Manual Reparação Mustang 2012

Gehl 1640E
Mustang 2012
Form No.
917400
Revision A
08/09
SKID-STEER LOADERS
Service Manual
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 TABLE OF CONTENTS
Hydrostatic System 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 GEHL 1640E / MUSTANG 2012
Electrical System 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 Page 147
4 PRINTED IN USA
GEHL 1640E / MUSTANG 2012 SPECIFICATIONS
SPECIFICATIONS
Model 1640E / 2012
Engine Make Yanmar
Engine Model 3TNV82A-BPMS
Fuel Diesel
Displacement 81.2 CID (1,33 L)
Horsepower - Net 23.9 hp (17,8 kW)
Peak Torque 68 lbf-ft. (86 N•m)
Rated Operating Capacity 850 lbs. (386 kg)
Operating Weight 2980 lbs. (1352 kg)
Shipping Weight 2820 lbs. (1279 kg)
Capacities Capacities
Engine Oil 5.8 US qts. (5,5 L)
Fuel Tank 7.7 US gal. (29,1 L)
Chaincase (each) 6.0 US qts. (5,7 L)
Hydraulic Reservoir 7.2 US gal. (27,2 L)
Engine Coolant 8.0 US qts. (7,57 L)
Electrical System Electrical

Battery 12-V DC, Group 24, 675 CCA, 115 Reserve
Starter 12-V DC (1,7 kW)
Alternator 40 A
Hydraulic System Hydraulic System

Hydraulic System Pressures 2255 PSI (156 bar)
Standard Auxiliary Flow Rate 10.1 gal/min (38,2 L/min)
Travel Speed (with standard tire) 0 to 5.5 mph (0 to 9,0 km/h)
Tire Options Tire Options Description

5.70 x 12 Heavy-Duty 4-Ply NHS Trac Loader Chevron
23 x 8.50-12 Heavy-Duty 6-Ply NHS Heavy-Duty 2000
Buckets and Capacities

Width - Description Capacity (Heaped)
36 inches (914 mm) - Dirt/Construction 5.3 cubic feet ; 0,15 cubic meters
44 inches (1118 mm) - Dirt/Construction 7.4 cubic feet ; 0,21 cubic meters
48 inches (1219 mm) - Utility/Snow 9.8 cubic feet ; 0,28 cubic meters
15.75-19.68-24 inches (400-500-610 mm) Pallet 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
A
G
B
F
C
R Q
W O
I
S Z
P X Y
V
D
Dimensional Specifications 1640E and 20121

in. mm
A Overall operation height - fully raised 124.7 3167
B Height to hinge pin - fully raised 96 2438
C Overall height - top of ROPS 74.7 1897
D Overall length - bucket down 101.4 2576
E Dump angle @ full height 45.9º
F Dump height 72.3 1836
G Dump reach - bucket (full height) 14.8 376
I Rollback at ground 23.4º
M Rollback angle @ full height 100.3º
O Seat-to-ground height 34.6 879
P Wheelbase - nominal 30.5 775
Q Overall width - less bucket 35.8 909
R Overall bucket width 36.0/44.0 914/1118
S Ground clearance to chassis (between wheels) 6.0 152
V Overall length (less bucket) 75 1905
W Departure angle 30.1º
X Clearance circle - front (with bucket) 58 1473
Y Clearance circle - front (less bucket) 32.8 833
Z Clearance circle - rear 43.2 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
General Information death or serious injury.
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. WARNING
Before operating or working on this machine, read and “WARNING” indicates a potentially hazardous
study the following safety information. In addition, be situation, which, if not avoided, could result in
sure that everyone who operates or works on this death or serious injury.
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 CAUTION
operator be capable of obtaining a valid motor vehicle “CAUTION” indicates a potentially hazardous
operator’s license. situation, which, if not avoided, may result in
The use of skid-steer loaders is subject to certain minor or moderate injury. May also alert
hazards that cannot be eliminated by mechanical means, against unsafe practices.
but only by exercising intelligence, care and common
sense. Such hazards include, but are not limited to,
hillside operation, overloading, instability of the load,
Additional Safety Reminders
poor maintenance and using the equipment for a Read and understand the Service Manual and all decals
purpose for which it is not intended or designed. before maintaining, adjusting or servicing this
Both Gehl and Mustang Company ALWAYS consider equipment.
the operator’s safety when designing machinery and Doors, Guards and Shields - Some photographs in this
guards exposed moving parts for the operator’s manual may show doors, guards and shields open or
protection. However, some areas cannot be guarded or removed for illustrative purposes only. BE SURE all
shielded in order to assure proper operation. The doors, guards and shields are in their proper operating
Operator’s Manual and the decals on the machine warn positions before starting engine to operate unit.
of additional hazards and should be read and observed
closely. Damaged or Worn-out Parts - For safe operation,
replace damaged or worn-out parts with genuine Gehl/
These topics in the Safety chapter of the service manual Mustang service parts, before operating this equipment.
include procedures, which, when followed, will allow
safe performance of service procedures: Mandatory Attachments - Gehl and Mustang loaders are designed
Safety Shutdown Procedure, Lift Arm Support Device, and intended to be used only with Gehl/Mustang
Roll-Over Protective Structure (ROPS)/Falling Object Company attachments or approved referral attachments.
Protective Structure (FOPS) Lock Mechanism, Loader The Company cannot be responsible for operator safety
Raising and Lowering Procedures, and Relieving if the loader is used with a non-approved attachment.
Hydraulic Pressure. 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.

SAFETY GEHL 1640E / MUSTANG 2012
Loader Stability - A skid-steer loader’s stability is strength to support the weight of the loader and the
determined by its wheelbase and tread width. The load.
following elements can affect stability: terrain, speed, DO NOT smoke or have any spark-producing
load being carried or dumped, and sudden control equipment in the area while filling the fuel tank or while
movements. DISREGARDING ANY OF THESE working on the fuel or hydraulic systems.
FACTORS CAN CAUSE THE LOADER TO TIP,
POSSIBLY RESULTING IN DEATH OR SERIOUS Exhaust Gases - Exhaust fumes can kill. DO
INJURY. Therefore, ALWAYS have the operator NOT operate this machine in an enclosed
restraint bar lowered and wear the seat belt. Operate the area unless there is adequate ventilation.
controls only from the operator’s seat. Operate the Engine - NEVER use ether or starting fluid.
controls smoothly and gradually at an appropriate
People - NEVER carry riders. DO NOT allow others to
engine speed that matches the operating conditions.
ride on the machine or attachment, because they could
DO NOT exceed the rated operating capacity of the fall or cause an accident.
machine. For additional stability when operating on
BE SURE all persons are away from the machine and
inclines or ramps, ALWAYS travel with the heavier
warn others in the area before starting the engine.
end of the loader toward the top of the incline.
ALWAYS face the machine and use handholds and
ALWAYS look to the rear before backing up.
steps when getting on and off. DO NOT jump off
When parking machine, before leaving seat, check machine.
restraint bar for proper operation. The restraint bar,
Wear appropriate ear protection for prolonged
when raised, applies the parking brake and deactivates
exposure to excessive noise.
lift/tilt controls and auxiliary hydraulics.
ALWAYS perform a daily inspection of the
Keyswitch - NEVER attempt to bypass the keyswitch
machine before using it. Look for damage, loose or
to start the engine. Use the jump-starting procedure
missing parts, leaks, etc.
detailed in the Service chapter of the Operator’s
Manual. Remove trash and debris from the machine and engine
compartment each day to minimize risk of fire.
Hydraulic Fluid Leaks - NEVER use
hands to search for hydraulic fluid leaks. New operators MUST operate loader in an open area
Instead, use paper or cardboard. Fluid under away from bystanders. Practice with controls until the
pressure can be invisible, penetrate the skin and cause a loader can be operated safely and efficiently.
serious injury. If any fluid is injected into skin, see a
doctor at once. Injected fluid MUST be surgically Mandatory Safety Shutdown Procedure
removed by a doctor or gangrene may result.
BEFORE cleaning, adjusting, lubricating or servicing
Wear Safety Glasses - ALWAYS wear the unit or leaving it unattended:
safety glasses with side shields when
operating the machine or striking metal 1. Move drive control handle(s) to the neutral position.
against metal. In addition, it is recommended that a 2. Lower the lift arm and attachment completely. If the
softer (chip-resistant) material be used to cushion the lift arm must be left in the “raised” position, BE SURE
blow. Failure to heed could lead to serious injury to to properly engage the lift arm support device.
eyes or other parts of the body.
3. Move the throttle to the low idle position, shut off the
ALWAYS wear safety glasses when searching for engine and remove the key.
hydraulic leaks or when working near batteries.
4. Before exiting, move the lift/tilt control(s) to verify
Loaded Bucket/Fork - DO NOT raise or drop a loaded that controls do not cause movement of the lift arm or
bucket or fork suddenly. Abrupt movements under load hitch.
can cause serious loader instability.
Only after these precautions can you be sure it is safe to
NEVER push the lift control into the “float” position proceed. Failure to follow the above procedure could
with the bucket or attachment loaded or raised, because lead to death or serious injury.
this will cause the lift arm to lower rapidly.
DO NOT drive too close to an excavation or ditch. BE
SURE that the surrounding ground has adequate

Lift Arm Support Device 4. Place the lift arm support device on the left cylin-
der 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 5. Return to the operator’s compartment and restart
from unexpectedly lowering. the engine.
BE SURE to engage the lift arm support device 6. Slowly lower the lift arm until the support device
whenever the lift arm is raised. When the device is not contacts the top end of the lift cylinder.
being used, secure it to the anchor on the underside of 7. Be sure the support device is secure against the cyl-
the lift arm using the slide latch and retainer provided. inder end. Then, stop the loader engine, remove the
The lift arm support device is a safety device which key and leave the operator’s compartment.
must be kept in proper operating condition at all times.
The following procedures outline the correct way to Lift Arm Support Device Disengagement
engage and disengage the lift arm support device.
Lift Arm Support Device Engagement

1. Raise the lift arm fully. WARNING
2. Turn keyswitch to OFF position to stop engine. NEVER leave the operator’s compartment to
disengage the lift arm support device with the
3. Remove the lift arm support device from its storage
engine running.
location.
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).

NOTE: With the keyswitch OFF, and the solenoid 4. Remove one capscrew and washer on each side of
valve functioning properly, the lift arm will not move the ROPS forward stantions.
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. To store the lift arm support device, remove it from
the lift cylinder rod and return it to its storage loca-
tion. Secure the support device under the lift arm
with the slide latch.
5. Lift ROPS up and tilt it back until the self-actuat-

ing 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 rolled-
back position.
1. The lift arm should be lowered or locked in the
raised position as per the “Lift Arm Support
Device Engagement” procedure in this chapter.
2. Turn the keyswitch to the OFF position to stop the
IMPORTANT
engine. Remove the key and take it with you. BEFORE raising the ROPS, position the seat
as far back as it will go. Avoid damaging con-
3. Leave the operator’s compartment.
trol 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.

ROPS – Lowering
1. Apply upward force on the ROPS and push the IMPORTANT
lock mechanism handle toward the back of the Avoid damaging control handles by slowly
loader. lowering the ROPS. BE SURE the control han-
dles 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.

result from improperly raising or blocking the

Relieving Hydraulic Pressure skid-steer loader.
The following procedure should be used to relieve 1. To raise and block the skid-steer loader, obtain
pressure in the hydraulic system before performing four jack stands (or blocks) of sufficient strength to
service procedures on hydraulic system components. support the loader. A reinforced pallet may also be
1. Completely lower the bucket or attachment. used.
2. Turn the keyswitch to the “OFF” position to shut 2. Using a jack or hoist capable of raising the fully-
off engine. equipped loader, lift the loader until the tires are
off the ground.
3. With the operator in the seat and the restraint bar
lowered, turn the keyswitch to the “ON” position, 3. Place the reinforced pallet, jack stands (or blocks)
but DO NOT start the engine. under the flat part of the loader chassis. Place them
parallel with, but not touching, the tires.
4. Move the lift, tilt and auxiliary hydraulics controls
through several cycles. 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

Loader Lowering Procedure
The following procedure is used to raise the skid-steer
loader so that all four tires are off the ground. When the service procedures are complete, the skid-
steer loader can be taken down from the “raised”
position. To lower the loader onto its tires:
WARNING 1. Using a jack or hoist, raise the loader until its

weight no longer rests on the reinforced pallet, jack
BEFORE servicing the machine, exercise the stands (or blocks).
“Mandatory Safety Shutdown Procedure” 2. Carefully remove the reinforced pallet, jack stands
described in this chapter. (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

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
WARNING convenient maintenance of the hydraulic oil level.
NEVER service this unit when any part of the Visual Hydraulic Oil Level Indicator
machine is in motion. ALWAYS BE SURE to
exercise the “Mandatory Safety Shutdown
Procedure” (see Safety chapter) BEFORE ser-
vicing 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, high-
quality lubricating oils. This chapter and the chart
below list locations, temperature ranges and types of
recommended lubricants to be used when servicing this
machine. In addition, refer to the engine manual for
specific grades and ratings as specified by the engine
manufacturer. The hydraulic oil reservoir should be drained and filled
after every 500 hours of operation or annually
(whichever occurs first).
IMPORTANT
Whenever service is performed on hydraulic
components (valves, cylinders, hoses, etc.),
fuel tanks and lines, care must be taken to pre- Hydraulic Oil Drain
vent discharging fluid onto the ground. Catch
and dispose of fluid per local waste disposal
regulations.
Hydraulic System
Chaincases Grease Fittings Crankcase Oil
Reservoir
Use Petro-Canada Pre- Use hydraulic system oil Use lithium-based grease Below 32°F (0°C) use SAE
mium HVI60, or equivalent or SAE grade 15W-40 Grade* 10 or 10W-30
that contains anti-rust, motor oil.
anti-foam, and anti-oxida- Capacity (each side): Above 32°F (0°C) use SAE
tion additives and con- 6.0 Quarts (5,7 L) Grade* 15W-40
forms to ISO VG46.
Capacity: *Service Classification:
7.2 Gallons (27,2 L) API - CI-4/SL
Capacity (w/ filter change):
5.8 Quarts (5,5 L)

LUBRICATION GEHL 1640E / MUSTANG 2012
Use Petro-Canada Premium HVI60 hydraulic oil (or Crankcase Oil

ISO VG46 equivalent) that contains anti-rust, anti-foam
and anti-oxidation additives. Hydraulic oil filter The Yanmar three-cylinder diesel engine crankcase has
element should be replaced after every 250 hours of a capacity of 5.8 U.S. quarts (5,5 liters). The chart
operation or annually (whichever occurs first). For below lists recommended oil viscosity for the Yanmar
details, refer to “Hydraulic Oil Filter Element engine.
Replacement” procedure in the Hydraulics System
chapter. Engine Oil Dipstick
Engine Oil Fill
Hydraulic Filter Location
Ambient
Hydraulic Oil Fill Cap Viscosity
Temperature
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

The engine oil filter is located on the left side of the Chaincases
engine. This view is taken from underneath the engine
and looking up through the belly pan. Each chaincase requires six quarts (5,7 L) of motor oil.
This quantity of oil should be maintained at all times.
Engine Oil Filter Location 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 3. Remove the oil fill plug.
details on changing oil, and to “Oil Filter Removal” and
“Oil Filter Installation” procedures in Engine chapter of Chaincase Fill Plug
this manual.
NOTE: Refer to engine operator’s manual for
additional information on oil change intervals,
including the 50-hour initial oil change.
4. Add six quarts (5,7 L) of motor oil through the fill

plug.
5. Reinstall the fill plug.

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.

Cooling System Drain Procedure Hydraulic Oil Cooler Plug/Cap Procedure
Gehl 1640E and Mustang 2012 model skid-steer loaders 1. On the cooler side, unscrew the 90º fitting from the
use a hydraulic oil cooler/radiator design to help keep top right cooler tube and plug/cap the tube and the
the hydraulic oil and engine coolant from overheating. 90º fitting.
Many procedures in this Service Manual require
partially or fully draining the radiator/cooler to perform
the procedures.
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.)
2. On the cooler side, unscrew the bottom right cooler
Radiator Drain Procedure tube from the straight fitting in the cooler port and
plug/cap the tube and the straight fitting.
1. Place a catch pan with a capacity of at least 10-gal-
lons (37,9 L) behind and underneath the chassis,
below the drain cock or plug.
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.

