occurs, don’t overlook simple causes.

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

Hydraulics - Non-Self Level and Self Level Valve Components 7

PART # L81195 REFERENCE ONLY

4

8 1

PART # L81195 REFERENCE ONLY 2

1 2 3 4 5 6 7 8

CLAMP/TUBE PLATE/TWIN NUT/CENTERLOCK TUBE/TILT CAP TUBE/LIFT ROD TUBE/LIFT ROD TUBE/TILT ROD SCREW/CAP

Non-Self Level 3

5

6 PART # L81195 REFERENCE ONLY

10 9 12

Self Level 1

8 4

13 2

11

3

5

7 11

1 2 3 4 5 6 7 8 9 10 11 12 13

FITTING/TEE VALVE/SELF-LEVEL NUT/CENTERLOCK SPACER TUBE/SELF-LEVEL RODS TUBE/SELF-LEVEL PORT A TUBE/SELF-LEVEL PORT C TUBE/SELF-LEVEL PORT D TUBE/SELF-LEVEL PORT C TUBE/SELF-LEVEL PORT D TUBE/SELF-LEVEL PORT B BOLT/CARRIAGE FITTING/STRAIGHT

13 6

PRINTED IN USA

917400/AP0809

79

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

Hydraulics - Lift Arm Components

30

30 24

21

5

3

5 18

3 28

18

31

29 26

15

35

28

27

34

12

35 19

32 5

36

10

1 4

15

11

15

36

9

32

9

19

8

34

5

20 7

20 22

1

13

23

4

6

14

1 33

16 16 17 5

1 FITTING/STRAIGHT 3 FITTING/90º 4 NUT/LOCK 5 NUT/HEX LOCK 6 CLAMP/HOSE 7 FITTING/45º ELBOW 8 CLAMP/HOSE 9 CLAMP/HOSE 10 QUICK COUPLER/MALE 11 QUICK COUPLER/FEMALE 12 FITTING/90º 13 PLUG/O-RING

80

14 15 16 17 18 19 20 21 22 23 24 26

17

NUT/SPIRALOCK CYLINDER/LIFT CYLINDER/TILT PIN/PIVOT PIN PIN PIN/LOWER HOSE/PRESSURE HOSE/PRESSURE HOSE/PRESSURE HOSE/PRESSURE TUBE/LEFT ROD

917400/AP0809

27 28 29 30 31 32 33 34 35 36

TUBE/LEFT ROD HOSE/PRESSURE HOSE/PRESSURE HOSE/PRESSURE TUBE/LIFT CYLINDER RING/SNAP SCREW/CAP SCREW/CAP SCREW/CAP SCREW/CAP

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

Hydraulics - Chassis Components

INSTALL INSIDE TOWER WALL

26

4

28

16

16 24 51

44

47 50

15 INSTALL IN TOWER WALL

51 4

4

51 37

3

43

35

33

51

36

32 22

33

15

21

23

34

6 32 18

INSTALL IN TOWER WALL

1

22

32

5

26 15 8

28

10

48

30 17 39

29

13

42

9 11

5

41

12

20

14 13 38 19

46

40 25

7

49 45

45

PRINTED IN USA

27

20 31

917400/AP0809

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 45 46 47 48 49 50 51

FITTING/TEE CLAMP/HOSE FITTING/90º FITTING/90º FITTING/STRAIGHT FITTING/STRAIGHT FITTING/90º PLATE/TWIN COVER SCREW/CAP LOCK CLAMP/TUBE CLAMP/HOSE NUT/HEX LOCK FITTING/90º O-RING NUT/SPIRALOCK STRAP FITTING/90º FITTING/90º PORT/TEST CLAMP/T-BOLT CLAMP/TUBE PLATE/TWIN FITTING/90º VALVE/CONTROL GEAR PUMP/DOUBLE NUT/HEX LOCK FITTING/45º VALVE/SOLENOID FILTER/HYD. OIL TUBE/FILTER OUT HOSE/SUCTION TUBE/MALE AUX. TUBE/FEMALE AUX. TUBE/LEFT LIFT TUBE/RIGHT LIFT TUBE/LIFT LOCK TUBE/TILT LOCK BRACKET/FILTER HOSE/PRESSURE TUBE/DRAIN TUBE/CHARGE ASSY/HYDR. FILTER SCREW/CAP SCREW/CAP SCREW/CAP BOLT/CARRIAGE BOLT/CARRIAGE BOLT/CARRIAGE WASHER/FLAT FITTING/90º FITTING/90º

81

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

Pressure Tests, Control Valve

6. If the pressure reading is NOT between the specified pressures, adjust pressure as follows:

The control valve on the skid-steer loader controls lift and tilt functions of the lift arm and standard auxiliary hydraulics. It is located on the right side of the chassis.

The relief valve in the control valve can be tested at the lift arm couplers.

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

Test Procedure

Shut off the engine.

WARNING

Tilt back ROPS/FOPS until lock engages.

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

(For detailed instructions, refer to the Safety chapter in this manual.) a. Standard auxiliary relief valve can be found at the top rear of the control valve.

Shut off the engine.

Relieve hydraulic system pressure.

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

Relief Valve Location

NOTE: To prevent contamination, ALWAYS clean the area around hydraulic fittings before disconnecting any hydraulic plug, hose or tube.

1. What you’ll need: an assistant and a minimum 5000 psi (345 bar) pressure gauge.

2. Perform the pressure tests at the auxiliary hydraulic couplers located on the left lift arm.

Auxiliary Couplers

b. Loosen the small lock nut threaded on the valve.

3. Install the pressure gauge in the end of the male coupler and activate the auxiliary hydraulic circuit to pressurize the line.

4. For this test, engine should be at HIGH IDLE. 5. Have assistant observe the pressure reading on the gauge. The pressure reading on the loader should be at least 2255 psi (156 bar), but NOT more than 2305 psi (159 bar).

82

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

b. With an Allen wrench, turn the adjuster screw IN to increase pressure or OUT to decrease pressure.

Adjuster Screw

Tilt Cylinder Test If the bucket (or attachment) drifts down with the tilt control in the NEUTRAL position, first check the tilt cylinders for external leakage. If external leakage is evident, a new seal kit should be installed in the leaking cylinder(s). If no external leakage is evident, check the tilt cylinders for internal leakage according to the following procedure.

NOTE: When checking for drifting, the ignition key MUST BE in the OFF position, operator in the seat, and the restraint bar lowered. The maximum allowable tilt cylinder circuit drifting with a loaded bucket is 0.4" (10 mm) of cylinder extension in 15 minutes.

Test Procedure

c. Repeat steps 4 and 5. d. After the pressure is within the correct PSI range, tighten the locknut on the control valve adjuster screw to secure the adjustment.

7. If, after the adjustment, there is NO CHANGE in the pressure reading, this indicates either a defective hydraulic gear pump or relief valve cartridge (on the control valve). To determine which is the cause, first replace the relief valve cartridge. If the pressure reading still does not change, the hydraulic gear pump should be repaired or replaced.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Shut off the engine.

Relieve hydraulic system pressure.

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

1. Load the bucket and allow it to rest on the ground.

NOTE: To prevent contamination, ALWAYS clean the area around hydraulic fittings before disconnecting any hydraulic hose or tube.

2. Checking the right tilt cylinder: Remove the inside lower hydraulic hose from the right tilt cylinder and cap or plug the hose and cylinder port. Caps or plugs MUST BE able to withstand full hydraulic pressure.

Right Tilt Cylinder

PRINTED IN USA

917400/AP0809

83

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

3. Crack open (slightly loosen) the inside upper hydraulic hose on the right tilt cylinder.

Right Tilt Cylinder

8. Checking the left tilt cylinder: Remove the two lower hydraulic hoses on the right tilt cylinder and cap or plug the cylinder ports. Caps or plugs MUST BE able to withstand full hydraulic pressure.

Right Tilt Cylinder

WARNING BEFORE raising a loaded bucket, BE SURE no personnel are near the loader. Serious personal injury can result if bucket drops suddenly or its contents spill out.

9. Connect the two hoses, just removed, together with a straight fitting.

10. Crack open (slightly loosen) the inside upper hydraulic hose on the left tilt cylinder.

Left Tilt Cylinder

4. Climb back into the operator’s seat, lower the restraint bar, and start the engine.

5. Raise the lift arm enough for the bucket (or attachment) to clear the ground.

6. Shut off the engine, turn the ignition key to the ON position (engine OFF) and operate the tilt control in both directions.

7. If the bucket drifts, the blocked tilt cylinder has leaking piston seals. If it DOES NOT drift, lower the lift arm and reconnect/retighten the hydraulic hose(s) to the cylinder.

11. Repeat steps 4 - 7 for the left tilt cylinder.

12. After both tilt cylinders have been tested, be sure the hydraulic hoses are reconnected or retightened.

NOTE: If both tilt cylinders have good seals, and the bucket still drifts, the fault could be in either the control valve or the self-leveling valve. Continue the test procedure with step 13, below. Also, refer to the Troubleshooting Guide in this chapter.

13. To determine if either the control valve or self-leveling valve is faulty and causing the bucket to drift, perform the “Self-Leveling Valve Test” procedure in this chapter.

84

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

Self-Leveling Valve Test

Lift Cylinder Test

Test Procedure

If the lift arm drifts with the lift control in NEUTRAL position, and the ignition key OFF, first check the lift cylinders for external leakage. If external leakage is evident, a new seal kit should be installed in the leaking cylinder(s). If no external leakage is evident, check the lift cylinders for internal leakage according to the following procedure.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Shut off the engine.

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

1. With the engine OFF, remove the rear belly pan on the chassis beneath the engine and locate the valve on the right side of the engine.

2. Loosen the jam nut on the self-leveling valve adjuster screw.

NOTE: When checking lift arm for drifting, BE SURE the ignition key is in the OFF position. The maximum allowable lift cylinder drifting is 0.75" (19 mm) of cylinder retraction in 15 minutes.

Test Procedure 1. Remove the bucket or attachment from the attachment bracket.

2. Raise the lift arm to maximum height. Then release the lift cylinder lift arm support device and slowly lower the lift arm to engage the device.

Self-Leveling Valve Adjuster Screw

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: Shut off the engine.

Relieve hydraulic system pressure.

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

NOTE: For step 3, BE SURE to count and record the number of turns, so the adjuster screw can be returned to its original setting after the test.

3. Remove the clamp securing the hydraulic tubes to the lift cylinder on the side being tested.

3. With an Allen wrench, turn the adjuster screw in (clockwise) until it bottoms out. The self-leveling valve is now disabled and will not affect the tilt operations.

4. Perform steps 4 - 7 of the “Tilt Cylinder Test” procedure. If the bucket no longer drifts, the self-leveling valve is defective. If the bucket continues to drift, the control valve is defective and in need of repair or replacement.

5. Refer to the “Self-Leveling Valve Adjustment” procedure in this chapter for correct adjustment of the self-leveling valve.

PRINTED IN USA

NOTE: To prevent contamination, ALWAYS clean around hydraulic fittings before disconnecting any hydraulic lines.

