Form No.

917231

Rev. A
08/06

Gehl SL4640E, SL4840E,

SL5640E and SL6640E
Skid-Steer Loaders

Mustang 2076 and 2086

Skid-Steer Loaders
Service Manual Addendum
For Dual Joystick Controls
 INTRODUCTION
With correct maintenance and proper use, Gehl and Mustang skid-steer loaders will give years of
dependable service. This service manual addendum 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 Gehl-Mustang "Dual Joystick Controls" skid-steer loaders and skid-
steer loaders equipped with electrical auxiliary hydraulics.

In many of the procedures found within, the installation steps are the exact opposite of the removal steps
and vice versa, and therefore, the opposite procedure is not written. Instead, a note to reverse the
procedure will be stated. This reduces redundancy and excessive pages in the manual. In cases though,
where the assembly and disassembly or removal and installation procedures differ and additional steps or
safety concerns are paramount, the entire reverse procedure will be written out to include the new
information.

The Table of Contents and Index can be used to make the procedure you need to find an easier process.
Also, there are black tabs extending off the pages highlighting the chapters for those who prefer to thumb
through the manual. Many schematics, photographs, and 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-Mustang Service Department for assistance.
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS TABLE OF CONTENTS

TABLE OF CONTENTS

Safety Page
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mainframe
Dual Joystick Control Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Controls
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control Handle Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control Handle Removal and Installation - Electrical Auxiliary Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control Handle Tracking Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Neutral Centering Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Hydrostatic System
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hydrostatic Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hydrostatic/Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Hydraulic System
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Electrical System
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

PRINTED IN USA 1
TABLE OF CONTENTS DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

SECTION NOTES

2 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS SAFETY

Signal Words

DANGER
“DANGER” indicates an imminently hazardous
situation which, if not avoided, will result in death or
General Information
serious injury.
The above safety alert symbol means: ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
It stresses an attitude of “Heads Up for Safety” and can
be found throughout this service manual and on the WARNING
decals on the machine.
“WARNING” indicates a potentially hazardous
Before operating or working on this machine, read and situation which, if not avoided, could result in death or
study the following safety information. In addition, be serious injury.
sure that everyone who operates or works on this
equipment is familiar with these safety precautions. It is
essential to have competent and careful operators, who
are not physically or mentally impaired, and who are
thoroughly trained in the safe operation of the machine
CAUTION
and the handling of loads. It is recommended that the “CAUTION” indicates a potentially hazardous situation
operator be capable of obtaining a valid motor vehicle which, if not avoided, may result in minor or moderate
operator’s license. injury. May also alert against unsafe practices.
The use of skid-steer loaders is subject to certain
hazards that cannot be eliminated by mechanical means, Additional Safety Reminders
but only by exercising intelligence, care and common
Read and understand the Service Manual and
sense. Such hazards include, but are not limited to,
all decals before maintaining, adjusting or
hillside operation, overloading, instability of the load,
servicing this equipment.
poor maintenance and using the equipment for a
purpose for which it is not intended or designed. Doors, Guards and Shields - Some photographs in this
manual may show doors, guards and shields open or
The Gehl-Mustang Company ALWAYS considers the
removed for illustrative purposes only. BE SURE all
operator’s safety when designing its machinery and
doors, guards and shields are in their proper operating
guards exposed moving parts for the operator’s
positions BEFORE starting engine to operate unit.
protection. However, some areas cannot be guarded or
shielded in order to assure proper operation. Damaged or Worn-out Parts - For safe operation,
Furthermore, the Operator’s Manual and the decals on replace damaged or worn-out parts with genuine Gehl-
the machine warn of additional hazards and should be Mustang service parts, BEFORE operating this
read and observed closely. equipment.
These topics in this chapter include procedures, which, Attachments - Gehl-Mustang skid-steer loaders are
when followed, will allow safe performance of service designed and intended to be used only with Gehl-
procedures: Mandatory Safety Shutdown Procedure, Mustang Company attachments or approved referral
Lift Arm Support Device, Roll-Over Protective attachments. The Gehl-Mustang Company cannot be
Structure (ROPS)/Falling Object Protective Structure responsible for operator safety if the loader is used with
(FOPS) Lock Mechanism, Loader Raising and a non-approved attachment.
Lowering Procedures, and Relieving Hydraulic Battery Safety - To avoid injury from a spark or short
Pressure. circuit, disconnect the negative (-) battery
cable before servicing any part of the electrical
system. Do not tip the battery more than 45º to
avoid spilling electrolyte.

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SAFETY DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

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

4 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS MAINFRAME

Control Covers - Joystick Controls

3
7

1 NUT/SPIRALOCK™
2 FLOOR/FRONT
3 SPACER
4 COVER/CONTROL
5 PAD/SOUND/HEEL
6 SCREW/MACHINE
7 SCREW/TORX DRIVE

Fig. 1: Exploded view of dual joystick control covers.

PRINTED IN USA 5
MAINFRAME DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Dual Joystick Control Cover/Floor Cover

Removal and Installation

WARNING
BEFORE beginning this Service procedure,
perform the following SAFETY procedures:
A) Raise lift arm, engage lift arm support
device.
B) Shut off the engine.
C) Loosen ratchet handles and rotate joystick
Fig. 2: The sound pad is held to the control cover drive stands to most forward positions.
with three screws, one of them shown. D) Roll back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of the service manual.)

Removal Procedure
1. Remove three screws securing the sound pad to the
Machine Screw control cover and carefully lift the sound pad up and
off the control cover. Fig. 2
2. Remove five thread-cutting screws securing rubber
boot flanges on two drive stands to the control
cover. Fig. 3
3. Remove two machine screws that secure the control
cover to the crossmember. Fig. 3
4. Remove two locknuts and two machine screws
securing the floor cover to chassis. Fig. 4
Fig. 3: View of two of five thread-cutting screws
securing rubber boot flange to the control cover, 5. Remove either cover at this time.
other side is the same. Installation Procedure - Follow all warnings first,
then reverse the removal steps.

Fig. 4: Location of two machine screws on the floor

cover. Two locknuts at the front of the floor cover not
shown.

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DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS CONTROLS

Introduction
This chapter covers the removal, installation, assembly Two-Speed Control
and adjustment procedures for standard and optional Two-speed loaders have a high and low speed option.
control equipment on Gehl-Mustang skid-steer loaders. The two-speed option is controlled by a button switch
in the left control handle and lights a panel light.
Equipment Identification
Because there are a variety of options available for Hydraglide™ Ride Control
these machines, it is IMPORTANT to properly identify The Hydraglide™ Ride Control is standard on dual
equipment BEFORE beginning service procedures. joystick controlled skid-steer loaders and is controlled
Illustrations and photographs are provided with proce- by a button switch in the right control handle and lights
dures to aid in servicing this equipment. a panel light.

Joystick Controls Float Control

On skid-steer loaders with "Joystick Controls", the left The Float Control is standard on dual joystick con-
joystick handle controls forward and reverse directions trolled skid-steer loaders and is controlled by a button
of the drive motors (drive control) and tandem pump switch in the right control handle and lights a panel
for both sides of the loader. The right joystick handle light.
controls the lift and tilt functions of the lift arm and
bucket. For control of engine speed, foot and hand
throttles are standard. On high-flow models, a lever in Electrical Auxiliary Hydraulics
front of the right joystick control handle activates high- Electrical auxiliary hydraulics is standard on dual joy-
flow auxiliary hydraulics. stick controlled skid-steer loaders and is controlled
with a proportional rocker switch in the right control
handle and a red continuous-flow locking button
switch at the front of the right control handle.

