SL4640 SL4840 SL5640 SL6640 Skid Loader PDF

SL46/4840 Form No.
917002
SL56/6640
Skid-Steer
Loaders
Service Manual
INTRODUCTION
With correct maintenance and proper use, Gehl 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 40 Series family of skid-steer
loaders.
In many of the procedures found within, the installation steps are the exact opposite of the
removal steps and vice versa, and therefore, the opposite procedure is not written. Instead, a
note to reverse the procedure will be stated. This reduces redundancy and excessive pages in
the manual. In cases though, where the assembly and disassembly or removal and
installation procedures differ and additional steps or safety concerns are paramount, the
entire reverse procedure will be written out to include the new information.
The Table of Contents and Index can be used to make the procedure you need to find an
easier process. Also, there are black tabs extending off the pages highlighting the chapters
for those who prefer to thumb through the manual. Many schematics, photographs, and line
art drawings are used to help perform the necessary repairs, tests, or adjustments that the 40
Series skid-steer loaders need to keep them in good running condition.
If you have any additional questions, please contact your authorized Gehl dealer or call the
Gehl Service Department for assistance.
Gehl is a registered trademark of the Gehl Company.

40 SERIES TABLE OF CONTENTS
TABLE OF CONTENTS
Specifications Page 1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Tire Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Buckets and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Page 2-1

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Additional Safety Reminders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Liftarm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Liftarm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Liftarm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Rollover Protective Structure (ROPS) - Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Rollover Protective Structure (ROPS) - Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Lubrication Page 3-1

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Hydraulic Oil Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Crankcase Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Grease Fitting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cooling System Drain Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Mainframe Page 4-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Engine Access Covers - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Rollover Protective Structure (ROPS) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Seat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Seat Slide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Air Duct Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Air Duct Louver Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
PRINTED IN USA i 917002/AP0704

TABLE OF CONTENTS 40 SERIES
Rollover Protective Structure (ROPS) Rear Window Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 4-9
Restraint Bar Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Gehl All-Tach™, Power-A-Tach™ Hitch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Liftarm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Liftarm Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Liftarm Stop Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Control Cover, Floor Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Fuel Sensor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Wheel Drives Page 5-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Axle Housing Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Drive Chain Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Axle and Wheel Bearing Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Controls Page 6-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Control Handle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Control Handle Position Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Control Handle Tracking Adjustment, Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
T-Bar Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Hand/Foot Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Dual Hand Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Pivot Tube Removal and Installation - T-Bar, Hand/Foot and Dual Hand. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Neutral Centering Device Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Control Arm Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Lift/Tilt Control Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Lift/Tilt Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Auxiliary Hydraulics Cable Removal and Installation - T-Bar and Dual Hand . . . . . . . . . . . . . . . . . . . . . . . 6-27
Auxiliary Hydraulics Cable Adjustment - T-Bar and Dual Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Auxiliary Hydraulics Cable Removal and Installation - Hand/foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Auxiliary Hydraulics Cable Adjustment - Hand/foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Hand Throttle, Rod and Cable Removal and Installation - T-Bar and Dual Hand . . . . . . . . . . . . . . . . . . . . . 6-33
Foot Throttle Removal and Installation - T-Bar and Dual Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Hand Throttle Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
All-Tach is a trademark of the Gehl Company.
917002/AP0704 ii PRINTED IN USA

40 SERIES TABLE OF CONTENTS
Hand Throttle and Throttle Cable Removal and Installation - Hand/Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Hand Throttle Adjustment - Hand/foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Foot Throttle Adjustment - T-Bar and Dual Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Hydrostatic System Page 7-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Charge Pressure Test and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Hydrostatic Pump Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Hydrostatic Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Hydrostatic Pump Drive Coupling Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Drive Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Hydraulic System Page 8-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Pressure Tests, Control Valve and High-Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Tilt Cylinder Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Self-Leveling Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Lift Cylinder Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Solenoid Valve Test - Safety Lock, Brake and Two-Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Tilt Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Lift and Tilt Cylinder Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Gear Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
Self-Leveling Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Self-Leveling Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Safety Lock Valves - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
Lift and Tilt Solenoid Valves - Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
High-Flow Manifold Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
High-Flow Manifold Valve Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
Pilot Valve Removal and Installation - Hand/Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
Control Valve Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
Spool Lock Solenoid Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Hydraulic Tank Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
Hydraglide™ Accumulator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
Hydraulic System Schematic, 40 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
PRINTED IN USA iii 917002/AP0704

917002/AP0704 iv PRINTED IN USA
40 SERIES SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS
4640 4840 5640 6640
Make of Engine Deutz Deutz Deutz Deutz
Model F3M2011/BF3M2011 F4M2011 F4M2011/BF4M2011 BF4M2011
Fuel Diesel Diesel Diesel Diesel
Displacement 142 CID (2,3 L) 190 CID (3,1 L) 190 CID (3,1 L) 190 CID (3,1 L)
Horsepower - Net 46/60 hp 60 hp 60/82 hp 82 hp
(34/45 kW) @ 2600 rpm (45 kW) @ 2500 rpm (45/61 kW) @ 2500 rpm (61 kW) @ 2500 rpm
Peak Torque 106/140 lb-ft 144 lb-ft 144/199 lb-ft 199 lb-ft
(144/190 N•m) @ 1700/1600 rpm (195 N•m) @ 1700 rpm (195/270 N•m) @ 1700/1600 rpm (270 N•m) @ 1600 rpm
Operating Load - SAE* 1500 lbs (680 kg) 1700 lbs (771 kg) 2000 lbs (907 kg) 2400 lbs (1089 kg)
Operating Weight 6200/6250 lbs (2812/2835 kg) 6480 lbs (2939 kg) 7380/7430 lbs (3348/3370 kg) 7800 lbs (3538 kg)
Shipping Weight 5715/5545 lbs (2592/2515 kg) 5825 lbs (2642 kg) 6740/6790 lbs (3057/3080 kg) 7160 lbs (3247 kg)
Hydraulic Reservoir 12 US gal (45 L) 12 US gal (45 L) 16 US gal (61 L) 16 US gal (61 L)
Engine Oil 8.3 US qts (7,9 L) 11.5 US qts (10,8 L) 11.5 US qts (10,8 L) 11.5 US qts (10,8 L)
Fuel Tank 15/17 US gal (56,8/64,4 L) 17 US gal (64,4 L) 19 US gal (71,9 L) 24 US gal (90,9 L)
Hydraulic System Pressure 2750 PSI (190 bar) 2750 PSI (190 bar) 3000 PSI (207 bar) 3000 PSI (207 bar)
Standard Aux. Flow Rate 19 gpm (72 L/min) 19 gpm (72 L/min) 23 gpm (87,1 L/min) 23 gpm (87,1 L/min)
Hi-Flow Aux. Flow Rate 30 gpm (114 L/min) 30 gpm (114 L/min) 36 gpm (136,3 L/min) 36 gpm (136,3 L/min)
Specifications below apply to all 40 Series Models

Capacities
Chaincases (each) 8 US qts (7,5 L)
Electrical
Battery 12-volt DC, 950 CCA
Starter 12-volt DC (2,3 kW)
Alternator 95 A
Hydraulic System
Travel Speed - Single Speed 0 to 8.4 mph (0 to 13,5 km/h)
Travel Speed - Two-Speed (optional on 4840, 5640, 6640) 0 to 12.5 mph (0 to 20 km/h)
Tire Options
10 (12) x 16.5 - 8 (10) - ply High Clearance Flotation tires
10 (12) x 16.5 - 8 (10) - ply Heavy Duty Poly-filled tires
10 (12) x 16.5 - 8 (12) - ply Severe Duty tires
10 (12) x 16.5 - 8 (12) - ply Severe Duty Poly-filled tires
6.50(7.50) x 16 Solid Solid Rubber tires
33 x 15.50 x 16.5 - 12-ply Heavy Duty 2000 II tires
14 x 17.5 - 14-ply High Clearance Flotation tires
Buckets and Capacities

Width - inches (millimeters) Bucket Description Capacity (Heaped)
65 inches (1651 mm) Dirt/Construction 10.8 cubic feet 0,31 cubic meters
65 inches (1651 mm) Utility/Snow 18.6 cubic feet 0,53 cubic meters
72 inches (1829 mm) Utility/Snow 32.5 cubic feet 0,92 cubic meters
15.75, 19.68, 24 inches Pallet Fork NA NA
(400, 500, 610 mm)
*Operating load rated with a 65" inch 4640/4840 (1651 mm) dirt/construction bucket or 68" inch 5640/6640 (1727 mm) dirt/construction bucket in accordance with SAE J818.
PRINTED IN USA 1-1 917002/AP0704

SPECIFICATIONS 40 SERIES
B G
C R Q
O
W
S
P X Z
V Y
D
1 1 2 2
Dimensional Specifications 4640 4840 5640 6640
in. mm in. mm in. mm in. mm
A Overall operation height - fully raised 149 3785 149 3785 162 4115 167 4242
B Height to hinge pin - fully raised 115.5 2934 115.5 2934 123 3124 123 3124
C Overall height - top of ROPS 78 1981 78 1981 81 2057 81 2057
D Overall length - bucket down 122.8 3118 126.3 3208 131 3327 141.5 3594
E Dump angle @ full height 40° 40° 40° 40°
F Dump height 89.5 2273 89.5 2273 93.5 2375 91.25 2318
G Dump reach - bucket (full height) 25 635 25 635 32.8 833 35.5 902
J Rollback at ground 27° 27° 30° 30°
M Rollback angle at full height 86° 86° 84° 84°
O Seat-to-ground height 37.5 953 37.5 953 42 1067 42 1067
P Wheelbase - nominal 37.5 953 41.5 1054 42.5 1080 48.4 1219
Q Overall width - less bucket 63.5 1613 63.5 1613 67 1702 67 1702
R Overall bucket width 66 1679 66 1679 70 1778 74 1880
S Ground clearance to chassis (between wheels) 7.5 191 7.5 191 8.0 203 8.0 203
U Maximum back grading angle 91° 91° 82° 82°
V Overall length (less bucket) 89.8 2291 93.3 2370 95.5 2426 101 2794
W Departure angle 25° 25° 26° 25°
X Clearance circle - front (with bucket) 74.5 1892 76 1930 82 2083 89.5 2273
Y Clearance circle - front (less bucket) 47 1194 48 1219 50.5 1283 53 1346
Z Clearance circle - rear 59.5 1511 61.5 1562 66 1676 68 1727
1 - w/ 0.4 cu. yd. bkt., w/ 10 x 16.5 tires