917400/AP0809

85

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

4. Disconnect the hydraulic tube from the rod end port of the lift cylinder to be tested.

Solenoid Valve Test - Tilt, Lift, Brake During normal operations, the solenoid valves should prevent operation of the lift arm and drive functions if any of the safety interlock system switches are open, for example: » Operator not sitting on the seat. » Restraint bar not lowered.

Test Procedure 1. Climb into the operator’s seat, lower the restraint bar and start the engine.

2. Using the lift control, raise the lift arm off the ground enough so that the attachment can be tilted.

5. Install a plug on hydraulic tube. Attach a hose to rod end port of the cylinder and run the other end of the hose into a suitable container. Lower the ROPS.

3. Raise the restraint bar, use the lift and tilt controls (one at a time) to see if either function will operate. » If the lift arm can be raised or lowered, the lift solenoid is malfunctioning.

6. Climb back into the operator’s seat, lower the restraint bar and start the engine.

7. Hold the lift control in the RAISE position. If the seals in the cylinder are defective and leaking, oil will flow out of the rod-end port.

Lift Solenoid

8. Lower the lift arm support device back against the lift cylinder. Shut off the engine and move the lift control in both directions to relieve hydraulic pressure.

9. Reconnect the hydraulic tube to the cylinder, then reattach the clamp around the hydraulic tubes and cylinder.

NOTE: If neither lift cylinder shows signs of external or internal leakage, and the lift arm still drifts, the problem could be due to leaking hydraulic hose fittings between the control valve and the lift cylinders. Check all hydraulic hose fittings thoroughly. The fault could also be in either the control valve or the self-leveling valve. Continue the test procedure with step 11. Also refer to the Troubleshooting Guide in this chapter.

» If the attachment can be tilted, the tilt solenoid is malfunctioning.

10. The other cylinder can be checked the same way.

11. To determine if either the control valve or the selfleveling valve is faulty, perform the “Self-Leveling Valve Test” procedure in this chapter.

Tilt Solenoid

86

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

4. Lower the restraint bar. BE SURE the parking brake on the instrument panel is in the OFF position.

Hydraulic Oil Filter Element Replacement

5. Raise the restraint bar. Use the drive controls (one at a time) to see if the tires will move.

Gehl 1640E and Mustang 2012 model skid-steer loaders have one hydraulic oil filter. The hydraulic oil filter element should be replaced after every 250 hours of operation or annually (whichever occurs first).

» If the skid loader moves forward or backward, the brake solenoid is malfunctioning.

NOTE: There is an initial 50-hour element replacement schedule for new skid-steer loaders with original filters.

Brake Solenoid

Hydraulic Oil Filter Location

6. If any solenoid in the above tests appears to be malfunctioning, test that solenoid coil as follows:

Replacement Procedure

WARNING

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedure: Raise lift arm; engage lift arm support device.

BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

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

» Have an assistant sit in the operator’s seat, lower the restraint bar and turn the keyswitch to ON. DO NOT start the engine.

1. Remove the floor cover/step cover/kickplate per the procedure in the Mainframe chapter.

» Using a thin strip of steel (such as a pocket ruler), check the suspected solenoid by moving the steel strip close to the solenoid coil.

2. Remove the crossmember per the procedure in the Mainframe chapter.

» If the steel strip is magnetically attracted to the solenoid coil, the coil works and the solenoid cartridge may be causing the malfunction.

7. For service procedures, refer to “Solenoid Valve Removal and Installation/Disassembly and Reassembly” procedure in this chapter.

PRINTED IN USA

917400/AP0809

87

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

3. Place the end of a rubber hose originating from the hydraulic filter bracket into a suitable container (one quart pan) to catch hydraulic oil.

and can cause permanent eyesight damage if safety glasses are not worn.

8. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

Tilt Cylinder Removal and Installation Removal Procedure NOTE: Refer to the “Lift Arm Removal/Disassembly” procedure in the Mainframe chapter for instructions on removing the complete lift arm group, including the tilt cylinders.

1. Remove the bucket or attachment.

4. Using a filter wrench, turn the filter element counterclockwise to remove it from the filter head.

2. With the engine running, lower the lift arm until it is in contact (or near contact) with the lift arm stops (on front of chassis).

5. Install the filter element. Before installation, apply a light coat of oil to the gasket, and then install it on the filter head.

6. Hand-tighten element until the gasket contacts the filter head. Turn element another 3/4 turn to seat the gasket.

7. Refer to the Lubrication chapter in this manual for the hydraulic fluid requirements and specifications.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: Shut off the engine.

Relieve hydraulic system pressure.

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

WARNING NEVER use your hands to search for hydraulic fluid leaks.

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

3. Disconnect the upper and lower tilt cylinder hoses from the cylinder ports. BE SURE to install plugs in the hoses and cap the fittings to prevent fluid loss and contamination of the hydraulic system.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible

88

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

4. While supporting the weight of the tilt cylinder, remove the capscrew and locknut securing the lower tilt cylinder pivot pin. Then drive the pivot pin out to release the lower end of the tilt cylinder.

Installation Procedure 1. Install the upper end of the tilt cylinder in position on the lift arm and insert the pivot pin. Use Loctite® 242 or equivalent on the capscrew before reinstalling and torque to 80 ft.-lbs. (108 N•m).

2. Position the lower end of the tilt cylinder and insert the pivot pin through the cylinder and attachment mount. Secure the pivot pin with a capscrew and locknut.

NOTE: The grease fitting on the base and rod end of the tilt cylinder should face inward as installed.

5. Remove three thread-cutting screws on each kneecap plate and remove the plates.

Kneecap Plate

3. Re-install the kneecap plates over both tilt cylinders with the three thread-cutting screws.

4. Remove plugs/caps and attach the upper and lower tilt cylinder hoses to the cylinder.

6. Remove the capscrew and locknut securing the cylinder to the lift arm.

NOTE: After removing/replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary.

Refer to the Lubrication chapter in this manual for the hydraulic fluid requirements and specifications.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

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

7. Using a punch, remove the upper tilt cylinder pins and remove the cylinders.

PRINTED IN USA

917400/AP0809

89

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012 NOTE: To aid in correct reassembly of the hydraulic hoses/tubes, mark the hoses/tubes to be removed BEFORE disassembly in step 3.

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.

4. Disconnect the two hydraulic hoses from their two hydraulic tubes on the lift cylinder. BE SURE to install plugs/caps in the hoses/tubes to prevent fluid loss and contamination of the hydraulic system.

5. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

Lift Cylinder Removal and Installation Removal Procedure 1. Remove the bucket or attachment.

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

5. Remove the capscrew and locknut securing the front lift cylinder pivot pin. Then drive the pivot pin out to release the rod end of the lift cylinder.

Shut off the engine.

Relieve hydraulic system pressure.

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

2. Attach a suitable hoist to the hitch and raise the lift arm to a position where access to the tubes and hoses on the lift cylinder is maximized.

3. Remove the clamp that secures the hydraulic tubes to the lift cylinder.

6. While supporting the weight of the lift cylinder, remove the capscrew and locknut securing the rear lift cylinder pivot pin. Drive the pivot pin out the hole on the outside of the chassis. Remove the lift cylinder from the chassis.

Installation Procedure 1. Attach a suitable hoist to the hitch and raise the lift arm to a position where access to the tubes and hoses on the lift cylinder is maximized.

90

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

Lift Cylinder Components

1 TUBE 2 PISTON 3 GLAND/HEAD 4 SPACER/ROD 5 ROD

6 BEARING/BRONZE 7 BEARING/BRONZE 8 NUT/LOCK 9 ZERK/STRAIGHT 10-18 KIT/SEAL

Tilt Cylinder Components

1 TUBE 2 PISTON 3 GLAND/HEAD 4 ROD 5 PLUG/SOCKET

PRINTED IN USA

6 BEARING/BRONZE 7 NUT/LOCK 8 ZERK/GREASE 9 FITTING/GREASE 10-18 KIT/SEAL

917400/AP0809

91

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

2. Install the lift cylinder on the chassis so the rod end is facing forward and the hydraulic tube ports on the cylinder are facing inward.

Lift/Tilt Cylinder Disassembly / Assembly

3. Insert the rear and front pivot pins through the lift cylinder pivots and secure them with capscrews and locknuts.

Remove the cylinder from the skid-steer loader. See “Lift Cylinder Removal” or “Tilt Cylinder Removal” in this chapter.

4. Remove the plugs/caps and connect the two hydraulic hoses to their hydraulic tubes on the lift cylinder according to the markings made at removal. If no markings were made or new parts were installed, refer to the Hydraulic System chapter exploded views.

1. Purge the oil from the cylinder by facing the ports downward and pumping the cylinder rod back and forth several times.

Disassembly Procedure

2. Use an Allen wrench to loosen the set screw on the cylinder collar.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter in this manual for the hydraulic fluid requirements and specifications.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

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

3. Clamp a suitable shaft in a vise and slide the cylinder onto the shaft to prevent the cylinder tube from turning.

4. Use a chain clamp to remove the collar from the cylinder tube.

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.

5. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

6. Remove the hoist.

92

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

5. Remove the rod assembly and inspect both the cylinder rod and the tube for dents or nicks that may cause damage to the o-rings and seals.

8. Slide the head gland, seals, and o-rings off the cylinder rod and inspect them for wear.

9. Change the seals as needed.

6. Loosen and remove the locknut that secures the head gland, seal kit and piston on the cylinder rod.

NOTE: Soaking the seals in warm water prior to installation will make them pliable and easier to install.

However, BE SURE to dry them and coat with hydraulic oil for proper installation.

Assembly Procedure 1. Slide the collar onto the cylinder rod (threaded end of the collar should face the threaded end of the cylinder rod).

2. Slide the head gland, larger diameter first, onto the cylinder rod.

3. Install the piston on the cylinder rod.

4. Secure the head gland and piston on the cylinder rod with a locknut. The locknut should be torqued to 350 ft.-lbs. (474 N•m).

7. Remove the piston assembly.

5. Install the cylinder rod into the tube.

Piston

6. Slide the collar down to the cylinder tube, thread it onto the tube and tighten with a chain clamp wrench. Tighten the set screw on the collar.

7. Install the cylinder on loader. See the “Lift Cylinder Installation” or the “Tilt Cylinder Installation” procedures in this chapter.

Head Gland

PRINTED IN USA

917400/AP0809

93

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

Gear Pump Removal and Installation

5. Disconnect the hydraulic tube on the gear pump at both ends and loosen the fittings.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Shut off the engine.

Relieve hydraulic system pressure.

Tilt back ROPS/FOPS until lock engages.

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

1. Drain the oil from the hydraulic reservoir per the procedure in the Lubrication chapter.

2. Remove the control cover and the floor cover per the procedure in the Mainframe chapter.

3. Remove the crossmember per the procedure in the Mainframe chapter.

4. Disconnect two hydraulic pressure hoses at the gear pump.

6. Support the gear pump. Remove two capscrews securing the gear pump to the hydrostatic pump.

The hydraulic oil filter bracket can rest on the hydrostatic pump.

7. Pull the gear pump forward and out of the hydrostatic pump. BE CAREFUL not to lose the o-ring.

Installation Procedure 1. Install the o-ring on the mating surface of the gear pump.