5
6

3 7
4 11

2
10
8

Fig. 5: Control locations on dual joystick skid-steer loaders.

1 - Drive Control 5 - Hydraglide™ Control Switch 9 - Hand Throttle Handle

2 - Lift/Tilt Control 6 - Float Control Switch 10 - High-Flow Aux. Flow Control
3 - Two-Speed Button Switch 7 - Auxiliary Hydraulics Switch 11 - Aux. Hyd. Lock Button
4 - Horn Button Switch 8 - Foot Throttle

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CONTROLS DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Lift and Tilt - Dual Joystick Controls (with Electric Auxiliary) - All Models

16
36

17
18

40
24

27

TO ELECTRIC 38 O NT
AUX HYD ENABLE
CONNECTOR ON
FR
CHASSIS WIRE
HARNESS 20
25
13 PORTS
PORTS T & P 14 1,2,3 & 4

19 TO JOYSTICK
PORT P
29
37 4
35
9 28 12
35
39 26
35
TO 30
5 P O JO
RT Y S 32
2 T IC
8 K
7 15
TO 1
P O JO 3 22
RT YST 21
34 1 IC
K

31
2
6
TO JOYSTICK 11
PORT T
6
TO JOYSTICK
10 PORT 4
TO JOYSTICK
PORT 3

33 4 23

1 FITTING/STRAIGHT 11 HOSE/ADAPTER 21 FITTING/VALVE 31 NUT/HEX

2 ELBOW/90° 12 ACCUMULATOR 22 LINE/ACCUMULATOR 32 NUT/HEX JAM
3 NUT/LOCK 13 ADAPTER 23 LINE/RETURN 33 TEE/SWIVEL
4 TEE/SWIVEL 14 ADAPTER 24 GRIP/ELEC AUX 34 SCREW/CAP
5 BUSHING/PIVOT 15 HOSE/ADAPTER 25 ADAPTOR/FLOAT 35 BOLT/CARRIAGE
6 FITTING/STRAIGHT 16 FLANGE/BOOT 26 BRACKET/ACCMLTR. 36 SCREW/THREAD
7 PIN/TILT CONSOLE 17 FLANGE/BOOT 27 BOOT/JOYSTICK 37 SCREW/MACHINE
8 MOUNT/TOWER 18 BOOT/JOYSTICK 28 COVER/CONSOLE 38 SCREW/THREAD
9 HANDLE/RATCHET 19 STAND/DRIVE 29 HOSE/ADAPTER 39 WASHER/FLAT
10 HOSE/ADAPTER 20 JOYSTICK 30 HOSE/PRESSURE 40 NUT/HEX

Fig. 6: Exploded view of the dual joystick lift and tilt controls for all models of skid-steer loaders.

8 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS CONTROLS

Wheel Drives - Dual Joystick Controls - 4640 and 4840 Models

33

21
22

24
10
10 10
10 20 TO JOYSTICK:
SINGLE SPD = PORT #4
TWO SPD = PORT #2
26 8
20
TO JOYSTICK:
SINGLE SPD = PORT #2
TWO SPD = PORT #4
TO JOYSTICK PORT #1 1
35 TO JOYSTICK PORT #3
11

4
PORTS T & P 19 18 PORTS 1,2,3 & 4
17 9
23 7 5
34 TO JOYSTICK
16 PORT #T
36
36 28
13
25 TO JOYSTICK
12
PORT #P
31 2 3
14 6 32

31
27

O NT
15
FR

29

1 FITTING/STRAIGHT 10 FITTING/90° 19 ADAPTER 28 HOSE AND ADAPTER

2 FITTING/TEE 11 JOYSTICK/DRIVE 20 HOSE AND ADAPTER 29 NUT/LOCK
3 FITTING/90° 12 VALVE/SOLENOID 21 FLANGE/BOOT 30 SCREW/CAP
4 FITTING/STRAIGHT 13 PLATE/SPACER 22 FLANGE/BOOT 31 BOLT/CARRIAGE
5 FITTING/TEE 14 PIN/TILT CONSOLE 23 STAND/DRIVE 32 SCREW/CAP
6 BUSHING/PIVOT 15 MOUNT/TOWER 24 BOOT/LEFT 33 SCREW/THREAD
7 NUT/SPIRALOCK™ 16 HANDLE/RATCHET 25 COVER/CONSOLE 34 SCREW/TAPPING
8 HOSE/PRESSURE 17 HOSE AND ADAPTER 26 BOOT/JOYSTICK 35 SCREW/THREAD
9 HOSE/PRESSURE 18 ADAPTER 27 HARNESS/JUMPER 36 WASHER/FLAT

Fig. 7: Exploded view of the 46/4840 dual joystick traction controls.

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CONTROLS DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Wheel Drives - Dual Joystick Controls - 5640 and 2076 Models

31

17
8

18 8 8
8 24
20 TO JOYSTICK
PORT #2
6
24
22 TO JOYSTICK
PORT #4
TO JOYSTICK
PORT #1
1
TO JOYSTICK
PORT #3
5
33
9 3

16

7
27
15 14 TO JOYSTICK
PORT #P
10
19 25
32
13 TO JOYSTICK 2
34 PORT #T 3
34 30
21

29
11 4 23

29

T
ON
FR
12

26

1 FITTING/STRAIGHT 10 VALVE/SOLENOID 19 STAND/DRIVE 28 SCREW/CAP

2 FITTING/TEE 11 PIN/TILT CONSOLE 20 BOOT/LEFT 29 BOLT/CARRIAGE
3 FITTING/90° 12 MOUNT/TOWER 21 COVER/CONSOLE 30 SCREW/CAP
4 BUSHING/PIVOT 13 HANDLE/RATCHET 22 BOOT/JOYSTICK 31 SCREW/THREAD
5 NUT/SPIRALOCK™ 14 ADAPTER 23 HARNESS/JUMPER 32 SCREW/TAPPING
6 HOSE/PRESSURE 15 ADAPTER 24 HOSE AND ADAPTER 33 SCREW/THREAD
7 HOSE/PRESSURE 16 HOSE AND ADAPTER 25 HOSE AND ADAPTER 34 WASHER/FLAT
8 FITTING/90° 17 FLANGE/BOOT 26 NUT/LOCK
9 JOYSTICK/DRIVE 18 FLANGE/BOOT 27 FITTING/TEE

Fig. 8: Exploded view of the 5640 and 2076 dual joystick traction controls.

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DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS CONTROLS

Wheel Drives - Dual Joystick Controls - 6640 and 2086 Models

26 5 5
5 18
TO JOYSTICK
PORT #2
13 1
14

18
16 TO JOYSTICK 3
PORT #4
TO JOYSTICK
PORT #1
TO JOYSTICK
PORT #3
20

4
1
28 19 23
6
TO JOYSTICK
PORT #P 7

1 1
12 11
23
15
27
10 19
29
TO JOYSTICK 21
29
PORT #T
17

25
8 2

25
T
ON
FR

22

1 FITTING/90° 9 MOUNT/TOWER 17 COVER/CONSOLE 25 BOLT/CARRIAGE

2 BUSHING/PIVOT 10 HANDLE/RATCHET 18 HOSE AND ADAPTER 26 SCREW/THREAD
3 HOSE/PRESSURE 11 ADAPTER 19 HOSE AND ADAPTER 27 SCREW/TAPPING
4 HOSE/PRESSURE 12 ADAPTER 20 BOOT/JOYSTICK 28 SCREW/THREAD
5 FITTING/90° 13 FLANGE/BOOT 21 HARNESS/JUMPER 29 WASHER/FLAT
6 JOYSTICK/DRIVE 14 FLANGE/BOOT 22 NUT/LOCK
7 VALVE/SOLENOID 15 STAND/DRIVE 23 FITTING/TEE
8 PIN/TILT CONSOLE 16 BOOT/LEFT 24 SCREW/CAP

Fig. 9: Exploded view of the 6640 and 2086 dual joystick traction controls.