2 - w/ 0.56 cu. yd. bkt., w/ 12 x 16.5 tires
917002/AP0704 1-2 PRINTED IN USA

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

SAFETY 40 SERIES
Loader Stability - A skid-steer loader’s stability is DO NOT drive too close to an excavation or ditch. BE
determined by its wheel base. The following elements SURE that the surrounding ground has adequate
can affect stability: terrain, engine speed, load being strength to support the weight of the loader and the load.
carried or dumped, and sudden control movements. DO NOT smoke or have any spark
DISREGARDING ANY OF THESE FACTORS CAN producing equipment in the area while
CAUSE THE LOADER TO TIP, POSSIBLY filling the fuel tank or while working on the
RESULTING IN DEATH OR SERIOUS INJURY. fuel or hydraulic systems.
Therefore, ALWAYS have the operator restraint bar Exhaust Gases - Exhaust fumes can kill. DO NOT
lowered and wear the seat belt. Operate the controls only operate this machine in an enclosed area unless there is
from the operator’s seat. Operate the controls smoothly adequate ventilation.
and gradually at an appropriate engine speed that
matches the operating 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 hand holds and steps
restraint bar for proper operation. The restraint bar, when getting on or off. DO NOT jump off machine.
when raised, applies parking brake and deactivates Wear appropriate ear protection for
lift/tilt controls and auxiliary hydraulics. prolonged exposure to excessive noise.
Keyswitch - NEVER attempt to bypass the keyswitch to ALWAYS perform a daily inspection of the
start the engine. Use the jump-starting procedure machine BEFORE using it. Look for
detailed in the Service chapter of your Operator’s damage, loose or 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
New operators MUST operate loader in an open area
or cardboard. Fluid under pressure can be
away from bystanders. Practice with controls until
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 removed by a doctor or gangrene may result. Mandatory Safety Shutdown Procedure
Wear Safety Glasses - ALWAYS wear safety glasses BEFORE cleaning, adjusting, lubricating, or
with side shields when operating the servicing 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
(chip-resistant) material be used to cushion NEUTRAL position.
the blow. Failure to heed could lead to serious injury to 2. Lower the liftarm and attachment completely.
eye(s) or other parts of the body.
3. Move the throttle to the low idle position, shut off
ALWAYS wear safety glasses when searching for the engine and remove the key.
hydraulic leaks or when working near batteries.
4. However, if the liftarm MUST be left in the
Loaded Bucket/Fork - DO NOT raise or drop a loaded “raised” position, BE SURE to properly engage the
bucket or fork suddenly. Abrupt movements under load liftarm support device.
can cause serious loader instability.
Only after these precautions can you be sure it is
NEVER push the lift control into the “float” position safe to proceed. Failure to follow the above
with the bucket or attachment loaded or raised, because procedure could lead to death or serious injury.
this will cause the liftarm to lower rapidly.

40 SERIES SAFETY
Liftarm Support Device
WARNING
BEFORE leaving the operator’s compartment
to work on the loader with the liftarm raised,
SAFETY
ALWAYS engage the liftarm support device.
Turn the keyswitch to OFF, remove the key
and take it with you.
Many service procedures require a raised liftarm to

allow easier access to loader components. For operator
and service personnel safety, a liftarm support device is
Fig. 2-1 The lock pin secures the liftarm support device standard on GEHL skid-steer loaders. Used as a cylinder
inside the left liftarm.
block, it helps prevent a raised liftarm from
unexpectedly lowering.
BE SURE to engage the liftarm support device
whenever the liftarm is raised. When the device is not
being used, secure it to the anchor on the underside of the
liftarm using the lock pin and retainer provided.
The liftarm support device is a safety device which must
be kept in proper operating condition at ALL times.
The following procedures outline the correct way to
engage and disengage the liftarm support device.
Liftarm Support Device Engagement

1. Lower liftarm until contact with loader frame.
Fig. 2-2 Press in and hold the lock pin button and pull it 2. Turn the keyswitch to the OFF position to stop the
out. engine.
3. Leave operator’s compartment. Press in and hold
lock pin button to release its locking mechanism.
Remove lock pin holding support device up against
liftarm. Allow support device to come down into
contact with lift cylinder. Figs. 2-1 and 2-2
4. Return to the operator’s compartment and restart the
engine.
5. Use lift control to raise liftarm until lift arm support
device drops over the end of the lift cylinder and
around cylinder rod. Slowly lower liftarm until free
end of support device contacts top end of lift
cylinder. Figs. 2-3 and 2-4
6. Make sure the support device is secure against the
cylinder end. Then, stop the loader engine, remove
Fig. 2-3 The liftarm support device rests on top of the lift
cylinder base. the key and leave the operator’s compartment.

SAFETY 40 SERIES
Liftarm Support Device Disengagement
WARNING
NEVER leave the operator’s compartment to
disengage the liftarm support device with the
engine running.
To return the liftarm support device to its storage

position, proceed as follows:
1. Raise the liftarm completely.
2. Turn the keyswitch to the OFF position to stop the
engine, remove the key and take it with you. Fig. 2-4 Secure the liftarm support device in it’s storage
position with liftarm fully raised, then lower
liftarm.
WARNING
BEFORE testing the machine, ALWAYS clear
people from the area.
3. Before leaving the operator’s compartment, check

to be sure the liftarm is being held in the raised
position by the solenoid valve (See NOTE).
NOTE: With the keyswitch OFF, and the solenoid
valve functioning properly, the liftarm will not move
when the lift control is moved forward. If the valve does
NOT hold the liftarm, do NOT leave the operator’s
compartment. Instead, have someone store the support
device for you. Then, contact your Gehl dealer to
determine the reason why the liftarm lowers while the Fig. 2-5 Front left ROPS mounting area where the ROPS
is secured to the chassis. Right side same.
keyswitch is in the OFF position.
4. To store liftarm support device, lift it up and inside
the liftarm. Insert lock pin through the hole in the
liftarm and through the support device. Fig. 2-4
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 liftarm should be lowered or locked in the raised
position as per the “Liftarm Support Device
Engagement” procedure in this chapter.
2. Turn the keyswitch to the OFF position to stop the Fig. 2-6 Use wrenches to release the front of the ROPS
engine. Remove the key and take it with you. from the chassis.
3. Leave the operator’s compartment.

40 SERIES SAFETY
WARNING
DO NOT leave the operator’s compartment
with the engine running. Before leaving the
loader shut off the engine according to the
SAFETY
“Mandatory Safety Shutdown Procedure”
described in this chapter.
4. Remove one capscrew, three flat washers, and one

locknut on each side of the ROPS. Fig. 2-6
5. Lift ROPS up and tilt it back until the self-actuating
Fig. 2-7 Location of the self-actuating lock mechanism.
lock mechanism engages. The lock mechanism
locks the ROPS in a rolled-back position. Fig. 2-7
IMPORTANT
BEFORE raising the ROPS, position the seat
as far back as it will go. Avoid damaging
control handles by slowly raising the ROPS.
BE SURE the control handles clear the ROPS.
ROPS – Lowering
1. With an assistant's help, apply upward force on the
Fig. 2-8 Lowering the ROPS is a two-person operation. ROPS while assistant pulls the lock mechanism
handle toward the front of the loader. Fig. 2-8
2. Lower ROPS until it contacts with the chassis. Fig.
2-9
IMPORTANT
Avoid damaging control handles by slowly
lowering the ROPS. BE SURE the control
handles clear the ROPS.
3. Reinstall the two capscrews, six flat washers and

two locknuts that attach the ROPS front uprights to
the chassis. Fig. 2-6
Fig. 2-9 BE SURE the ROPS/FOPS clears the control

handles.

SAFETY 40 SERIES
Relieving Hydraulic Pressure

The following procedure should be used to relieve Lift and Tilt
pressure in the hydraulic system prior to performing
service procedures on hydraulic system components.
1. Completely lower the bucket or attachment.
2. Turn keyswitch to OFF position to shut down
engine. Auxiliary Hydraulics
3. With the operator in the seat and the restraint bar

lowered, turn the keyswitch to the ON position but
DO NOT start the engine.
4. Move the lift, tilt and auxiliary hydraulics controls
through several cycles. Figs. 2-10, 2-11, 2-12 Fig. 2-10 On Hand/Foot models, the lift and tilt functions
5. Turn the keyswitch to the OFF position. are controlled with the foot pedals on the floor of
the ROPS. The auxiliary hydraulics are
controlled in the right control handle.
Auxiliary Hydraulics
Lift and Tilt
Fig. 2-11 On Dual Hand models, lift and tilt functions are
controlled by the left and right control handles.
The auxiliary hydraulics are controlled with the
left foot on the auxiliary pedal assembly.
Auxiliary Hydraulics
Lift and Tilt
Fig. 2-12 On T-Bar models, lift and tilt functions are

controlled with the right control handle. The
auxiliary hydraulics are controlled with the left
foot on the auxiliary pedal assembly.
40 SERIES SAFETY
Loader Raising Procedure

The following procedure is used to raise the skid-steer
loader so that all four tires ARE NOT contacting the
ground.
Tie Down Support
SAFETY
WARNING
BEFORE servicing the machine, exercise the
“Mandatory Safety Shutdown Procedure”
Stand Placement Location
described in this chapter.
Fig. 2-13 View of the stand placement and tie down

support locations.
WARNING
DO NOT rely on a jack or hoist to maintain the
“raised” position without additional blocking
and supports. Serious personal injury could
result from improperly raising or blocking the
skid-steer loader.
1. To raise and block the skid-steer loader, obtain four

jack stands or wooden blocks of sufficient strength
to support the loader.
2. Using a jack or hoist capable of raising the
fully-equipped loader, lift rear of loader until tires
are off ground. Fig. 2-14
3. Place two jack stands under flat part of loader
chassis. Place them parallel with, but not touching,
the rear tires. Fig. 2-15
Fig. 2-14 Locations underneath the skid loader to position
stands or blocks at the front and rear. (View is 4. Slowly lower loader so its weight rests on jack
from the rear of the loader.) stands or the wooden blocks.
5. Repeat steps 2-4 for the front end. When the
procedure is finished, all four tires are off the
ground, and they can be removed as necessary.
Loader Lowering Procedure

When service procedures are complete, the skid-steer
loader can be taken down from the “raised” position. To
lower the loader onto its tires:
1. Using a jack or hoist, raise front of loader until its
weight no longer rests on the jack stands.
2. Carefully remove jack stands or wooden blocks
under front of loader.
Fig. 2-15 View of stand supporting right rear of skid-steer
loader. 3. Slowly lower loader until front tires are on ground.
4. Repeat steps 1-3 for rear of loader.