CHAPTER NOTES

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 The lift arm and the lift and tilt cylinders are mounted
have a welded steel chassis. Maintenance, service and with pivot pins. Capscrews are used to secure the pivot
repair may be performed through standard access pins. A Rollover Protective Structure/Falling Object
panels. Protective Structure (ROPS/FOPS) is standard for
Two side chaincases provide mounting for the drive operator safety, and both the seat and restraint bar
motors and for the front and rear axles. The side cases include interlock switches.
also serve as sealed housings for the drive chains and
Mainframe (Chassis), Rear Grille and Engine Cover Components
17 15 1 BOLT/SHOULDER
14 6 3 2 BUSHING/OILITE
31 22 43
19
18 3 NUT/HEX LOCK
23 12 4 SCREW/CAP WHIZLOCK
16 14
26 30 5 HANDLE/ THROTTLE
21
6 SPRING/COMPRESSION
7 WASHER/BELLEVILLE
8 CAP/HYD. RESERVOIR
2 11 9 BREATHER/HYD. RESERVOIR
21 20
25 42 44 10 PLUG
9
42 32 11 BUMPER
23
28 12 BUSHING
39 13 SIGHT PORT/OIL LEVEL
22
38 14 NUT/SPIRALOCK
15 CLIP/RETAINING
36 32 16 PIN/LOCK
32
17 ASSY/LATCH ROD
5 24
37 7 18 LATCH
35 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
10 26 COVER/ENGINE
27 COVER/HYD. RESERVOIR
41
29
28 SENSOR/FUEL
29 BELLYPAN/REAR
4
30 TIE/ZIP WITH CLIP
31 GAS SPRING/RESTRAINT BAR
34 32 SEAL/BULB
33 COVER/CHAINCASE
34 BELLYPAN/FRONT
35 WASHER/FRICTION
36 GRIP/THROTTLE
37 BOLT/CARRIAGE
8 1
2 38 BOLT/CARRIAGE
13 49 BOLT/CARRIAGE
45 40 SCREW/MACHINE
41 SCREW/TAPPING
NOTE: SHOULDER BOLT THREADS INTO 42 NUT/HEX JAM
ROPS PIN.
27 43 WASHER/FLAT
40
44 NUT/SPIRALOCK
45 CAP/FUEL FILL

MAINFRAME GEHL 1640E / MUSTANG 2012
Engine Access Cover - Removal and Installation Procedure - Follow all warnings first,
Installation then reverse the removal steps.
NOTES
WARNING
Shut off the engine.
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.

Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS
16
17
22
14
29 27
10
6
28 9 8
24
14
35
34
21 2
21
34
20
15 19
2 3 2
1
3 26 18
2
26
18
30 36
7 12 38
11
32
13 5
36 30
37 12
23
4
31
1 TETHER/MANUAL 14 INSERT/INTERNALLY THREADED 27 STRIP/LOCKING

2 WASHER/FLAT 15 HOLDER/MANUAL 28 REAR WINDOW/ROPS
3 MOUNTING/ISOLATOR 16 ROPS/FOPS 29 SEAL/WINDOW
4 NUT/HEX LOCK 17 SCREW/SEMS 30 SCREW/CAP
5 NUT/HEX LOCK 18 NUT/HEX CENTERLOCK 31 SCREW/CAP
6 CLAMP/TUBE 19 NUT/TINNERMAN FLAT 32 SCREW/CAP
7 SPRING/TORSION 20 NUT/SPECIAL 33 BOLT/CARRIAGE
8 NUT/HEX LOCK 21 WINDOW 34 SCREW/CAP
9 TAG/RIP CORD 22 TOP WINDOW/ROPS 35 SCREW/MACHINE
10 RING 23 GAS SPRING/ ROPS 36 WASHER/FLAT
11 PIN 24 TOP HARNESS COVER 37 WASHER/FLAT
12 ROPS SUPPORT 25 FOAM/SOUND SUPPRESSION 38 PIN/COTTER
13 SPACER/TUBE 26 WASHER/FLAT

ROPS/FOPS Removal and Installation 1. Remove one capscrew and flat washer securing
each gas spring to the ROPS/FOPS.
WARNING
Removal Procedure
1. Remove the engine access cover per the procedure
in this chapter.
2. Disconnect the negative (-) battery cable at the bat- 2. Disconnect the ROPS/FOPS lock mechanism from
tery, or, if equipped, turn the electrical disconnect the chassis by removing the capscrew, washer,
switch to OFF. spacer and locknut.
3. Disconnect two harness connectors at the harness

bulkhead attached at the rear of the ROPS/FOPS.
Harness Connectors 3. On each side, carefully remove the capscrew secur-

ing the ROPS/FOPS pivot pin to the frame.
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 follow-
ing steps may cause the ROPS to swing as the
bolts are removed. This could cause serious
bodily injury and/or damage the loader.

4. Using a punch, force the pivot pin outward until Seat Removal and Installation
the ROPS/FOPS is released from the pin.
WARNING
perform the following SAFETY procedures:
Tilt back ROPS/FOPS until lock engages.
Removal Procedure
1. Remove four nuts from the studs attaching the seat
5. Lift the ROPS/FOPS off the loader. to the seat pan underneath the ROPS/FOPS.
Installation Procedure - Follow all warnings first, 2. Release the lock mechanism and lower the ROPS/
then reverse the removal steps. 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.

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

Installation Procedure 6. Use the pigtail hook tool to “pull down” weather-
1. Recommended but not required: Mix a solution of strip seal on the outside of the ROPS/FOPS to
10% liquid dish soap and 90% water in a spray bot- secure the window.
tle.
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 rip-

cord in the ripcord lip, starting at top of weather-
strip. Be sure to have emergency exit tag slipped
over the ripcord before performing this step.
2. Apply soap solution to window, weatherstrip and
8. Using L-hook tool, secure the ripcord in the rip-
metal frame surfaces.
cord lip by “pulling down” the lip over the cord.
3. Start at top of window frame and install weather-
9. Test the window for security and mating of all
strip with the ripcord lip facing inside the ROPS/
seals.
FOPS and the glass lip facing out.
4. From inside the ROPS/FOPS, spray soap solution
between glass window and inside edge of rear win-
dow.
5. Use L-hook tool between glass and weatherstrip
and work it underneath the glass. Lift the glass lip
up over the weatherstrip.

Restraint Bar Components
16 13 12
2 5
5 1
10 2 18
1
3
10 19
19 16
17
4 20 18 7
6 18 21
18 20
8
10
14 11 4
15 9
8
1 SCREW/SHOULDER 12 MOUNT/RESTRAINT BAR/LH

2 BUSHING 13 MOUNT/RESTRAINT BAR/RH
3 NUT/HEX LOCK 14 GAS SPRING/RESTRAINT BAR
4 BUMPER 15 MOUNT/GAS SPRING
5 SPACER/TUBE 16 BOLT/CARRIAGE
6 SWITCH/PROXIMITY 17 BOLT/CARRIAGE
7 MAGNET/SWITCH ACTUATOR 18 WASHER/FLAT
8 STUD/BALL 19 NUT/HEX MACHINE
9 NUT/SERRATED LOCK 20 WASHER/EXTERNAL LOCK
10 NUT/SPIRALOCK 21 SCREW/MACHINE
11 BAR/RESTRAINT

All-Tach® Hitch Components
3.28 .06 7 NOTE 1

14
20
2 NOTE 1
10
8 19
11
17 15
5 16
NOTE 1 4 18
12
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 11 2-PIN ALL-TACH

2 NUT/HEX LOCK 12 WASHER/SPECIAL
3 NUT/HEX LOCK 13 WASHER/FLAT
4 SPRING/COMPRESSION 14 WASHER/FLAT
5 PIN 15 GRIP
6 ADAPTOR/ROD 16 ZERK/GREASE
7 SPRING/COMPRESSION 17 SCREW/CAP
8 ADAPTOR/PUSH ROD 18 SCREW/CAP
9 PIN 19 SCREW/CAP
10 HANDLE/HITCH 20 SCREW/CAP

Restraint Bar Removal and Installation 3. Through the instrument panel openings, remove
two locknuts on carriage bolts securing the
Removal Procedure 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 NOTE: For restraint bar switch removal, refer to the
ROPS/FOPS wire harness. Electrical chapter.
Installation Procedure - Reverse the removal steps.

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 1. Lower the lift arm.
cylinders. 2. Remove the bucket or attachment from the loader.
NOTE: Support the hitch with suitable hoisting 3. Remove the hitch per the procedure in this chapter.
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,
Relieve hydraulic system pressure.
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.

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 strik-
ing metal against metal. In addition, it is rec-
ommended that a softer (chip-resistant)
material be used to cushion the blow. Failure 6. While supporting the lift cylinder, remove the lift
to heed could lead to serious injury to eyes or cylinder pins from the lift arm.
other parts of the body.
7. Repeat steps 4 and 5 for other side of the lift arm.
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.

Lift Arm Components
12
15
15
12
13 3
6
10
5
13
9
16
18 11
13
4
13
18
8
16
17 14
NOTE 1
NOTES:
1. APPLY LOCTITE™ 242
2
2. ADDITIONAL SHIMS MAY BE USED TO INSURE CONTACT
NOTE 2 BETWEEN SHIMS AND CHASSIS STOP BLOCKS.
13
1 NUT/HEX LOCK 10 LOCK/LIFT ARM

2 SHIM 11 LATCH/SLAM
3 ARM/LIFT 12 ZERK/GREASE
4 STANDOFF 13 SCREW/TAPPING THREAD CUTTING
5 PIN/LIFT ARM 14 SCREW/CAP
6 PLATE/KNEECAP RH 15 SCREW/CAP
7 PLATE/KNEECAP LH 16 SCREW/TAPPING THREAD CUTTING
8 PLATE/COVER/HYD TUBES 17 WASHER/LOCK
9 AUXILIARY CAP 18 WASHER/FLAT

8. Disconnect four upper and lower tilt cylinder hoses 11. Underneath the hydraulic tubes cover plate,
from the tilt cylinder. remove the hose clamp and locknut securing the tilt
cylinder hoses to the front of the lift arm.
Upper Tilt Cylinder Hoses
12. Remove three self-tapping screws securing the
auxiliary cap plate to the lift arm at the quick cou-
plers.
Lower Tilt Cylinder Hoses
13. Disconnect two hydraulic hoses from their 90° fit-

tings 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.

16. On the right lift arm, disconnect two tilt cylinder 20. If replacing the lift arm, carefully pull the four
hydraulic hoses, one from the tilt solenoid and one hydraulic hoses inside the lift arm rearward out of
from the chassis riser. the lift arm.

Tilt Solenoid
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
procedure in this chapter if bushings require
17. On the left liftarm remove two auxiliary hydraulic replacement.
hoses from the chassis riser.

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.

Lift Arm Bushing Replacement Lift Arm Stop Installation and Adjustment
Installation/Adjustment Procedure
NOTE: Lift arm stops should be shimmed as needed
WARNING 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
ALWAYS wear safety glasses with side
lowered.
shields when operating the machine or strik-
ing metal against metal. In addition, it is rec- 1. Lower lift arm and measure gaps between stops
ommended that a softer (chip-resistant) and chassis.
material be used to cushion the blow. Failure
to heed could lead to serious injury to eyes or
other parts of the body.
Replacement Procedure
1. Remove the lift arm from the loader per the proce-
dure 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 sur-
face for installation of the new bushings.
NOTE: It will be necessary to add one shim for every
4. If replacing the spring bushing in each lower lift 1/8" (3 mm) gap.
arm, use a punch to drive them out of the lift arm.
2. Raise lift arm and engage the lift arm support
5. Install new spring bushings by pressing them into device.
place or using a rubber mallet to drive them into
the lift arm. 3. Remove two capscrews on each stack of shims.
6. Reinstall the lift arm on the loader per the proce- 4. Install shim(s) and secure with capscrews. Use
dure in this chapter. Loctite® 242 or equivalent retaining compound.
5. Start engine and lower lift arm. Verify gaps and
repeat procedure as needed.

Floor Cover/Step Cover/Kickplate Removal 2. On the floor cover, remove the five thread-forming
and Installation 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
Raise lift arm, engage lift arm support
device.
Tilt back ROPS/FOPS until lock engages. 3. EU Only Skid-Steer Loaders: At this time, care-
fully pull the sound pad up and out of the machine.
chapter of this manual.) 4. Remove the floor cover from the skid-steer loader.
5. On the kickplate, remove four thread-forming
Removal Procedure screws securing the kickplate to the crossmember
1. On the step cover, remove two thread-forming and remove the kickplate.
screws securing the cover to the kickplate and
remove the step cover.

Crossmember Removal and Installation 3. Underneath the crossmember, locate the two wheel
drive control rods that connect the pivot tube to the
The crossmember can be removed as a complete unit top of the hydrostatic pump at the pump control
with the control handles to facilitate work on the arms. Disconnect control rods at the pivot tube.
hydraulic/hydrostatic tandem pump found beneath it or
to perform work on the control handles.
Removal Procedure
WARNING
Raise lift arm; engage lift arm support
device.
Tilt back ROPS/FOPS until lock engages. 4. Disconnect the electrical connector in the left con-
(For detailed instructions, refer to the Safety trol 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 crossmem-

ber to the chassis on each side.

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 #765-
1211 (or equivalent) to seal sensor opening on fuel
tank.

Fuel Sensor Removal and Installation 3. With the float to the rear of the fuel tank, install the
Removal Procedure sensor in the fuel tank.
WARNING
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. 4. Install new gasket using Form-A-Gasket #765-
3. Remove the five screws securing the sensor, then 1211 (or equivalent) to the five screws.
remove the sensor and gasket from the tank.
Form-A-Gasket On Screws and Gasket

5. Install the five screws through the sensor into the Rear Grille Latch Removal and Installation
fuel tank. DO NOT OVERTIGHTEN.
Removal Procedure
6. Attach #25 (brown) wire to center stud with a nut,
and #0 (black) wire to ground stud with the fifth 1. Open the rear grille and lock open with the lock
screw. 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 bush-

ing and remove the latch assembly.
3. Support the rear grille with a suitable hoist.

4. Remove two cotter pins on two grille pins fasten-
ing the grille to the chassis.

CHAPTER NOTES

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
This chapter covers removal, installation, assembly and loader through a chain and sprocket system.
adjustment procedures for wheel drive system Service procedures related to the hydrostatic pump and
components on Gehl 1640E and Mustang 2012 model drive motors can be found in the Hydrostatic System
skid-steer loaders. Wheel drive components covered in chapter.
this chapter are shown below.
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
20
O NT 3
FR
21
17
1
18
15 8
2 17 19
16
5
3
11
10
7 EXPLODED VIEW
RIGHT HAND SIDE
9
13
12
1 BOLT/HUB 9 ROLLER CHAIN ASSY

2 CONE/BEARING 10 SPROCKET
3 CUP/BEARING 11 SHAFT W/SPROCKET/LONG
4 SEAL/AXLE 12 SHAFT W/SPROCKET/SHORT
5 THRUST WASHER 13 AXLE HUB
6 NUT WHEEL BOLT 14 AXLE HUB
7 NUT/HEX LOCK 15 HUB
8 ROLLER CHAIN ASSY 16 O-RING
17 O-RING
18 WASHER/ SPECIAL
19 SCREW/CAP

WHEEL DRIVES GEHL 1640E / MUSTANG 2012
spreader bar, push the axles outward in their slots

Drive Chain Adjustment to tighten the chain.
Skid-steer loader drive chain tension should be checked

every 250 hours of operation.
Adjustment Procedure
WARNING
perform the following SAFETY procedures: Axle Nut
Raise and securely block the loader so all 6. After the proper chain tension is obtained,
four tires are off the ground. retighten the locknuts on the axle. Axle housing
(For detailed instructions, refer to the Safety locknuts should be torqued to 280 ft.-lbs. (380
chapter of this manual.) N•m).
1. Remove the wheels and tires on the side of the NOTE: The drive chain must have a minimum of 1/2"
loader to be serviced. (13 mm) deflection; overtightening causes premature
drive chain and sprocket wear.
2. Remove six self-tapping screws on the chaincase
access cover (between tires) to access the drive 7. Scrape off the old oil-resistant RTV and reapply
chain. new RTV. Reinstall the access cover.
Chaincase Access Cover Screws
Fill Plug
3. Drain the oil from the chaincase. See the procedure 8. Remove the fill plug on the chaincase access cover.
in the Lubrication chapter. 9. Refill the chaincase oil until the oil is up to the fill
4. Correct chain deflection is ½" @ 20 lbs. force (13 plug.
mm @ 89 N) - halfway between the sprockets. 10. Reinstall the wheels and tires. Axle nut torque is:
5. To adjust chain tension, loosen the six locknuts on 100 ft.-lbs. (136 N•m) to press the bearings into
two axles on one side of the loader. Using a place. Loosen the nut, then retighten to 30 ft.-lbs.
(41 N•m).
11. Repeat the adjustment procedure for the other side.