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CONTROLS DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Control Handle Assembly Removal and

Backup Alarm Installation

WARNING
BEFORE beginning this Service procedure,
perform the following SAFETY procedures:
A) Raise lift arm; engage lift arm support
device.
B) Shut off the engine.
C) Roll back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
Fig. 10: Location of four joystick hoses on tandem
chapter of the service manual.)
pump to disconnect. Note that two backup alarm
lines are “teed” into two of the four hoses.
Removal Procedure
1. Remove the control cover per the procedure in the
Mainframe chapter.
2. Underneath the crossmember, disconnect the
connector on the electrical cord found in the left and
right drive stands.

IMPORTANT
Note the wire terminal connections in the
electrical connector for assembling the
joystick handles if replacing the handle’s
electrical cable.
Fig. 11: Location of two joystick hoses to disconnect
at the front of the control valve. 3. Remove four joystick pressure hoses connected at
the tandem pump and four more hoses at the control
valve. Figs. 10, 11 and 12
NOTE: Mark the joystick hydraulic hoses prior to
removing them from the control valve and the tandem
pump for reinstallation later. Cap or plug after they are
disconnected to prevent contaminants from entering
hydraulic system.
1. Remove six capscrews securing the joystick control
handle assembly to the chassis crossmember. Fig.
13
2. Remove the assembly. Fig. 14
Installation Procedure: Follow all warning first,
then reverse the removal steps.
Fig. 12: Location of two joystick hoses to disconnect
at the rear of the control valve.

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DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS CONTROLS

SECTION NOTES

Fig. 13: View of three capscrews securing the control

handle assembly to the crossmember, there are three
more on the opposite end.

Fig. 14: View of the joystick control handle

assembly.

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CONTROLS DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Control Handle Removal and Installation -

Electrical Auxiliary Grip

WARNING
BEFORE beginning this Service procedure,
perform the following SAFETY procedures:
A) Raise lift arm; engage lift arm support
device.
B) Shut off the engine. Console Cover
Drive Stand
C) Roll back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of the service manual.) Fig. 15: Console cover lifts away from drive stand
after removal of four tapping screws.
Removal Procedure
1. Underneath crossmember, disconnect connector on
electrical cord found in right drive stand.
2. Loosen rachet handle on drive stand and tilt right
control handle forward.
Locking Hex Nut
3. Remove four tapping screws securing console cover
to drive stand and remove cover. Fig. 15
4. Pull joystick boot up and inside-out to expose
locking hex nut of electric auxiliary grip and
electrical cord to the grip. Fig. 16
5. Remove two hose lines at ports 1 and 4 attached at
Thread Screw
the bottom of the joystick drive. Mark hoses with
their corresponding port numbers for reinstallation.
Figs. 17, 18 Fig. 16: Location of the locking hex nut that secures
the control grip to the joystick.
6. Remove four thread screws securing joystick drive
to drive stand and rotate drive to access hose line at
port 3. Remove hose line at port three after marking
it. Figs. 19, 20
7. Pull disconnected hose lines down and out of the
drive stand.
8. Pull electrical cord and connector through
remaining hydraulic hose lines and out of the drive
stand. Fig. 21
9. Pull joystick drive up and out of the drive stand and
set the drive on top of the drive stand. Loosen
locking hex nut and unscrew the grip from the
joystick drive. Figs. 16, 22
10.Pull the connector out of the drive stand. Fig. 23
11.Remove the grip from the skid-steer loader. Fig. 17: Hose line at port 4 is removed first.

Installation Procedure: Follow all warnings first,

then reverse the removal steps.

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DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS CONTROLS

Fig. 18: Hose line at port 1 is removed second. Fig. 21: Electrical connector shown coming out of
the bottom of the drive stand.

Joystick Drive

Fig. 19: Remove four thread screws securing joystick Fig. 22: Pull up on joystick drive until it rests on top
drive to drive stand. of the drive stand.

Fig. 20: After rotating joystick drive, hose line at port Fig. 23: Electrical connector shown coming out of
3 is more easily removed. the drive stand.

PRINTED IN USA 15
CONTROLS DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Control Handle Tracking Adjustment

When to Adjust:
With joystick engaged FORWARD or REVERSE, unit
turns slightly left or right (won’t drive in a straight line.)
Forward or Reverse Speed Adjustment Procedure

WARNING
BEFORE beginning this Service procedure,
perform the following SAFETY procedures:
A) Raise lift arm; engage lift arm support
device.
B) Shut off the engine. Fig. 24: Gehl 4640 and 4840 single-speed models
C) Roll back ROPS/FOPS until lock engages. FORWARD position tracking adjustment locations.
(For detailed instructions, refer to the Safety
chapter of the service manual.)

1. Decide which side needs adjusting. If loader turns

right going FORWARD, left side speed must be
reduced and vice versa. DO NOT attempt to
increase speed of either side, it may cause damage
to tandem pumps.

IMPORTANT
46/4840 single-speed models have FORWARD
adjustment points on front right and left rear
locations of the tandem pump (Fig. 24).
REVERSE adjustment points are front left and Fig. 25: Gehl 46/4840 two-speed, 5640 and 6640
right rear. models and Mustang 2076 and 2086 models
FORWARD position tracking adjustment locations.
All other Gehl and Mustang models have
FORWARD adjustment points on the right side
of the pump (Fig. 25). REVERSE adjustment
points are found on the left side of the pump.

2. If loader is turning right in FORWARD position,

remove front plastic cap on tandem pump with
pliers. Use allen wrench to hold stud in place while
loosening locknut. With allen wrench in clockwise
motion, tighten 1/4 turn. Retighten locknut.
3. If loader is turning right in REVERSE position, use 5. If loader is turning left in REVERSE position, use
the adjustment points opposite the FORWARD the adjustment points opposite the FORWARD
position adjustment points in Step 2. position adjustment points in Step 4.
4. If loader is turning left in FORWARD position, 6. Lower and secure ROPS. Start loader. Test loader
remove rear plastic cap on tandem pump with tracking, repeat adjustment as needed.
pliers. Use allen wrench to hold stud in place while
loosening locknut. With allen wrench in clockwise
motion, tighten 1/4 turn. Retighten locknut.

16 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS CONTROLS

Neutral Centering Adjustment

The control piston has strong centering springs to

ensure that once the pump is adjusted for the NEU-
TRAL position so it will always return to NEUTRAL.
Adjustment Procedure - Figs. 26-28

WARNING
BEFORE beginning this Service procedure,
perform the following SAFETY procedures:
A) Raise and block the skid-steer loader so
Fig. 26: Locations for pressure ports X3 and X4. that the tires are off the ground.
B) Raise lift arm; engage lift arm support
device.
C) Roll back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of the service manual.)