SAFETY 40 SERIES
NOTES

40 SERIES LUBRICATION
General Information
2 WARNING
NEVER service this unit when any part of the
machine is in motion. ALWAYS BE SURE to
exercise the “Mandatory Safety Shutdown
3 1 Procedure” (see Safety chapter) BEFORE
servicing this equipment.
LUBRICATION
Routine lubrication is an important factor in preventing
excessive part wear and early failure. Loader and engine
operation depends on using correct grade, high-quality
Fig. 3-1 Hydraulic oil level indicator (1), hydraulic oil fill lubricating oils. This chapter and the chart below list
(2), and hydraulic filter indicator (3).
locations, temperature ranges and types of
recommended lubricants to be used when servicing this
machine. In addition, refer to the engine manual for
Fig. 3-2 Hydraulic oil drain plug accessed behind the Fig. 3-3 Remote engine oil drain located behind the left
right rear tire. rear tire.
Hydraulic System Chaincases Grease Crankcase Oil

Reservoir Fittings (Diesel Engine)
Use a Mobil DTE 15M, or Use hydraulic system oil or SAE Use lithium-based grease µ Below 32°F (0°C) use SAE
Petro-Canada Premium HVI60, or grade 15W-40 motor oil. Grade* 10 or 10W-30
equivalent that contains anti-rust,
Capacity (each side): µ Above 32°F (0°C) use SAE
anti-foam, and anti-oxidation
8.0 Quarts (7,5 L) Grade* 15W-40
additives & conforms to ISO
VG46. *Service Classification: API -
CF-4/CG-4
Capacity:
12 Gallons (45 L) - 46/4840 Capacity:
16 Gallons (61 L) - 56/6640 8.3 Quarts (7,9 L) - 46/4840
11.5 Quarts (10,8 L) - 56/6640

LUBRICATION 40 SERIES
specific grades and ratings as specified by the engine

manufacturer. 4
2
NOTE: Whenever service is performed on hydraulic
components (valves, cylinders, hoses, etc.), fuel tanks
and lines, care must be taken to prevent discharging
fluid onto the ground. Catch and dispose of fluid per
local waste disposal regulations. 1
Hydraulic Oil Reservoir

The oil reservoir for hydraulic and hydrostatic systems
has a capacity of 12 U.S. gallons (45 liters) (46/4840), or
16 U.S. gallons (61 liters) (56/6640). A visual oil level 3
indicator (Fig. 3-1) is located on right riser for
convenient maintenance of hydraulic oil level. Fig. 3-4 Location of engine oil filter (1), oil fill (2), oil
drain cock (3), and dipstick tube (4) on left side
The hydraulic oil reservoir should be drained (Fig. 3-2)
of engine.
and filled after every 500 hours of operation or annually
(whichever happens first). Use Mobil DTE 15M or
Petro-Canada Premium HVI60 hydraulic oil (or ISO
VG46-48 equivalent) which contains anti-rust,
anti-foam and anti-oxidation additives. Hydraulic oil
filter element should be replaced when filter indicator
on filter head shows red (See NOTE, Fig. 3-1). For
details, refer to “Hydraulic Oil Filter Element
Replacement” procedure in the Hydraulic chapter.
NOTE: Hydraulic filter indicator should be read with
engine running at full throttle and normal operating
temperature.
Crankcase Oil
The Deutz diesel engine crankcase has a capacity of 8.3 Fig. 3-5 Oil filter access location behind the left engine
U.S. quarts (7,9 liters) (3-cyl.), or 11.5 U.S. quarts (10,8 side cover.
liters) (4-cyl.). The chart below lists recommended oil
viscosity for the Deutz engine.
Engine oil should be changed and filter element replaced
every 500 hours of service. A remote engine oil drain
can be found behind left rear tire. Refer to engine
operator’s manual (see NOTE) for details on changing
oil and to “Oil Filter Removal” and “Oil Filter
Installation” procedures in Engine chapter. 2
NOTE: Refer to engine operator’s manual for
additional information on oil change intervals, 1
including a 50-hour initial oil change interval.
Ambient Temperature Viscosity
Below 32°F (0°C) SAE 10 or 10W-30

Fig. 3-6 Location of engine oil fill (1) and oil dipstick (2).
Above 32°F (0°C) SAE 15W-40
Service classification: API-CF-4/CG-4

40 SERIES LUBRICATION
Chaincases
Each chaincase requires 2 gallons (7,5 L) of motor oil.
This quantity of oil should be maintained at all times.
1 The oil in both chaincases should be drained and refilled
every 500 hours of operation or annually, whichever
occurs first.
Change Chaincase Oil

2
1. Remove drain plug on chaincase and drain the oil.
LUBRICATION
Fig. 3-7
2. Reinstall the drain plug.
3. Remove both oil fill and oil level check plugs. Figs.
Fig. 3-7 Location of chaincase check plug (1) and drain 3-7, 3-8
plug (2) behind right front tire. Left side same.
4. Add oil through the fill plug until the oil starts to
flow out of the check plug. Fig. 3-7
5. Reinstall the check plug, then the fill plug.
Grease Fitting Locations

Use lithium-based grease on all grease fittings. Figs.
3-9, 3-10
Grease every 10 hours of operation (or daily)

1. Grease liftarm, lift and tilt cylinder pivots
2. Grease All-Tach™ attachment pivots
Fig. 3-8 Location of the left chaincase oil fill plug. Right
side same.
Fig. 3-9 Grease fitting locations. Fig. 3-10 Grease fitting locations.

LUBRICATION 40 SERIES
Cooling System Drain Procedures

NOTES
Gehl 40 Series skid-steer loaders use a hydraulic oil
radiator design to help keep the engine and hydraulic oil
from overheating. Many procedures in this Service
Manual require you to partially or fully drain the radiator
to perform those procedures.
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedure:
q Shut off the engine and allow to cool.
(For detailed instructions, refer to the Safety
chapter of this manual.)
Hydraulic Oil Drain Procedure

1. Place a 15-gallon (56,8 L) catch pan under the
hydraulic oil drain plug. Fig. 3-2
2. Remove the drain plug and drain oil.
3. Replace the drain plug.

40 SERIES MAINFRAME
Introduction
Gehl 40 Series skid-steer loaders have a welded steel The liftarm and the lift and tilt cylinders are mounted
chassis. Maintenance, service and repair may be with pivot pins. Capscrews are used to secure the pivot
performed through standard access panels. pins. A Rollover Protective Structure/Falling Object
Two side cases provide mounting for the drive motors Protective Structure (ROPS/FOPS) is standard for
and for the front and rear axles. The side cases also serve operator safety, and both the seat and restraint bar
as sealed housings for the drive chains and sprockets. include interlock switches.
Oil is used inside these cases to ensure the chains always
receive proper lubrication.
Rollover & Falling Object - Protective Structure (ROPS/FOPS) Components
MAINFRAME
24
1 WASHER/FLAT
39 39
2 NUT/LOCK
3 MTG/ISOLATION
34
39
4 NUT/SPEED
11 29 16 28
5 NUT/LOCK
39
6 NUT/LOCK
7 NUT/LOCK
10 8 SPRING/TORSION
9 BUSHING
4 10 TAG/RIPCORD
9 11 RING
42
12 NUT/LOCK™
5 13 WASHER/SEAL
33
40
34
14 COVER/BOX
20 5 15 HINGE/PIANO
42
26 36 9 16 WINDOW/REAR
41
17 CHANNEL
2 43
27 18 ROPS
35
8 19
19 SUPPORT/ROPS
7
20 PIN
21 WINDOW
39
22 GROMMET
13 18 23 GROMMET
21
24 HEADLINER
14 39
39
25 PAD FOAM
22
26 SPRING/GAS
39
39 12 27 SPACER/TUBE
28 WEATHERSTRIP
29 RIPCORD
30 SEAL/FOAM
31 SEAL/FOAM
25 15
12
12 32 SEAL/FOAM
12
4
33 SCREW/CAP
38
12 38 34 SCREW/CAP
37
35 SCREW/CAP
37 36 SCREW/CAP
17
1
1
37 BOLT/CARRIAGE
12 38 SCREW/CAP
12
31
30
4
39 SCREW/PHILLIPS
3 3 40 WASHER/FLAT
1
41 WASHER/FLAT
1 31 17 23 12 42 WASHER/FLAT
6
32 1
1
43 PIN/COTTER
6 37 37
Fig. 4-1 Exploded view of ROPS/FOPS components.