Axle Housing Assembly Removal and 5. Remove a large cotter pin on a slotted axle nut on
Installation the axle hub.
Removal Procedure Axle Nut
WARNING
BEFORE beginning this service procedure, Axle Hub
Cotter Pin
Raise and securely block the loader so all
four tires are off the ground.
(For detailed instructions, refer to the Safety 6. With a wrench, remove the slotted axle nut and the
chapter of this manual.) special washer beneath it.
1. Remove the wheels and tires on the side of loader 7. Pull the axle hub off the axle assembly.
being serviced.
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.

Installation Procedure 5. Place the special washer on the axle and secure it to
1. Apply oil-resistant RTV sealant (or equivalent) the axle with the slotted axle nut. Axle nut torque
between the axle housing and the chassis. 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).
2. Align the holes in the axle housing with the studs

in the chassis and push the axle housing into place.
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 oil-
resistant 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).

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
Removal Procedure housing sprocket to drop inside the chaincase.
WARNING
1. Remove the wheels and tires on the side of the 6. Slip the drive chain off the axle housing sprocket.
loader being serviced. Then, slip the drive chain off the drive motor-
sprocket.
2. Drain the oil from the chaincase. See the procedure
in the Lubrication chapter.
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-resis-
tant RTV sealant (or equivalent) between the cov-
ers 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).

Axle and Wheel Bearing Disassembly and 2. Install the double-lip axle seal in the axle housing.
Assembly Use suitable drivers or a press to countersink all
components until they bottom out.
Disassembly Procedure
Axle Seal
1. Remove the axle housing assembly per the proce-
dure in this chapter.
2. Remove the outer bearing cone from the axle shaft.
3. Remove the axle shaft from the chassis per the pro-
cedure 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.
3. Turn the axle housing over and press an additional

Assembly Procedure bearing cup into the other side of the axle housing
NOTE: Pack the tapered bearing cones with synthetic with a force of 6000 lbf. (26,7 kN) using a bearing
grease before assembling. 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

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

CHAPTER NOTES

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
T-Bar Controls
controls on Gehl 1640E and Mustang 2012 model skid-
steer loaders. On skid-steer loaders with “T-Bar Controls,” the left T-
Bar operates the drive wheels and pumps for both sides
Equipment Identification
of the skid-steer loader. The right T-Bar controls the lift
Because there are a variety of options available for Gehl and tilt functions of the lift arm and bucket. Engine
1640E and Mustang 2012 models, it is necessary to speed is controlled by the hand and/or foot throttles.
properly identify the controls before beginning the Standard-flow auxiliary hydraulics is controlled by a
service procedures. Illustrations and photographs are foot pedal.
Control Locations - T-Bar
4
5
2
1
1 - Drive Control 3 - Horn Button Switch (EU Models) 5 - Foot Throttle

2 - Lift/Tilt Control 4 - Auxiliary Hydraulics 6 - Hand Throttle Handle

CONTROLS GEHL 1640E / MUSTANG 2012
Wheel Drive, Foot Throttle and Lift Tilt Components - Illustration - Later Models
Right
51
48
23 75
67 55 56
45
66
73 34
34 48
71
57
46 75 70
35 28 25
64
73
69
61 1 67
5
28
10 39
5 9
11
12 61 9
69 53
36 10 11
29
6 70 43
1
70 26
64
16 70 30
41
14 TO FOOT THROTTLE
2 42 IN ENGINE GROUP
66
62 60
70
26 58 47
13
4 30
29 26
40
7
63 59
18
70
3
44
65
68
74
27 73
Left
52
20
24
72 22
54
15 53
21
17 34
8 19
19 8
66
49
24
64
19 35
32
33
17 15 1
68 65
38 17 69
74
B
20 61
72 19
24 5
24 17
73 28
10
A A 72
31
27 11
11
37 B
10 61
54
72
21 17
36
5 37
1
69
17
21
72
64
50
65
15
24

Wheel Drive, Foot Throttle and Lift Tilt Components - Parts Listing - Later Models
1 BEARING/FLANGE MOUNT 39 KICKPLATE

2 SCREW/SHOULDER 40 MOUNT/CONTROL
3 BUSHING/SUPER OILITE 41 FLOOR
4 BUSHING/OILITE 42 PEDAL/THROTTLE
5 BUSHING/OILITE FLANGED 43 COVER/STEP
6 JOINT/BALL 44 PEDAL/AUXILIARY
7 ASSEMBLY/ BALL JOINT 45 ROD/CONTROL/LIFT
8 WASHER/FLAT 46 ROD/CONTROL/LIFT
9 NUT/HEX LOCKING 47 CABLE
10 NUT/LOCK 48 YOKE/CLEVIS
11 NUT/LOCK 49 ARM/ASSEMBLY
12 NUT/LOCK 50 ASSEMBLY/PIVOT
13 NUT/LOCK 51 LINKAGE SLEEVE/ CONTROL VALVE
14 SPACER 52 ARM/ASSEMBLY
15 PIN/ROLL 53 PIVOT/CONTROL
16 END/ROD 54 ARM/PUMP
17 END/ROD 55 BONNET/AUXILIARY SWITCH
18 NUT/LOCK NYLON INSERT 56 CABLE END VALVE
19 BEARING 57 PIN
20 ROD END/ELASTOMERIC 58 CABLE/LIFT
21 NUT/SPIRALOCK 59 SCREW/CAP WHIZLOCK
22 HANDLE ASSEMBLY/LEFT GRIP 60 SPRING
23 HANDLE ASSEMBLY/RIGHT GRIP 61 BUSHING
24 NUT/HEX TOP LOCK 62 SCREW/CAP
25 SWITCH/DX 63 SCREW/CAP
26 YOKE/CLEVIS 64 SCREW/CAP
27 RETAINER/PUMP ARM 65 SCREW/CAP
28 HN LF CLOC 66 BOLT/CARRIAGE
29 PIN/CLEVIS 67 BOLT/CARRIAGE
30 PIN/CLIP/ RUE 68 SCREW/CAP
31 PIVOT 69 BOLT/CARRIAGE
32 SHAFT/PIVOT 70 SCREW/ CAP HEX HEAD TAPPING
33 ASSEMBLY/PIVOT TUBE 71 SCREW/CAP SOCKET HEAD
34 PLATE/CROSS/CONTROLS 72 NUT/JAM HEX
35 BRACKET/CONTROL ARM 73 NUT/JAM HEX
36 STOP/T-BAR 74 WASHER/LOCK
37 ROD 75 NUT/HEX
38 ROD

Wheel Drive, Foot Throttle and Lift Tilt Components - Illustration - Earlier Models
Right
54
50
23 74
67
47
66
72 33
33 50
48 74 70
34 27
64
72
69
60 1 67
5
27
10 38
5 9
11
12 60 9
69 56
35 10 11
28
6 70 42
1
70 25
64
16 70 29
40
14 TO FOOT THROTTLE
2 IN ENGINE GROUP
41
66
62 59
70
25 46 49
13
4 29
28 25
61
39 45
7
63 58
18
70 52
44
3
43
68
65
Left
73
26 72
55
20
24
71 22
57
15 56
21
17 33
8 19
19 8
66
51
24
64
19 34
31
32
17 15 1
68 65
37 17 69
73
B
20 60
71 19
24 5
24 17
72 27
10
A A 71
30
26 11
11
36 B
10 60
57
71
21 17
35
5 36
1
69
17
21
71
64
53
65
15
24

Wheel Drive, Foot Throttle and Lift Tilt Components - Parts Listing - Earlier Models
1 BEARING/FLANGE MOUNT 38 KICKPLATE

2 SCREW/SHOULDER 39 MOUNT/CONTROL
3 BUSHING/SUPER OILITE 40 FLOOR
4 BUSHING/OILITE 41 PEDAL/THROTTLE
5 BUSHING/OILITE FLANGED 42 COVER/STEP
6 JOINT/BALL 43 PEDAL/AUXILIARY
7 JOINT/BALL 44 MOUNT/SOLENOID
8 WASHER/FLAT 45 LINKAGE/AUXILIARY
9 NUT/SERRATED LOCK 46 CABLE/AUXILIARY CONTROL
10 NUT/HEX LOCK 47 ROD CONTROL /LIFT
11 NUT/HEX LOCK 48 ROD CONTROL/LIFT
12 NUT/HEX LOCK 49 CABLE/FOOT THROTTLE
13 NUT/HEX LOCK 50 YOKE/CLEVIS
14 SPACER 51 ARM/ASSEMBLY
15 PIN/ROLL 52 SWITCH/NEUTRAL CENTERING
16 ROD END/FEMALE 53 PIVOT ASSEMBLY
17 ROD END/FEMALE 54 LINKAGE SLEEVE/CONTROL VALVE
18 NUT/HEX LOCK 55 ARM/ASSEMBLY
19 BEARING/BRONZE 56 PIVOT/CONTROL
20 ROD END/ELASTOMERIC 57 ARM/PUMP
21 NUT/SPIRALOCK™ 58 SCREW/CAP WHIZLOCK
22 STEERING ARM/LEFT 59 SPRING
23 STEERING ARM/RIGHT 60 BUSHING
24 NUT/HEX TOP LOCK 61 SCREW/TAPPING
25 YOKE/CLEVIS 62 SCREW/CAP
26 RETAINER/PUMP ARM 63 SCREW/CAP
27 NUT/CENTERLOCK 64 SCREW/CAP
28 PIN/CLEVIS 65 SCREW/CAP
29 PIN/CLIP RUE 66 BOLT/CARRIAGE
30 PIVOT 67 BOLT/CARRIAGE
31 SHAFT/PIVOT 68 SCREW/CAP
32 TUBE/PIVOT TUBE 69 BOLT/CARRIAGE
33 PLATE/CROSSMEMBER CONTROLS 70 SCREW/TAPPING
34 BRACKET/CONTROL ARM 71 NUT/HEX JAM
35 STOP/T-BAR 72 NUT/HEX JAM
36 ROD 73 WASHER/LOCK
37 ROD 74 NUT/HEX

Control Handle Removal and Installation

IMPORTANT
Note the wire terminal connections in the elec-
trical connector for reassembling the control
WARNING handle if replacing the handle’s electrical
cable.
perform the following SAFETY procedures: 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.
device.
Removal Procedure
1. Remove the control cover per the procedure in the
Mainframe chapter. Left
2. Disconnect the electrical connector in the left con-

trol handle from the wiring harness (if so
equipped).
Horn Button Wiring in Control Handle
Left
Horn Button Connection Location

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 han- 2. Right control handle vertical orientation: Change
dle assembly to the chassis crossmember. Remove the lift control rod length attached to the bottom of
the handle assembly. the pivot assembly.
Installation Procedure: Follow all warnings first, Right
then reverse the removal steps (see NOTE below).
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. 3. Right control handle orientation: Change the tilt
Adjustment Procedure 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 adjust-
ment allows for the full actuation of the control
WARNING valve in both directions of handle operation.
Tilt Control Rod

device.
1. Left control handle: Adjust the two control rod

lengths connected at the pivot assembly, so the

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.

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 10
11
2
3
5
6
1
7
4
4
1 CLAMP/INSULATED HOSE 7 TRIGGER/BACKUP ALARM
2 NUT/LOCK 8 SWITCH/MOUNT/BACKUP ALARM
3 NUT/LOCK 9 SCREW/CAP
4 NUT/LOCK 10 BOLT/CARRIAGE
5 SWITCH/BACKUP ALARM 11 BOLT/CARRIAGE
6 ALARM/BACKUP

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
device.
4. Remove the four lock nuts and carriage bolts secur-
Shut off the engine. ing the control pivot to the crossmember.
1. Remove the floor cover/step cover/kickplate per

the procedure in the Mainframe chapter.
2. At the left control handle pivot assembly, discon-
nect 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 work-
bench to replace parts as needed. Refer to the
exploded views for the correct positioning of the
pivot tube parts.
Installation Procedure: Follow all warnings first,

NOTE: If the skid-steer loader is equipped with a then reverse the removal steps.
backup alarm, remove the two carriage bolts and
locknuts securing the alarm switch bracket mount to the 1. Attach all the control rods and centering devices to
pivot tube. Set them aside. the appropriate levers on the pivot tube assembly.
NOTE: It’s recommended that good notes be taken to 2. Install the floor cover/step cover/kickplate per the
procedure in the Mainframe chapter.
aid in reassembly. If necessary, mark the holes on the
levers.

Pump Control Arm Assembly Removal and 3. Slide the control arm assembly off the hydrostatic
Installation 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
WARNING is made to fit the rod end in the control arm assembly,
no adjustment should be necessary.
Raise lift arm; engage lift arm support Lift/Tilt Controls Removal and Installation
device.
(For detailed instructions, refer to the Safety WARNING
1. Remove the locknut and capscrew on each elasto- perform the following SAFETY procedures:
meric rod end attached to the two pump control Raise lift arm; engage lift arm support
arm assemblies. device.
Pump Control Arms
Removal Procedure
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.

3. Disconnect the electrical connector in the left con-

trol handle at the end of the wire (if so equipped).
Locknuts
6. Pull the left and right control handle assemblies

4. Disconnect the two drive control rods on the left forward and out of the chassis.
control handle pivot at the pivot tube arm assem- Installation Procedure: Follow all warnings first,
blies. then reverse the removal steps.
Lift/Tilt Control Adjustment
WARNING
device.
5. Remove the two carriage bolts and locknuts secur- Shut off the engine.
ing each control arm bracket to the front of the
crossmember.
The lift and tilt control rod lengths can be adjusted to
obtain proper position of the T-Bar. Refer to “Control
Carriage Bolts 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.

Auxiliary Hydraulics Cable Removal and 2. Loosen the large jam nut on the auxiliary control
Installation cable.
Refer to the exploded views as a reference in

identifying the parts and components.
With Spool Electric Lock
Removal Procedure
WARNING
device.
(For detailed instructions, refer to the Safety With Pedal Electric Lock
1. At the main control valve, disconnect the electrical

connector (if so equipped) on the auxiliary hydrau-
lics spool.
3. Unscrew the cable end from the bonnet.

4. Remove the two (spool lock) or four (pedal lock) 6. Disconnect the ball joint and hex nut on the auxil-
socket-head capscrews securing the bonnet to the iary cable from the auxiliary pedal assembly.
main control valve.
With Pedal 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.
Whisker Switch
5. Remove the pin securing the auxiliary cable to the

control valve, and remove the cable. 8. Remove the cable. If replacing the cable, remove
the ball joints, hex nuts and jam nuts from the old
With Spool Electric Lock cable.
* For cable adjustment, refer to the “Auxiliary
Hydraulics Cable Adjustment” procedure in this
chapter.

Auxiliary Hydraulics Cable Adjustment 5. Disconnect the ball joint on the cable from the aux-
iliary pedal assembly by removing the hex nut.
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
device.
6. Loosen the jam nut on the ball joint.
7. Twist the ball joint in to tighten or out to loosen the
(For detailed instructions, refer to the Safety auxiliary hydraulics cable (most adjustments will
chapter of this manual.) require a tightening of the cable.)
1. Sit in the seat, pull the restraint bar down and turn 8. Reinstall the ball joint and hex nut and secure it to
the key to the “ON” or “ACCESSORY” position the auxiliary hydraulics pedal assembly.
(DO NOT START ENGINE) to release the electri- 9. Retighten the jam nut snug against the ball joint to
cal detent on the auxiliary hydraulics valve spool set the adjustment.
(if so equipped).
10. Check operation of auxiliary hydraulics cable by
2. Remove the floor cover/step cover/kickplate per 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.