1. Remove plugs covering the adjustment screws for

pressure ports X3 and X4. Ports X3 and X4 are open.
2. Install pressure gauges at MA and MB in this
configuration: MA/MB forward valves together and
MA/MB rearward valves together.
3. With the A and B ports blocked and with the
hydrostatic pump running, loosen the jam nuts on
X3 and X4 adjustment screws for the valves tested.
Turn the mechanical centering adjusting screw in-
Fig. 27: Locations for MA valves. or-out until equal pressure is measure on both
gauges.
4. Tighten the jam nut on the adjustment screws when
equal pressure is measured on both gauges.

Fig. 28: Locations for MB valves.

PRINTED IN USA 17
CONTROLS DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

This Page Intentionally Left Blank

18 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS HYDROSTATIC SYSTEM

Introduction
This chapter covers troubleshooting, testing, removal, For detailed information on tandem pump or drive
installation, and adjustment procedures for the tandem motor internal repair, consult the Gehl or Mustang Ser-
pump system components on Gehl and Mustang skid- vice Department and/or the tandem component manu-
steer loaders. facturer’s service manual.

Single-Speed Tandems - Dual Joystick Controls - 4640/4840 Models

MAIN -10 ORB (B,D) 1 FITTING/STRAIGHT
DRAIN -8 ORB (K,L)
CASE FLUSH-DRAIN -8 ORB
2 FITTING/TEE
3 FITTING/STRAIGHT
BRAKE -6 ORB (H,J)
4 FITTING/45°
5 FITTING/TEE
6 FITTING/90°
7 CAP/FLARE
DRAIN -8 ORB
8 CAP/FLARE
MAIN -10 ORB (A,C)
9 FITTING/TEE
DRIVE MOTOR PORT REFERENCE
SINGLE SPEED (STANDARD) WITHOUT SHUTTLES 10 CLAMP/TUBE
11 FITTING/STRAIGHT
33
5 1
1
42 APPLY LOCTITE 242
12 PLUG
TORQUE TO 55 FT-LBS
13 HOSE/PRESSURE
16
13 34 14 SWITCH/TEMPERATURE
F 15 NUT/SPIRALOCK™
16 WASHER/HARD
35 17 HOSE/PRESSURE
G
32 37 18 WASHER/FLAT
11 11 19 HOSE/PRESSURE
36 D 20 SCREW/CAP
4

38
39 21 MOTOR/SINGLE-SPEED
B
21 22 TUBE/MOTOR DRAIN LEFT
A C
6 12
26 N
23 TUBE/BRAKE LEFT
H 30 41
D
43 24 TUBE/BRAKE RIGHT
10
44 L
G
3 25 HOSE/PRESSURE
18 25
15 26 VALVE/SOLENOID
C
30 27 PLATE/SPACER
27 6 28 MANIFOLD
17
H 24
8 2
19 29 TUBE/BRAKE VALVE
7
N
30 FITTING/STRAIGHT
M
J
29 31 TUBE/MOTOR DRAIN RIGHT
28
32 PUMP/TANDEM
20 9
14 M
23
33 TUBE/CHARGE
K
34 FITTING/TEE
35 FITTING/45°
L 40
7
K 1
21 36 HOSE/PRESSURE
22 F 37 HOSE/PRESSURE
31 18
44
38 HOSE/PRESSURE
30 J 39 HOSE/PRESSURE
B
40 HOSE/PRESSURE
12 6
41 HOSE/PRESSURE
A
30
42 SCREW/CAP
43 SCREW/CAP
44 SCREW/CAP

Fig. 29: Exploded view of single-speed tandems for 4640 and 4840 dual joystick controls.

PRINTED IN USA 19
HYDROSTATIC SYSTEM DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Two-Speed Tandems - Dual Joystick Controls - 4640/4840 Models

1
34 APPLY LOCTITE 242
43
TORQUE TO 55 FT-LBS
1

E 16
5
13

10

35 27
39 4
D
33 E
12

N
11
38 37 3
B
A C
36 25
40
F
9 G 44
2
41 6
J 15
D J 19
45
26
18 H
H L
31
C
12 M
N
21
7 32
17 K
M 22 42
20
30
28 F
14 18
45
9
G
12

L
24 B
K
A
MAIN IN -12 ORB (B,D)

23
41 29
2-SPEED -08 ORB (J,K)

MAIN OUT -12 ORB (A,C)

BRAKE -08 ORB (H,L)
CASE FLUSH-DRAIN -10 ORB (G)

DRIVE MOTOR PORT REFERENCE WITH SHUTTLE

1 FITTING/STRAIGHT 13 HOSE/PRESSURE 25 MANIFOLD/VALVE 37 HOSE/PRESSURE

2 FITTING/TEE 14 SWITCH/TEMP 26 PLATE/SPACER 38 HOSE/PRESSURE
3 FITTING/STRAIGHT 15 NUT/SPIRALOCK™ 27 HOSE/PRESSURE 39 HOSE/PRESSURE
4 FITTING/45° 16 WASHER/HARD 28 MANIFOLD 40 HOSE/PRESSURE
5 FITTING/TEE 17 HOSE/PRESSURE 29 TUBE/BRAKE LEFT 41 FITTING/STRAIGHT
6 FITTING/90° 18 WASHER/FLAT 30 TUBE/DRAIN 42 FITTING/TEE
7 CAP/FLARE 19 HOSE/PRESSURE 31 TUBE/BRAKE 43 SCREW/CAP
8 CAP/FLARE 20 SCREW/CAP 32 TUBE/MOTOR 44 SCREW/CAP
9 FITTING/STRAIGHT 21 MOTOR/RIGHT 33 PUMP/TANDEM 45 SCREW/CAP
10 FITTING/90° 22 MOTOR/LEFT 34 TUBE/CHARGE
11 CLAMP/TUBE 23 TUBE/MOTOR LEFT 35 FITTING/45°
12 FITTING/STRAIGHT 24 TUBE/DRAIN 36 HOSE/PRESSURE
Fig. 30: Exploded view of two-speed tandems for 4640 and 4840 dual joystick controls.

20 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS HYDROSTATIC SYSTEM

Single-Speed Tandems - 5640 and 2076 Models

1
34
16
H 39
5

22 L
APPLY LOCTITE 242
TORQUE TO 55 FT-LBS

11 12

30 37

33 H
18

D
36 37
41 18
17 F
B C
35 L
23
18
A 20 28
38 D 21 13 40 4
3

J 7

10 N 40 N
K
F 15 6

M G 2
14 31
19
8
C
32
M K
18 29 24 J

27
18

B E

10 9
25
G
41
18
38 A 17

26 BRAKE -8 ORB (E,J)

MAIN IN -12 ORB (B,D)

MAIN OUT -12 ORB (A,C)

CASE FLUSH-DRAIN -10 ORB (G,M)

DRIVE MOTOR PORT REFERENCE
SINGLE SPEED WITH SHUTTLE
1 FITTING/STRAIGHT 12 FITTING/90° 23 MOTOR/RIGHT 34 TUBE/CHARGE
2 FITTING/TEE 13 HOSE/PRESSURE 24 MOTOR/LEFT 35 HOSE/PRESSURE
3 FITTING/STRAIGHT 14 SWITCH/TEMP. 25 HOSE/PRESSURE 36 HOSE/PRESSURE
4 FITTING/45° 15 NUT/SPIRALOCK™ 26 TUBE/BRAKE LEFT 37 HOSE/PRESSURE
5 FITTING/TEE 16 WASHER/HARD 27 TUBE/BRAKE RIGHT 38 FITTING/STRAIGHT
6 FITTING/90° 17 WASHER/FLAT 28 VALVE/SOLENOID 39 SCREW/CAP
7 CAP/FLARE 18 FITTING/STRAIGHT 29 TUBE/DRAIN 40 SCREW/CAP
8 CAP/FLARE 19 HOSE/PRESSURE 30 HOSE/PRESSURE 41 SCREW/CAP
9 FITTING/TEE 20 HOSE/PRESSURE 31 MANIFOLD
10 FITTING/STRAIGHT 21 SCREW/CAP 32 TUBE/BRAKE
11 FITTING/45° 22 HOSE/PRESSURE 33 PUMP/TANDEM

Fig. 31: Exploded view of single-speed tandems for 5640 and 2076 dual joystick controls.