2. Attach the gear pump to the hydrostatic pump (BE SURE the gear pump shaft engages the splined coupler). Install two capscrews with Loctite® 242 applied to secure the gear pump to the hydrostatic pump.

3. Remove the caps/plugs and connect the hydraulic hoses to the gear pump.

4. Reinstall the crossmember and the floor cover/control cover per the procedures in the Mainframe chapter.

5. Reinstall the hydraulic reservoir drain plug.

6. Replace the hydraulic oil drained out of the reservoir in step 1.

Note: Mark the hoses, tubes and fittings for reassembly, and cap or plug them after they are disconnected to prevent contaminants from entering the hydraulic system.

94

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of the hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for the hydraulic fluid requirements and specifications.

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM NOTE: In order to remove the hydraulic tubes from their fittings on the self-leveling valve, it may be necessary to loosen the hydraulic tube at the other end to give it some free-play.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

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

1. With the engine OFF, remove the rear belly pan on the chassis beneath the engine and locate the selfleveling valve right of the engine.

2. Disconnect all the hydraulic tubes and hoses from their hydraulic fittings on the self-leveling valve.

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.

3. Remove the two capscrews, spacers and locknuts securing the self-leveling valve to the chassis.

7. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

Self-Leveling Valve Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of the hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for the hydraulic fluid requirements and specifications.

Shut off the engine.

Relieve hydraulic system pressure.

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

NOTE: Cap or plug the hydraulic hoses and fittings after disconnecting them to prevent fluid loss and contamination of the hydraulic system.

PRINTED IN USA

4. Remove the self-leveling valve.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

917400/AP0809

95

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012 be adjusted according to steps 5 - 9 of this procedure.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

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

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.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Shut off the engine.

Self-Leveling Valve Adjustment

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

Adjustment Procedure 1. Raise and lower the lift arm several times to ensure there is no air in the hydraulic system.

2. Lower the lift arm completely then fully retract the tilt cylinders (roll back).

3. Raise the lift arm to its maximum height; then lower it to the ground.

4. Measure how far the tilt cylinder rod extends from the tilt cylinder. The distance should be between 11-1/2 and 11-3/4” (292-298 mm). If measurement is outside this range, the self-leveling valve should

WARNING Surfaces inside the engine compartment may be extremely hot, particularly the engine muffler and exhaust pipes. Serious injury may occur from touching components that have become hot while the engine was running.

5. The self-leveling valve can be accessed from the right side of the chassis.

6. Remove the rear belly pan on the chassis beneath the engine and locate the valve on the right side of the engine.

96

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

7. Loosen the jam nut on the self-leveling valve adjuster screw.

Safety Lock Valves - Removal/Installation Gehl 1640E and Mustang 2012 model skid-steer loaders have separate electric solenoid safety interlock valves for the lift and tilt functions of the hydraulic system.

The lift safety interlock valve is located on the left side of the chassis above the suction hose running off the gear pump. The tilt safety interlock valve is located in the right riser at the base end of the lift cylinder. The brake solenoid valve is located on the right side of the chassis forward of the main control valve.

Lift, Tilt and Brake Solenoid Valve Removal Procedure

8. Insert an Allen wrench into the adjuster screw on the self-leveling valve and adjust the valve. Turn the screw IN (clockwise) to shorten the cylinder extension. Turn the screw OUT (counterclockwise) to lengthen the cylinder extension.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

Shut off the engine.

Relieve hydraulic system pressure.

Tilt back ROPS/FOPS until lock engages.

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

9. To check for proper operation, lower the ROPS, climb into the operator’s seat, lower the restraint bar and start the engine. Disengage the lift arm support device and secure it to the lift arm.

1. Disconnect the electrical connector on the solenoid coil. Disconnect the hydraulic tubes from their fittings on the solenoid body. Remove the two carriage bolts, straps and locknuts securing the solenoid to the chassis.

10. Repeat steps 2 through 4 above to check for proper operation of the self-leveling valve. If further adjustment is needed, perform the safety procedures again and repeat steps 7 through 9.

11. After adjustment is complete, tighten the adjuster screw locknut.

2. Remove the solenoid from the skid-steer loader.

PRINTED IN USA

917400/AP0809

97

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

NOTE: Cap or plug ALL hydraulic hoses, tubes, fittings, and control valve ports immediately after they are disconnected to prevent fluid loss and contamination of the hydraulic system.

3. Unscrew cartridge from the valve body.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for hydraulic fluid requirements and specifications.

Lift, Tilt and Brake Solenoid Valves - Disassembly and Assembly Lift, tilt and brake solenoid valves can be removed from the loader for parts replacement, but it may not be necessary. If it is necessary, refer to the procedure in this chapter.

4. Install seal kit (or other new parts). Assemble solenoid valve in reverse order of disassembly.

O-Ring

O-Ring

O-Ring

Disassembly Procedure 1. Remove the nut that secures the coil to the cartridge.

Backup Rings

IMPORTANT DO NOT torque coil retaining nut more than 45 in.-lbs. (5.1 N•m).

2. Remove the coil from the cartridge.

98

5. If removed from the loader, install the lift, tilt or brake solenoid on the hydraulic system. Refer to the applicable procedure in this chapter.

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

Control Valve Removal and Installation The main hydraulic control valve is located on the right side of the chassis, in front of the engine. This procedure highlights steps for removing the hydraulic hoses/tubes that connect to the control valve in order to remove the control valve. The removal of the lift, tilt and auxiliary connections at the control valve are highlighted in their respective procedures in the Controls chapter of this manual. The control valve ports are numbered for reference.

3. Disconnect the electrical connector on the neutralcentering spool lock at the rear and bottom of the control valve from the main chassis electrical harness.

Neutral-Centering Lock

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

4. If so equipped, disconnect the electrical connector on the auxiliary spool lock solenoid at the front of the control valve.

Shut off the engine.

With Spool Electric Lock

Relieve hydraulic system pressure.

Tilt back ROPS/FOPS until lock engages.

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

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

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

2. Remove control rods and/or cables that control the lift, tilt and auxiliary hydraulics of the skid-steer loader. Refer to their removal procedures in the Controls chapter of this manual.

1 3 2

5

4

7 8 6

PRINTED IN USA

917400/AP0809

99

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

NOTE: To aid in re-assembly of hydraulic hoses and tubes, mark hoses and tubes to be removed before disassembly.

NOTE: Cap or plug ALL hydraulic hoses, tubes, fittings and control valve ports immediately after being disconnected to prevent fluid loss and contamination of the hydraulic system.

1 3 2

Installation Procedure 1. Secure the control valve to the chassis with four capscrews and locknuts. If straight or 90° fittings are not in the valve, install them at this time.

5

4

14. Lift out the control valve. Removal may require loosening the opposite ends of some of the disconnected tubes.

7

2. Port 8: Connect the hydraulic oil cooler tube to the bottom 90° fitting on the control valve.

8

3. Port 7: Connect the auxiliary hydraulic tube to the straight fitting on the control valve.

6 5. Port 1: Disconnect the hydraulic hose from the 90° fitting on the control valve (other end connects to gear pump).

6. Port 2: Disconnect the hydraulic self-leveling valve tube from the long 90° fitting on the control valve.

7. Port 3: Disconnect the hydraulic self-leveling valve tube from the 90° fitting on the control valve.

8. Port 4: Disconnect the hydraulic self-leveling valve tube from the long 90° fitting on the control valve.

9. Port 5: Disconnect the hydraulic self-leveling valve tube from the 90° fitting on the control valve.

10. Port 6: Disconnect the auxiliary hydraulic tube from the straight fitting on the control valve.

4. Port 6: Connect the auxiliary hydraulic tube to the straight fitting on the control valve.

5. Port 5: Connect the hydraulic self-leveling valve tube to the 90° fitting on the control valve.

6. Port 4: Connect the hydraulic self-leveling valve tube to the long 90° fitting on the control valve.

7. Port 3: Connect the hydraulic self-leveling valve tube to the 90° fitting on the control valve.

8. Port 2: Connect the hydraulic self-leveling valve tube to the long 90° fitting on the control valve.

9. Port 1: Connect the hydraulic hose at the 90° fitting on the control valve (other end connects to gear pump).

11. Port 7: Disconnect the auxiliary hydraulic tube from the straight fitting on the control valve.

Main Control Valve

12. Port 8: Disconnect the hydraulic oil cooler tube from the bottom 90° fitting on the control valve.

13. Remove four capscrews and locknuts securing the control valve to the chassis.

10. Re-connect the auxiliary hydraulics spool lock electrical connector at the front of the control valve.

11. Re-connect the electrical connector on the neutral centering spool lock at the rear and bottom of the control valve to the main chassis electrical harness.

100

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

12. Connect control rods and/or cables that control the lift, tilt and auxiliary hydraulics of the skid-steer loader. Refer to their installation procedures in the Controls chapter of this service manual.

13. Install hydraulic reservoir drain plug and refill with correct type of hydraulic oil. Refer to the Lubrication chapter for hydraulic oil requirements and specifications.

14. ALWAYS check for hydraulic fluid leaks after reassembling any component of the hydraulic system.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

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

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.

PRINTED IN USA

917400/AP0809

101

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

Main Control Valve Components

1 SD6/AC(HG3)-SAE INLET COVER 2 SD6 SECTION 3 SD6 SECTION FLOAT 4 SD6 OUTLET 5 1CS/SD6 SPOOL 6 5Y(13NZ)/SD6 SPOOL 7 S5 SLP KIT 8 TP50 KIT 9 BANKING KIT SD 6/3 10 8/S5-MC KIT 11 SD6 13NZ KIT 12 SD6 8K KIT W/WEATHER PACK 13 P3T/SD6 PLUG

102

14 P(G3)/SD6 CARTRIDGE 15 S06 FIXING BRACKET (SD6) 16 SD6 SPOOL O-RING 17 SD6 BRASS WASHER 18 SD6 SAE08 PLUG 19 SD6 SV PLUG 20 SD6 MAIN RELIEF 21 SD6 O-RING 22 SD6 CHECK VALVE 23 FS O-RING 24 FS WASHER 25 FS O-RING

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

Control Valve Disassembly and Assembly The main control valve is made up of serviceable spool sections. These sections may be removed for service.

4. Lift each section off the valve stack bolts as needed, being sure to account for all o-rings.

Retain all o-rings.

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 spill.

2. Remove three hex nuts on outside of end cover.

End cover hex nuts should be torqued to 22 lbf-ft (30 N•m).

5. Check condition of o-rings on each section removed.

6. Repeat steps 1 - 4 for all spools needing to be removed from the control valve.

7. To remove the port relief valve from the control valve, use a wrench to loosen the valve from the control valve.

3. Pull end cover off three long valve stack bolts.

Port Relief Valve

Assembly Procedure - Reverse the disassembly steps.

PRINTED IN USA

917400/AP0809

103

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

Main Relief Valve Removal and Installation

Control Valve Spool Seal Replacement

A relief valve is integrated within the control valve. It activates when oil pressure inside the control valve reaches an unacceptable level, to relieve that pressure and prevent damage to valve and the hydraulic system.