Engine and Hand Throttle Components
51
28
34
32 46
56
39 55
36
43
47 8
29 37
56 1
29
22
12 59
26 57
52 38
42
54 45
32 15 41
27
33
45 35
4
40 45 44
2
14
49
16 40
45
54 6
58 23
1
43
39
31
1 BUSHING/OILITE FLANGED 36 CABLE/THROTTLE

2 JOINT/BALL 37 PLATE/FLEXIBLE DRIVE
4 NUT/HEX LOCK 38 SCREW/CAP
5 NUT/HEX LOCK 39 WASHER/FLAT
6 NUT/HEX LOCK 40 WASHER/PLATED
8 SCREW/CAP WHIZLOCK 41 WASHER/FLAT
12 NUT/SPIRALOCK 42 MOUNT/ENGINE
14 ISOLATOR 43 BUSHING
15 SCREW/SHOULDER 44 SCREW/CAP
16 PLATE/PUMP MOUNT 45 NUT/HEX
22 PIVOT/THROTTLE HAND 46 SCREW/CAP
23 PIVOT/THROTTLE FOOT 47 SCREW/CAP
26 BRACE/ENGINE TOP 49 BOLT/CARRIAGE
27 ROD/THROTTLE 51 WASHER/FLAT
28 ENGINE/YANMAR 3TNV82A 52 WASHER/FLAT
29 YOKE/CLEVIS 54 WASHER/LOCK
31 NUT/CENTERLOCK 55 WASHER/LOCK
32 PIN/CLEVIS 56 PIN/COTTER
33 MOUNT/ENGINE 57 SCREW/CAP
34 BRACKET/ENGINE MOUNT/FRONT 58 SCREW/CAP
35 LINKAGE/THROTTLE 59 SCREW/CAP

Hand Throttle, Foot Throttle Pedal and 3. Loosen the large jam nut on the throttle cable
Throttle Cables/Throttle Rod Removal and bracket tab and slide out the foot throttle cable.
Installation
Removal Procedure
WARNING
chapter of this manual.) 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
Long Capscrew
yoke from the throttle cable.
5. Remove the clevis pin and cotter pin securing the

hand throttle cable yoke to the hand throttle.
Cable Yoke

6. Remove three Belleville washers, one carriage 9. Remove both the foot and hand throttle cables from
bolt, friction washer and locknut on the hand throt- the skid-steer loader. If replacing one or both
tle securing it to the chassis. Remove the hand cables, remove the clevis yokes, hex nuts and jam
throttle (if needed) at this time. 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 11. At the engine’s throttle linkage, disconnect the
respective pivots. 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.
* Perform “Throttle Adjustment” procedure in this
chapter after the installation is complete.
Hand Throttle Nut

Hand Throttle Tension Adjustment Foot Throttle Adjustment

Hand throttle tension should be tight enough to A foot throttle is used to control the engine RPM to
maintain any desired engine RPM, but loose enough to match increased power requirements. The foot throttle
allow easy operation. The hand throttle tension can be is coupled to the hand throttle through a throttle pivot
INCREASED or DECREASED. assembly. The foot throttle is properly adjusted when
Adjustment Procedure pushing the hand throttle FULLY FORWARD causes
the foot pedal to be pressed flush against the floor plate.
WARNING
WARNING
Raise lift arm; engage lift arm support BEFORE beginning this service procedure,
device. perform the following SAFETY procedures:
Shut off the engine. Raise lift arm; engage lift arm support
device.
chapter of this manual.) Tilt back ROPS/FOPS until lock engages.
NOTE: The three Belleville-type washers must be chapter of this manual.)
installed properly to provide tension against the hand
1. With the hand throttle pulled back to an IDLE posi-
throttle.
tion, remove the clevis pin and cotter pin to discon-
nect the throttle yoke from the foot pedal.
Belleville Washers
1. To INCREASE TENSION tighten locknut secur-

ing hand throttle pivot assembly to chassis.
2. Push down on the foot pedal until it is flush with
2. To DECREASE TENSION loosen locknut secur- the floor plate.
ing hand throttle pivot assembly to chassis.
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.

CHAPTER NOTES

GEHL 1640E / MUSTANG 2012 HYDROSTATIC SYSTEM
Introduction of the loader through a chain-and-sprocket system. The

pumps and motors are controlled individually, allowing
This chapter covers troubleshooting, testing, removal, complete flexibility in forward, reverse, gradual, pivot
installation, and adjustment procedures for the tandem and spin turns.
pump system on Gehl 1640E and Mustang 2012 model For detailed information on pump and motor internal
skid-steer loaders. repairs, consult the Gehl-Mustang Service Department
A hydrostatic pump assembly coupled to the engine or the component manufacturer’s service manual.
provides power to two fixed-displacement hydrostatic Related hydraulic components are covered in the
drive motors. The motors drive the wheels on each side Hydraulic System chapter of this manual.
Hydrostatic Components - Standard Drive Motor
1 TUBE/BRAKE RELEASE
Hydrostatic Components - Drive Motor with Brake Release Valve
8
1 CLAMP/HOSE
USE EXISTING HARDWARE TO INSTALL 2 NUT/LOCK
10
7 3 FITTING/90º
3
4 HOSE/PRESSURE
5 HOSE/PRESSURE
6 6 TUBE/HANDLE
2
3
7 VALVE/BRAKE RELEASE
9
8 BRACKET/PUMP
4
9 DECAL
10 SCREW/CAP
1
USE EXISTING 5
HARDWARE TO INSTALL
DECAL VIEW
1
LEFT INSIDE TOWER

HYDROSTATIC SYSTEM GEHL 1640E / MUSTANG 2012
Hydrostatic Components
40
33
3 37
43
6
21 7
5
13 14 38 20 34
12 16 35 36 19
30
3 44
30 15
9 39
23 22
8
32 28
23 8
29
17
29 2 27
31
1 8
49
25 8 26
4
18
1
42
11
DRIVE MOTOR AND FITTING ORENTATION REFERENCE.
8 10 8 8
8
19
41 35
4
19
44
34
8 49
1
1
8
46 47 2
24
49 45
48
17
LEFT DRIVE MOTOR, RIGHT SIDE OF PUMP
RIGHT DRIVE MOTOR, LEFT SIDE OF PUMP

4
1 49 1
1 FITTING/STRAIGHT 11 WASHER/FLAT 21 NUT/LOCK 31 TUBE/BRAKE 41 SCREW/CAP

2 FITTING/TEE 12 VALVE/SOLENOID 22 TUBE/DRAIN 32 TUBE/BRAKE 42 SCREW/CAP
3 FITTING/90º 13 PLATE/SPACER 23 TUBE/DRAIN 33 TUBE/TANK 43 BOLT/CARRIAGE
4 FITTING/90º 14 MANIFOLD/HYD. 24 PLATE/PUMP 34 PUMP/FRONT 44 WASHER/FLAT
5 CAP/37º FLARE 15 CLAMP/DUAL 25 HOSE/PRESSURE 35 CROSS/TEE 45 SCREW/CAP
6 CLAMP/TWIN TUBE 16 PLATE/CLAMP 26 HOSE/PRESSURE 36 TUBE/JUMP 46 SCREW/CAP
7 FITTING/STRAIGHT 17 FITTING/90º 27 HOSE/PRESSURE 37 PLATE/TWIN 47 WASHER/FLAT
8 FITTING/90º 18 MOTOR/MS02 28 HOSE/PRESSURE 38 SCREW/CAP 48 WASHER/FLAT
9 SWITCH/TEMP. 19 PUMP/REAR 29 HOSE/PRESSURE 39 SCREW/CAP 49 FITTING/45º
10 O-RING 20 NUT/LOCK 30 TUBE/DRAIN 40 SCREW/CAP

Charge Pressure Test and Adjustment

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

perform the following SAFETY procedures: 3. Install the pressure gauge on the charge pressure
Shut off the engine. test port.
Tilt back ROPS/FOPS until lock engages. 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
Test Procedure or higher than specified, refer to the manufacturer’s
1. Remove the step cover to access the test port. service manual for the hydrostatic pump, and the
charge pressure adjustment procedure that follows.
2. Remove the metal cap from the test port located
over the double gear pump. 6. When finished, reinstall the metal cap to the test
port.
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

Hydrostatic Pump Relief Valves Hydrostatic Pump Removal / Installation

Each hydrostatic pump is equipped with two high-
pressure 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
WARNING
assembly control the front hydrostatic pump, which BEFORE beginning this service procedure,
drives the left side of the skid loader. The two rear relief perform the following SAFETY procedures:
valves on the hydrostatic pump assembly control the Raise lift arm; engage lift arm support
rear hydrostatic pump, which drives the right side of the device.
skid-steer loader. Refer to the manufacturer’s manual Shut off the engine.
for service procedures.
Relief Valve Location
chapter of this service manual.)
Removal Procedure
1. Drain the oil from the hydraulic reservoir per the
procedure in the Lubrication chapter.
3. Remove the crossmember per the procedure in the
Mainframe chapter.
4. Disconnect two hydraulic pressure hoses at the
gear pump.
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.

5. Label and disconnect all the hydraulic hoses con- 6. Position a hoist above the hydrostatic pump.
nected to 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 hydro-

static pump to the flywheel housing and two cap-
screws securing the pump support plate to the
flywheel housing.

8. Shift the hydrostatic pump forward to disengage 2. Remove the six capscrews securing the flywheel
the splined shaft drive of the pump. housing to the engine.
Splined Shaft Drive
9. Lift and maneuver the hydrostatic pump out of the 3. Remove the eight capscrews attaching the flexible
skid-steer loader. coupling plate to the engine.
Hydrostatic Pump Drive Coupling Removal

and Installation
Removal Procedure
WARNING
Raise lift arm, engage lift arm support Installation Procedure - Follow all warnings first,
device. then reverse the removal steps.*
Shut off the engine. * Regrease the tooth spline of the flexible drive
coupling plate before reinstalling the hydrostatic pump.
1. Remove the hydrostatic pump per the procedure in

this chapter.

Drive Motor Removal and Installation 5. Disconnect all hydraulic hoses and tubes on each
drive motor.
WARNING
device.
Removal Procedure
1. Underneath the skid-steer loader, remove four cap-
screws 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).


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

Troubleshooting Guide
The troubleshooting guide lists potential hydrostatic When a problem occurs, don’t overlook simple causes.
system problems, as well as possible causes and A malfunction could be caused by something as simple
remedies. as low fluid level in the hydraulic reservoir. After a
If you cannot locate a particular hydrostatic system mechanical failure has been corrected, be sure to locate
problem in this chart, consult the troubleshooting chart the cause of the problem.
in the Hydraulic System chapter.
Problem Possible Cause Remedy

No response from the hydrostatic drive Hydraulic oil viscosity too high Allow longer warm-up or replace oil
or the lift/tilt systems 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 Check for broken or worn pump drive
Drive coupling failure. coupling and replace, as needed.
Traction drive will not operate in either Parking brake engaged. Disengage parking brake.
direction
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 mecha-
nisms. Reconnect linkage.
Low or no charge pressure See hydrostatic pump manual.
Hydrostatic pump relief valves malfunc- Inspect and clean the relief valves.
tioning Replace them as needed.
Drive wheels do not turn in proper High pressure hydraulic hoses Reconnect hoses to proper ports on
direction for T-Bar movement between hydrostatic pump and drive the drive motors. Refer to schematic
motors connected incorrectly 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 malfunc- Check switches.

tion


Neutral difficult to maintain Rod ends loose on centering mecha- Check and tighten or replace compo-
nism or servo rod nents.
Neutral centering mechanism(s) out of Adjust neutral centering mechanism(s).

adjustment See Controls chapter for procedure.
Clamping bolt loose Tighten clamp bolt.
Hydrostatic pump out of adjustment See hydrostatic pump manual.
Sluggish acceleration Air in the hydraulic system Cycle the lift and tilt cylinders to maxi-
mum 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 pres- See hydrostatic pump manual.

sure
Drive motor(s) or hydrostatic pump(s) Refer to component manufacturer’s

have internal damage or leakage service manual.
Engine not responding under load Troubleshoot engine.
Automatic parking brake partially Units with brake release valve, cycle
engaged the valve to release the parking brake
pressure. Other units without brake
release valve, contact your dealer.
Hydrostatic drive overheating Drive system overloaded continuously Improve efficiency of operation.
Lift and tilt system overloaded continu- Improve efficiency of operation.

ously

Oil cooler plugged with debris Clean oil cooler fins.
Loader being operated in a high tem- Reduce duty cycle and improve air cir-
perature area with no air circulation culation.


Hydrostatic (drive) system noisy Hydraulic oil viscosity too high Allow longer warm-up or replace oil
with the proper viscosity oil.

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.
Right side doesn’t drive in either direc- Excessive internal leakage in right Repair or replace as needed. Refer to
tion. Left side operates normally drive motor motor manufacturer’s service manual.
Excessive leakage in engine-end Refer to the pump manufacturer’s man-

hydrostatic pump ual for service procedures. Repair or
replace rear pump as needed.
Servo controller malfunctioning Refer to the pump manufacturer’s man-

ual for service procedures. Repair or
Relief valves on engine-end hydrostatic Switch valves with those on front

pump malfunctioning 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 Reattach control rod linkage.

hydrostatic servo is disconnected
Right side doesn’t drive in one direction Relief valve on engine-end hydrostatic Switch one relief valve with the other
pump malfunctioning relief valve on rear pump; problem
should switch to reverse direction.
Clean or replace the faulty valve as
needed.
Engine-end hydrostatic pump malfunc- Refer to pump manufacturer’s manual

tioning for service procedures. Repair or
Servo controller malfunctioning Refer to pump manufacturer’s manual

for service procedures. Repair or


Left side doesn’t drive in either direc- Excessive internal leakage in left drive Repair or replace as needed. Refer to
tion. Right side operates normally motor motor manufacturer’s service manual.
Excessive leakage in gear-end hydro- Refer to pump manufacturer’s manual

static pump for service procedures. Repair or
replace the front pump as needed.
Relief valves on gear-end hydrostatic Switch valves with those on rear hydro-
pump malfunctioning static pump. See “Hydrostatic Pump
Relief Valves” information in this chap-
ter; problem should switch to the right
side. Replace defective relief valve as
needed.
Servo controller malfunctioning Refer to the pump manufacturer’s man-

ual for service procedures. Repair or
Control rod linkage to gear-end hydro- Reattach control rod linkage.

static servo disconnected
Left side doesn’t drive in one direction Relief valve on gear-end hydrostatic Switch relief valve with other relief
pump malfunctioning valve on front pump; problem should
switch to the reverse direction. Clean
or replace the faulty valve as needed.
Gear-end hydrostatic pump malfunc- Refer to pump manufacturer’s manual

tioning 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.