PRINTED IN USA 21
HYDROSTATIC SYSTEM DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Two-Speed Tandems - 5640 and 2076 Models

S 36
1
42 16
21 L APPLY LOCTITE 242
TORQUE TO 55 FT-LBS

5 12

32

11
40

40
35
D
18 S
44 18
17
39
18 B
38 P
22 D
10 20
A N
7 13 C
41 37 3
33 29
J M

K L

14 P 15
H G 43
41
M 6 4
3
31
H N
28 8
C
19
18 26
9 2
J K
F 30

G 34
23
24
F E
10
9
27
18 44

B 17

18
41 E
MAIN IN -12 ORB (B,D)
25

2-SPEED -08 ORB (F,H)

MAIN OUT -12 ORB (A,C)

BRAKE -08 ORB (E,J)
CASE FLUSH-DRAIN -10 ORB (G,M)

DRIVE MOTOR PORT REFERENCE WITH SHUTTLE

1 FITTING/STRAIGHT 12 FITTING/90° 23 MOTOR/LEFT 34 TUBE/BRAKE

2 FITTING/TEE 13 HOSE/PRESSURE 24 HOSE/PRESSURE 35 PUMP/TANDEM
3 FITTING/STRAIGHT 14 SWITCH/TEMP. 25 TUBE/BRAKE LEFT 36 TUBE/CHARGE
4 FITTING/45° 15 NUT/SPIRALOCK™ 26 TUBE/BRAKE RIGHT 37 HOSE/PRESSURE
5 FITTING/TEE 16 WASHER/HARD 27 TUBE/TWO-SPEED 38 HOSE/PRESSURE
6 FITTING/90° 17 WASHER/FLAT 28 TUBE/TWO-SPEED 39 HOSE/PRESSURE
7 CAP/FLARE 18 FITTING/STRAIGHT 29 MANIFOLD/VALVE 40 HOSE/PRESSURE
8 CAP/FLARE 19 HOSE/PRESSURE 30 TUBE/VALVE 41 FITTING/STRAIGHT
9 FITTING/TEE 20 SCREW/CAP 31 TUBE/DRAIN 42 SCREW/CAP
10 FITTING/STRAIGHT 21 HOSE/PRESSURE 32 HOSE/PRESSURE 43 SCREW/CAP
11 FITTING/45° 22 MOTOR/RIGHT 33 MANIFOLD 44 SCREW/CAP

Fig. 32: Exploded view of two-speed tandems for 5640 and 2076 dual joystick controls.

22 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS HYDROSTATIC SYSTEM

Single-Speed Tandems - 6640 and 2086 Models

1 33

S 1 16 APPLY LOCTITE 242

38
TORQUE TO 55 FT-LBS
R
36
5

12

28
40
17 11 31
31
32 S
18
22 18
D
D
B 34
37 34
C
J F
A 20
27 39
M
10 R

C 3
4
18 15
21 7 N
6
N 2

29 25 8
J 19
K 13
14
F K
26
G
M
30
23 9
18 E

B 17

G
10 40

35
37 18
A
E

24
BRAKE -8 ORB (E,J)

MAIN IN -12 ORB (B,D)

MAIN OUT -12 ORB (A,C)

CASE FLUSH-DRAIN -10 ORB (G,M)

DRIVE MOTOR PORT REFERENCE

SINGLE SPEED WITH SHUTTLES

1 FITTING/STRAIGHT 11 FITTING/45° 21 SCREW/CAP 31 HOSE/PRESSURE

2 FITTING/TEE 12 FITTING/90° 22 MOTOR/SRIGHT 32 PUMP/TANDEM
3 FITTING/STRAIGHT 13 HOSE/PRESSURE 23 MOTOR/LEFT 33 TUBE/CHARGE
4 FITTING/45° 14 SWITCH/TEMP. 24 TUBE/BRAKE LEFT 34 HOSE/PRESSURE
5 FITTING/TEE 15 NUT/SPIRALOCK™ 25 TUBE/BRAKE RIGHT 35 HOSE/PRESSURE
6 FITTING/90° 16 WASHER/HARD 26 TUBE/DRAIN RIGHT 36 HOSE/PRESSURE
7 CAP/FLARE 17 WASHER/FLAT 27 VALVE/SOLENOID 37 FITTING/STRAIGHT
8 CAP/FLARE 18 FITTING/STRAIGHT 28 HOSE/PRESSURE 38 SCREW/CAP
9 FITTING/TEE 19 HOSE/PRESSURE 29 MANIFOLD 39 SCREW/CAP
10 FITTING/STRAIGHT 20 HOSE/PRESSURE 30 TUBE/BRAKE 40 SCREW/CAP

Fig. 33: Exploded view of single-speed tandems for 6640 and 2086 dual joystick controls.

PRINTED IN USA 23
HYDROSTATIC SYSTEM DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Two-Speed Tandems - 6640 and 2086 Models

S 35
1
38
5 16
R
APPLY LOCTITE 242
LIFT & TILT JOYSTICK PILOT 41 S
TORQUE TO 55 FT-LBS
11
12

43 30
34
17
33
4
D

18
C
40 J D
P 3 N 29
18 36
M
H
B R
C 39 3 42
A
10 40 15
N 6
18 26
20
7 2 19
21 J
8 27
H
13 9
31
K 24 K
F
P 22
14 G
32
E
18 9

B 17
28 43
M
F

G 10
A 18
37
E

25 40

23 MAIN IN -12 ORB (B,D)

BRAKE -08 ORB (E,J)

2-SPEED -08 ORB (F,H)

CASE FLUSH-DRAIN -10 ORB (G,M)

MAIN OUT -12 ORB (A,C)

DRIVE MOTOR PORT REFERENCE

1 FITTING/STRAIGHT 12 FITTING/90° 23 TUBE/BRAKE LEFT 34 PUMP/TANDEM

2 FITTING/TEE 13 HOSE/PRESSURE 24 TUBE/BRAKE RIGHT 35 TUBE/CHARGE
3 FITTING/STRAIGHT 14 SWITCH/TEMP. 25 TUBE/LEFT 36 HOSE/PRESSURE
4 FITTING/45° 15 NUT/SPIRALOCK™ 26 TUBE/RIGHT 37 HOSE/PRESSURE
5 FITTING/TEE 16 WASHER/HARD 27 TUBE/VALVE 38 HOSE/PRESSURE
6 FITTING/90° 17 WASHER/FLAT 28 TUBE/DRAIN 39 HOSE/PRESSURE
7 CAP/FLARE 18 FITTING/STRAIGHT 29 MANIFOLD/VALVE 40 FITTING/STRAIGHT
8 CAP/FLARE 19 HOSE/PRESSURE 30 HOSE/PRESSURE 41 SCREW/CAP
9 FITTING/TEE 20 SCREW/CAP 31 MANIFOLD 42 SCREW/CAP
10 FITTING/STRAIGHT 21 MOTOR/RIGHT 32 TUBE/BRAKE 43 SCREW/CAP
11 FITTING/45° 22 MOTOR/LEFT 33 HOSE/PRESSURE

Fig. 34: Exploded view of two-speed tandems for 6640 and 2086 dual joystick controls.