The main control valve spool seals are replaceable using the following procedure.

Replacement Procedure 1. Remove the centering hardware from the spool.

Removal Procedure

2. Lubricate the spool, bore, and o-ring groove.

3. Position the spool as shown (location of first o-ring to be replaced).

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Shut off the engine.

Relieve hydraulic system pressure.

Tilt back ROPS/FOPS until lock engages.

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

4. Install the new o-ring.

1. With a wrench, loosen and remove the relief valve from the main control valve.

5. Reposition the spool as shown (location of second o-ring to be replaced).

Stop Spool Here to Prevent O-Ring Damage

IMPORTANT 2. Check condition of o-rings and clean off debris.

The spool MUST NOT be moved past the position shown in step 5 or o-ring damage may occur.

6. Install the second new o-ring.

7. Reposition the spool as shown (view of spool correctly repositioned).

8. Reinstall the centering hardware on the spool.

104

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

Troubleshooting Guide Problem Lift/tilt controls fail to respond

Lift arm does not raise; bucket tilt works properly

Possible Cause

Remedy

Hydraulic oil viscosity too heavy

Allow longer warm-up or replace with proper viscosity oil.

Solenoid valve(s) malfunctioning

Check electrical connections to solenoid and repair connections as needed. Perform “Solenoid Valve Test.” Replace solenoid as needed.

Hydraulic oil level low

Check oil level in reservoir. If oil is low, check for an external leak.

Repair and add oil.

Hydraulic oil flow to the gear pump blocked

Inspect suction hose. Clean or replace as needed.

System relief valve malfunctioning

Adjust or replace relief valve as needed.

Drive disconnected

Check for broken or worn pump drive coupling. Replace as needed.

Sheared spline or broken shaft in hydrostatic pump assembly

Check splined shaft of pump closest to engine. Replace shaft if broken or if splines are sheared.

Sheared spline or broken shaft in gear pump

Remove gear pump from hydrostatic pump and inspect the splined shaft and coupler. Replace components as needed.

Restraint bar switch or seat switch not closing

Check switches and wiring. Replace as needed.

Lift spool in control valve not actuated or leaking

Check hose or tube connection to valve. Check pressure and flow.

Lift solenoid malfunctioning

Check electrical connections to solenoid. Repair or replace as needed.

This troubleshooting guide lists potential hydraulic system problems, as well as possible causes and remedies, for Gehl 1640E and Mustang 2012 skid-steer loaders.

If you cannot locate a particular hydraulic system problem in this chart, consult the Hydrostatic System chapter troubleshooting chart.

When a problem occurs, don’t overlook simple causes.

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

PRINTED IN USA

917400/AP0809

105

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

Troubleshooting Guide Problem Hydraulic cylinder action slow for lift/tilt function

Jerky lift arm and bucket action

Auxiliary hydraulics function slowly

106

Possible Cause

Remedy

Low engine speed

Operate engine at higher speeds.

Hydraulic oil viscosity too heavy

Allow longer warm-up or replace existing oil with proper viscosity oil.

Hydraulic oil leaking past cylinder piston seals

Replace cylinder seals and o-rings as needed.

Hydraulic oil level low

Check oil level in reservoir. If oil is low, check for an external leak.

Repair and add oil.

Control linkage is restricted

Check for control linkage restriction and adjust.

Worn gear pump

Remove gear pump from hydrostatic pump and inspect. Replace components as needed.

Solenoid valve(s) malfunctioning

Check electrical connections to solenoid. Repair or replace as needed.

Relief valve in control valve malfunctioning (squealing noise evident while operating)

Check pressures in relief valve.

Repair or replace as needed.

Restraint bar switch or seat switch malfunction

Check electrical connections to the switch. Replace switch as needed.

Air in hydraulic system

Cycle lift and tilt cylinders to maximum stroke and maintain pressure for short time to clear air from system.

Oil in hydraulic reservoir low

Check and add oil to reservoir as needed.

Low engine speed

Operate engine at higher engine speeds.

Hydraulic oil level low

Add oil to reservoir.

Hydraulic oil viscosity is heavy

Allow long warm-up period.

Auxiliary spool in control valve leaking or not fully activated

Repair any leak found; readjust the auxiliary spool for full travel.

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

HYDRAULIC SYSTEM

Troubleshooting Guide Problem Lift arm doesn’t maintain raised position with lift control in NEUTRAL

Lift arm will not lower or raise

Bucket drifts downward with tilt control in NEUTRAL

No downward pressure on bucket

PRINTED IN USA

Possible Cause

Remedy

Oil leaking past lift cylinder seals (internal or external)

Check cylinder tube bore condition.

Replace seals or cylinder tube as needed.

Oil leaking past lift spool in control valve

Check valve body for scores or cracks. Replace control valve as needed.

Self-leveling valve malfunctioning

Repair or replace as needed.

Leaking hydraulic hoses, tubes or fittings between control valve and cylinders

Inspect hoses and tubes; tighten fittings as needed. Replace hoses or tubes as needed.

Lift cylinder lift arm support device engaged

Raise lift arm and disengage the lift arm support device.

Solenoid valve malfunctioning

Check electrical connections to solenoid. Repair or replace as needed.

Restraint bar not lowered

Lower restraint bar.

Restraint bar switch or seat switch malfunction

Check electrical connections to the switch. Replace switches as needed.

Blown fuse or relay

Replace fuse or relay.

Oil leaking past tilt cylinder seals (external or internal)

Check cylinder tube bore condition.

Replace seals, o-rings or cylinder as needed.

Self-leveling valve malfunctioning

Repair or replace as needed.

Leaking hydraulic hoses, tubes; or fittings between control valve and cylinders

Inspect hoses and tubes, tighten fittings as needed. Replace hoses or tubes as needed.

Control valve in “float” position

Take control out of “float” position.

Tilt cylinders malfunctioning

Check condition of cylinder tube bore. Replace seals, o-rings and/or cylinder tube as needed.

Main relief valve malfunctioning (squealing noise evident while operating)

Check pressures in relief valve.

Repair or replace as needed.

917400/AP0809

107

HYDRAULIC SYSTEM

GEHL 1640E / MUSTANG 2012

Troubleshooting Guide Problem Lift arm will not raise a heavy load or any load

Possible Cause

Remedy

Lift solenoid malfunctioning

Check electrical connections to solenoid. Repair or replace as needed.

Lift spool in control valve not actuated or leaking

Check valve body for scores or cracks. Replace control valve as needed.

Main relief valve malfunctioning (squealing noise evident while operating)

Check pressures in relief valve.

Repair or replace as needed.

Bucket does not level on the lift cycle

Self-leveling valve misadjusted or malfunctioning

Repair or replace self-leveling valve as needed.

Bucket will not tilt; lift arm works properly

Tilt solenoid valve malfunctioning

Check electrical connections to tilt solenoid and repair connections as needed. Replace solenoid as needed.

Tilt spool in control valve not actuated or leaking

Check hose or tube connection to valve. Check pressure and flow.

Control linkage misadjusted

Check linkage; readjust for full spool travel.

Low engine speed

Operate engine at higher speeds.

Hydraulic oil level low

Add oil to reservoir.

Hydraulic oil viscosity too heavy

Allow for longer warm-up period.

Control valve relief pressure low

Check pressure at control valve.

Readjust if necessary.

Restraint bar raised

Lower restraint bar

Restraint bar switch or seat switch malfunctioning

Replace malfunctioning switch

Blown fuse or relay

Replace fuse or relay.

Faulty electrical connections

Check electrical connections for security, broken or damaged wires.

Replace as needed.

Solenoid valve malfunctioning

Check electrical connections to solenoid. Repair or replace as needed.

Auxiliary hydraulics functions slowly

Auxiliary hydraulics do not function

108

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ELECTRICAL SYSTEM

Introduction Description of Operation - Right and Left Instrument Panels

Hourmeter

Right Instrument Panel The right instrument panel for Gehl 1640E and Mustang 2012 model skid-steer loaders includes a parking brake switch, engine preheat switch, light switch, 12-VDC power outlet and keyswitch.

Light Switch

The following items describe the normal operation of electrical system components on the skid-steer loaders.

Parking Brake Switch

P P

Engine Preheat Switch

1. Parking Brake Switch - used to apply the parking brake.

2. Light Switch - used to control all lights on the loader. Symbols denote the four positions of the switch. In a clockwise direction these are:

On

OFF, Tail lights ON, Front work lights with tail lights ON, both front and rear work lights

Off Start Keyswitch

3. 12-VDC Power Outlet - a plug-in outlet with rubber boot used for external electrical connections.

4. Hourmeter - used to display the total operating hours on the loader.

12-VDC Power Outlet

5. Engine Preheat Switch - used to apply power to glow plugs on the engine.

NOTE: When the keyswitch turned to the “ON” position, but with the engine not running the engine preheat switch can be manually activated (pressed), cycling the glow plugs ON, and when the switch is released the glow plugs cycle OFF. 6. The keyswitch can then be turned to the START position.

The engine oil pressure and battery lamps will go out after the engine starts.

7. The lift and tilt safety lock valves should be energized when the operator is on the seat, the restraint bar is down, and the keyswitch is turned to the ON position.

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

PRINTED IN USA

917400/AP0809

109

ELECTRICAL SYSTEM

GEHL 1640E / MUSTANG 2012

Left Instrument Panel The left instrument panel for Gehl 1640E and Mustang 2012 model skid-steer loaders holds the fuel level and engine coolant temperature gauges. Six light indicators are also on this panel.

Fuel Level Gauge

1. When the operator is in the seat, with the restraint bar down, and the keyswitch turned to the “ON” position, but with the engine not running the following indicator lamps will light on the left instrument panel:

Engine Coolant Temperature Gauge

Fasten Seat Belt (momentary) Low Engine Oil Pressure Battery Condition Fasten Seat Belt buzzer will sound for five seconds 2. The keyswitch can then be turned to the START position.

The engine oil pressure and battery lamps will go out after the engine starts.

3. Engine Preheat Indicator Lamp - it lights when the engine preheat switch is engaged.

Fasten Seat Belt

Engine Coolant Temperature

4. Engine Coolant Temperature Lamp - it lights to indicate an abnormal coolant temperature rise in the engine.

5. Engine Oil Pressure Lamp - it lights to indicate an abnormal engine oil pressure rise in the engine.

Engine Oil Pressure

Battery

Hydraulic Oil Temperature

Engine Preheat Indicator

6. Hydraulic Oil Temperature Lamp - it lights to indicate an abnormal hydraulic oil temperature rise in the hydraulic oil system.

110

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ELECTRICAL SYSTEM

Troubleshooting Guide Problem Entire electrical system does not function.

No instrument panel lamps light with keyswitch turned to “ON”.

No glow indicator lamp with keyswitch turned to “ON”.

Possible Cause Battery disconnect switch is “OFF”

Turn battery disconnect switch to “ON”.

Circuit breaker(s) tripped

Consult wiring diagram, check circuit and locate trouble i.e. pinched wires, faulty connections, etc. before resetting breaker.

Main wiring harness connectors at rear of ROPS not properly plugged in

Check main connectors.

Battery terminals or cables loose or corroded

Clean battery terminals and cables and tighten them.