THIS PAGE INTENTIONALLY LEFT BLANK

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
PORT A OPTIONAL BRAKE RELEASE

B
LIFT
SAUER DANFOSS LPV
1.53
L1 L2 A
B
AUX
3046 3046 A
PORT B T
PORT A
L R R L
15.6
15.6
CID
CID

Hydrostatic/Hydraulic Schematic
1750 PSI
STANDARD FLOW
NON SELF LEVEL
B
TILT
TILT
B
LIFT
LIFT
B
AUX
A A
B EATON SELF-LEVEL VALVE W/ RELIEF UNLOAD SPOOL)
T C D
TILT
LIFT
OPTIONAL SELF LEVEL

CHAPTER NOTES

GEHL 1640E / MUSTANG 2012 HYDRAULIC SYSTEM
Introduction Information on recommended hydraulic fluids,

capacities and filter change intervals is in the
This chapter covers troubleshooting, testing, removal, Lubrication chapter. For detailed information on gear
installation and adjustment procedures for hydraulic pump or control valve internal repair, consult the Gehl-
system components on Gehl 1640E and Mustang 2012 Mustang Service Department and/or the hydraulic
model skid-steer loaders. Primary hydraulic system component manufacturer’s service manual. Hydraulic
components in this chapter are shown below and on components related to the drive system are covered in
following pages. the Hydrostatic System chapter.
Power for the lift arm functions and auxiliary hydraulics When a problem occurs, don’t overlook simple causes.
is provided by a gear pump attached to the front of the A malfunction could be caused by something as simple
tandem pumps. as low fluid level in the hydraulic reservoir. After a
mechanical failure has been corrected, be sure to locate
Models include a standard-flow auxiliary hydraulics the cause of the problem.
system with two hydraulic couplers on the left lift arm
for attachment hookup.
Hydraulics - Non-Self Level and Self Level Valve Components
PART # L81195 REFERENCE ONLY 7
1 CLAMP/TUBE
4 2 PLATE/TWIN
3 NUT/CENTERLOCK
4 TUBE/TILT CAP
8 5 TUBE/LIFT ROD
6 TUBE/LIFT ROD
1 PART # L81195 REFERENCE ONLY 7 TUBE/TILT ROD
2 8 SCREW/CAP
Non-Self Level
3
5
6
PART # L81195 REFERENCE ONLY
10
9
1 FITTING/TEE
2 VALVE/SELF-LEVEL
12 3 NUT/CENTERLOCK
Self Level
4 SPACER
1
8 5 TUBE/SELF-LEVEL RODS
4
13 6 TUBE/SELF-LEVEL PORT A
2 7 TUBE/SELF-LEVEL PORT C
8 TUBE/SELF-LEVEL PORT D
9 TUBE/SELF-LEVEL PORT C
10 TUBE/SELF-LEVEL PORT D
11 5 11 TUBE/SELF-LEVEL PORT B
3
12 BOLT/CARRIAGE
7 13 FITTING/STRAIGHT
11
13
6

HYDRAULIC SYSTEM GEHL 1640E / MUSTANG 2012
Hydraulics - Lift Arm Components
30
30
24
21
3 5
5
18 3
18 28
31
29
26
8
28
27 34 12 34
9
15
35
15
32
9
19
15 11 35
36
32 19
5 36
10
1
5
4 20
7 20
22
4
13
1 23
6
14
1
33
16
16
17
5 17
1 FITTING/STRAIGHT 14 NUT/SPIRALOCK 27 TUBE/LEFT ROD

3 FITTING/90º 15 CYLINDER/LIFT 28 HOSE/PRESSURE
4 NUT/LOCK 16 CYLINDER/TILT 29 HOSE/PRESSURE
5 NUT/HEX LOCK 17 PIN/PIVOT 30 HOSE/PRESSURE
6 CLAMP/HOSE 18 PIN 31 TUBE/LIFT CYLINDER
7 FITTING/45º ELBOW 19 PIN 32 RING/SNAP
8 CLAMP/HOSE 20 PIN/LOWER 33 SCREW/CAP
9 CLAMP/HOSE 21 HOSE/PRESSURE 34 SCREW/CAP
10 QUICK COUPLER/MALE 22 HOSE/PRESSURE 35 SCREW/CAP
11 QUICK COUPLER/FEMALE 23 HOSE/PRESSURE 36 SCREW/CAP
12 FITTING/90º 24 HOSE/PRESSURE
13 PLUG/O-RING 26 TUBE/LEFT ROD

Hydraulics - Chassis Components
INSTALL INSIDE
TOWER WALL
1 FITTING/TEE
26 2 CLAMP/HOSE
4
3 FITTING/90º
4 FITTING/90º
16 28
16
5 FITTING/STRAIGHT
6 FITTING/STRAIGHT
24
7 FITTING/90º
51 47 8 PLATE/TWIN COVER
44
15 50
INSTALL IN
9 SCREW/CAP LOCK
TOWER WALL 51 51
4
10 CLAMP/TUBE
4 37 11 CLAMP/HOSE
3 12 NUT/HEX LOCK
43
35 33
51 13 FITTING/90º
36 32
14 O-RING
15
33 22 15 NUT/SPIRALOCK
21 16 STRAP
23
34
6 INSTALL IN 17 FITTING/90º
32 TOWER WALL
1
18 FITTING/90º
18
22 19 PORT/TEST
32
5
20 CLAMP/T-BOLT
26
15 21 CLAMP/TUBE
8
22 PLATE/TWIN
28
23 FITTING/90º
10
48
24 VALVE/CONTROL
25 GEAR PUMP/DOUBLE
26 NUT/HEX LOCK
27 FITTING/45º
28 VALVE/SOLENOID
30 29 FILTER/HYD. OIL
30 TUBE/FILTER OUT
17
42 31 HOSE/SUCTION
39 29
13 32 TUBE/MALE AUX.
33 TUBE/FEMALE AUX.
9 34 TUBE/LEFT LIFT
41 5 11 35 TUBE/RIGHT LIFT
12 20
14
36 TUBE/LIFT LOCK
13
37 TUBE/TILT LOCK
38 38 BRACKET/FILTER
39 HOSE/PRESSURE
46
19 40 40 TUBE/DRAIN
25 41 TUBE/CHARGE
7 49 42 ASSY/HYDR. FILTER
45 27 20
45 31
43 SCREW/CAP
44 SCREW/CAP
45 SCREW/CAP
46 BOLT/CARRIAGE
47 BOLT/CARRIAGE
48 BOLT/CARRIAGE
49 WASHER/FLAT
50 FITTING/90º
51 FITTING/90º

Pressure Tests, Control Valve 6. If the pressure reading is NOT between the speci-
fied 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 WARNING
lift arm couplers.
Test Procedure
WARNING Tilt back ROPS/FOPS until lock engages.

BEFORE beginning this service procedure, chapter in this manual.)
a. Standard auxiliary relief valve can be found at
Shut off the engine. the top rear of the control valve.
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).

b. With an Allen wrench, turn the adjuster screw Tilt Cylinder Test
IN to increase pressure or OUT to decrease pres-
sure. If the bucket (or attachment) drifts down with the tilt
control in the NEUTRAL position, first check the tilt
Adjuster Screw 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 WARNING
range, tighten the locknut on the control valve
adjuster screw to secure the adjustment. BEFORE beginning this service procedure,
7. If, after the adjustment, there is NO CHANGE in
the pressure reading, this indicates either a defec- Shut off the engine.
tive hydraulic gear pump or relief valve cartridge Relieve hydraulic system pressure.
(on the control valve). To determine which is the (For detailed instructions, refer to the Safety
cause, first replace the relief valve cartridge. If the chapter of this manual.)
pressure reading still does not change, the hydrau-
lic gear pump should be repaired or replaced. 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

3. Crack open (slightly loosen) the inside upper 8. Checking the left tilt cylinder: Remove the two
hydraulic hose on the right tilt cylinder. lower hydraulic hoses on the right tilt cylinder and
cap or plug the cylinder ports. Caps or plugs
Right Tilt Cylinder MUST BE able to withstand full hydraulic pres-
sure.
Right Tilt Cylinder
WARNING 9. Connect the two hoses, just removed, together with

BEFORE raising a loaded bucket, BE SURE no a straight fitting.
personnel are near the loader. Serious per- 10. Crack open (slightly loosen) the inside upper
sonal injury can result if bucket drops sud- hydraulic hose on the left tilt cylinder.
denly or its contents spill out.
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 attach-
ment) 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-lev-
eling valve is faulty and causing the bucket to drift,
perform the “Self-Leveling Valve Test” procedure
in this chapter.

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
WARNING cylinder(s). If no external leakage is evident, check the
lift cylinders for internal leakage according to the
BEFORE beginning this service procedure, following procedure.
NOTE: When checking lift arm for drifting, BE SURE
Shut off the engine. the ignition key is in the OFF position. The maximum
(For detailed instructions, refer to the Safety allowable lift cylinder drifting is 0.75" (19 mm) of
chapter in this manual.) cylinder retraction in 15 minutes.
Test Procedure
1. With the engine OFF, remove the rear belly pan on
the chassis beneath the engine and locate the valve 1. Remove the bucket or attachment from the attach-
on the right side of the engine. ment bracket.
2. Loosen the jam nut on the self-leveling valve 2. Raise the lift arm to maximum height. Then release
adjuster screw. the lift cylinder lift arm support device and slowly
lower the lift arm to engage the device.
Self-Leveling Valve Adjuster Screw
WARNING
chapter in this manual.)
3. Remove the clamp securing the hydraulic tubes to

NOTE: For step 3, BE SURE to count and record the the lift cylinder on the side being tested.
number of turns, so the adjuster screw can be returned
to its original setting after the test.
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” pro-
cedure. If the bucket no longer drifts, the self-level-
ing 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. NOTE: To prevent contamination, ALWAYS clean
around hydraulic fittings before disconnecting any
hydraulic lines.

4. Disconnect the hydraulic tube from the rod end Solenoid Valve Test - Tilt, Lift, Brake
port of the lift cylinder to be tested.
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 3. Raise the restraint bar, use the lift and tilt controls
rod end port of the cylinder and run the other end (one at a time) to see if either function will operate.
of the hose into a suitable container. Lower the
ROPS. » 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
Lift Solenoid
seals in the cylinder are defective and leaking, oil
will flow out of the rod-end port.
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 pres-
sure.
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 » If the attachment can be tilted, the tilt solenoid is
problem could be due to leaking hydraulic hose fittings malfunctioning.
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.
10. The other cylinder can be checked the same way.
11. To determine if either the control valve or the self-
leveling valve is faulty, perform the “Self-Leveling
Valve Test” procedure in this chapter.
Tilt Solenoid

4. Lower the restraint bar. BE SURE the parking Hydraulic Oil Filter Element Replacement
brake on the instrument panel is in the OFF posi-
tion. Gehl 1640E and Mustang 2012 model skid-steer loaders
have one hydraulic oil filter. The hydraulic oil filter
5. Raise the restraint bar. Use the drive controls (one element should be replaced after every 250 hours of
at a time) to see if the tires will move. operation or annually (whichever occurs first).
» If the skid loader moves forward or backward, NOTE: There is an initial 50-hour element replacement
the brake solenoid is malfunctioning. 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 Replacement Procedure

malfunctioning, test that solenoid coil as follows:
WARNING WARNING
BEFORE continuing this service procedure, perform the following SAFETY procedure:
device. Tilt back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety (For detailed instructions, refer to the Safety
chapter of this manual.) chapter in this manual.)
» Have an assistant sit in the operator’s seat, lower 1. Remove the floor cover/step cover/kickplate per
the restraint bar and turn the keyswitch to ON. the procedure in the Mainframe chapter.
DO NOT start the engine. 2. Remove the crossmember per the procedure in the
» Using a thin strip of steel (such as a pocket ruler), Mainframe chapter.
check the suspected solenoid by moving the
steel strip close to the solenoid coil.
» 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 Reas-
sembly” procedure in this chapter.

3. Place the end of a rubber hose originating from the and can cause permanent eyesight damage if
hydraulic filter bracket into a suitable container safety glasses are not worn.
(one quart pan) to catch hydraulic oil.
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.
2. With the engine running, lower the lift arm until it
4. Using a filter wrench, turn the filter element coun- is in contact (or near contact) with the lift arm stops
terclockwise to remove it from the filter head. (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. WARNING
6. Hand-tighten element until the gasket contacts the
filter head. Turn element another 3/4 turn to seat BEFORE continuing this service procedure,
the gasket. perform the following SAFETY procedures:
7. Refer to the Lubrication chapter in this manual for Shut off the engine.
the hydraulic fluid requirements and specifications. Relieve hydraulic system pressure.
WARNING 3. Disconnect the upper and lower tilt cylinder hoses
NEVER use your hands to from the cylinder ports. BE SURE to install plugs
search for hydraulic fluid leaks. in the hoses and cap the fittings to prevent fluid
Use a piece of cardboard or loss and contamination of the hydraulic system.
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 doc-
tor 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

4. While supporting the weight of the tilt cylinder, Installation Procedure

remove the capscrew and locknut securing the 1. Install the upper end of the tilt cylinder in position
lower tilt cylinder pivot pin. Then drive the pivot on the lift arm and insert the pivot pin. Use Loc-
pin out to release the lower end of the tilt cylinder. tite® 242 or equivalent on the capscrew before re-
installing 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 knee-

cap plate and remove the plates.
Kneecap Plate
3. Re-install the kneecap plates over both tilt cylin-

ders with the three thread-cutting screws.
4. Remove plugs/caps and attach the upper and lower
tilt cylinder hoses to the cylinder.
NOTE: After removing/replacing any component in
the hydraulic system, ALWAYS check the level of
hydraulic fluid in the reservoir. Add fluid if necessary.
6. Remove the capscrew and locknut securing the cyl- Refer to the Lubrication chapter in this manual for the
inder to the lift arm. hydraulic fluid requirements and specifications.
WARNING
NEVER use your hands to
search for hydraulic fluid leaks.
Use a piece of cardboard or
7. Using a punch, remove the upper tilt cylinder pins
and remove the cylinders.

NOTE: To aid in correct reassembly of the hydraulic

hoses/tubes, mark the hoses/tubes to be removed
WARNING BEFORE disassembly in step 3.
4. Disconnect the two hydraulic hoses from their two
ALWAYS wear safety glasses hydraulic tubes on the lift cylinder. BE SURE to
when checking for hydraulic install plugs/caps in the hoses/tubes to prevent
fluid leaks. Escaping fluid fluid loss and contamination of the hydraulic sys-
under pressure can be invisible tem.
and can cause permanent eye-
sight damage if safety glasses are not worn.

Lift Cylinder Removal and Installation

Removal Procedure
1. Remove the bucket or attachment.
WARNING 5. Remove the capscrew and locknut securing the

front lift cylinder pivot pin. Then drive the pivot
BEFORE continuing this service procedure, pin out to release the rod end of the lift cylinder.
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.

Lift Cylinder Components
1 TUBE 6 BEARING/BRONZE
2 PISTON 7 BEARING/BRONZE
3 GLAND/HEAD 8 NUT/LOCK
4 SPACER/ROD 9 ZERK/STRAIGHT
5 ROD 10-18 KIT/SEAL
Tilt Cylinder Components
1 TUBE 6 BEARING/BRONZE
2 PISTON 7 NUT/LOCK
3 GLAND/HEAD 8 ZERK/GREASE
4 ROD 9 FITTING/GREASE
5 PLUG/SOCKET 10-18 KIT/SEAL

2. Install the lift cylinder on the chassis so the rod end Lift/Tilt Cylinder Disassembly / Assembly
is facing forward and the hydraulic tube ports on
the cylinder are facing inward. Disassembly Procedure
3. Insert the rear and front pivot pins through the lift Remove the cylinder from the skid-steer loader. See
cylinder pivots and secure them with capscrews “Lift Cylinder Removal” or “Tilt Cylinder Removal” in
and locknuts. this chapter.
4. Remove the plugs/caps and connect the two 1. Purge the oil from the cylinder by facing the ports
hydraulic hoses to their hydraulic tubes on the lift downward and pumping the cylinder rod back and
cylinder according to the markings made at forth several times.
removal. If no markings were made or new parts 2. Use an Allen wrench to loosen the set screw on the
were installed, refer to the Hydraulic System chap- cylinder collar.
ter exploded views.
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
Use a piece of cardboard or 3. Clamp a suitable shaft in a vise and slide the cylin-
paper. Escaping fluid under der onto the shaft to prevent the cylinder tube from
pressure can be invisible and turning.
any fluid is injected into your skin, see a doc- 4. Use a chain clamp to remove the collar from the
tor at once. Injected fluid MUST be surgically cylinder tube.
WARNING

6. Remove the hoist.

5. Remove the rod assembly and inspect both the cyl- 8. Slide the head gland, seals, and o-rings off the cyl-
inder rod and the tube for dents or nicks that may inder rod and inspect them for wear.
cause damage to the o-rings and seals.
9. Change the seals as needed.