24 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS HYDROSTATIC SYSTEM

Hydrostatic Pump Removal / Installation

WARNING
BEFORE beginning this Service procedure,
perform the following SAFETY procedures:
A) Raise lift arm; engage lift arm support
device.
B) Shut off the engine.
C) Roll back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
Fig. 35: Remove the gear pump with the hoses still chapter of the service manual.)
attached.
Removal Procedure - Figs. 35-37
1. Drain oil from hydraulic reservoir. Refer to the
Lubrication chapter of the service manual.
2. Remove control and floor cover per the procedure
in the Mainframe chapter of this addendum.
3. Remove six bolts securing the crossmember to the
chassis and remove the crossmember.
4. Support the gear pump. Remove two capscrews
securing the gear pump to the hydrostatic pump.
Pull the gear pump forward.
5. Disconnect hydraulic hoses connected to the
hydrostatic pump.
NOTE: Mark hoses and fittings for reassembly and cap
Fig. 36: View of the many hoses on the sides and top or plug them after they are disconnected to prevent
of the hydrostatic pump to remove. contaminants from entering hydraulic system.
1. Position a hoist above the hydrostatic pump. Attach
lifting straps around pump and raise hoist to remove
slack from strap. The hoist should now support the
weight of the pump.
2. Remove capscrews securing pump to flywheel
housing.
3. Three-Cylinder Engines Only: Unbolt two
capscrews underneath the front of the pump
securing the pump support to the hydrostatic pump.
4. Shift the pump forward to disengage the splined
shaft drive of the pump.
5. Lift and maneuver pump out of skid-steer loader.
Installation Procedure - Follow all WARNINGS
Fig. 37: Some units have backup alarms “teed” into first, then reverse the removal steps.*
the hoses that are to be removed. Remove the hoses
* Before reassembling the pump to the engine, grease
at the 90° fittings with alarms attached.
the spline shaft drive of the pump with silver anti-seize
ithium grease.

PRINTED IN USA 25
HYDROSTATIC SYSTEM DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Troubleshooting Guide
Problem Possible Cause Remedy

Traction drive will not operate Inadequate pilot supply oil Check pilot supply oil pressure.
in either direction. pressure to joystick control. Check pilot supply cut out
solenoid.
Drive wheels do not turn in Joystick pilot controller hoses Reconnect hoses to proper ports
proper direction for connected wrong. on hydrostatic pump. Refer to
movement. schematic and figures.
Neutral is difficult to Joystick control valve Replace joystick control valve.
maintain. malfunction.
Right side/Left side doesn’t Joystick control valve Replace joystick control valve.
drive in one direction. malfunction.
Creeps in NEUTRAL. Hydrostatic pump needs Refer to the “Neutral Centering
adjustment. Adjustment” procedure in the
Controls chapter of this
addendum.
Turns slightly left or right in Hydrostatic pump needs Refer to the “Control Handle
FORWARD or REVERSE adjustment. Tracking Adjustment”
position when using the procedure in the Controls
traction drive control handle. chapter of this addendum.

The troubleshooting guide lists potential hydrostatic

system problems, as well as possible causes and reme-
dies, for Gehl-Mustang skid-steer loaders.

If you cannot locate a particular hydrostatic system

problem in this chart, you should also consult the
Hydraulic 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.

26 PRINTED IN USA
HYDROSTATIC SYSTEM

27
MAIN RELIEF VALVE
HIGH FLOW VALVE
HIGH FLOW MAIN CONTROL VALVE 2750 PSI - 46/4840 (OPTION) 3 MICRON RETURN
COUPLERS 3000 PSI - 56/6640-2076/86 FILTER 50 PSI
(OPTION) (3 BAR) BYPASS
P
PORT RELIEF: 3500 PSI
HIGH FLOW CASE DRAIN LIFT
DRIVE 1A T
MOTOR* 4.5 CU IN TILT 1B
4 140 PSI 2A
T PRECHARGE 2B
2
3
P 3A
1 AUXILIARY
3B
PB T
LIFT/TILT
JOYSTICK P OIL
COOLER
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

HYD. ALT-TACH
CYLINDER SAFETY LOCK HYDROSTATIC
(OPTION) SOLENOID TANDEM PUMP
2.81 CU. IN. TANK
HIGH FLOW
5500 PSI RELIEF
Hydrostatic/Hydraulic Schematic - Dual Joystick Controls

S X1 X2 MA A A MA X2 X1
2500 PSI - 46/4840
G1
2900 PSI - 56/6640-2076/86
OPTIONAL
HIGH FLOW
PUMP R MB G Y MB T R
B B
TILT CYLINDERS LIFT CYLINDERS
2 SPEED
SOLENOID
(OPTION) DRIVE MOTOR
BRAKE DISPLACEMENTS:
SOLENOID
HYDRAULIC SAFETY LOCK 46/4840 SINGLE-SPEED
ALT-TACH SOLENOID 24.3 CU. IN.
SOLENOID
(OPTION) 46/4840 TWO-SPEED
34.2 CU. IN.
TRAVEL TRAVEL
JOYSTICK 56/6640-2076/86 SINGLE-SPEED
JOYSTICK SOLENOID
4 38.4 CU. IN.
T
2 56/6640-2076/86 TWO-SPEED
DRIVE 38.4 CU. IN.

PRINTED IN USA
3 MOTOR*
P
85 CU IN D C ONE-WAY
1 700 PSI G A B SELF LEVEL
PRECHARGE AB
AC 1A 1
3 T
AUXILIARY HYDRAULIC
COUPLERS HYDRAGLIDE
HYDROSTATIC SYSTEM DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

SECTION NOTES

28 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS HYDRAULIC SYSTEM

Introduction
This chapter covers troubleshooting, testing, removal, equipped with high-flow hydraulics, which includes a
installation, and adjustment procedures for hydraulic connectors on the right side of the lift arm, for
system components on Gehl-Mustang skid-steer operating attachments that require higher hydraulic
loaders. Primary hydraulic system components in this flow.
chapter are shown below and on following pages.
Information on recommended hydraulic fluids,
Power for the lift arm functions and auxiliary capacities and filter change intervals is in the
hydraulics is provided by a gear pump attached to the Lubrication chapter. For detailed information on gear
front of the tandem pumps. pump or control valve internal repair, consult the Gehl
or Mustang Service Department and/or the hydraulic
Standard and high-flow models include a standard-flow component manufacturer’s service manual. Hydraulic
auxiliary hydraulics system with connections on the lift components related to the drive system are covered in
arm for attachment hookup. High-flow models are the Hydrostatic System chapter.