MAINFRAME 40 SERIES
Engine Access Cover - Removal and

Installation
WARNING
q It is recommended that this service
procedure be performed by a certified Welded Tab
Gehl dealer mechanic.
q Shut off the engine.
chapter of this manual.) Fig. 4-3 Capscrew and washers to remove off the ROPS
bolt.
Removal Procedure
1. Open engine access cover until gas spring is
completely extended.
2. Loosen hose clamp on flanged tube coming out of
engine cover and separate hose from tube. Fig. 4-2
3. Disconnect the tail light wire harness, and gas spring
from engine access cover by removing gas spring
clip at access cover end of gas spring, then pull gas
spring off ball stud on access cover. Fig. 4-2
4. Remove two capscrews and all washers on ROPS
bolts securing access cover to frame. Fig. 4-3
5. Turn both ROPS bolts out until flush with welded
tab, remove engine cover. Figs. 4-4, 4-5
Fig. 4-4 ROPS bolt turned out just enough to release
Installation Procedure - Follow all warnings first, engine cover while still supporting the ROPS
then reverse the removal steps. structure.
Hose Clamp
Wire Harness
Gas Spring
Fig. 4-2 View of the engine with the engine access cover Fig. 4-5 View of ROPS bolt turned out just enough to
fully extended. release the engine access cover, but not enough
to release the ROPS.

40 SERIES MAINFRAME
Chassis Components
3
17 29 11
31
17 9 SEE NOTE 2
5
33
20
12 31 10
21 6
5
26
28 2
31 22 24
12 12
SEE NOTE 4 37 34
4
33 12 14
28 31
MAINFRAME
1
SEE NOTE 1
33
4 ON
CK
. BLORISER
G
MT NER
25 TO FT IN
L E
SEE NOTE 2 16
28
23
4
15
33
16 SEE NOTE 2
13
32
7 36 33
30 36 32
32 18
7 13
8
37 SEE NOTE 4
NOTES:
35
1. APPLY HI-TACK GASKET ADHESIVE 35
2. APPLY OIL-RESISTANT RTV 35
27
3. APPLY LOCTITE 290 27 35 19
4. APPLY PIPE THREAD SEALANT 27 27
1 GASKET/FUEL SENDER 14 SENSOR/FUEL 27 SCREW/CAP

2 CAP ASSEMBLY/FILLER 15 CHASSIS 28 SCREW/CAP
3 BREATHER/RESERVOIR 16 COVER/CHAINCASE 29 SCREW/CAP
4 PLUG 17 FILLER/ROPS 30 SCREW/CAP
5 NUT/LOCK 18 PLATE/FLOOR 31 SCREW/CAP
6 STRAINER/FUEL FILL 19 BELLYPAN/FRONT 32 SCREW/MACHINE
7 WASHER/SEAL 20 COVER/SEAT 33 SCREW/MACHINE
8 COVER/TOEPLATE 21 PLATE/CROSSMEMBER 34 SCREW/MACHINE
9 ASSY/RESERVOIR 22 COVER/SEAT 35 WASHER/LOCK
10 SIGHT PORT/OIL LEVEL 23 FENDER/LEFT 36 WASHER/FLAT
11 TRAY/BATTERY 24 FENDER/RIGHT 37 PLUG/PIPE
12 NUT/LOCK 25 BRACKET/SOLENOID
13 WASHER/SEALING 26 STRIP/TRIM
Fig. 4-6 Exploded view of the chassis.

MAINFRAME 40 SERIES
Control Cover Components - Hands Only

1
1
HANDS ONLY CONTROLS (ABOVE) HAND AND FOOT CONTROLS (BELOW)
1 NUT/LOCK 1 FLOOR ASSY/FRONT

2 FLOOR ASSY/FRONT 2 NUT/LOCK
3 COVER/CONTROL 3 COVER/CONTROL
4 SCREW/MACHINE 4 SCREW/MACHINE
Control Cover Components - Hand and Foot

2
2
Fig. 4-7 Exploded view of the control covers.

40 SERIES MAINFRAME
Rear Grille and Engine Cover Components
35
19 TO ROPS PIVOT BRACKETS
ON FRAME
6
23
21
13
12
13 6
33
MAINFRAME
16 TO THREADED BOSS LOCATED INSTALL ON RAIL
ON LEFT INNER RISER OF FRAME
OF FRAME
30 34
17 15 21
30 22
30
17
24
9
27 4
B 5
26 18
30
30
8 20 2
25 7
14 11 2
32 32
3
29
FASETEN TO SIDE
PANELS OF ROPS 30
APPLY ANTI-SEIZE COMPOUND 28

25 TO PIVOT PINS
27
14
32
32
TO HINGE BRACKETS
ON FRAME
31 10
TO REAR FLOOR
PLATE OF FRAME
1 NUT/LOCK 19 COVER/ENGINE
2 NUT/LOCK 20 LATCH
3 NUT/LOCK 21 STRIP/TRIM
4 CLAMP/HOSE 22 STRIP/TRIM
5 SPRING/COMPRESSION 23 HANDLE/GRAB
6 STUD/BALL 24 PIN/LOCK
7 MOUNT/LATCH 25 SEAL/EDGE
8 ROD ASSEMBLY/LATCH 26 SCREW/CAP
9 NUT/LOCK 27 SCREW/CAP
10 BUMPER 28 BOLT/CARRIAGE
11 BUSHING 29 BOLT/CARRIAGE
12 SPRING/GAS 30 SCREW/PHILLIPS PAN HEAD
13 CLIP/GAS SPRING 31 NUT/JAM HEX
14 NUT/LOCK 32 WASHER/FLAT
15 COVER/LEFT 33 WASHER/LOCK
16 COVER/RIGHT 34 NUT/HEX
17 SEAL/BULB 35 SCREW/CAP
18 GRILLE/REAR
Fig. 4-8 Exploded view of the rear grille and engine cover.

MAINFRAME 40 SERIES
ROPS Removal and Installation
WARNING
Removal Procedure
1. Remove the engine access cover per the procedure
Fig. 4-9 The harness bulkhead is where the engine
in this chapter. harness assembly meets the instrument panel
2. Disconnect negative (-) battery cable from battery. harness. Remove instrument panel harness at
front of bulkhead.
3. Disconnect instrument panel wiring harness
connector at harness bulkhead attached to chassis
bracket. Fig. 4-9
4. Raise the ROPS per the procedure found in the
Safety chapter.
5. With the ROPS rolled and locked back, attach a
hoist so that it is supporting the weight of the ROPS.
WARNING
The hoist MUST BE situated precisely above
the ROPS or else performing the following
steps may cause the ROPS to swing as the Fig. 4-10 Right side gas spring attached at ROPS, left side
bolts are removed. This could cause serious is the same.
bodily injury and/or damage the loader.
6. Remove one capscrew and flat washer securing Pin

each gas spring to the ROPS. Fig. 4-10
7. Disassemble ROPS lock mechanism by removing
cotter pin, torsion spring and pin. Remove limiter Torsion Spring Cotter Pin
assembly from ROPS. Fig. 4-11
8. On each side, carefully remove capscrew securing
ROPS pivot to frame. Fig. 4-5
9. Lift the ROPS off the loader.
Installation Procedure - Follow all warnings first,

then reverse the removal steps.
Fig. 4-11 ROPS lock mechanism.

40 SERIES MAINFRAME
Seat Removal and Installation
WARNING
perform the following SAFETY procedures:
q Roll ROPS back until lock engages.
Seat Switch Ground
Removal Procedure
MAINFRAME
Fig. 4-12 Location of four hex nuts securing the seat to the
seat pan. 1. Remove four nuts from extending studs attaching
seat to seat pan underneath ROPS. Fig. 4-12
2. Release lock mechanism and lower ROPS.
Disconnect seat switch from wiring harness. Fig.
4-13
3. Lift the seat from the seat pan.

Wiring Harness
Seat Slide Replacement (Fig. 4-14)
Replacement Procedure
1. Remove the seat per the procedure in this chapter.
Fig. 4-13 This wiring harness must be disconnected from 2. Remove four screws attaching seat slides to seat.
the seat switch to remove the seat from the 3. Replace with new slides using existing screws.
ROPS.
Seat Switch
Seat Slide
Fig. 4-14 Front slide screw shown. Rear slide screws

become visible after moving the suspension seat
slide forward.

MAINFRAME 40 SERIES
Air Duct Removal and Installation

Air ducts in the ROPS are optional and utilized when
HVAC options are installed.
Removal Procedure
1. Remove the seat in the ROPS per the procedure in
this chapter.
2. On the outside of the ROPS remove four screws
securing the air ducts to the ROPS. Fig. 4-15
3. Slide the back of the air duct out first, then slide the
front out. Remove air duct from ROPS. Fig. 4-16
Installation Procedure - Reverse the removal steps Fig. 4-16 Removal of left side air duct. Slide back out first.
Air Duct Louver Replacement (Fig. 4-17)

1. On 3” round louvers, open louver, insert fingers and
pop out louver. On rectangular roll nozzle louvers,
unscrew two screws securing nozzle louver to air
duct.
2. On 3” round louvers, pop new louver into existing
bezel until click sound tells you it is seated. On roll
nozzle louver, drop it in rectangular space and
secure with two screws.
Fig. 4-17 Location of two screws securing the rectangular

louver in the console.
Fig. 4-15 Location of four screws securing the console to Fig. 4-18 Location of emergency exit tag at top of the rear
the inside of the ROPS. window.