Battery faulty

Test battery and replace as needed.

Circuit breaker tripped

Consult wiring diagram, check circuit and locate trouble before resetting breaker.

Battery terminals or cables loose or corroded

Clean battery terminals and cables and tighten them.

Bulb is burned out.

Replace bulb.

Seat belt buzzer indicator not sounding Plugged or obstructed buzzer when keyswitch turned to “ON”, indicator lamps work properly.

Faulty buzzer

Fuel gauge does not work.

Engine temperature gauge does not work.

Hourmeter does not work.

PRINTED IN USA

Remedy

Clean out buzzer.

Replace buzzer.

Buzzer is disconnected

Reconnect wires to buzzer.

Faulty fuel gauge sender

Replace fuel gauge sender.

Loose wiring/terminal connections

Verify wiring connections.

Faulty fuel gauge

Replace fuel gauge.

Faulty sender

Replace temperature sender.

Loose wiring/terminal connections

Verify wiring connections.

Faulty temperature gauge

Replace temperature gauge.

Loose wiring/terminal connections

Verify wiring connections

Faulty alternator

Repair or replace alternator.

Faulty hourmeter

Replace hourmeter.

917400/AP0809

111

ELECTRICAL SYSTEM

GEHL 1640E / MUSTANG 2012

Troubleshooting Guide Problem Starter will not engage when keyswitch is turned to “START”.

Battery will not recharge.

Work lights not functioning properly.

Lift/Tilt and/or Drive Solenoids do not work.

112

Possible Cause

Remedy

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

Verify relay connections.

Faulty starter relay in panel

Test starter relay. Replace as needed.

Battery terminals or cables are loose or corroded

Clean battery terminals and cables and tighten them.

Battery discharged or defective

Recharge or replace battery.

Starter solenoid in chassis malfunctioning

Troubleshoot circuit per wiring diagram, located trouble. Replace starter solenoid.

Ignition wiring, seat switch, restraint bar switch, etc. loose or disconnected

Check wiring for poor connections, broken leads; repair wiring or connection.

Starter or pinion faulty

Remove starter; repair or replace as needed.

Battery terminals or cables loose or corroded

Clean battery terminals and cables and tighten them. Replace cables as needed.

Battery or alternator defective

Test battery and alternator. Replace as needed.

Single light doesn’t work; light bulb is burned out or faulty wiring

Check and replace light bulb.

No lights at all; circuit breaker tripped

Consult wiring diagram, check circuit and find trouble before resetting breaker.

Faulty light switch or poor ground

Replace light switch. Check ground wire connections.

Wiring to solenoids disconnected or faulty

Refer to wiring diagram, locate trouble and repair as needed.

Faulty seat or restraint bar switch

Replace seat or restrain bar switches as needed.

Faulty solenoid valve coil

Replace solenoid valve coil.

Faulty hydraulic solenoid relay in the instrument panel

Test relay, replace as needed.

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ELECTRICAL SYSTEM

Electrical Chassis Components

8 18 26 21 10

12 INSTALL TIMER INCLUDED WITH ENGINE HERE

8

12

8

8

9

12

2

17

20 ASSEMBLE AND MOUNT TO WELD STUDS ON TOWER WALL

7

1

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

CLAMP/HOSE NUT/HEX LOCK ROD/BATTERY HOLDDOWN PLATE/TWIN COVER CLAMP/TUBE TWO-PIECE BATTERY NUT/SPIRALOCK NUT/SPIRALOCK SOLENOID BRACKET/RELAY MOUNTING ANGLE/BATTERY HOLDDOWN RELAY/SEALED 40 A HARNESS/CHASSIS COVER/RELAY BRACKET BATTERY CABLE/NEGATIVE BATTERY CABLE/POSITIVE CIRCUIT BREAKER 35 A SCREW/CAP SCREW/CAP BOLT/CARRIAGE NUT/HEX WASHER/FLAT WASHER/LOCK WASHER/EXTERNAL LOCK NUT/HEX SCREW/CAP

ROUTE POSITIVE AND NEGATIVE BATTERY CABLES THROUGH TUBE CLAMPS. NOTE: POSITIVE BATTERY CABLE IS ON TOP

5 MOUNT TO EXISITING WELD STUDS 4

11

19

2

22

2

22

23 3

15

24

GROUND TO ENGINE USE EXISTING BOLT

3 16

25 CONNECT TO STARTER

PRINTED IN USA

6

917400/AP0809

113

ELECTRICAL SYSTEM

GEHL 1640E / MUSTANG 2012

Electrical Battery Disconnect Switch Components (EU)

12

10

9 11

5

2

7

E

3

6

8

14

GROUND TO ENGINE USE EXISTING BOLT 13 THREAD OVER EXISTING STARTER STUD

15 17 16

CONNECT TO STARTER

12

ROUTE BOTH POS CABLE FROM BATTERY AND CABLE FROM JUMP STUD THROUGH HERE

ROUTE POS FROM STARTER THROUGH HERE 1 4

1 2 3 4 5 6

CLAMP/HOSE SWITCH/DISCONNECT PLATE/FACE CLAMP/HOSE NUT/SPIRALOCK TERMINAL/REMOTE RED

7 TERMINAL/REMOTE BLACK 8 CHANNEL/CONTROL MOUNT 9 BATTERY CABLE/NEGATIVE 10 BATTERY CABLE/NEGATIVE 11 BATTERY CABLE/NEGATIVE 12 BATTERY CABLE/POSITIVE

13 14 15 16 17

STUD EXTENDER/STARTER SCREW/CAP NUT/HEX NUT/HEX JAM WASHER/EXTERNAL LOCK

Electrical Battery Disconnect Switch Components (Standard)

2

1

1 2

114

917400/AP0809

BATTERY CABLE/NEGATIVE WASHER/EXTERNAL LOCK

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ELECTRICAL SYSTEM

Electrical ROPS/FOPS Components

26

31 30 8 33

31 9 30 3 11

23

33

12 20

19

LEFT SIDE ASSY

33

15

13

14 13

18

35 24

29

34

32

16

33

6

7

2 28

RELAY ASSY 35

21

10

27

2 25

22

17 5

1

4

RIGHT SIDE ASSY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

NUT/HEX LOCK GAUGE/HOURMETER HOUSING/DISPLAY SWITCH/GLOW PLUG SWITCH/BRAKE BUZZER NUT/HEX LOCK BULB/LAMP GASKET/DISPLAY HOUSING TIMER/DELAY GAUGE/FUEL LEVEL GAUGE/ENG OIL TEMP BREAKER/CIRCUIT 15 A BREAKER/CIRCUIT 25 A SWITCH/LIGHT KNOB/LIGHT SWITCH SWITCH/IGNITION STANDOFF

PRINTED IN USA

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

DECAL/LEFT INSTRUMENT PANEL PANEL/LH PANEL/RH PANEL/CIRCUIT BREAKER COVER/LEFT COVER/RIGHT DECAL/RIGHT INSTRUMENT PANEL WIRE HARNESS/ROPS DECAL/CIRCUIT BREAKER TIMER/SEAT BELT CIRCUIT BREAKER 8 A WASHER/HELICAL LOCK NUT/HEX MACHINE NUT/HEX MACHINE SCREW/MACHINE SCREW/MACHINE WASHER/HELICAL LOCK

917400/AP0809

115

ELECTRICAL SYSTEM

GEHL 1640E / MUSTANG 2012

Relay Test and Operation Gehl 1640E and Mustang 2012 model skid-steer loaders utilize relays in the electrical system to maximize the efficiency of engine, hydraulic, power and electrical operations. Following in this section are test and operation procedures.

2. Relay coil test: Using a volt/ohm multimeter with all wires disconnected, measure the resistance across terminals #85 and #86. There should be 75 ohms ± 5 ohms. There should be no continuity between terminals #30 and #87.

87 Relay Test - Fuel Pull, Starter, Safety Lock and Auxiliary Neutral The following procedure can be used to test four relays located on the left chassis riser, near the radiator/cooler.

87a 85

86 Safety Lock Relay

30

Relay Terminals

Starter Relay

Auxiliary Neutral Relay

Fuel Pull Relay

1. There should be 12-VDC on terminal #87 (#2 red wire from battery supply) at all times. Pushing horn button on left control handle should provide 12-VDC to terminal #86 and produce an audible “click” from relay. There should be 12-VDC on terminal #30 while horn button is pressed.

116

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ELECTRICAL SYSTEM

Glow Solenoid Test The following procedure can be used to the glow solenoid located on the left chassis riser, near the radiator/cooler.

2. Unplug the control current connector and install a test lamp between #85 and #86. Have an assistant turn the keyswitch to the “ON” position and the test lamp should light when the glow switch is pressed.

Seat Switch Removal and Installation Removal Procedure

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

Glow Solenoid

Shut off the engine.

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

1. Remove seat per the procedure found in the Mainframe chapter. Turn the seat over. #85

#86

2. Remove the two Phillips-head screws and nuts securing the seat switch to the seat. Press the three tabs to separate the dome from the base. Press the two tabs to remove the switch from the base.

Seat Switch Load

Live Power

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine.

Raise engine cover, lock open the rear grille.

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

1. Using a volt/ohm multimeter or test lamp, confirm the following condition with the wiring connected.

With keyswitch in “OFF” position, there should be 12 VDC only on left large copper stud of each solenoid.

PRINTED IN USA

WARNING DO NOT attempt to operate the loader without the seat switch installed.

Installation Procedure - Follow all warnings first, then reverse the removal steps*. * Install seat on loader per the procedure in the Mainframe chapter.

917400/AP0809

117

ELECTRICAL SYSTEM

GEHL 1640E / MUSTANG 2012

Restraint Bar Switch Removal and Installation

Engine Disconnect Switch - Remote Battery Terminal Removal and Installation

Removal Procedure

Gehl 1640E and Mustang 2012 model skid-steer loaders have, as an option, a master electrical disconnect switch located underneath the battery at the rear of the loader.

Removal Procedure

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

WARNING

Shut off the engine.

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

BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine.

1. Remove the restraint bar assembly per the procedure in the Mainframe chapter.

2. Remove the two machine screws, washers and hex nuts that secure the restraint bar switches to the restraint bar and restrain bar mount.

Turn electrical disconnect switch to OFF. (For detailed instructions, refer to the Safety chapter of this manual.)

1. Raise the engine access cover and lock open the rear grille.

2. On the switch, find a small screw securing the switch knob to the switch. Remove the screw from the switch and remove the knob.

Disconnect Switch Screw

Restraint Bar Actuator Switches

3. Remove the switches from the bracket assembly.

WARNING DO NOT attempt to operate loader without the restraint bar switch installed.

Installation Procedure - Follow all warnings first, then reverse the removal steps*. * Adjust position of restraint bar switch and actuator switch so they are aligned with each other when restraint bar is down against the rubber stops. * Install the restraint bar according to the procedure in the Mainframe chapter.