Standard Auxiliary - Dual Joystick Controls - 4640 and 4840 Models

10

7 2
9
15

14 16

18 11
17 13
4
8 12
6
18
17

1 FITTING/90° 5 FITTING/90° - 4840 10 TUBE/RETURN 15 BOLT/CARRIAGE

2 WASHER/FLAT 6 FITTING/45° 11 TUBE/SUCTION 16 SCREW/CAP
3 NUT/LOCK 7 CLAMP/HOSE 12 HOSE/SUCTION 17 SCREW/CAP
4 NUT/HEX 8 PUMP/GEAR SINGLE 13 CLAMP/TUBE 18 WASHER/LOCK
5 FITTING/STRT - 4640 9 HOSE/PRESSURE 14 PLATE/TUBE CLAMP

Fig. 38: Exploded view of standard auxiliary hydraulics for 4640 and 4840 dual joystick controls.

PRINTED IN USA 29
HYDRAULIC SYSTEM DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Standard Auxiliary - Dual Joystick Controls - 5640 and 6640 Models

4 8
7

3
6
9
2
10

1 FITTING/90° 4 CLAMP/HOSE 7 HOSE/PRESSURE 10 WASHER/LOCK

2 FITTING/90° 5 HOSE/SUCTION 8 TUBE/RETURN
3 FITTING/45° 6 PUMP/GEAR SINGLE 9 SCREW/CAP

Fig. 39: Exploded view of standard auxiliary hydraulics for 5640 and 6640 dual joystick controls.

30 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS HYDRAULIC SYSTEM

Standard Auxiliary - Dual Joystick Controls - 2076 and 2086 Models

2076 Models
1

TO HYDRAULIC
OIL RESERVOIR
7

3
12 11 7 2

4 10
9
3
8
13
15
5

7
14 6
16

1 ELBOW/FITTING 90° 7 CLAMP/HOSE 13 HOSE/SUCTION

2 WASHER/FLAT 8 O-RING 14 SCREW/CAP
3 NUT/HEX WHIZLOCK 9 PUMP/GEAR SINGLE 15 BOLT/CARRIAGE
4 FITTING/90° 10 TUBE/SUCTION 16 WASHER/LOCK
5 SCREW/CAP WHIZLOCK 11 TUBE/RETURN
6 FITTING/45° 12 HOSE/PRESSURE

1
2086 Models

1 ELBOW/FITTING 90°
2 CLAMP/HOSE
3 PUMP/GEAR SINGLE
4 SCREW/CAP
5 WASHER/LOCK

4 3

Fig. 40: Exploded view of standard auxiliary hydraulics for 2076 and 2086 dual joystick controls.

PRINTED IN USA 31
HYDRAULIC SYSTEM DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

High Flow Auxiliary - Dual Joystick Controls - 4640 and 4840 Models

21

22
24

16
34 23
31
5

7
33
REPLACES BOLT 17
FROM THROTTLE
PIVOT HANDLE 14

2 32 11
39
10
2 3

25
20 30
10
3
13
26 9
19
1

35

36

18 29
6

15
28
6

4
38 27

12 8
37

1 WASHER/FLAT 11 NUT/SPIRALOCK™ 21 TUBE/HIGH FLOW 31 ROD/CONTROL

2 RING/RETAINING 12 PUMP/GEAR DOUBLE 22 TUBE/HIGH FLOW 32 HANDLE
3 NUT/HEX WHIZLOCK 13 PLUG/POWER 23 VALVE/HIGH FLOW 33 SCREW/CAP
4 NUT/HEX 14 BRACKET/VALVE 24 TUBE/OUTLET 34 SCREW/CAP
5 FITTING/STRAIGHT 15 HOSE/PRESSURE 25 TUBE/RETURN 35 BOLT/CARRIAGE
6 FITTING/90° 16 TUBE/INLET 26 TUBE/SUCTION 36 SCREW/CAP
7 FITTING/TEE 17 CLEVIS 27 HOSE/SUCTION 37 SCREW/CAP
8 FITTING/45° 18 FITTING/TEE 28 CLAMP/TUBE 38 WASHER/LOCK
9 CLAMP/HOSE 19 HOSE/PRESSURE 29 PLATE/TUBE CLAMP 39 NUT/HEX
10 BUSHING/PIVOT 20 CLIP/RETAINING 30 SHAFT/PIVOT

Fig. 41: Exploded view of high-flow auxiliary hydraulics for 4640 and 4840 dual joystick controls.

32 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS HYDRAULIC SYSTEM

High Flow Auxiliary - Dual Joystick Controls - 5640 and 6640 Models

29 22

18

19 4
2
28

6 11

14 13 23
32

12 9
REPLACES BOLT 27
FROM THROTTLE
PIVOT HANDLE
21
10
1
25

15
8

17 26 7

5
31

30
16 3

24

1 RING/RETAINING 9 NUT/SPIRALOCK™ 17 CLIP/RETAINING 25 SHAFT/PIVOT

2 FITTING/STRAIGHT 10 PLUG/POWER 18 TUBE/HIGH FLOW 26 HANDLE
3 FITTING/90° 11 BRACKET/VALVE 19 TUBE/HIGH FLOW 27 ROD/CONTROL
4 FITTING/TEE 12 TUBE/INLET 20 VALVE/HIGH FLOW 28 SCREW/CAP
5 FITTING/45° 13 NUT/SPIRALOCK™ 21 HOSE/PRESSURE 29 SCREW/CAP
6 CLAMP/HOSE 14 CLEVIS 22 TUBE/OUTLET 30 SCREWCAP
7 BUSHING/PIVOT 15 FITTING/TEE 23 TUBE/RETURN 31 WASHER/LOCK
8 HOSE/SUCTION 16 PUMP/GEAR DOUBLE 24 HOSE/PRESSURE 32 NUT/HEX

Fig. 42: Exploded view of high-flow auxiliary hydraulics for 5640 and 6640 dual joystick controls.

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HYDRAULIC SYSTEM DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

High Flow Auxiliary - Dual Joystick Controls - 2076 Models

34 22

19

REPLACES BOLT 20
27
FROM THROTTLE 4
28 32
PIVOT HANDLE
8 12
TO HYDRAULIC
25
15 OIL RESERVOIR
14
9 37

10
13
17 2 11
16

3
1
30
24 8

23

5 26
35
5

8 18

36

29 7 31
33

1 WASHER/FLAT 14 NUT/SPIRALOCK™ 27 HANDLE

2 RING/RETAINING 15 CLEVIS 28 ROD/CONTROL
3 NUT/HEX WHIZLOCK 16 FITTING/TEE 29 PUMP/GEAR DOUBLE
4 FITTING/STRAIGHT 17 CLIP/RETAINING 30 HOSE/PRESSURE
5 FITTING/90° 18 SCREW/CAP 31 HOSE/SUCTION
6 FITTING/TEE 19 TUBE/HIGH FLOW 32 SCREW/CAP
7 FITTING/45° 20 TUBE/HIGH FLOW 33 SCREW/CAP
8 CLAMP/HOSE 21 VALVE/HIGH FLOW 34 SCREW/CAP
9 BUSHING/PIVOT 22 TUBE/OUTLET/FILTER 35 BOLT/CARRIAGE
10 NUT/SPIRALOCK™ 23 TUBE/SUCTION 36 WASHER/LOCK
11 PLUG/POWER 24 TUBE/RETURN 37 NUT/HEX
12 BRACKET/VALVE 25 SHAFT/PIVOT
13 TUBE/INLET 26 HOSE/PRESSURE

Fig. 43: Exploded view of high-flow auxiliary hydraulics for 2076 dual joystick controls.