40 SERIES MAINFRAME
ROPS Rear Window Removal and

Installation
WARNING
Removal Procedure
MAINFRAME
Fig. 4-19 Remove the window weatherstrip around the
metal frame. 1. Grab and pull emergency exit tag until ripcord pulls
free of rubber seal. Fig. 4-18
2. With an assistant to catch window outside ROPS,
push window outward.
3. Slowly pull weatherstrip away from window frame.
Fig. 4-19
L-Hook Pigtail Hook
Installation Procedure
1. Recommended but not required: Mix a solution of
10% liquid dish soap to 90% water in a spray bottle.
NOTE: To install rear window, you will need to
purchase two insert tools at your nearest glass dealer.
Fig. 4-20
2. Apply soap solution to window, weatherstrip and
metal frame surfaces.
Fig. 4-20 Insert tools required to install the ROPS rear
window.
3. Start at top of window frame and install weatherstrip
with ripcord lip facing inside ROPS and glass lip
facing out.
4. From inside ROPS spray soap solution in-between
glass window and inside edge of rear window.
5. Use L-hook insert tool between glass and
weatherstrip and work it underneath glass. Lift
glass lip up over weatherstrip.
6. Use pigtail hook insert tool to “pull down”
weatherstrip seal on outside of ROPS which secures
window. Fig. 4-21
7. On inside of ROPS install ripcord in ripcord lip
starting at top of weatherstrip. DO NOT forget to
have emergency exit tag slipped over ripcord before
performing this step.
Fig. 4-21 Pigtail hook pulls weatherstrip over the rear 8. Using L-hook insert tool, secure ripcord in ripcord
window to secure it.
lip by “pulling down” lip over cord.
9. Test window for security and mating of all seals.
MAINFRAME 40 SERIES
Restraint Bar Components
1 RING/RETAINING
2 NUT/LOCK
3 SPRING
4 ACTUATOR
5 SWITCH
6 BEARING/BRONZE
7 BUMPER
8 PIN/PIVOT
9 PIN/PIVOT
10 ROD/SPRING 22
11 NUT/HEX
12 CLIP/RETAINING
13 BAR/RESTRAINT
8
14 BRACKET/PIVOT 6
12
15 BRACKET/PIVOT 18
6
16 BRACKET/PIVOT
17 BRACKET/PIVOT 10
3 6 22
12
27
12 15 6
6
1 9 8 12
1
6
23
7
11 3
24 27 10
20 5 6 19
6 26 1 6
25 1
D 12
21 20
9
1 14
6
20
2
7 25
21 26
16
13 11 24 1 20
23
4
6
17
2
18 COVER/RESTRAINT
19 COVER/RESTRAINT
20 SCREW/CAP
21 BOLT/CARRIAGE
22 SCREW/CAP
23 SCREW/PHILLIPS
24 NUT/JAM
25 WASHER/FLAT
26 WASHER/FLAT
27 WASHER/FLAT
Fig. 4-22 Exploded view of the restraint bar.

40 SERIES MAINFRAME
Restraint Bar Removal and Installation

Removal Procedure
1. Raise engine cover.
2. Underneath the ROPS, remove screw securing the
rear of the restraint bar pivot. Fig. 4-23
3. Inside ROPS, remove one screw securing pivot
cover and remove cover. Fig. 4-24
Front restraint bar pivot
screw accessed from 4. Disconnect restraint bar switch from wire harness
inside the ROPS
located above restraint bar on right side. Figs. 4-24,
4-25
5. Remove one screw on each side securing front of
MAINFRAME
Fig. 4-23 Location of capscrew securing the rear of the restraint bar pivot to ROPS. Lift restraint bar up and
restraint bar pivot underneath the ROPS frame. out of loader. Figs. 4-25, 4-26
View is from underneath ROPS.
NOTE: For restraint bar switch removal, refer to the
Electrical chapter.
Installation Procedure - Reverse the removal steps
Pivot Cover
Fig. 4-24 Location of restraint bar switch wire connected

to wire harness.
Fig. 4-25 Location of screw securing front of right Fig. 4-26 Location of screw securing front of left restraint
restraint bar pivot to the ROPS. bar pivot to the ROPS.

MAINFRAME 40 SERIES
All-Tach™ Hitch Components

13
11
10
15
5
15
13
1
4 7 11
3
2
16
1
6
4
14
2
12
16
6
8
14
12
NOTES
1. WHEN ASSEMBLING TO THE LIFT ARM
ADD SHIMS 136765 AND 136766 AS REQUIRED TO
ACHIEVE A GAP BETWEEN THE LIFT ARM AND THE
ALL-TACH FROM O.OOO" TO 0.060" WIDE.
1 PIN/SPRING 9 HANDLE/LEFT
2 NUT/HEX ½ 10 HANDLE/RIGHT
3 SPRING/COMPRESSION 11 WASHER/THRUST
4 PIN 12 FITTING/GREASE
5 ROD/PUSH 13 SCREW/CAP
6 SPRING/COMPRESSION 14 SCREW/CAP
7 ADAPTER/PUSH ROD 15 SCREW/CAP
8 BODY/ALL-TACH™ 16 WASHER/FLAT
Fig. 4-27 Exploded view of the All-Tach™ hitch.

40 SERIES MAINFRAME
Power-A-Tach™ Components
1 TIE/WIRE 17 ADAPTOR
2 WASHER/FLAT 18 PIN/LATCH 10 NOTE 1
3 PIN/SPRING 19 ROD/EXTENSION
4 NUT/HEX 20 ROD/EXTENSION
5 TIE/NYLON 21 COVER
6 CLAMP/HOSE 22 BRACKET/COVER
7 SPRING 23 FLAG
8 ROD/PUSH 24 WASHER/BEVEL
9 SPRING 26 ACTUATOR
10 SWITCH/ELECTRIC 27 HARNESS
11 HARNESS 29 HARNESS
12 WELDMENT 30 SCREW/CAP
13 LINK/LATCH LEFT 31 SCREW/CAP
MAINFRAME
14 LINK/LATCH RIGHT 32 SCREW/CAP
15 PLATE/LATCH LINK 33 NUT/JAM
16 BUSHING/OILITE 34 WASHER/FLAT
NOTE 1 10
30
29
21
30
11 5 22
12
LEFT 13 4
34 30
27
9
23
16
31
NOTE 2 32
33 14 RIGHT
24
6
19 NOTE 2
2
17 15
7 26
8
33
32 NOTE 2 20 NOTE 2
18 NOTE 1: SWITCH ASSEMBLY MOUNTED/INSTALLED AS SHOWN

WITH SHROUD TYPE CONNECTOR UP.
3 NOTE 2: USE LOCTITE 242
Fig. 4-28 Exploded view of the Power-A-Tach™ hitch.

MAINFRAME 40 SERIES
Liftarm Components
1 NUT/HEX
2 STEM/RUBBER
3 NUT/HEX 27
4 PAD/ARM BRACE 19
5 ARM/SAFETY 13
1
6 STEP
7 SHIM 13
9 PIN/RELEASE 27
10 CAP/GREASE
11 RIVET/BLIND 23
19
12 PIN
13 PIN
14 WASHER/FLAT
15 SHIM
16 SHIM
17
17 ARM/LIFT
18 SCREW/CAP 20 SEE NOTE 1
19 FITTING/GREASE
4
20 SCREW/CAP
21 SCREW/CAP
6 2
22 SCREW/CAP 9
23 SCREW/CAP 18
24 SCREW/CAP 11
25 WASHER/LOCK
26 BUSHING
27 BUSHING 10 SEE NOTE 1 3
SEE NOTE 2 21
SEE NOTE 4 24
10
14
26
26 22 21 SEE NOTE 2
SEE NOTE 2
15 19
SEE NOTE 5 25
7
16 22 SEE NOTE 2
SEE NOTE 3
SEE NOTE 5
24 SEE NOTE 4 25
12
7 SEE NOTE 3
NOTES
1. DO NOT OVERTIGHTEN.
2. APPLY LOCTITE 242
3. ADDITIONAL SHIMS MAY BE USED TO INSURE CONTACT
BETWEEN SHIMS AND CHASSIS STOP BLOCKS.
4. 220 FT-LBS
5. ADD SHIMS 136765 AND 136766 AS REQUIRED TO
ACHIEVE A GAP BETWEEN THE LIFT ARM AND THE
ALL-TACH FROM O.OOO" TO 0.060" WIDE.
Fig. 4-29 Exploded view of the liftarm.

40 SERIES MAINFRAME
Gehl All-Tach™ or Power-A-Tach™ Hitch

Removal and Installation
Removal Procedure
1. Lower the liftarms and slightly extend the two tilt
Pivot Pin cylinders.
2. While supporting the tilt cylinder, remove two
capscrews and locknuts securing the lower tilt
cylinder pivot pins, and drive the lower pivot pins
out of their mounts. Fig. 4-30
3. Remove six capscrews securing the grease caps to
the liftarm. Remove the grease caps. Fig. 4-31
MAINFRAME
Fig. 4-30 Location of capscrew and locknut securing 4. Remove two capscrews and washers securing the
lower tilt cylinder pivot pin. Left side same. pivot pins to the hitch assembly. Fig. 4-32
NOTE: Support the hitch with suitable hoisting
equipment before performing the next step.
5. Insert a 5/8” x 6” capscrew into each pivot pin and
force the pin out by hammering on the capscrew.
Fig. 4-33
Fig. 4-31 Location of three capscrews securing grease cap

to liftarm. Right side same.
Fig. 4-32 Location of capscrew and washer securing hitch Fig. 4-33 Hitch pivot pin ready to hammer out.
pivot pin.

MAINFRAME 40 SERIES
Liftarm Removal and Installation

Removal Procedure
1. Lower the liftarm.
2. Remove the bucket or attachment from the loader.
WARNING
BEFORE continuing this service procedure,
q Relieve hydraulic system pressure. Fig. 4-34 Location of lift cylinder pivot pin.
3. Attach a suitable hoist to the liftarm.

4. Remove locknut and capscrew that secures the lift
cylinder pivot pin to the liftarm. Fig. 4-34
5. While supporting the lift cylinder, remove the lift
cylinder pin from the liftarm. Fig. 4-35
6. Repeat steps 4 and 5 for other side of the liftarm.
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 Fig. 4-35 Remove lift cylinder pivot pin.
disassembly with an oil resistant chalk or marker or
other suitable marking material.
7. Disconnect upper and lower tilt cylinder hoses from
steel tubes on top of liftarm crossmember. Fig. 4-36
8. Repeat step 7 for other side of the liftarm
crossmember.
9. Remove the hitch per the procedure in this chapter.
10. Remove both tilt cylinders from the liftarm per the
procedure in the Hydraulics chapter.
11. Remove six capscrews securing the step to the top of
the liftarm crossmember. Fig. 4-37
12. Remove capscrews, cover plates and tube clamps
from tilt tubes. Remove the tilt tubes. Fig. 4-37
13. Using a suitable hoist, raise liftarm to gain access to
Fig. 4-36 Lower and upper tilt cylinder hoses connect to
the hydraulic hoses and the tilt tube fittings. steel tubes on both sides of the liftarm
crossmember.