118

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ELECTRICAL SYSTEM

Restraint Bar Components

16

2

13

5

12 5

10

2

1

18

1 3 10

20 18

4

14 15

PRINTED IN USA

16 6 18

21

7 18

8

10

1 SCREW/SHOULDER 2 BUSHING/OILITE 3 NUT/HEX LOCK 4 BUMPER 5 SPACER/TUBE 6 SWITCH/PROXIMITY 7 MAGNET/SWITCH ACTUATOR 8 STUD/BALL 9 NUT/SERRATED LOCK 10 NUT/SPIRALOCK 11 BAR/RESTRAINT

19

19

17

9

11

20

4

8

12 13 14 15 16 17 18 19 20 21

MOUNT/RESTRAINT BAR/LH MOUNT/RESTRAINT BAR/RH GAS SPRING/RESTRAINT BAR MOUNT/GAS SPRING BOLT/CARRIAGE BOLT/CARRIAGE WASHER/FLAT NUT/HEX MACHINE WASHER/EXTERNAL LOCK SCREW/MACHINE

917400/AP0809

119

ELECTRICAL SYSTEM

GEHL 1640E / MUSTANG 2012

3. Remove the switch plate jam nut securing the switch plate and the switch into the mounting hole.

Front and Rear Work Light Bulb Replacement Removal Procedure

Switch Plate Jam Nut

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine.

Raise engine cover; lock open the rear grille.

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

4. Unbolt the capscrews and locknuts securing the disconnect switch to the battery tray.

5. On the back of the disconnect switch, remove the two nuts attaching the cables. Remove the two nuts with a socket wrench and remove the cables. Pull the disconnect switch rearward and out of the skidsteer loader.

1. With a torx-head socket wrench, remove the four screws on the front work light and remove the lens.

Rear work lights are in the rear grille.

2. Release the bulb retaining clip and remove the bulb.

NOTE: Keep a record of the cable connections for reinstallation.

Clip

Installation Procedure - Follow all warnings first, then reverse the removal steps.

120

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ELECTRICAL SYSTEM

Electrical Lights Components

Front Work Lamp and Rear Grille 1 2 3 4

NUT/SPIRALOCK LIGHT/WHITE 55 W LIGHT/RED 35 W SCREW/CAP

1 3

2 4

3

2

Dome Lamp - EU Completing 1 2 3 4

2

1

NUT/HEX LOCK MOUNT/DOME LIGHT SCREW/CAP LIGHT/DOME

1 4

3

Rearview Mirror - EU Completing 1

2

1 2

PRINTED IN USA

917400/AP0809

MIRROR/REARVIEW SCREW/TAPPING

121

ELECTRICAL SYSTEM

GEHL 1640E / MUSTANG 2012 Dome Light Bulb Replacement Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine.

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

1. Climb into the cab and find dome light assembly on ceiling of the cab.

IMPORTANT Halogen bulbs SHOULD NOT be touched with bare fingers; they can fail prematurely. Wear clean gloves or use a clean rag if you must handle the halogen bulbs.

2. Pop the dome light lens cover out of the base by pressing on one side of the cover and releasing small tabs from the base.

3. Replace the used bulb with a new 55 W H3 bulb (if a white work light), or a new 35 W H3 bulb (for red warning light).

Installation Procedure - Follow all warnings first, then reverse the removal steps.

3. Replace the used bulb with a new 5 W incandescent bulb.

122

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ELECTRICAL SYSTEM

Lift and Tilt Solenoid Test and Operation

Brake Solenoid Test and Operation

The lift and tilt solenoid valves suppling oil to the right T-Bar are located inside the chassis. The tilt solenoid is located in the right riser and the lift solenoid is located along the left inside chassis wall. When the restraint bar and seat switch are closed, a 12 VDC signal to the solenoid opens to supply oil to the right T-Bar to engine the lift and tilt functions.

The solenoid valve that supplies oil to the left T-Bar is located on the left side of the chassis. When the restraint bar and seat switch are closed, a 12 VDC signal to the solenoid opens to supply oil to the left T-Bar control to engage the wheel drive functions.

Brake Solenoid Lift Solenoid

Auxiliary Neutral Start Switch The mechanically-operated standard auxiliary control has a switch to ensure the start circuit will not function if the standard auxiliary is engaged. The neutral start switch is located on the valve/cable connection assembly.

Neutral Start Switch

Tilt Solenoid

The neutral start switch is open when the auxiliary valve spool is not in the neutral position. Once the auxiliary valve spool is in the neutral position, the switch closes and the signal to the start solenoid is complete. The restraint bar and seat switch must also be closed for the start solenoid to engage.

PRINTED IN USA

917400/AP0809

123

ELECTRICAL SYSTEM

GEHL 1640E / MUSTANG 2012

Electrical Schematic

B

ENGINE COOLANT TEMPERATURE 183644

GLOW PLUG SWITCH

F TA FUEL GAUGE 183634

6 ORG 0 BLK 13 RED

0 BLK 143 BRN

15 BRN

12 RED

34 YEL

0 BLK

12 RED

143 BRN

25 BRN

0 BLK

12 RED

143 BRN

22 GRN

0 BLK

12 RED

ALT/HR MTR 34 YEL ENG PRESS 14 PUR 12 RED 15 BRN

58 YEL

12 RED 12 RED

0 BLK

15 BRN 14 PUR

31 ORG

15 BRN

12 RED

40 GRY

40 GRY

31 ORG

14 PUR

48 WHT

42 GRN

56B RED

POWER PORT

43 ORG

56A RED

ACC POWER

HORN BUTTON OPTION

11 RED

0 BLK

12 RED

12 RED ENG TEMP 31 ORG HYD TEMP 40 GRY

12 RED

0 BLK

BRAKE SOL 36 BLU

30 PUR

58 YEL

13 RED

AUXILIARY POWER

B

C

D

E

0 BLK

12 RED, IGNITION

02 RED 20 BRN

A

F

12 RED

33 PNK

11 RED, LIGHTS 56 RED

ENGINE HARNESS 13 RED, CHASSIS POWER

30 PUR 35 BLU 0 BLK

12 RED 11 RED, LIGHTS 0 BLK

GLOW SOLENO 193856

ROPS HARNESS

12 RED 25 BRN 10 WHT

35 BLU 36 BLU 58 YEL

17 GRN

48 WHT 42 GRN 43 ORG 13 RED

12 RED

SAFETY L AUX-LIFT(SEAT SW & RESTRAIN BAR)

AUX NEUTR

34 YEL 31 ORG 22 GRN 10 WHT 40 GRY 14 PUR 33 PNK

02 RED 0 BLK

124

917400/AP0809

PRINTED IN USA

STARTE

GEHL 1640E / MUSTANG 2012

ELECTRICAL SYSTEM Electrical Schematic

BACKUP ALARM SWITCH (OPTION)

0 BLK

13 RED

O1G, BLK

35 BLU 0 BLK 43 ORG

AUXILIARY POWER 13 RED

40 GRY

POSITIVE POST

0 BLK 42 GRN

DISCONNECT SWITCH

NEGATIVE POST

0 BLK

6 ORG

36 BLU

0 BLK 13 RED

0 BLK 143 BRN

15 BRN

12 RED

0 BLK

143 BRN

34 YEL

HORN BUTTON OPTION

0 BLK 43 ORG

12 RED

15 BRN

0 BLK

12 RED

HOLD GRND PULL

0 BLK

0 BLK

47 WHT

FUEL CONTROL SOLENOID

15 BRN

0 BLK

0 BLK

35 BLU 112 PUR

34 YEL 13 RED

31 ORG

40 GRY

12 RED

35 BLU

14 PUR B

C

D

E

F

R

46 PUR 45 YEL

TIMER PULL COIL

R/W Y

0 BLK

25 BRN 0 BLK

12 RED

49 GRN

48 WHT

0 BLK

0 BLK

FLASHER POWER TAP

UGE

A

AUXILIARY SPOOL LOCK

BACKUP ALARM KIT (OPTION)

B

46 PUR

35 BLU

RELAY 195482

FUEL SOLENOID 01 RED

47 WHT 45 YEL

0 BLK

ENGINE HARNESS

0 BLK

31 ORG

0 BLK

22 GRN

02 RED 01 RED

14 PUR

58 YEL

GLOW SOLENOID 193856

ROPS HARNESS

12 RED 25 BRN 35 BLU 36 BLU 58 YEL 48 WHT 42 GRN 43 ORG 13 RED

SAFETY LOCK AUX-LIFT-TILT (SEAT SWITCH & RESTRAINT BAR)

22 GRN 10 WHT

30

B

87

01 RED 81 RED

GROUND CABLE

GLOW PLUGS

0 BLK 02 RED 10 WHT 01 RED

0 BLK 35 BLU

01 RED

82 WHT

35 BLU

AUX NEUTRAL

112 PUR

0 BLK

21 GRN 33 PNK

34 YEL 31 ORG

A

STARTER

0 BLK

ENGINE

40 GRY 14 PUR 33 PNK

02 RED 0 BLK

PRINTED IN USA

917400/AP0809

125

ELECTRICAL SYSTEM

GEHL 1640E / MUSTANG 2012

CHAPTER NOTES

126

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ENGINE

Introduction

When ordering engine parts, always check the Gehl or Mustang Parts Manual to see if a special part has been fitted to the engine. If Gehl or Mustang parts are required, they can be ordered from Gehl Company.

This chapter covers troubleshooting, removal, installation, and adjustment procedures for engine components on Gehl 1640E and Mustang 2012 model skid-steer loaders. The primary engine system components are shown on following pages.

They are equipped with a Yanmar model 3TNV82A turbocharged diesel engine. The three-cylinder engine is 81.2 cubic inch (1,33 L) displacement engine with an 19:2 compression ratio. The direct injection four-stroke engine has a firing order of 1, 3, 2.

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

As with any engine, clean oil, fuel and air are critical to satisfactory performance and long engine life. If properly maintained, this engine can be expected to provide thousands of hours of trouble-free operation.

Troubleshooting Guide The following troubleshooting guide lists potential engine problems, as well as possible causes and remedies, for Gehl 1640E and Mustang 2012 model skid-steer loaders.

When a problem occurs, don’t overlook simple causes.

A malfunction could be caused by something as simple as an empty fuel tank. After a mechanical failure has been corrected, be sure to locate the cause of the problem. For further troubleshooting information, refer to the engine manufacturer’s manual.

Troubleshooting Guide Problem Starter will not engage when keyswitch is turned to “START”

PRINTED IN USA

Possible Cause

Remedy

Seat or restraint bar switch malfunctioning or not activated

Replace switches as needed.

Faulty starter relay in panel

Test starter relay. Replace as needed.

Battery terminals or cables are loose or corroded

Clean battery terminals and cables and tighten them.

Battery discharged or defective

Recharge or replace battery.

Starter solenoid in chassis malfunctioning

Troubleshoot circuit per wiring diagram to locate trouble. Replace starter solenoid.

Ignition wiring, seat switch, restraint bar switch, etc. loose or disconnected

Check wiring for poor connections, broken leads; repair wiring or connection.

Starter or pinion faulty

Remove starter; repair or replace as needed.

Auxiliary pedal not in NEUTRAL position

Ensure pedal is in NEUTRAL position. Neutral switch located on main control valve. Replace switch as needed.