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DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS HYDRAULIC SYSTEM

High Flow Auxiliary - Dual Joystick Controls - 2086 Models

25 18
15

16

24 4
5 12 17
28
9
7 11
10

22 8
REPLACES BOLT
FROM THROTTLE
PIVOT HANDLE

1 19
20 13

14 21 27
6

23
26

1 RING/RETAINING 11 NUT/SPIRALOCK™ 21 HANDLE

2 FITTING/STRAIGHT 12 CLEVIS 22 ROD/CONTROL
3 FITTING/90° 13 FITTING/TEE 23 PUMP/DOUBLE GEAR
4 FITTING/TEE 14 CLIP/RETAINING 24 SCREW/CAP
5 CLAMP/HOSE 15 TUBE/HIGH FLOW 25 SCREW/CAP
6 BUSHING/PIVOT 16 TUBE/HIGH FLOW 26 SCREW/CAP
7 NUT/SPIRALOCK™ 17 VALVE/HIGH FLOW 27 WASHER/LOCK
8 PLUG/POWER 18 TUBE/OUTLET 28 NUT/HEX
9 BRACKET/VALVE 19 HOSE/PRESSURE
10 TUBE/INLET 20 SHAFT/PIVOT

Fig. 44: Exploded view of high-flow auxiliary hydraulics for 2086 dual joystick controls.

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HYDRAULIC SYSTEM DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Troubleshooting Guide
Problem Possible Cause Remedy

Hydraulic cylinder action is Inadequate pilot supply oil Check pilot supply oil pressure.
slow for lift/tilt control pressure to joystick control.
functions. Lift/Tilt controls
fail to respond. Inadequate pilot signal from Check signal pressure, clean or
joystick control to the main replace as needed.
control valve.
Lift Arm doesn’t maintain Hydraglide/Float control block Repair or replace as needed.
raised position with lift with internal leakage.
control in NEUTRAL.
Lift cylinder leakage. Repair or replace as needed.

Float control is activated. Deactivate float control by

pressing the button on the
control handle (top-center light
blue button in right joystick
control).
Lift Arm will not raise a heavy Float control is activated. Deactivate float control by
load or any load at all. pressing the button on the
control handle (top-center light
blue button in right joystick
control).
No downward pressure on the Float control is activated. Deactivate float control by
bucket. pressing the button on the
control handle (top-center light
blue button in right joystick
control).

The troubleshooting guide lists potential hydraulic

system problems, as well as possible causes and
remedies, for Gehl-Mustang skid-steer loaders.

If you cannot locate a particular hydraulic system

problem in this chart, you should also 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.

36 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS ELECTRICAL SYSTEM

Introduction
Gehl and Mustang dual joystick controls have, as stan- flow button at the front of the right control handle that
dard equipment, electrically-controlled auxiliary when pressed while the rocker is fully activated in
hydraulics. Electrical auxiliary hydraulics with a yel- either direction, allows for the continuous flow of aux-
low-colored proportional flow control rocker switch in iliary hydraulic oil without having to maintain the yel-
the right control handle can be moved forward or rear- low rocker switch. Push the red button again, or bump
ward, providing for flow in one direction or the other. the yellow rocker switch in either direction and auxil-
The further the switch is moved from neutral, the faster iary hydraulic oil flow will stop.
the auxiliary flow. There is a red-colored continuous

Proportional Aux. Hyd. Control Rocker

Auxiliary Hydraulic Lock

Electrical Auxiliary Harness Assembly - Dual Joystick Controls

TO:
KEYED POWER
FLOAT
RIDE CONTROL
1
2
4

TO:
TO: SAFETY
JOYSTICK
INTERLOCK
CKT.
3

1 RELAY 3 HARNESS
2 NUT/SERRATED 4 DIODE

Fig. 45: Exploded view of the electrical auxiliary harness for dual joystick controls.

PRINTED IN USA 37
ELECTRICAL SYSTEM DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

Electrical Auxiliary Main Control Valve

3 7

8 FROM ACCUMULATOR
RETURN TO
6
MANIFOLD

9 14

NOTES:
13 1) PILOT TYPE MAIN RELIEF SET TO 2750 PSI AT 20 GPM
2) DIRECT ACTING PORT RELIEF SET TO 3500 PSI AT 1 GPM
3) NEUTRAL SPOOL LOCK TO BE ENERGIZED TO OPERATE AUX
4) SERIES CONNECTION FROM LIFT TO TILT AND TILT TO AUX
5) NO FLOAT IN LIFT
6) 9/16-18 O-RING PILOT PORTS ON LIFT AND TILT
7) 7/8-14 O-RING WORK PORTS
8) 7/8-14 O-RING INLET PORT
9) 1-1/16-12 O-RING OUTLET PORT

1 SECTION/OUTLET 8 SECTION/VALVE TILT

2 SECTION/INLET 9 SECTION/VALVE ELECTRIC AUXILIARY
3 VALVE/RELIEF 13 CARTRIDGE ON-OFF
6 VALVE/WORK PORT RELIEF 14 SOLENOID/PROPORTIONAL
7 SECTION/VALVE LIFT

Fig. 46: Exploded view of the electrical auxiliary main control valve.

38 PRINTED IN USA
DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS INDEX

A
Adjustment
Neutral Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

C
Controls
Control Handle Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control Handle Removal and Installation - Electrical Auxiliary Grip . . . . . . . . . . . . . . . . . . . . . . . . 14
Control Handle Tracking Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Neutral Centering Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

E
Electrical System
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Exploded Views
Control Covers - Joystick Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Auxiliary Harness Assembly - Dual Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Electrical Auxiliary Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
High Flow Auxiliary - Dual Joystick Controls - 2076 Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
High Flow Auxiliary - Dual Joystick Controls - 2086 Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
High Flow Auxiliary - Dual Joystick Controls - 4640 and 4840 Models. . . . . . . . . . . . . . . . . . . . . . 32
High Flow Auxiliary - Dual Joystick Controls - 5640 and 6640 Models. . . . . . . . . . . . . . . . . . . . . . 33
Lift and Tilt - Dual Joystick Controls (with Electric Auxiliary) - All Models . . . . . . . . . . . . . . . . . . . 8
Single-Speed Tandems - 5640 and 2076 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Single-Speed Tandems - 6640 and 2086 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Single-Speed Tandems - Dual Joystick Controls - 4640/4840 Models . . . . . . . . . . . . . . . . . . . . . . . 19
Standard Auxiliary - Dual Joystick Controls - 2076 and 2086 Models . . . . . . . . . . . . . . . . . . . . . . . 31
Standard Auxiliary - Dual Joystick Controls - 4640 and 4840 Models . . . . . . . . . . . . . . . . . . . . . . . 29
Standard Auxiliary - Dual Joystick Controls - 5640 and 6640 Models . . . . . . . . . . . . . . . . . . . . . . . 30
Two-Speed Tandems - 5640 and 2076 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Two-Speed Tandems - 6640 and 2086 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Two-Speed Tandems - Dual Joystick Controls - 4640/4840 Models . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wheel Drives - Dual Joystick Controls - 4640 and 4840 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wheel Drives - Dual Joystick Controls - 5640 and 2076 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wheel Drives - Dual Joystick Controls - 6640 and 2086 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

H
Hydraulic System
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Hydrostatic System
Hydrostatic Pump Removal / Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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INDEX DUAL JOYSTICK/ELECTRIC AUXILIARY HYDRAULICS

M
Mainframe
Dual Joystick Control Cover/Floor Cover Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

S
Safety
Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mandatory Safety Shutdown Procedur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e 4
Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Schematics
Hydrostatic/Hydraulic Schematic - Dual Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

T
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Troubleshooting Guides
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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