40 SERIES MAINFRAME
14. Disconnect hydraulic hoses from hydraulic tubes on

both liftarm sides. On High-Flow models there are
three additional high-flow hydraulics tubes on the
right front liftarm to remove. Figs. 4-39
15. Disconnect hydraulic tubes from couplers and
remove couplers from liftarm. Fig. 4-40
16. Remove capscrews, cover plates, and tube clamps
securing hydraulic tubes to liftarm. Remove
hydraulic tubes from liftarm. Fig. 4-41
17. Remove capscrew and locknut securing liftarm
pivot pin to chassis, repeat for opposite side. Fig.
4-42
MAINFRAME
Fig. 4-37 Remove step on liftarm crossmember. Three of 18. Drive liftarm pivot pins out of chassis. Fig. 4-43
six capscrews shown.
19. Remove the liftarm assembly from the loader with a
suitable hoist.
1. Use a suitable hoist to position the liftarm assembly
on the chassis.
NOTE: Align the liftarm in a manner that allows access
to the hydraulic hose and tilt tube fittings that will be
attached to the underside of the liftarm.
2. Secure the liftarm to the chassis riser with two pivot
pins. Fig. 4-43
NOTE: Refer to liftarm bushing installation procedure
in this chapter if bushings require replacement.
Fig. 4-38 Remove hardware connecting tilt tubes to the 3. Secure the liftarm pivot pin in place with two
liftarm crossmember and remove tilt tubes.
capscrews and locknuts. Fig. 4-42
4. Before assembly, clean all the hydraulic fittings to
prevent contamination of the hydraulic system.
NOTE: For location of the hydraulic hose and tube
mounting hardware refer to the hydraulics chapter.
5. Attach the couplers and hydraulic tubes to the
liftarm with capscrews, tube clamps and cover
plates. Figs. 4-40, 4-41
6. Connect the hydraulic tubes to the hydraulic hose
assemblies according to markings made at removal.
On High-Flow models there are three additional
high-flow hydraulic tubes on the right front liftarm
to attach. If no markings were made prior to removal
refer to the Hydraulics chapter for the correct fit up.
Fig. 4-39 Disconnect hydraulic hoses from hydraulic Fig. 4-39
tubes underneath both sides of the liftarm. 7. Attach the tilt cylinder tubes to the forward part of
the liftarm with a clamp and capscrew.

MAINFRAME 40 SERIES
8. Attach the tilt tubes to the liftarm crossmember with

the capscrews, cover plates and tube clamps used to
secure them. Fig. 4-38
9. Attach the step to the top of the liftarm crossmember
with six capscrews. Fig. 4-37
10. Using the hoist, lower the liftarm.
11. Install the tilt cylinders on the liftarm as per the
procedure in the Hydraulics chapter.
12. Install the hitch per the procedure in this chapter.
13. Connect the lower and upper tilt cylinder hoses to
the steel tubes on the top of the liftarm
crossmember. Fig. 4-36
Fig. 4-41 Remove hardware securing hydraulic tubes
14. Connect the lift cylinder to the lower liftarm with underneath the liftarm.
two pivot pins, capscrews and locknuts. Repeat this
step for the other side. Figs. 4-34, 4-35
NOTE: After removing/replacing any components of
the lift and tilt system, ALWAYS prime hydraulic
system by operating the liftarm 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 indicator on the inside
right rear riser.
Fig. 4-42 Remove capscrew and locknut securing liftarm

pivot pin to the riser on both sides.
Fig. 4-40 Disconnect hydraulic tubes from couplers on Fig. 4-43 After unseating the liftarm pivot pins, guide the
both sides of the liftarm. liftarm out of the risers.

40 SERIES MAINFRAME
Liftarm Bushing Replacement

(Figs. 4-44 - 4-47)
1. Remove the liftarm from the loader as per the
procedure in this chapter.
2. Use a punch to drive out the four upper liftarm
bushings, two on each side of the liftarm. Figs. 4-44
and 4-47
NOTE: Applying heat to the upper liftarm bushings
will release the adhesive and simplify removal.
3. Clean inside the opening to provide a smooth
MAINFRAME
Fig. 4-44 Two bushings inside the upper liftarm. surface for installation of the new bushings.
4. Apply Loctite® 680 or equivalent to the new liftarm
bushings and press or drive them into the liftarm.
5. If replacing the spring bushing in each lower liftarm,
use a punch to drive them out of the liftarm. Figs.
4-45 and 4-46
6. Install new spring bushings by pressing them into
place or use a rubber mallet to drive them into the
liftarm.
7. Reinstall the liftarm on the loader per the procedure
in this chapter.
Loctite is a registered trademark of the Loctite Corporation.
Fig. 4-45 Spring bushing inside the lower liftarm.
Fig. 4-46 Lower liftarm bushing driven out with a hammer Fig. 4-47 Upper liftarm bushing driven out with a hammer
and punch. and punch.

MAINFRAME 40 SERIES
Liftarm Stop Installation and Adjustment

Installation/Adjustment Procedure (Fig. 4-48) Liftarm Shim
NOTE: Liftarm stops should be shimmed as needed to
assure a gap of no more than 1/8" (3 mm) between stop
and the liftarm when the liftarm is fully lowered.
1. Lower liftarm and measure gap between stop and
liftarm. Liftarm Stop
2. Add one shim for every 1/8" (3 mm) gap.

3. Raise liftarm and engage the liftarm support device.
4. Remove two capscrews on each stack of shims.
5. Install shim(s) and secure with capscrews. Use
Fig. 4-48 Measurement location to adjust the gap between
Loctite® 242 or equivalent retaining compound. the lift stop and the liftarm shims.
6. Start engine and lower liftarm. Verify gap and
repeat procedure as needed.
Control Cover/Floor Cover Removal and

Installation
Control Cover
The control cover may be removed for access to handle
assemblies and connections to control rods.
Floor Cover
WARNING
BEFORE beginning this Service procedure,
q Raise liftarm, engage liftarm support
Fig. 4-49 Location of capscrews on control cover and floor
device.
cover.
Removal Procedure
1. Remove two screws that secure the control cover to
the welded frame tab. Remove two screws and
locknuts that secure floor cover to chassis. Fig. 4-49
2. Hands-only: Remove toe plate. Disconnect
auxiliary hydraulics cable from auxiliary pedal and
cable bracket. Fig. 4-50
3. Remove either cover at this time.
Fig. 4-50 Auxiliary hydraulic cable attached at cable
Installation Procedure - Follow all warnings first, bracket and pedal assembly. Accessed through
then reverse the removal steps. toe plate cover.

40 SERIES MAINFRAME
Crossmember Removal and Installation

The crossmember can be removed as a complete unit
with the control handles to facilitate work on the
hydraulic/hydrostatic tandem pump found beneath it or
to perform work on the control handles.
Lever Box Removal Procedure
WARNING
q Raise liftarm, engage liftarm support device.
MAINFRAME
Fig. 4-51 Location of high-flow lever box linkage
underneath the crossmember.
1. Remove the control cover per the procedure in this

chapter.
2. Disconnect the high-flow valve linkage at the lever
box. Fig. 4-51
3. Main Control Valve:
a. T-Bar: Disconnect the lift and tilt control rods
at the control valve. Fig. 4-52
b. Hand/Foot: Disconnect the auxiliary hydraulic
Fig. 4-52 T-Bar Controls: Location of lift and tilt control control cable at the control cable bracket and
rods connected to the control valve. control valve. Disconnect the lift and tilt control
rods at the control valve. Fig. 4-53
c. Dual Hand: Disconnect two control cables at
the control cable bracket and the control valve.
Fig. 4-54
4. Underneath the crossmember, find two wheel drive
control rods connecting the pivot tube to the top of
the hydrostatic pump at pump control arms.
Disconnect both control rods at the pivot tube. Fig.
4-55
5. Disconnect any electrical connectors attached to the
Aux. Control control handles. Fig. 4-56
6. On the outside of the chassis, remove three
capscrews securing the ROPS filler panels on each
side of the chassis and remove fillers. Fig. 4-57
Fig. 4-53 Hand/Foot Controls: Location of lift and tilt
controls rods and auxiliary control cable. 7. Remove six locking capscrews securing the
crossmember on each side to the chassis. Fig. 4-58

MAINFRAME 40 SERIES
8. With an assistant’s help, carefully lift the

crossmember out of the chassis.

Fig. 4-55 Control handle electrical connector underneath

the crossmember.
Fig. 4-54 Dual Hand Controls: Location of lift and tilt Fig. 4-56 Location of three capscrews securing the ROPS
control cables connected to cable brackets at the filler panels on inside wall of chassis.
control valve.
Pivot Tube
Fig. 4-57 Disconnect wheel drive control rods at pivot Fig. 4-58 Three capscrews securing crossmember on right
tube. side. Left side same.

40 SERIES MAINFRAME
Fuel Sensor Removal and Installation

Removal Procedure
WARNING
#0 BEFORE beginning this service procedure,
#25
1. Drain fuel tank into a clean approved container.
MAINFRAME
Fig. 4-59 Fuel level sensor location in the left riser. Drain fuel below sensor mounting (½ full).
2. Disconnect two wires from sensor. Fig. 4-59
3. Remove five screws securing sensor, then remove
sensor and gasket from tank. Figs. 4-60, 4-61
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.
Fig. 4-61
Fuel Sensor 3. With float to rear of fuel tank, install sensor in fuel
tank. Fig. 4-62, 4-6 -Item #14
4. Install four of five screws through sensor into fuel
tank. DO NOT OVERTIGHTEN.
Fig. 4-60 Remove five screws securing the fuel sensor. 5. Attach #25 (brown) wire to center stud with a nut
and #0 (black) wire to ground stud with the fifth
screw.
Gasket
Fig. 4-61 Replace old gasket with a new gasket prior to Fig. 4-62 Orient fuel sensor correctly when installing in
installing the fuel sensor. fuel tank.