917400/AP0809

127

ENGINE

GEHL 1640E / MUSTANG 2012

Troubleshooting Guide Problem Engine turns over but will not start

Engine overheats

Possible Cause

Remedy

Engine cranking speed too slow

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

Fuel tank empty or faulty fuel gauge sender

Refill fuel tank. Replace fuel gauge sender.

Glow module malfunctioning

Check connection and voltage; replace as needed.

Fuel shutoff solenoid not energizing

Check electrical connections and voltage to shutoff solenoid.

Engine oil not warm enough

Cycle glow plug; check glow plug wiring connections

Ambient temperature too low

Install a block heater.

Fuel pump not working

Refer to engine manual or contact Gehl Service.

Moisture in the fuel line

Bleed water out of fuel filter and fuel tank.

Auxiliary valve engaged

Return the control valve to NEUTRAL.

Crankcase oil level too low or too high

Add or remove oil as required.

Engine overloaded

Reduce operating load.

Fan air circulation blocked or restricted

Turn engine OFF, wait for fan to stop, remove blockage or restriction.

Fan shroud improperly positioned

Perform “Fan Shroud Adjustment” procedure in this chapter.

Grade of oil improper or excessively dirty

Drain and replace with clean oil of proper grade.

Exhaust restricted

Allow exhaust to cool and remove the restriction.

Air filter restricted

Replace the filter(s).

Radiator/cooler flow restricted

Flush radiator/cooler inside and out.

IMPORTANT DO NOT attempt to service or repair major components, such as the fuel injector pump, unless authorized to do so by your Gehl or Mustang dealer. Any unauthorized repair will void the warranty.

128

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ENGINE

Engine Components and Engine Controls

25

24 13

53

3 50

21

48

50 10

19

20

7

30

9

18

60

11 NOTES: 1. APPLY LOCTITE™ 242 OR EQUIVALENT 2. TORQUE TO 110 FT/LBS 3. TORQUE TO 55 FT/LBS 4. TORQUE TO 48 FT/LBS

5 51

28

34 32

46

56

56

55

39

36

NOTE #2 47

43 29

29

22

1 26

NOTE #1 & #4 57 52

NOTE #1 8

37

NOTE #1 38

59

12

54

45

15

32

27

33

45

4 40

2

NOTE #1 & #4

42 41

35 44 NOTE #3

45

14 49

54 58 NOTE #1

16

GOVERNED ENGINE SPEED SPECIFICATIONS

40

45

SPEED SETTING RPM TOLERANCE 25 RPM LOW IDLE, NO LOAD 1600 HIGH IDLE, NO LOAD 2500 10 RPM *THE FULL LOAD GOVERNED SPEED THAT THE ENGINE PASSED U.S. EPA EMISSIONS STANDARDS

6 23 1 39

43 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

BUSHING/FLANGED JOINT/BALL CLAMP/HOSE NUT/LOCK NUT/LOCK NUT/LOCK HOSE/FUEL SCREW/CAP PLATE/TWIN COVER CLAMP/TUBE NUT/SPIRALOCK NUT/SPIRALOCK HOSE/FUEL ISOLATOR SCREW/SHOULDER

PRINTED IN USA

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

PLATE/PUMP MOUNT HOSE/FUEL HOSE/FUEL FITTING/90º PUMP/FUEL FEED SEPARATOR PIVOT/THROTTLE PIVOT/THROTTLE VALVE/SHUT OFF HOSE/FUEL BRACE/ENGINE TOP ROD/THROTTLE ENGINE/YANMAR YOKE/CLEVIS NUT/LOCK

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

NUT/CENTERLOCK PIN/CLEVIS MOUNT/ENGINE BRACKET/ENGINE LINKAGE/THROTTLE CABLE/THROTTLE PLATE/DRIVE SCREW/CAP WASHER/FLAT WASHER/PLATED WASHER/FLAT MOUNT/ENGINE BUSHING SCREW/CAP NUT/HEX

917400/AP0809

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

SCREW/CAP SCREW/CAP SCREW/CAP BOLT/CARRIAGE SCREW/CAP WASHER/FLAT WASHER/FLAT WASHER/LOCK WASHER/LOCK WASHER/LOCK PIN/COTTER SCREW/CAP SCREW/CAP SCREW/CAP HOSE/FUEL

129

ENGINE

GEHL 1640E / MUSTANG 2012

Air Cleaner and Exhaust Components

10

4

2

9

3

8

1 14

PRIMARY ELEMENT IS 242541 7

13

SECONDARY ELEMENT IS 242540

12 11

1 2 3 4 5 6 7

130

CLAMP/HOSE INDICATOR/RESTRICTION CLEANER/AIR NUT/SPIRALOCK MOUNT/MUFFLER SPACER/MUFFLER HOSE/MOLDED AIR FILTER

1 5

8 9 10 11 12 13 14

BRACKET/AIR CLEANER MUFFLER SCREW/CAP SCREW/CAP WASHER/FLAT WASHER/LOCK NUT/HEX

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ENGINE

Radiator/Cooler Components 7

13

5

3

6

12 8 10

3

1

8

14 4

2

NOTE: CONNECT TO TANK PORT ON CONTROL VALVE

9

14 15

1 11 16

1 2 3 4 5 6 7 8

CLAMP/HOSE CLAMP/HOSE CLAMP/HOSE FITTING/STRAIGHT SEAL/SHROUD FITTING/90º HOSE/FUEL SCREW/CAP SERRATED LOCK

PRINTED IN USA

NOTE: CONNECT TO PORT ON HYDRAULIC TANK 9 10 11 12 13 14 15 16

BOTTLE/OVERFLOW HOSE/RADIATOR HOSE/RADIATOR COOLER/RADIATOR SHROUD/FAN SUPPORT/SHROUD COOLER TUBE/HYDRAULIC COOLER TUBE/HYDRAULIC

917400/AP0809

131

ENGINE

GEHL 1640E / MUSTANG 2012

Oil Filter Element Removal and Installation

Installation Procedure

The engine oil filter is located on the left side of the engine and can be accessed through a belly pan in the chassis.

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

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

3. Hand-tighten filter element, turning it clockwise, until gasket contacts filter mating surface, then turn element another 3/4 turn to seat gasket.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Shut off the engine and allow to cool.

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

4. If old oil has been removed, fill crankcase with 5.8 qts. (5,5 L) of oil. (See Lubrication chapter.)

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

6. Replace the belly pan.

Removal Procedure 1. Remove two capscrews on the rearmost belly pan and remove the pan.

2. Place a suitable container beneath the oil filter to catch any leaking oil. This view is taken from underneath the engine, looking up through the belly pan Engine Oil Filter Location

3. Clean the area around the oil filter element.

4. Turning counterclockwise, loosen the oil filter element with a filter wrench.

5. Turn the filter element by hand until it is free of the oil filter mating surface.

132

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ENGINE

Air Cleaner Assembly Removal and Installation

4. Remove the top capscrew and locknut securing the air cleaner bracket to the left riser to release the air cleaner canister.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine and allow to cool.

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

1. Open the engine access cover and lock open the rear grille.

5. Pull up on the bracket until it releases from itself and slide the air cleaner out of the bracket.

2. Clean the area around the hose connection.

3. At the front of the air cleaner assembly, loosen the hose clamp securing the air filter hose to the assembly and pull the hose away from the air cleaner. Cover the air cleaner hose opening to help prevent contamination

6. Remove the lower capscrew and locknut on the air cleaner bracket and remove the bracket.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

PRINTED IN USA

917400/AP0809

133

ENGINE

GEHL 1640E / MUSTANG 2012

Air Filter Element Removal and Installation Service the air filter element when the restriction gauge shows in the red zone. The red zone indicates a clogged air filter. If the gauge shows red with the engine stopped, replace the air filter element. After fitting a clean element, push the gauge reset button.

3. Pull the primary and secondary air filters from the air cleaner assembly.

Primary Air Filter

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine and allow to cool.

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

Secondary Air Filter

1. Open the engine access cover and lock open the rear grille.

2. Pull the air cleaner end cap off the air cleaner assembly. Clean out any dirt build-up in the end cap.

4. Replace both air filter elements, if needed. (See Service chapter of the Operator's Manual.)

5. Check the condition of the dust ejector.

Installation Procedure - Follow all warnings first, then reverse the removal steps.* * Clean the radial seal surfaces of the mating plastic body.

134

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ENGINE

Battery and Battery Tray Removal and Installation

2. First, disconnect and remove the negative (-) battery cable and then disconnect the positive (+) battery cable from the battery.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine and allow to cool.

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

3. Remove the two locknuts from the battery clamp rods and the hold-down battery angle.

WARNING Review the following safety considerations before working on or around the battery: Keep sparks and flames away from battery.

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

Avoid contact with battery electrolyte; wash off any electrolyte immediately.

Wear safety glasses when working near battery.

Do not tip battery more than 45° to avoid spilling electrolyte solution.

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

1. Remove the floor cover/step cover/kickplate per the procedure in the Mainframe chapter.

PRINTED IN USA

4. Lift the battery up and out of the chassis.

5. If equipped with an engine disconnect switch, refer to its removal procedure in the Electrical System chapter of this manual.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

917400/AP0809

135

ENGINE

GEHL 1640E / MUSTANG 2012

Starter Removal and Installation

5. Remove the two capscrews securing the starter to the engine.

For wiring connections to the starter and solenoid, refer to the Electrical System chapter of this manual.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Shut off the engine.

Tilt back ROPS/FOPS until lock engages.

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

1. Open the engine access cover and lock open the rear grille.

6. Remove the starter from the engine.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

2. Remove the floor cover/step cover/kickplate per the procedure in the Mainframe chapter.

3. Disconnect and remove the negative (-) battery cable from the battery.

4. On the starter solenoid, remove the nut that secures the positive (+) battery cable and two smaller wires. There will be an additional positive (+) battery cable to remove if a remote engine disconnect switch is installed. Also, remove the push-on connector attached at the solenoid.

136

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ENGINE

Exhaust Assembly Removal and Installation

Installation Procedure - Follow all warnings first, then reverse the removal steps.*

Removal Procedure

*Tighten the mounting hardware only after checking the alignment of the exhaust assembly so that the tailpipe is centered in the opening on the engine cover when closed.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Lower the lift arm completely.

Fan Belt Adjustment Adjustment Procedure

Shut off the engine and allow to cool.

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

1. Open the engine access cover and lock open the rear grille.

2. Remove the capscrew securing the side of the muffler to the muffler mount.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine and allow to cool.

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

1. Open the engine access cover and lock open the rear grille.

2. Test the fan belt tension by pushing on the belt midway between the alternator and the engine crankshaft pulley. The belt should deflect about ½" (13 mm) under a load of 20 lbs. (90 N). If adjustment is needed, follow the steps below.

3. Remove four locknuts securing the muffler to four studs on the engine.

4. Lift the muffler up and remove it from the loader.

PRINTED IN USA

917400/AP0809

137

ENGINE

GEHL 1640E / MUSTANG 2012

3. Loosen the two bolts on the alternator, one at the low pivot area and one on top in the slide bracket.

3. Open the engine access cover and lock open the rear grille.

4. If so equipped, remove two capscrews securing the brake release valve to the shroud.

4. Rotate the alternator in a clockwise direction (viewed from the engine end) until the correct belt tension is achieved.