6. Loosen and remove the locknut that secures the NOTE: Soaking the seals in warm water prior to
head gland, seal kit and piston on the cylinder rod. 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.
6. Slide the collar down to the cylinder tube, thread it
Piston
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 Cylin-
der Installation” or the “Tilt Cylinder Installation”
procedures in this chapter.
Head Gland

Gear Pump Removal and Installation 5. Disconnect the hydraulic tube on the gear pump at
both ends and loosen the fittings.
Removal Procedure
WARNING
device.
(For detailed instructions, refer to the Safety 6. Support the gear pump. Remove two capscrews
chapter in this manual.) securing the gear pump to the hydrostatic pump.
The hydraulic oil filter bracket can rest on the
1. Drain the oil from the hydraulic reservoir per the hydrostatic pump.
procedure in the Lubrication chapter.
7. Pull the gear pump forward and out of the hydro-
2. Remove the control cover and the floor cover per static pump. BE CAREFUL not to lose the o-ring.
Installation Procedure
3. Remove the crossmember per the procedure in the
1. Install the o-ring on the mating surface of the gear
Mainframe chapter.
pump.
4. Disconnect two hydraulic pressure hoses at the
2. Attach the gear pump to the hydrostatic pump (BE
gear pump.
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/con-
trol cover per the procedures in the Mainframe
chapter.
5. Reinstall the hydraulic reservoir drain plug.
6. Replace the hydraulic oil drained out of the reser-
voir in step 1.
Note: Mark the hoses, tubes and fittings for component in the hydraulic system, ALWAYS check
reassembly, and cap or plug them after they are the level of the hydraulic fluid in the reservoir. Add
disconnected to prevent contaminants from entering the fluid if necessary. Refer to the Lubrication chapter for
hydraulic system. the hydraulic fluid requirements and specifications.

NOTE: In order to remove the hydraulic tubes from

their fittings on the self-leveling valve, it may be
WARNING necessary to loosen the hydraulic tube at the other end
to give it some free-play.
NEVER use your hands to 1. With the engine OFF, remove the rear belly pan on
search for hydraulic fluid leaks. the chassis beneath the engine and locate the self-
Use a piece of cardboard or leveling valve right of the engine.
2. Disconnect all the hydraulic tubes and hoses from
their hydraulic fittings on the self-leveling valve.
WARNING
sight damage if safety glasses are not worn. 3. Remove the two capscrews, spacers and locknuts
securing the self-leveling valve to the chassis.
Self-Leveling Valve Removal and

Installation
Removal Procedure
WARNING
perform the following SAFETY procedures: 4. Remove the self-leveling valve.
Raise lift arm; engage lift arm support NOTE: After removing and/or replacing any
device. component in the hydraulic system, ALWAYS check
Shut off the engine. 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.
NOTE: Cap or plug the hydraulic hoses and fittings ALWAYS check for hydraulic fluid leaks after
after disconnecting them to prevent fluid loss and reassembling components of the hydraulic system.
contamination of the hydraulic system.

be adjusted according to steps 5 - 9 of this proce-

dure.
WARNING
WARNING
fluid leaks. Escaping fluid WARNING
and can cause permanent eye- BEFORE continuing this service procedure,
sight damage if safety glasses are not worn. perform the following SAFETY procedures:
device.
Self-Leveling Valve Adjustment Shut off the engine.
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). WARNING
3. Raise the lift arm to its maximum height; then
Surfaces inside the engine
lower it to the ground.
compartment may be extremely
4. Measure how far the tilt cylinder rod extends from hot, particularly the engine muf-
the tilt cylinder. The distance should be between fler and exhaust pipes. Serious
11-1/2 and 11-3/4” (292-298 mm). If measurement injury may occur from touching
is outside this range, the self-leveling valve should 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.

7. Loosen the jam nut on the self-leveling valve Safety Lock Valves - Removal/Installation
adjuster screw.
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
WARNING
extension. Turn the screw OUT (counterclockwise) BEFORE beginning this service procedure,
to lengthen the cylinder extension. perform the following SAFETY procedures:
device.
1. Disconnect the electrical connector on the solenoid

coil. Disconnect the hydraulic tubes from their fit-
tings on the solenoid body. Remove the two car-
riage bolts, straps and locknuts securing the
solenoid to the chassis.
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.
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 proce-
dures 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.

NOTE: Cap or plug ALL hydraulic hoses, tubes, 3. Unscrew cartridge from the valve body.
fittings, and control valve ports immediately after they
are disconnected to prevent fluid loss and
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 - Dis-

assembly and Assembly
4. Install seal kit (or other new parts). Assemble sole-
Lift, tilt and brake solenoid valves can be removed from noid valve in reverse order of disassembly.
the loader for parts replacement, but it may not be
necessary. If it is necessary, refer to the procedure in O-Ring O-Ring O-Ring
this chapter.
1. Remove the nut that secures the coil to the car-
tridge.
Backup Rings
IMPORTANT
DO NOT torque coil retaining nut more than 45
in.-lbs. (5.1 N•m).
5. If removed from the loader, install the lift, tilt or

2. Remove the coil from the cartridge. brake solenoid on the hydraulic system. Refer to
the applicable procedure in this chapter.

Control Valve Removal and Installation 3. Disconnect the electrical connector on the neutral-
centering spool lock at the rear and bottom of the
The main hydraulic control valve is located on the right control valve from the main chassis electrical har-
side of the chassis, in front of the engine. This ness.
procedure highlights steps for removing the hydraulic
hoses/tubes that connect to the control valve in order to Neutral-Centering Lock
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.
Removal Procedure
WARNING
BEFORE beginning this service procedure, 4. If so equipped, disconnect the electrical connector
perform the following SAFETY procedures: on the auxiliary spool lock solenoid at the front of
Raise lift arm; engage lift arm support the control valve.
device.
Shut off the engine. With Spool Electric Lock

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
2. Remove control rods and/or cables that control the
lift, tilt and auxiliary hydraulics of the skid-steer 1
loader. Refer to their removal procedures in the
Controls chapter of this manual. 3
2
5
4
7
8

NOTE: To aid in re-assembly of hydraulic hoses and 14. Lift out the control valve. Removal may require
tubes, mark hoses and tubes to be removed before loosening the opposite ends of some of the discon-
disassembly. nected tubes.
NOTE: Cap or plug ALL hydraulic hoses, tubes,
fittings and control valve ports immediately after being
disconnected to prevent fluid loss and contamination of
1
the hydraulic system.
3 Installation Procedure
2 1. Secure the control valve to the chassis with four
5 capscrews and locknuts. If straight or 90° fittings
4 are not in the valve, install them at this time.
7
2. Port 8: Connect the hydraulic oil cooler tube to the
8
bottom 90° fitting on the control valve.
3. Port 7: Connect the auxiliary hydraulic tube to the
6 straight fitting on the control valve.
5. Port 1: Disconnect the hydraulic hose from the 90° 4. Port 6: Connect the auxiliary hydraulic tube to the
fitting on the control valve (other end connects to straight fitting on the control valve.
gear pump).
5. Port 5: Connect the hydraulic self-leveling valve
6. Port 2: Disconnect the hydraulic self-leveling valve tube to the 90° fitting on the control valve.
tube from the long 90° fitting on the control valve.
7. Port 3: Disconnect the hydraulic self-leveling valve tube to the long 90° fitting on the control valve.
tube from the 90° fitting on the control valve.
8. Port 4: Disconnect the hydraulic self-leveling valve tube to the 90° fitting on the control valve.
tube from the long 90° fitting on the control valve.
9. Port 5: Disconnect the hydraulic self-leveling valve tube to the long 90° fitting on the control valve.
tube from the 90° fitting on the control valve.
9. Port 1: Connect the hydraulic hose at the 90° fitting
10. Port 6: Disconnect the auxiliary hydraulic tube on the control valve (other end connects to gear
from the straight fitting on the control valve. pump).
11. Port 7: Disconnect the auxiliary hydraulic tube Main Control Valve
from the straight fitting on the 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.

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 Lubrica-
tion chapter for hydraulic oil requirements and
specifications.
reassembling any component of the hydraulic sys-
tem.
WARNING
WARNING

Main Control Valve Components

1 SD6/AC(HG3)-SAE INLET COVER 14 P(G3)/SD6 CARTRIDGE

2 SD6 SECTION 15 S06 FIXING BRACKET (SD6)
3 SD6 SECTION FLOAT 16 SD6 SPOOL O-RING
4 SD6 OUTLET 17 SD6 BRASS WASHER
5 1CS/SD6 SPOOL 18 SD6 SAE08 PLUG
6 5Y(13NZ)/SD6 SPOOL 19 SD6 SV PLUG
7 S5 SLP KIT 20 SD6 MAIN RELIEF
8 TP50 KIT 21 SD6 O-RING
9 BANKING KIT SD 6/3 22 SD6 CHECK VALVE
10 8/S5-MC KIT 23 FS O-RING
11 SD6 13NZ KIT 24 FS WASHER
12 SD6 8K KIT W/WEATHER PACK 25 FS O-RING
13 P3T/SD6 PLUG

Control Valve Disassembly and Assembly 4. Lift each section off the valve stack bolts as
needed, being sure to account for all o-rings.
The main control valve is made up of serviceable spool Retain all o-rings.
sections. These sections may be removed for service.
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.

Main Relief Valve Removal and Installation Control Valve Spool Seal Replacement
A relief valve is integrated within the control valve. It The main control valve spool seals are replaceable
activates when oil pressure inside the control valve using the following procedure.
reaches an unacceptable level, to relieve that pressure Replacement Procedure
and prevent damage to valve and the hydraulic system.
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
WARNING to be replaced).

chapter of this manual.) 4. Install the new o-ring.
1. With a wrench, loosen and remove the relief valve 5. Reposition the spool as shown (location of second
from the main control valve. o-ring to be replaced).
Stop Spool Here to Prevent O-Ring Damage
IMPORTANT
The spool MUST NOT be moved past the posi-
tion shown in step 5 or o-ring damage may
2. Check condition of o-rings and clean off debris. occur.
6. Install the second new o-ring.

7. Reposition the spool as shown (view of spool cor-
rectly repositioned).
8. Reinstall the centering hardware on the spool.

Lift/tilt controls fail to respond 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 Inspect suction hose. Clean or
blocked 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 Check splined shaft of pump closest

hydrostatic pump assembly to engine. Replace shaft if broken or
if splines are sheared.
Sheared spline or broken shaft in Remove gear pump from hydrostatic

gear pump pump and inspect the splined shaft
and coupler. Replace components
as needed.
Restraint bar switch or seat switch Check switches and wiring. Replace
not closing as needed.
Lift arm does not raise; bucket tilt Lift spool in control valve not Check hose or tube connection to
works properly actuated or leaking 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.

Hydraulic cylinder action slow for Low engine speed Operate engine at higher speeds.
lift/tilt function
Hydraulic oil viscosity too heavy Allow longer warm-up or replace

existing oil with proper viscosity oil.
Hydraulic oil leaking past cylinder Replace cylinder seals and o-rings
piston seals 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

needed.
Relief valve in control valve Check pressures in relief valve.

malfunctioning (squealing noise Repair or replace as needed.
evident while operating)
Jerky lift arm and bucket action Restraint bar switch or seat switch Check electrical connections to the
malfunction 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.
Auxiliary hydraulics function slowly 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 Repair any leak found; readjust the
leaking or not fully activated auxiliary spool for full travel.

Lift arm doesn’t maintain raised Oil leaking past lift cylinder seals Check cylinder tube bore condition.
position with lift control in (internal or external) Replace seals or cylinder tube as
NEUTRAL needed.
Oil leaking past lift spool in control Check valve body for scores or
valve cracks. Replace control valve as
needed.
Self-leveling valve malfunctioning Repair or replace as needed.
Leaking hydraulic hoses, tubes or Inspect hoses and tubes; tighten

fittings between control valve and fittings as needed. Replace hoses or
cylinders tubes as needed.
Lift arm will not lower or raise Lift cylinder lift arm support device Raise lift arm and disengage the lift
engaged arm support device.
Solenoid valve malfunctioning Check electrical connections to

needed.
Restraint bar not lowered Lower restraint bar.
Restraint bar switch or seat switch Check electrical connections to the

malfunction switch. Replace switches as needed.
Blown fuse or relay Replace fuse or relay.
Bucket drifts downward with tilt Oil leaking past tilt cylinder seals Check cylinder tube bore condition.
control in NEUTRAL (external or internal) Replace seals, o-rings or cylinder as
needed.
Self-leveling valve malfunctioning Repair or replace as needed.
Leaking hydraulic hoses, tubes; or Inspect hoses and tubes, tighten

fittings between control valve and fittings as needed. Replace hoses or
cylinders tubes as needed.
No downward pressure on bucket 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 Check pressures in relief valve.

(squealing noise evident while Repair or replace as needed.
operating)

Lift arm will not raise a heavy load or Lift solenoid malfunctioning Check electrical connections to
any load solenoid. Repair or replace as
needed.
Lift spool in control valve not Check valve body for scores or
actuated or leaking cracks. Replace control valve as
needed.
Main relief valve malfunctioning Check pressures in relief valve.

(squealing noise evident while Repair or replace as needed.
operating)
Bucket does not level on the lift Self-leveling valve misadjusted or Repair or replace self-leveling valve
cycle malfunctioning as needed.
Bucket will not tilt; lift arm works Tilt solenoid valve malfunctioning Check electrical connections to tilt
properly solenoid and repair connections as
needed. Replace solenoid as
needed.
Tilt spool in control valve not Check hose or tube connection to

actuated or leaking valve. Check pressure and flow.
Auxiliary hydraulics functions Control linkage misadjusted Check linkage; readjust for full
slowly 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.
Auxiliary hydraulics do not function Restraint bar raised Lower restraint bar
Restraint bar switch or seat switch Replace malfunctioning switch

malfunctioning
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

needed.

GEHL 1640E / MUSTANG 2012 ELECTRICAL SYSTEM
Introduction
Description of Operation - Right and Left
Hourmeter
Instrument Panels
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
Light Switch power outlet and keyswitch.
The following items describe the normal operation of
electrical system components on the skid-steer loaders.
Parking Brake Engine Preheat 1. Parking Brake Switch - used to apply the parking
Switch
P Switch brake.
2. Light Switch - used to control all lights on the
P On
loader. Symbols denote the four positions of the
switch. In a clockwise direction these are:
Off OFF, Tail lights ON, Front work lights with tail
Start
lights ON, both front and rear work lights
Keyswitch 3. 12-VDC Power Outlet - a plug-in outlet with rub-
ber boot used for external electrical connections.
4. Hourmeter - used to display the total operating
hours on the loader.
12-VDC Power 5. Engine Preheat Switch - used to apply power to
Outlet
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 ener-
gized 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.

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
Fuel Level
are also on this panel. 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 fol-
lowing indicator lamps will light on the left instru-
ment panel: Engine
Fasten Seat Belt (momentary) Coolant
Temperature
Low Engine Oil Pressure Gauge
Battery Condition
Fasten Seat Belt buzzer will sound for five sec-
onds
2. The keyswitch can then be turned to the START
position. Fasten Seat Belt
The engine oil pressure and battery lamps will

go out after the engine starts.
Engine Coolant Engine Oil
3. Engine Preheat Indicator Lamp - it lights when the Temperature Pressure
engine preheat switch is engaged.
4. Engine Coolant Temperature Lamp - it lights to
Battery
indicate an abnormal coolant temperature rise in
the engine.
5. Engine Oil Pressure Lamp - it lights to indicate an Engine Preheat
Hydraulic Oil
abnormal engine oil pressure rise in the engine. Indicator
Temperature
6. Hydraulic Oil Temperature Lamp - it lights to indi-
cate an abnormal hydraulic oil temperature rise in
the hydraulic oil system.

Entire electrical system does not Battery disconnect switch is “OFF” Turn battery disconnect switch to “ON”.
function.
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 Check main connectors.

of ROPS not properly plugged in
Battery terminals or cables loose or Clean battery terminals and cables and
corroded tighten them.
Battery faulty Test battery and replace as needed.

No instrument panel lamps light with Circuit breaker tripped Consult wiring diagram, check circuit
keyswitch turned to “ON”. and locate trouble before resetting
breaker.
Battery terminals or cables loose or Clean battery terminals and cables and
No glow indicator lamp with keyswitch Bulb is burned out. Replace bulb.
turned to “ON”.
Seat belt buzzer indicator not sounding Plugged or obstructed buzzer Clean out buzzer.
when keyswitch turned to “ON”, indicator
lamps work properly. Faulty buzzer Replace buzzer.
Buzzer is disconnected Reconnect wires to buzzer.