MAINFRAME 40 SERIES
Rear Grille Removal and Installation

The rear grille is bolted onto the chassis and can be Lock Pin
removed to perform work on the cooler system, engine,
engine fan and shrouds.
Removal Procedure
1. Open the engine access cover and swing the rear
grille fully open.
2. Remove two capscrews, washers, and locknuts that
fasten the grille to the chassis. Fig. 4-63
3. Support the rear grille with a suitable hoist and lift
the rear grille off its mounts.
Fig. 4-63 Location of hardware securing rear grille to the
Installation Procedure - Reverse the removal steps chassis.
Rear Grille Latch Removal and Installation

Removal Procedure
1. Open rear grille and lock open with lock pin. Fig.
4-63
2. Remove two locknuts securing latch to rear grille.
Fig. 4-64
3. Pull out two carriage bolts, washers and one bushing
and remove latch.
Fig. 4-64 Location of two locknuts securing latch to rear

grille.

40 SERIES WHEEL DRIVES
Introduction
This chapter covers removal, installation, assembly, and fixed-displacement hydrostatic drive motors. The drive
adjustment procedures for wheel drive system motors are directly connected to chaincases. Single
components on Gehl 40 Series skid-steer loaders. Wheel speed or two-speed, each motor drives one set of wheels
drive components covered in this chapter are shown on each side of the loader through a chain and sprocket
below. system.
40 Series skid-steer loaders are equipped with a Service procedures related to the hydrostatic pump and
hydrostatic pump assembly coupled to the diesel engine drive motors can be found in the Hydrostatic System
providing hydrostatic power to the two chapter.
Wheel Drives Components
WHEEL DRIVES
1
3
7
8
2
1 7
3
8
4
2
4
7
8
3
5
1
6
7
4
3
TORQUE TO 180 FT-LBS
6
1
5
1 NUT/WHEEL
2 CHAIN
3 NUT/LOCK
TORQUE TO 280 FT-LBS
4 BOLT/CARRIAGE (LUBED HARDWARE)
5 ASSEMBLY/SPROCKET
6 CHAIN
7 ASSEMBLY/AXLE
8 WASHER/FLAT
Fig. 5-1 Exploded view of the wheel drive components.

WHEEL DRIVES 40 SERIES
Drive Chain Adjustment

Chaincase Fill Port
Skid-steer loader drive chain tension should be checked
every 250 hours of operation.
Adjustment Procedure
WARNING
q Raise and securely block the loader so
Fig. 5-2 Remove machine screws on the chaincase access
all four tires are off the ground.
cover located between the wheels of the
(For detailed instructions, refer to the Safety skid-steer loader (tires removed for clarity).
1. Remove wheels and tires on side of loader serviced.

2. Remove 14 machine screws on chaincase access
cover (between tires) to gain access to drive chain.
Fig. 5-2
3. Correct chain deflection is ½" @ 20 lbs force (13
mm @ 89 N) - halfway between the sprockets.
Axle
4. To adjust chain tension, loosen eight locknuts on
two axles on one side of the loader. Using a spreader
bar push axles outward in their slots to tighten chain.
Fig. 5-3
5. After proper chain tension is obtained, retighten
Fig. 5-3 Spreader bar used to push axles apart and tighten
locknuts on axle. Axle housing locknuts should be
the drive chain.
torqued to 280 ft-lbs (380 N•m).
NOTE: The drive chain must have a minimum of ½"
(13 mm) deflection, overtightening causes premature
drive chain and sprocket wear.
6. Scrap off old oil-resistant RTV on access cover and
reapply with new RTV. Reinstall access cover.
7. Remove pipe plug on chaincase access cover. Fig.
5-2
8. Refill chaincase oil until oil is up to oil level check
plug. Fig. 5-4
9. Reinstall tires. Wheel nut torque is: 180 ft-lbs (244
N•m).
10. Repeat adjustment procedure for other side.
Fig. 5-4 Location of chaincase oil check plug. Fill
chaincase until oil begins to flow out of this plug.

Axle Housing Assembly Removal and

Installation
Removal Procedure
WARNING
Fig. 5-5 Remove the locknuts and washers on the axle (For detailed instructions, refer to the Safety
housing assembly. chapter of this manual.)
WHEEL DRIVES
1. Remove wheels and tires on side of loader being
serviced. Wheel nut torque is 180 ft-lbs (244 N•m).
2. Remove chaincase access cover. Fig. 5-2
3. Drain oil from chaincase. See the procedure in the
Lubrication chapter.
4. Attach a suitable hoist to axle assembly to support
weight of assembly. Remove eight locknuts and
Hoist
washers attaching axle housing to chassis. Fig. 5-5
5. Pull axle housing away from chassis. Fig. 5-6
NOTE: It may be necessary to insert a pry bar or chisel
between chassis and axle housing to loosen axles.
Fig. 5-6 Remove axle housing assembly. Installation Procedure

1. Support axle housing assembly with a suitable hoist.
2. Install new o-ring on axle housing assembly and
secure it with grease.
3. Align holes in axle housing with studs in chassis and
push it in place.
4. Install eight washers and locknuts securing axle
housing to chassis (hand tighten at this point).
5. Install and adjust drive chains per the procedure in
this chapter. Axle nut torque is 280 ft-lbs (380 N•m).
6. Fill chaincase with motor oil to oil level check plug.
7. Reinstall chaincase access cover using oil-resistant
RTV sealant (or equivalent) between cover and
chaincase. Fig. 5-7
Fig. 5-7 New RTV sealant applied to frame of chaincase
before attaching cover.

Drive Chain Removal and Installation

Removal Procedure
Axle Nut
WARNING
chapter of this manual.) Fig. 5-8 Loosen nuts on axle and slide axle in its slots to
produce slack in the drive chain.
1. Remove wheels and tires on side of loader being
serviced. Wheel nut torque is 180 ft-lbs (244 N•m).
2. Remove 14 machine screws on chaincase access
cover to gain access to drive chain.
Drive Motor
3. For each drive chain: Loosen eight locknuts on axle Sprocket
assembly attached to chain. Slide axle assembly in
its slots to loosen chain tension. Fig. 5-8
4. Supporting the axle with a suitable hoist, pull axle
housing out of chaincase to allow axle housing
sprocket to drop inside chaincase.
5. Slip drive chain off axle housing sprocket. Then,
slip drive chain off drive motor sprocket. Figs. 5-9,
5-10
6. Remove drive chain from chaincase. Fig. 5-9 After loosening the axle housing locknuts and
sliding the axle inward, slack appears in the
chain. Remove the chain on the drive motor
sprockets.
Installation Procedure - Follow Removal Procedure
warnings first, then: Axle Housing
Sprocket
NOTE: When installing left and right side drive chains
of loader, install inside chain first.
1. Wrap chain around sprocket of axle.
2. Wrap chain around drive motor sprocket.
3. Adjust drive chain to proper tension per the
4. Refill chaincase oil level until oil is up to oil level
check plug. Then install chaincase access covers
using oil-resistant RTV sealant (or equivalent)
between covers and chaincase.
Fig. 5-10 View is inside the chaincase. Reach in to slip
drive chain off the axle housing sprocket.

Axle Assembly Components
5
4
2
1 6 3
WHEEL DRIVES
2
11
10
Assembly Note: 9
1) Press inner seal into casting(500 lbs) 13
2) Press outside bearing cup into casting(6000 lbs)
3) Press outer seal into casting(500 lbs) 12
14
4) Press inner bearing cup into casting(6000 lbs) 15
5) Pack bearing with synthetic grease 16
6) Press bearing cone onto axle(6000 lbs)
7) Assemble axle into housing 7
8) Pack bearing with synthetic grease
9) Press bearing onto axle and into casting(6000 lbs)
10) Install retaining ring
11) Measure gap between bearing and snap ring
12) Remove retaining ring
13) Install special washer of appropiate thickness
14) Install retaining ring and remove pressure
1 CUP/BEARING 9 WASHER/SPECIAL
2 CONE/BEARING 10 WASHER/SPECIAL
3 ASSEMBLY/AXLE 11 WASHER/SPECIAL
4 SEAL/AXLE 12 WASHER/SPECIAL
5 ASSEMBLY/AXLE AND BOLT 13 WASHER/SPECIAL
6 SEAL/OIL 14 WASHER/SPECIAL
7 RETAINING RING/EXTERNAL 15 WASHER/SPECIAL
8 O-RING 16 WASHER/SPECIAL
Fig. 5-11 Exploded view of the axle drive components.

Axle and Wheel Bearing Disassembly and

Assembly
Disassembly Procedure
1. Remove axle housing assembly per procedure in
this chapter.
2. Move axle housing assembly to a workbench and
clamp it in a vise. Use caution not to clamp web
members in a way that they might be damaged.
3. Remove external retaining ring and washers from
axle shaft.
4. Remove bearing cone from axle shaft.
5. Remove axle from axle housing. Fig. 5-13 Inner oil seal ready to be seated in axle housing.
Note axle housing orientation.
6. Remove outer oil seal, double lip seal, outer bearing
cup and inner bearing cup from axle housing.
7. Remove bearing cone from axle shaft.
Assembly Procedure
NOTE: Pack tapered bearing cones with grease before
assembling.
1. Place axle housing in a vice so axle can be rotated.
Use caution not to clamp web members of axle
housing in such a way that they might be damaged.
2. With webs of axle housing facing up, install inner
oil seal, bearing cup and double lip seal in axle
housing. Use suitable drivers to countersink all
components until they bottom out. Figs. 5-12, 5-13,
5-14, 5-15 Fig. 5-14 Press one bearing cup in axle housing with
3. Turn axle housing over and press an additional suitable driver.
bearing cup into other side of axle housing.
Fig. 5-12 Press this oil seal into axle housing with a Fig. 5-15 Press the double lip seal into the axle housing
suitable driver. with suitable driver.