5. Retighten the bolts.

5. Remove coolant hoses and hydraulic oil lines from the inlets and outlets of the radiator/oil cooler. Disconnect the hose clamps on the two radiator hoses and the two hydraulic oil lines from their fittings.

Radiator/ Oil Cooler Removal and Installation

Upper Radiator and Hydraulic OIl Line

The radiator/oil cooler is mounted on a shroud located just behind the engine.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine and allow to cool.

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

Lower Radiator Hose

1. If necessary, drain the oil from the hydraulic reservoir per the procedure in the Lubrication chapter.

2. If necessary, drain the engine coolant from the radiator per the procedure in the Lubrication chapter.

NOTE: Hydraulic oil lines should be plugged to prevent contaminants from entering the hydraulic system. If the hydraulic oil lines are plugged after removal to prevent oil leakage, it should not be necessary to drain the hydraulic reservoir.

138

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ENGINE

Lower Hydraulic OIl Line

WARNING

6. Remove remote radiator overflow line at the top of the radiator.

NEVER use your hands to search for hydraulic fluid leaks.

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

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.

9. ALWAYS check for hydraulic fluid leaks after installing any components of the hydraulic system.

7. Remove three locking capscrews on each side securing the radiator/oil cooler tab to the shroud.

8. Using a suitable hoist, remove the radiator/oil cooler from the skid-steer loader.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

PRINTED IN USA

917400/AP0809

139

ENGINE

GEHL 1640E / MUSTANG 2012

Fan Shroud and Support Brackets Removal and Installation

shroud support brackets to the floor of the chassis, on each side of the skid-steer loader.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine and allow to cool.

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

WARNING DO NOT attempt to service any part of radiator/oil cooler system until engine has been allowed to cool. Serious injury may result from high temperature oil or water coolant 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.

NOTE: Hydraulic oil lines should be plugged after disconnecting to prevent contaminants from entering the hydraulic system. If the hydraulic lines are plugged after disconnecting to prevent leakage, it should not be necessary to drain the hydraulic reservoir.

2. Remove the radiator/oil cooler per the procedure in this chapter.

3. Underneath the skid-steer loader there are holes to access and remove two capscrews securing the

140

4. Remove the fan shroud assembly with the shroud supports still attached.

5. Unbolt the shroud supports at this time, if necessary.

Installation Procedure - Follow all warnings first, then reverse the removal steps.* * BE SURE and uncap/unplug the hydraulic oil lines prior to reconnecting them to the radiator/oil cooler.

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ENGINE

Fan Shroud Adjustment

Fan Removal and Installation

Adjustment Procedure

Removal Procedure

WARNING

WARNING

BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine and allow to cool.

BEFORE beginning this service procedure, perform the following SAFETY procedure: Shut off the engine and allow to cool.

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

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

1. Loosen, but do not remove, the two locking capscrews on the shroud support connected to the shroud.

1. If necessary, drain the oil from the hydraulic reservoir per the procedure in the Lubrication chapter.

2. If necessary, drain the engine coolant from the radiator per the procedure in the Lubrication chapter.

NOTE: Hydraulic oil lines should be plugged to prevent contaminants from entering the hydraulic system. If the hydraulic oil lines are plugged after removal to prevent oil leakage, it should not be necessary to drain the hydraulic reservoir.

3. Remove the radiator/oil cooler per the procedure in this chapter.

4. Unbolt four nuts securing the fan to the engine.

2. Move the shroud and radiator/oil cooler assembly up or down until the fan is centered in the shroud opening.

5. Carefully pull the fan out the rear of the skid-steer loader.

6. Repair or replace the engine fan.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

3. Tighten the locking capscrews on the fan shroud supports to secure the height adjustment.

PRINTED IN USA

917400/AP0809

141

ENGINE

GEHL 1640E / MUSTANG 2012

Engine Removal and Installation

9. Remove the fan shroud and support brackets per the procedure in this chapter.

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

10. Turn fuel/water separator petcock (small red petcock) to the OFF position.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: Raise lift arm; engage lift arm support device.

11. Disconnect fuel lines from the fuel filter.

Shut off the engine.

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

1. Drain the hydraulic oil reservoir and the engine oil.

2. Remove the engine access covers per the procedure in the Mainframe chapter.

3. Remove the rear grille per the procedure in the Mainframe chapter.

NOTE: The following step is not required, but it is recommended.

4. Remove the ROPS/FOPS per the procedure found in the Mainframe chapter.

5. Remove the battery per the procedure in this chapter.

12. Disconnect the fuel line in front of the fuel pump and unplug the electrical connector on the fuel pump.

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

Fuel Pump

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

7. Remove the exhaust assembly per the procedure in this chapter.

8. Remove the radiator/oil cooler per the procedure in this chapter.

142

13. Remove the engine throttle cable per the procedure in the Controls chapter.

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ENGINE

14. Unplug engine harness connectors located in several areas on the engine.

Block Heater Plug

15. Disconnect and unplug two harness connectors from the alternator on the engine.

Glow Plug Wire

NOTE: The following step includes disconnection of hydraulic hoses. If hoses cannot be capped/plugged to prevent fluid loss, the hydraulic reservoir should be drained BEFORE disconnecting hoses. Refer to the Hydraulic System chapter for the procedure.

Oil Pressure Wire

NOTE: ALWAYS clean area around hydraulic fittings BEFORE disconnecting any hydraulic hose or tube.

16. Label and disconnect all the hydraulic hoses connected to the hydrostatic pump. Refer to the “Hydrostatic Pump Removal” procedure in the Hydrostatic System chapter for hydraulic hose removal procedure on the pump.

PRINTED IN USA

917400/AP0809

143

ENGINE

GEHL 1640E / MUSTANG 2012

17. Remove the negative (-) battery cables from the bottom left of the engine’s flywheel cover.

20. Remove one capscrew, lock nut (110 ft-lbs) (149 N•m) and three washers on two forward engine mounts.

Engine Mount - Underneath View

18. On the starter solenoid, remove the nut that secures the positive (+) battery cable and two smaller wires. There will be an additional positive (+) battery cable to remove if a remote engine disconnect switch is installed. Also, remove the push-on connector attached at the solenoid.

Engine Mount - Top View

21. Remove one capscrew, locknut (55 ft-lbs) (75 N•m) and two washers on the rear engine mount.

19. Attach lift hooks to engine lifting locations on the front and rear of the cylinder head.

144

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

ENGINE

22. With the hoist attached to the engine, lift slightly and pull the engine rearward. Continue pulling the engine rearward until the pump is free from the drive coupling, then remove the engine from the chassis.

and can cause permanent eyesight damage if safety glasses are not worn.

ALWAYS check for hydraulic fluid leaks after installing any components of the hydraulic system.

Installation Procedure - Follow all warnings first, then reverse the removal steps.* * Bleed the fuel system. Also check engine oil and hydraulic oil levels prior to starting the engine. * Safely check for hydraulic fluid leaks observing the correct procedure in doing so (refer to Hydraulic System chapter).

WARNING NEVER use your hands to search for hydraulic fluid leaks.

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

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible

PRINTED IN USA

917400/AP0809

145

ENGINE

GEHL 1640E / MUSTANG 2012

CHAPTER NOTES

146

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

INDEX

INDEX A Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air Cleaner and Exhaust Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Air Cleaner Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Air Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 All-Tach® Hitch Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 All-Tach® Hitch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Auxiliary Hydraulics Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Auxiliary Hydraulics Cable Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Auxiliary Neutral Start Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Axle and Wheel Bearing Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Axle Housing Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

B Backup Alarm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Battery and Battery Tray Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Brake Solenoid Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

C Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Charge Pressure Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Control Handle Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Control Handle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Control Locations - T-Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Control Valve Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Control Valve Spool Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Cooling System Drain Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

PRINTED IN USA

917400/AP0809

147

INDEX

GEHL 1640E / MUSTANG 2012

D Description of Operation - Right and Left Instrument Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Dome Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Drive Chain Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Drive Chain Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Drive Motor Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

E Electrical Battery Disconnect Switch Components (EU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Electrical Battery Disconnect Switch Components (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Electrical Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Electrical Lights Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Electrical ROPS/FOPS Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124, 125 Engine Access Cover - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine and Hand Throttle Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Engine Components and Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Engine Disconnect Switch - Remote Battery Terminal Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Exhaust Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

F Fan Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Fan Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Fan Shroud Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Fan Shroud and Support Brackets Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Floor Cover/Step Cover/Kickplate Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Foot Throttle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Front and Rear Work Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Fuel Sensor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

G Gear Pump Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Glow Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Grease Fitting Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

148

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

INDEX

H Hand Throttle Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Hand Throttle, Foot Throttle Pedal and Throttle Cables/Throttle Rod Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . 59 Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulics - Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Hydraulics - Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Hydraulics - Non-Self Level and Self Level Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Hydrostatic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Hydrostatic Components - Drive Motor with Brake Release Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Hydrostatic Components - Standard Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Hydrostatic Pump Drive Coupling Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Hydrostatic Pump Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Hydrostatic Pump Removal / Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Hydrostatic/Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76, 77

I Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

L Lift and Tilt Solenoid Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Lift Arm Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Lift Arm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Lift Arm Stop Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Arm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Arm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Lift Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Lift, Tilt and Brake Solenoid Valves - Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Lift/Tilt Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Lift/Tilt Controls Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Lift/Tilt Cylinder Disassembly / Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Loader Lowering Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PRINTED IN USA

917400/AP0809

149

INDEX

GEHL 1640E / MUSTANG 2012

M Main Control Valve Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Main Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Mainframe (Chassis), Rear Grille and Engine Cover Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Mandatory Safety Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

O Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

P Pivot Tube Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Pressure Tests, Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Pump Control Arm Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

R Radiator/ Oil Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Radiator/Cooler Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Rear Grille Latch Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Relay Test - Fuel Pull, Starter, Safety Lock and Auxiliary Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Relay Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Restraint Bar Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Restraint Bar Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Restraint Bar Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Restraint Bar Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ROPS – Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ROPS – Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ROPS/FOPS Rear Window Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ROPS/FOPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

150

917400/AP0809

PRINTED IN USA

GEHL 1640E / MUSTANG 2012

INDEX

S Safety Lock Valves - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Seat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Seat Slide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Seat Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Self-Leveling Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Self-Leveling Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Self-Leveling Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Solenoid Valve Test - Tilt, Lift, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

T T-Bar Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Tilt Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Tilt Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Tilt Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

W Wheel Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Wheel Drive, Foot Throttle and Lift Tilt Components - Parts Listing - Earlier Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Wheel Drive, Foot Throttle and Lift Tilt Components - Parts Listing - Later Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Wheel Drive, Foot Throttle and Lift Tilt Components - Illustration - Earlier Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Wheel Drive, Foot Throttle and Lift Tilt Components - Illustration - Later Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

PRINTED IN USA

917400/AP0809

151

INDEX

GEHL 1640E / MUSTANG 2012

THIS PAGE INTENTIONALLY LEFT BLANK

152

917400/AP0809

PRINTED IN USA

This Page Intentionally Left Blank

® Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 USA www.gehl.com

917400/AP0809

© 2009 GEHL COMPANY All Rights Reserved.

PRINTED IN USA