Fuel gauge does not work. Faulty fuel gauge sender Replace fuel gauge sender.
Loose wiring/terminal connections Verify wiring connections.
Faulty fuel gauge Replace fuel gauge.

Engine temperature gauge does not Faulty sender Replace temperature sender.
work.
Loose wiring/terminal connections Verify wiring connections.
Faulty temperature gauge Replace temperature gauge.

Hourmeter does not work. Loose wiring/terminal connections Verify wiring connections
Faulty alternator Repair or replace alternator.
Faulty hourmeter Replace hourmeter.

Starter will not engage when keyswitch Seat, restraint bar switch or neutral Operator is in the seat with the restraint
is turned to “START”. auxiliary hydraulics malfunctioning or not bar down. Replace switches as needed.
activated
Poor connections to starter relay in Verify relay connections.

instrument panel
Faulty starter relay in panel Test starter relay. Replace as needed.
Battery terminals or cables are loose or Clean battery terminals and cables and
Battery discharged or defective Recharge or replace battery.
Starter solenoid in chassis Troubleshoot circuit per wiring diagram,

malfunctioning located trouble. Replace starter
solenoid.
Ignition wiring, seat switch, restraint bar Check wiring for poor connections,
switch, etc. loose or disconnected broken leads; repair wiring or
connection.
Starter or pinion faulty Remove starter; repair or replace as

needed.
Battery will not recharge. Battery terminals or cables loose or Clean battery terminals and cables and
corroded tighten them. Replace cables as needed.
Battery or alternator defective Test battery and alternator. Replace as

needed.
Work lights not functioning properly. Single light doesn’t work; light bulb is Check and replace light bulb.
burned out or faulty wiring
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.
Lift/Tilt and/or Drive Solenoids do not Wiring to solenoids disconnected or Refer to wiring diagram, locate trouble
work. faulty 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 Test relay, replace as needed.

instrument panel

Electrical Chassis Components
18
26
21
10
12
INSTALL TIMER INCLUDED
8 WITH ENGINE HERE
12
1 CLAMP/HOSE
8
2 NUT/HEX LOCK
3 ROD/BATTERY HOLDDOWN
8
4 PLATE/TWIN COVER
12
5 CLAMP/TUBE TWO-PIECE
9 2 6 BATTERY
17 7 NUT/SPIRALOCK
8 NUT/SPIRALOCK
9 SOLENOID
20 10 BRACKET/RELAY MOUNTING
ASSEMBLE AND MOUNT TO WELD
STUDS ON TOWER WALL 11 ANGLE/BATTERY HOLDDOWN
12 RELAY/SEALED 40 A
7
13 HARNESS/CHASSIS
1
14 COVER/RELAY BRACKET
15 BATTERY CABLE/NEGATIVE
16 BATTERY CABLE/POSITIVE
17 CIRCUIT BREAKER 35 A
18 SCREW/CAP
19 SCREW/CAP
20 BOLT/CARRIAGE
21 NUT/HEX
22 WASHER/FLAT
23 WASHER/LOCK
24 WASHER/EXTERNAL LOCK
25 NUT/HEX
26 SCREW/CAP
ROUTE POSITIVE AND NEGATIVE BATTERY CABLES
THROUGH TUBE CLAMPS.
NOTE: POSITIVE BATTERY CABLE IS ON TOP
5
11
MOUNT TO EXISITING
WELD STUDS
2 2 22
4 22
19
23
24
15
GROUND TO ENGINE
USE EXISTING BOLT
3
16
25
CONNECT
TO
STARTER 6

Electrical Battery Disconnect Switch Components (EU)
9
10 12
11
E 7
6 14
3 8
GROUND TO ENGINE
USE EXISTING BOLT
13
THREAD OVER
15 EXISTING STARTER STUD
17
16 CONNECT
TO
STARTER
12
ROUTE POS FROM STARTER ROUTE BOTH POS CABLE FROM BATTERY
THROUGH HERE AND CABLE FROM JUMP STUD
THROUGH HERE
1 CLAMP/HOSE 7 TERMINAL/REMOTE BLACK 13 STUD EXTENDER/STARTER

2 SWITCH/DISCONNECT 8 CHANNEL/CONTROL MOUNT 14 SCREW/CAP
3 PLATE/FACE 9 BATTERY CABLE/NEGATIVE 15 NUT/HEX
4 CLAMP/HOSE 10 BATTERY CABLE/NEGATIVE 16 NUT/HEX JAM
5 NUT/SPIRALOCK 11 BATTERY CABLE/NEGATIVE 17 WASHER/EXTERNAL LOCK
6 TERMINAL/REMOTE RED 12 BATTERY CABLE/POSITIVE
Electrical Battery Disconnect Switch Components (Standard)
1
2
1 BATTERY CABLE/NEGATIVE
2 WASHER/EXTERNAL LOCK

Electrical ROPS/FOPS Components
26
31
30
8
33
31
9
30
11 23
33
12
20
19
LEFT SIDE ASSY
33
15 14
13
18 13
35 29
24 34 6
16 32
7
33
2
RELAY ASSY 28
35 10 27
21 2
25 1
17 22
5 4
RIGHT SIDE ASSY
1 NUT/HEX LOCK 19 DECAL/LEFT INSTRUMENT PANEL

2 GAUGE/HOURMETER 20 PANEL/LH
3 HOUSING/DISPLAY 21 PANEL/RH
4 SWITCH/GLOW PLUG 22 PANEL/CIRCUIT BREAKER
5 SWITCH/BRAKE 23 COVER/LEFT
6 BUZZER 24 COVER/RIGHT
7 NUT/HEX LOCK 25 DECAL/RIGHT INSTRUMENT PANEL
8 BULB/LAMP 26 WIRE HARNESS/ROPS
9 GASKET/DISPLAY HOUSING 27 DECAL/CIRCUIT BREAKER
10 TIMER/DELAY 28 TIMER/SEAT BELT
11 GAUGE/FUEL LEVEL 29 CIRCUIT BREAKER 8 A
12 GAUGE/ENG OIL TEMP 30 WASHER/HELICAL LOCK
13 BREAKER/CIRCUIT 15 A 31 NUT/HEX MACHINE
14 BREAKER/CIRCUIT 25 A 32 NUT/HEX MACHINE
15 SWITCH/LIGHT 33 SCREW/MACHINE
16 KNOB/LIGHT SWITCH 34 SCREW/MACHINE
17 SWITCH/IGNITION 35 WASHER/HELICAL LOCK
18 STANDOFF

Relay Test and Operation 2. Relay coil test: Using a volt/ohm multimeter with
all wires disconnected, measure the resistance
Gehl 1640E and Mustang 2012 model skid-steer loaders across terminals #85 and #86. There should be 75
utilize relays in the electrical system to maximize the ohms ± 5 ohms. There should be no continuity
efficiency of engine, hydraulic, power and electrical between terminals #30 and #87.
operations. Following in this section are test and
operation procedures.
87
Relay Test - Fuel Pull, Starter, Safety Lock
and Auxiliary Neutral
The following procedure can be used to test four relays 87a
located on the left chassis riser, near the radiator/cooler.
86 85
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.

Glow Solenoid Test 2. Unplug the control current connector and install a
test lamp between #85 and #86. Have an assistant
The following procedure can be used to the glow turn the keyswitch to the “ON” position and the
solenoid located on the left chassis riser, near the test lamp should light when the glow switch is
radiator/cooler. pressed.
Seat Switch Removal and Installation

Removal Procedure
WARNING
Glow Solenoid BEFORE beginning this service procedure,
1. Remove seat per the procedure found in the Main-

frame chapter. Turn the seat over.
#85 2. Remove the two Phillips-head screws and nuts
#86
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
Raise engine cover, lock open the rear grille.
(For detailed instructions, refer to the Safety WARNING
DO NOT attempt to operate the loader without
1. Using a volt/ohm multimeter or test lamp, confirm the seat switch installed.
the following condition with the wiring connected.
With keyswitch in “OFF” position, there should be Installation Procedure - Follow all warnings first,
12 VDC only on left large copper stud of each sole- then reverse the removal steps*.
noid. * Install seat on loader per the procedure in the
Mainframe chapter.

Restraint Bar Switch Removal and Installa- Engine Disconnect Switch - Remote Bat-
tion tery 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
WARNING
(For detailed instructions, refer to the Safety BEFORE beginning this service procedure,
chapter of this manual.) perform the following SAFETY procedure:
1. Remove the restraint bar assembly per the proce-
dure in the Mainframe chapter. Turn electrical disconnect switch to OFF.
2. Remove the two machine screws, washers and hex (For detailed instructions, refer to the Safety
nuts that secure the restraint bar switches to the chapter of this manual.)
restraint bar and restrain bar mount. 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.

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.

Restraint Bar Components
16 13 12
2 5
5 1
10 2 18
1
3
10 19
19 16
17
4 20 18 7
6 18 21
18 20
8
10
14 11 4
15 9
8
1 SCREW/SHOULDER 12 MOUNT/RESTRAINT BAR/LH

2 BUSHING/OILITE 13 MOUNT/RESTRAINT BAR/RH
3 NUT/HEX LOCK 14 GAS SPRING/RESTRAINT BAR
4 BUMPER 15 MOUNT/GAS SPRING
5 SPACER/TUBE 16 BOLT/CARRIAGE
6 SWITCH/PROXIMITY 17 BOLT/CARRIAGE
7 MAGNET/SWITCH ACTUATOR 18 WASHER/FLAT
8 STUD/BALL 19 NUT/HEX MACHINE
9 NUT/SERRATED LOCK 20 WASHER/EXTERNAL LOCK
10 NUT/SPIRALOCK 21 SCREW/MACHINE
11 BAR/RESTRAINT

3. Remove the switch plate jam nut securing the Front and Rear Work Light Bulb Replace-
switch plate and the switch into the mounting hole. ment
Removal Procedure
Switch Plate Jam Nut
WARNING
Raise engine cover; lock open the rear grille.
4. Unbolt the capscrews and locknuts securing the
1. With a torx-head socket wrench, remove the four
disconnect switch to the battery tray.
screws on the front work light and remove the lens.
5. On the back of the disconnect switch, remove the Rear work lights are in the rear grille.
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 skid-
steer loader.
2. Release the bulb retaining clip and remove the

bulb.
NOTE: Keep a record of the cable connections for Clip

reinstallation.

Electrical Lights Components
Front Work Lamp and Rear Grille
1 NUT/SPIRALOCK
2 LIGHT/WHITE 55 W
3 LIGHT/RED 35 W
4 SCREW/CAP
1
3
2
3
4
Dome Lamp - EU Completing
1 NUT/HEX LOCK
2
2 MOUNT/DOME LIGHT
3 SCREW/CAP
4 LIGHT/DOME
1 1
Rearview Mirror - EU Completing
1 2
1 MIRROR/REARVIEW
2 SCREW/TAPPING

Dome Light Bulb Replacement

Removal Procedure
WARNING
1. Climb into the cab and find dome light assembly

on ceiling of the cab.
IMPORTANT 2. Pop the dome light lens cover out of the base by
pressing on one side of the cover and releasing
Halogen bulbs SHOULD NOT be touched with small tabs from the base.
bare fingers; they can fail prematurely. Wear
clean gloves or use a clean rag if you must
handle the halogen bulbs.
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).
3. Replace the used bulb with a new 5 W incandes-

cent bulb.

Lift and Tilt Solenoid Test and Operation Brake Solenoid Test and Operation
The lift and tilt solenoid valves suppling oil to the right The solenoid valve that supplies oil to the left T-Bar is
T-Bar are located inside the chassis. The tilt solenoid is located on the left side of the chassis. When the restraint
located in the right riser and the lift solenoid is located bar and seat switch are closed, a 12 VDC signal to the
along the left inside chassis wall. When the restraint bar solenoid opens to supply oil to the left T-Bar control to
and seat switch are closed, a 12 VDC signal to the engage the wheel drive functions.
solenoid opens to supply oil to the right T-Bar to engine
the lift and tilt 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.

Electrical Schematic
F
TA
ENGINE
COOLANT
TEMPERATURE FUEL GAUGE
GLOW PLUG SWITCH 183644 183634
AUXILIARY POWER
13 RED
58 YEL
ENG PRESS 14 PUR

12 RED
ALT/HR MTR 34 YEL
6 ORG
12 RED
12 RED
0 BLK
BRAKE SOL 36 BLU
30 PUR
12 RED
ENG TEMP 31 ORG

HORN
15 BRN
34 YEL
HYD TEMP 40 GRY
BUTTON
12 RED
12 RED
OPTION
12 RED
22 GRN
143 BRN
25 BRN
12 RED
15 BRN
0 BLK
143 BRN
58 YEL
12 RED
12 RED
0 BLK
0 BLK
0 BLK
143 BRN
0 BLK
0 BLK
13 RED
0 BLK
11 RED
15 BRN
56A RED 56B RED
42 GRN
48 WHT
43 ORG
14 PUR
ACC POWER POWER PORT
40 GRY
12 RED
31 ORG
31 ORG
40 GRY
15 BRN
0 BLK
14 PUR
02 RED
12 RED, IGNITION
20 BRN
A B C D E 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
ROPS HARNESS SOLENO
193856
SAFETY L
AUX-LIFT-
(SEAT SW
12 RED &
RESTRAIN
25 BRN
BAR)
10 WHT 35 BLU
36 BLU
58 YEL AUX
17 GRN 48 WHT NEUTR
42 GRN
43 ORG
12 RED 13 RED
34 YEL
31 ORG STARTE
22 GRN
10 WHT
40 GRY
14 PUR
33 PNK
02 RED
0 BLK

Electrical Schematic
BACKUP ALARM SWITCH
(OPTION)
AUXILIARY
BACKUP ALARM KIT SPOOL LOCK
(OPTION)
FLASHER POWER
TAP
0 BLK
0 BLK
48 WHT
O1G, BLK
UGE
13 RED
0 BLK
49 GRN
35 BLU
0 BLK
43 ORG
AUXILIARY POWER 40 GRY
POSITIVE
POST DISCONNECT NEGATIVE POST
13 RED
0 BLK SWITCH
42 GRN
0 BLK
36 BLU
6 ORG
0 BLK
43 ORG
HORN
34 YEL
BUTTON
12 RED
OPTION
143 BRN
12 RED
15 BRN
0 BLK
0 BLK
143 BRN
0 BLK
13 RED
12 RED
0 BLK
15 BRN
12 RED
HOLD
0 BLK
GRND
47 WHT
PULL
0 BLK
35 BLU FUEL
CONTROL
12 RED
SOLENOID
31 ORG
0 BLK
40 GRY
15 BRN
0 BLK
14 PUR
35 BLU
R
46 PUR TIMER
R/W
45 YEL
112 PUR PULL COIL
13 RED
Y
0 BLK
B
34 YEL
46 PUR
A B C D E F
25 BRN
35 BLU
0 BLK
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
A 30
GLOW 01 RED
SOLENOID GROUND CABLE
ROPS HARNESS B 87 81 RED
GLOW PLUGS
193856
0 BLK
02 RED
SAFETY LOCK 10 WHT
AUX-LIFT-TILT 01 RED
(SEAT SWITCH
12 RED & 0 BLK 01 RED
RESTRAINT
25 BRN 35 BLU
BAR) 82 WHT
35 BLU 35 BLU
36 BLU 112 PUR
58 YEL AUX
48 WHT NEUTRAL 0 BLK
42 GRN
43 ORG
13 RED
21 GRN
34 YEL 33 PNK
31 ORG STARTER
0 BLK
22 GRN
10 WHT ENGINE
40 GRY
14 PUR
33 PNK
02 RED
0 BLK

CHAPTER NOTES

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
This chapter covers troubleshooting, removal, fitted to the engine. If Gehl or Mustang parts are
installation, and adjustment procedures for engine required, they can be ordered from Gehl Company.
components on Gehl 1640E and Mustang 2012 model
skid-steer loaders. The primary engine system Troubleshooting Guide
components are shown on following pages.
The following troubleshooting guide lists potential
They are equipped with a Yanmar model 3TNV82A engine problems, as well as possible causes and
turbocharged diesel engine. The three-cylinder engine remedies, for Gehl 1640E and Mustang 2012 model
is 81.2 cubic inch (1,33 L) displacement engine with an skid-steer loaders.
19:2 compression ratio. The direct injection four-stroke
When a problem occurs, don’t overlook simple causes.
engine has a firing order of 1, 3, 2.
A malfunction could be caused by something as simple
A “full-flow” oil filter is used in the lubrication system. as an empty fuel tank. After a mechanical failure has
As with any engine, clean oil, fuel and air are critical to been corrected, be sure to locate the cause of the
satisfactory performance and long engine life. If problem. For further troubleshooting information, refer
properly maintained, this engine can be expected to to the engine manufacturer’s manual.
provide thousands of hours of trouble-free operation.
Starter will not engage when Seat or restraint bar switch Replace switches as needed.
keyswitch is turned to “START” malfunctioning or not activated
Faulty starter relay in panel Test starter relay. Replace as

needed.
Battery terminals or cables are Clean battery terminals and cables

loose or corroded and tighten them.
Battery discharged or defective Recharge or replace battery.
Starter solenoid in chassis Troubleshoot circuit per wiring

malfunctioning diagram to locate trouble. Replace
starter solenoid.
Ignition wiring, seat switch, restraint Check wiring for poor connections,
bar switch, etc. loose or broken leads; repair wiring or
disconnected connection.
Starter or pinion faulty Remove starter; repair or replace as

needed.
Auxiliary pedal not in NEUTRAL Ensure pedal is in NEUTRAL

position position. Neutral switch located on
main control valve. Replace switch
as needed.

ENGINE GEHL 1640E / MUSTANG 2012
Engine turns over but will not start Engine cranking speed too slow Battery requires recharging or
replacing, or, in cold temperatures,
pre-warm the engine.
Fuel tank empty or faulty fuel gauge Refill fuel tank. Replace fuel gauge
sender 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.
Engine overheats Crankcase oil level too low or too Add or remove oil as required.
high
Engine overloaded Reduce operating load.
Fan air circulation blocked or Turn engine OFF, wait for fan to
restricted stop, remove blockage or
restriction.
Fan shroud improperly positioned Perform “Fan Shroud Adjustment”

procedure in this chapter.
Grade of oil improper or excessively Drain and replace with clean oil of
dirty 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.

Engine Components and Engine Controls
25 24
13 53
3
50
21
50 48
10
19
20 18
7
9 30
60
11
NOTES:
1. APPLY LOCTITE™ 242 OR EQUIVALENT
2. TORQUE TO 110 FT/LBS
5
51
28
34
32 46
56
39 55
36 NOTE #2
43 NOTE #1
47 8
29 37
56 1
29 NOTE
22 #1 & #4
NOTE #1 12 59
26 57
52 38 NOTE
42 #1 & #4
54 45
32 15 41
27
33
45 35
4
40 45 44
2 NOTE #3
14
49 GOVERNED ENGINE SPEED SPECIFICATIONS

16 40
45 SPEED SETTING RPM TOLERANCE
LOW IDLE, NO LOAD 1600 25 RPM
HIGH IDLE, NO LOAD 2500 10 RPM
54 6
*THE FULL LOAD GOVERNED SPEED THAT THE
58 23 ENGINE PASSED U.S. EPA EMISSIONS STANDARDS
NOTE #1 1
43
39
31
1 BUSHING/FLANGED 16 PLATE/PUMP MOUNT 31 NUT/CENTERLOCK 46 SCREW/CAP

2 JOINT/BALL 17 HOSE/FUEL 32 PIN/CLEVIS 47 SCREW/CAP
3 CLAMP/HOSE 18 HOSE/FUEL 33 MOUNT/ENGINE 48 SCREW/CAP
4 NUT/LOCK 19 FITTING/90º 34 BRACKET/ENGINE 49 BOLT/CARRIAGE
5 NUT/LOCK 20 PUMP/FUEL FEED 35 LINKAGE/THROTTLE 50 SCREW/CAP
6 NUT/LOCK 21 SEPARATOR 36 CABLE/THROTTLE 51 WASHER/FLAT
7 HOSE/FUEL 22 PIVOT/THROTTLE 37 PLATE/DRIVE 52 WASHER/FLAT
8 SCREW/CAP 23 PIVOT/THROTTLE 38 SCREW/CAP 53 WASHER/LOCK
9 PLATE/TWIN COVER 24 VALVE/SHUT OFF 39 WASHER/FLAT 54 WASHER/LOCK
10 CLAMP/TUBE 25 HOSE/FUEL 40 WASHER/PLATED 55 WASHER/LOCK
11 NUT/SPIRALOCK 26 BRACE/ENGINE TOP 41 WASHER/FLAT 56 PIN/COTTER
12 NUT/SPIRALOCK 27 ROD/THROTTLE 42 MOUNT/ENGINE 57 SCREW/CAP
13 HOSE/FUEL 28 ENGINE/YANMAR 43 BUSHING 58 SCREW/CAP
14 ISOLATOR 29 YOKE/CLEVIS 44 SCREW/CAP 59 SCREW/CAP
15 SCREW/SHOULDER 30 NUT/LOCK 45 NUT/HEX 60 HOSE/FUEL

Air Cleaner and Exhaust Components
10 4
9 2
8
3
1
14
PRIMARY
ELEMENT IS 242541
7 SECONDARY
13 ELEMENT IS 242540
12
1
11
5
1 CLAMP/HOSE 8 BRACKET/AIR CLEANER

2 INDICATOR/RESTRICTION 9 MUFFLER
3 CLEANER/AIR 10 SCREW/CAP
4 NUT/SPIRALOCK 11 SCREW/CAP
5 MOUNT/MUFFLER 12 WASHER/FLAT
6 SPACER/MUFFLER 13 WASHER/LOCK
7 HOSE/MOLDED AIR FILTER 14 NUT/HEX

Radiator/Cooler Components
5 3
13
12
8
10
3
1
14 8
4
2
NOTE:
CONNECT TO TANK PORT 9
ON CONTROL VALVE
14
15 1
11
16
NOTE:
CONNECT TO PORT ON
HYDRAULIC TANK
1 CLAMP/HOSE 9 BOTTLE/OVERFLOW
2 CLAMP/HOSE 10 HOSE/RADIATOR
3 CLAMP/HOSE 11 HOSE/RADIATOR
4 FITTING/STRAIGHT 12 COOLER/RADIATOR
5 SEAL/SHROUD 13 SHROUD/FAN
6 FITTING/90º 14 SUPPORT/SHROUD
7 HOSE/FUEL 15 COOLER TUBE/HYDRAULIC
8 SCREW/CAP SERRATED LOCK 16 COOLER TUBE/HYDRAULIC

Oil Filter Element Removal and Installation Installation Procedure
The engine oil filter is located on the left side of the 1. Clean oil filter mating surface of any debris before
engine and can be accessed through a belly pan in the installing new element.
chassis. 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
WARNING element another 3/4 turn to seat gasket.
BEFORE beginning this service procedure, 4. If old oil has been removed, fill crankcase with 5.8
perform the following SAFETY procedures: qts. (5,5 L) of oil. (See Lubrication chapter.)
Shut off the engine and allow to cool. 5. Start engine and check for leaks near oil filter. Shut
off engine, recheck oil level, and fill as needed.
chapter of this manual.) 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 ele-
ment with a filter wrench.
5. Turn the filter element by hand until it is free of the
oil filter mating surface.

Air Cleaner Assembly Removal and Instal- 4. Remove the top capscrew and locknut securing the
lation air cleaner bracket to the left riser to release the air
cleaner canister.
Removal Procedure
WARNING
Shut off the engine and allow to cool.
1. Open the engine access cover and lock open the

rear grille.
5. Pull up on the bracket until it releases from itself
2. Clean the area around the hose connection.
and slide the air cleaner out of the bracket.
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.

Air Filter Element Removal and Installation 3. Pull the primary and secondary air filters from the
air cleaner assembly.
Service the air filter element when the restriction gauge
shows in the red zone. The red zone indicates a clogged Primary Air Filter
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.
Removal Procedure
WARNING
chapter of this manual.) Secondary Air Filter

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.
* Clean the radial seal surfaces of the mating plastic
body.

Battery and Battery Tray Removal and 2. First, disconnect and remove the negative (-) bat-
Installation tery cable and then disconnect the positive (+) bat-
tery cable from the battery.
Removal Procedure
WARNING
3. Remove the two locknuts from the battery clamp

WARNING rods and the hold-down battery angle.
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 solu-
tion is extremely explosive.
Avoid contact with battery electrolyte; wash
off any electrolyte immediately.
Wear safety glasses when working near bat-
tery.
Do not tip battery more than 45° to avoid
spilling electrolyte solution.
To avoid injury from spark or short circuit, 4. Lift the battery up and out of the chassis.
disconnect negative (-) battery cable before
5. If equipped with an engine disconnect switch, refer
servicing electrical system.
to its removal procedure in the Electrical System
chapter of this manual.
the procedure in the Mainframe chapter. Installation Procedure - Follow all warnings first,

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
chapter of this manual.) 6. Remove the starter from the engine.
1. Open the engine access cover and lock open the then reverse the removal steps.
rear grille.
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 (+) bat-
tery cable to remove if a remote engine disconnect
switch is installed. Also, remove the push-on con-
nector attached at the solenoid.

Exhaust Assembly Removal and Installa- Installation Procedure - Follow all warnings first,
tion 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, Fan Belt Adjustment
Lower the lift arm completely.
chapter of this manual.) WARNING
1. Open the engine access cover and lock open the BEFORE beginning this service procedure,
rear grille. perform the following SAFETY procedure:
2. Remove the capscrew securing the side of the muf- Shut off the engine and allow to cool.
fler to the muffler mount. (For detailed instructions, refer to the Safety

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 adjust-
ment 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.

3. Loosen the two bolts on the alternator, one at the 3. Open the engine access cover and lock open the
low pivot area and one on top in the slide bracket. 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. Remove coolant hoses and hydraulic oil lines from
5. Retighten the bolts. the inlets and outlets of the radiator/oil cooler. Dis-
connect the hose clamps on the two radiator hoses
and the two hydraulic oil lines from their fittings.
Radiator/ Oil Cooler Removal and Installa-
Upper Radiator and Hydraulic OIl Line
tion
The radiator/oil cooler is mounted on a shroud located
just behind the engine.
Removal Procedure
WARNING
Lower Radiator Hose
1. If necessary, drain the oil from the hydraulic reser-

voir per the procedure in the Lubrication chapter.
2. If necessary, drain the engine coolant from the
radiator per the procedure in the Lubrication chap-
ter.
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.

Lower Hydraulic OIl Line
WARNING
6. Remove remote radiator overflow line at the top of
the radiator.
WARNING

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.

Fan Shroud and Support Brackets shroud support brackets to the floor of the chassis,
Removal and Installation on each side of the skid-steer loader.
Removal Procedure
WARNING
WARNING
DO NOT attempt to service any part of radia-
tor/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 4. Remove the fan shroud assembly with the shroud
after disconnecting to prevent leakage, it should not be supports still attached.
necessary to drain the hydraulic reservoir. 5. Unbolt the shroud supports at this time, if neces-
2. Remove the radiator/oil cooler per the procedure in sary.
this chapter. Installation Procedure - Follow all warnings first,
3. Underneath the skid-steer loader there are holes to then reverse the removal steps.*
access and remove two capscrews securing the * BE SURE and uncap/unplug the hydraulic oil lines
prior to reconnecting them to the radiator/oil cooler.

Fan Shroud Adjustment Fan Removal and Installation

Adjustment Procedure Removal Procedure
WARNING WARNING
BEFORE beginning this service procedure, BEFORE beginning this service procedure,
perform the following SAFETY procedure: perform the following SAFETY procedure:
Shut off the engine and allow to cool. Shut off the engine and allow to cool.
(For detailed instructions, refer to the Safety (For detailed instructions, refer to the Safety
chapter of this manual.) chapter of this manual.)
1. Loosen, but do not remove, the two locking cap- 1. If necessary, drain the oil from the hydraulic reser-
screws on the shroud support connected to the voir per the procedure in the Lubrication chapter.
shroud. 2. If necessary, drain the engine coolant from the
radiator per the procedure in the Lubrication chap-
ter.
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.
3. Tighten the locking capscrews on the fan shroud
supports to secure the height adjustment.

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 10. Turn fuel/water separator petcock (small red pet-
assembly. Some hydraulic hoses/oil lines need to be cock) to the OFF position.
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.
Removal Procedure
WARNING
device. 11. Disconnect fuel lines from the fuel filter.
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. 12. Disconnect the fuel line in front of the fuel pump
5. Remove the battery per the procedure in this chap- and unplug the electrical connector on the fuel
ter. 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.
13. Remove the engine throttle cable per the procedure
in the Controls chapter.

14. Unplug engine harness connectors located in sev-

eral 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 con-
nected to the hydrostatic pump. Refer to the
“Hydrostatic Pump Removal” procedure in the
Hydrostatic System chapter for hydraulic hose
removal procedure on the pump.

17. Remove the negative (-) battery cables from the 20. Remove one capscrew, lock nut (110 ft-lbs) (149
bottom left of the engine’s flywheel cover. 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 (+) bat-
tery cable to remove if a remote engine disconnect Engine Mount - Top View
switch is installed. Also, remove the push-on con-
nector attached at the solenoid.
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.

22. With the hoist attached to the engine, lift slightly and can cause permanent eyesight damage if
and pull the engine rearward. Continue pulling the safety glasses are not worn.
engine rearward until the pump is free from the
drive coupling, then remove the engine from the ALWAYS check for hydraulic fluid leaks after
chassis. installing any components of the hydraulic system.

* 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
WARNING

CHAPTER NOTES

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

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

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

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

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

THIS PAGE INTENTIONALLY LEFT BLANK

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 PRINTED IN USA

All Rights Reserved.

Manual Reparação Mustang 2012

Uploaded by

Copyright:

Available Formats

Manual Reparação Mustang 2012

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Reparação Mustang 2012

Uploaded by

Copyright:

Available Formats

Gehl 1640E

All-Tach® Hitch Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Wheel Drives Page

Hydrostatic System Page

Hydraulic System Page

Electrical System Page

INDEX Page 147

Electrical System Electrical

Hydraulic System Hydraulic System

Tire Options Tire Options Description

Buckets and Capacities

PRINTED IN USA 917400/AP0809 1

Dimensional Specifications 1640E and 20121

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

2 917400/AP0809 PRINTED IN USA

PRINTED IN USA 917400/AP0809 3

4 917400/AP0809 PRINTED IN USA

Many service procedures require a raised lift arm to

Lift Arm Support Device Engagement

3. Before leaving the operator’s compartment, check

PRINTED IN USA 917400/AP0809 5

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

6 917400/AP0809 PRINTED IN USA

3. Be sure control handles clear the ROPS.

2. Lower the ROPS until it contacts the chassis.

PRINTED IN USA 917400/AP0809 7

result from improperly raising or blocking the

Lift and Tilt

Loader Raising Procedure

WARNING 1. Using a jack or hoist, raise the loader until its

8 917400/AP0809 PRINTED IN USA

General Information Hydraulic Oil Reservoir

Routine lubrication is an important factor in preventing

PRINTED IN USA 917400/AP0809 9

Use Petro-Canada Premium HVI60 hydraulic oil (or Crankcase Oil

Engine Oil Fill

Hydraulic Filter Location

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

Engine Oil Drain

10 917400/AP0809 PRINTED IN USA

Chaincase Drain Plugs

A side view of the engine oil filter location.

Engine Oil Filter Location

2. Reinstall the drain plug.

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

PRINTED IN USA 917400/AP0809 11

Grease Fitting Locations

2. Grease tilt cylinder pivots.

3. Grease lift cylinder pivots.

12 917400/AP0809 PRINTED IN USA

Cooling System Drain Procedure Hydraulic Oil Cooler Plug/Cap Procedure

Shut off the engine and allow it to cool.

(For detailed instructions, refer to the Safety

Anti-freeze Drain Cock

Note: Plugging or capping the two tubes in steps 1 and

3. Close the drain cock or screw the plug back into