4. Place axle shaft on flat surface with the shaft in a

Bearing Cone
vertical position. Press bearing cone onto the axle
shaft with a suitable driver. Note orientation of the
first bearing cone in Figs. 5-16 and 5-17.
5. Insert axle shaft into axle housing. Fig. 5-17
NOTE: Allowable end play tolerance on axle shaft is
0.000” to 0.005” (0.0 mm to 0.127 mm) with axle
turning freely. Add shims to increase end play or remove
shims to decrease end play.
6. Install inner bearing cone and special washer(s).
Figs. 5-18, 5-19, 5-20
7. Seat external retaining ring in axle shaft groove.
Fig. 5-21 Fig. 5-18 Press the second bearing cone onto the axle
shaft.
WHEEL DRIVES
Retaining Ring
Axle Shaft
Washer
Fig. 5-16 Press the bearing cone onto the axle shaft. Note Fig. 5-19 Location of groove on axle shaft.
orientation of bearing cone.
Axle Housing
Fig. 5-17 Slide the axle housing over the axle shaft. Fig. 5-20 Pressing special washers onto axle shaft.

8. Apply grease on spline of axle shaft and face of axle

housing to protect o-rings and seals from damage. NOTES
Fig. 5-22
9. Mount axle housing assembly on chassis per the
Fig. 5-21 Seat the external retaining ring onto the axle
shaft.
O-Ring
Fig. 5-22 Apply some grease as a final step to facilitate

reassembly of axle assembly onto the skid loader
chassis and prevent o-ring damage.

40 SERIES CONTROLS
Introduction
This chapter covers removal, installation, assembly, and high-flow models, a lever on the crossmember activates
adjustment procedures for standard and optional control high-flow hydraulics.
equipment on Gehl 40 Series skid-steer loaders. Dual Hand Controls
Equipment Identification On loaders with “Dual Hand controls,” left and right
Because there are a variety of options available for 40 drive control handles with pivoting grips operate
Series, it is IMPORTANT to properly identify independently of each other. Pushed forward together
equipment BEFORE beginning service procedures. moves loader forward, but push either one further
Illustrations and photographs are provided with forward than the other and the loader turns. The left
procedures to aid in servicing this equipment. control handle also operates lift functions of liftarm. The
T-Bar Controls right control handle also operates tilt functions of
On loaders with “T-Bar controls,” the left T-Bar bucket. Engine speed is controlled by hand and/or foot
controls forward and reverse directions of hydrostatic throttles. Standard-flow auxiliary hydraulics is
drive motors (drive control) and pumps for both sides of controlled by a foot pedal. On high-flow models, a lever
loader. The right T-Bar controls lift and tilt functions of on the crossmember activates high-flow auxiliary
liftarm and bucket. For control of engine speed, foot and hydraulics.
hand throttles are standard. A pivoting foot pedal control Two-Speed Control
is standard on floor for control of standard-flow Two-speed loaders have a high and low speed option.
auxiliary hydraulics. On high-flow models, a lever on The two-speed option is controlled by a button switch in
the crossmember activates high-flow auxiliary left control handle and lights a panel light. More
CONTROLS
hydraulics. information may be found in the Electrical System
Hand/Foot Controls chapter of this manual.
On loaders with “Hand/Foot controls,” left and right Hydraglide™ Ride Control
drive control handles operate independently of each The Hydraglide™ Ride Control option on loaders is
other. Pushed forward together moves the loader controlled by a button switch in right control handle and
forward, but push either one further forward than the lights a panel light. More information may be found in
other and the loader turns. Separate foot pedals control the Hydraulic System chapter of this manual.
lift and tilt functions of liftarm and bucket. Engine speed
is controlled with hand throttle lever located right of
operator’s seat. A lock pin is located on right control
handle which controls auxiliary hydraulics. On
T-Bar Controls Hand/Foot Controls Dual Hand Controls
1&7 1, 2, 7 1, 3, 8
2, 3, 8
1&7 1, 6, 8
5 5
6 6
2 3 4 4
4
1 - Drive Control 5 - Foot Throttle

2 - Lift Control 6 - Auxiliary Hydraulics Control
3 - Tilt Control 7 - Two-Speed Control (option)
4 - Hand Throttle 8 - Ride Control (option)
Fig. 6-1 Control locations on T-Bar, Hand/Foot and Dual Hand controls.

CONTROLS 40 SERIES
T-Bar Control Models - Lift and Tilt Components
22
12
13
23 15 20
1
3
9 6
24 21
19
23
11
21
7 20
SEE NOTE 3 24
2
8 6
17 9 19
4
7 14
5
16 23
18
NOTES:
SEE NOTE 1 & 2 1) ROUTE ELECTRICAL WIRES BEFORE INSTALLING
TERMINALS INTO CONNECTORS
2) INSERT RED WIRE INTO PIN 1, GRAY INTO 2,
BLUE INTO 3, AND BLACK INTO 4
3) INSERT WEDGE AFTER TERMINALS ARE INSTALLED.
1 ROD END/FEMALE STUD 9 ROD END/ELASTOMERIC 17 WEDGE/4-PIN
2 WASHER/FLAT 10 NUT/LOCK 18 SCREW/CAP
3 BOOT/CONTROL LEVER 11 PIVOT 19 SCREW/CAP
4 SPACER 12 GRIP/KAWASAKI 20 PIN/COTTER
5 ROD END 13 LEVER/CONTROL RIGHT 21 SCREW/CAP
6 PIN/CLEVIS 14 ROD/LIFT CONTROL 22 PIN/ROLL
7 BUSHING/PIVOT 15 ROD/TILT CONTROL 23 NUT/JAM
8 T-BAR STOP 16 PLUG/4-PIN 24 WASHER/FLAT
Fig. 6-2 Exploded view of T-Bar lift and tilt control components.

40 SERIES CONTROLS
Hand/Foot Control Models - Lift and Tilt Components
23
13 8
19
9 3
27 18
17
5
22 22
21
14 3
13
2 12 26
24
9 6
7
9 4 13
22 27 27
3
11 25
13
15
CONTROLS
10 3
5 13
9
1
20
9
1
24
16
1
9
11
1 WASHER/FLAT 10 NUT/LOCK 19 CONTROL ROD/LIFT 10

2 STUD 11 BRACKET/BEARING 20 PEDAL ASSEMBLY/RIGHT
3 SPACER 12 SPACER/PIVOT 21 ROD/CONTROL
4 PIN/ROLL 13 NUT/LOCK 22 SCREW/CAP
5 ROD END 14 PIVOT ASSEMBLY 23 PIN/COTTER
6 WASHER/HEAVY 15 LEVER ASSEMBLY 24 BOLT/CARRIAGE
7 ROD END 16 PEDAL ASSEMBLY/LEFT 25 BOLT/CARRIAGE
8 PIN/CLEVIS 17 TAB/THREADED 26 NUT/JAM
9 BUSHING/PIVOT 18 CLIP/RETAINING 27 NUT/JAM
Fig. 6-3 Exploded view of Hand/Foot lift and tilt components.

CONTROLS 40 SERIES
Dual Hand Control Models - Lift and Tilt Components
12 1
10
16
14 4 NOTE 1
14
17
4
NOTE 1 15
12
5 13
1
9
SEE NOTES 2 & 3
4
NOTE 1
14
11
2
8 SEE NOTE 4 14 15
17
7 4 16
NOTE 1 3
13
5
NOTES:
1) APPLY LOCTITE 242
6
2) ROUTE ELECTRICAL WIRES BEFORE INSTALLING
3) INSERT RED WIRE INTO PIN LOCATION 1, GRAY
INTO 2, BLUE INTO 3, AND BLACK INTO 4
4) INSERT WEDGE AFTER ALL TERMINALS ARE INSTALLED
1 NUT/LOCK 7 MOUNT/GRIP 13 SCREW/SET SQUARE

2 PIVOT/SPACER 8 MOUNT/GRIP 14 SCREW/CAP
3 ROD END/FEMALE 9 PLUG 4-PIN 15 WASHER/FLAT
4 BEARING/FLANGED 10 WEDGE 4-PIN 16 SCREW/CAP
5 HANDLE/LOWER 11 CABLE 54" 17 PIN/ROLL
6 GRIP 12 CABLE 72"
Fig. 6-4 Exploded view of Dual Hand lift and tilt components.

40 SERIES CONTROLS
Two-Speed Control Module Components
2
1
1 - Wedge Lamp Bulb

2 - Hex Nut
3- Control Module
3
Fig. 6-5 Exploded view of the two-speed control module found on the electrical control panel.
CONTROLS
Hydraglide™ Ride Control Components
1 FITTING/STRAIGHT 7 ASSEMBLY/MANIFOLD
2 FITTING/90° 8 ACCUMULATOR
3 FITTING/TEE 9 PLATE/SPACER
4 NUT/LOCK 10 HOSE/MEDIUM PRESSURE 3
5 TUBE/MANIFOLD 11 SCREW/CAP
6 TUBE/MANIFOLD
6
10
REMOVE CAP FROM MANIFOLD

PORT AND CONNECT HOSE
4
1
BLK
BRN
9
8
11
7
Fig. 6-6 Exploded view of the Hydraglide™ Ride Control.

CONTROLS 40 SERIES
Control Handle Removal and Installation Elastomeric Elastomeric

Rod End Rod End
WARNING
Capscrew
q Raise liftarm, engage liftarm support Capscrew
device.
q Roll ROPS back until lock engages. Rod End
Rod End
chapter of this manual.) Fig. 6-7 Left T-Bar control handle.
Removal Procedure
1. Remove control cover per the procedure in the
Mainframe chapter.
Elastomeric Elastomeric
2. Disconnect electrical connector in control handle Rod End Rod End
from wiring harness.
Locknut
IMPORTANT
Note the wire terminal connections in the Electrical
electrical connector for assembling the Connector
Rod End
control handle if replacing the handle’s
electrical cable.
Rod End
3. Remove locknuts to disconnect studded rod end(s)
on control rod(s) from control handle assemblies on Fig. 6-8 Right T-Bar control handle.
handle(s) being removed. Figs. 6-7, 6-8, 6-9
4. Remove two capscrews, washers and locknuts on
elastomeric rod ends attaching control handle
assembly to chassis crossmember. Remove
Elastomeric
assembly. Figs. 6-7, 6-8, 6-9 Elastomeric Rod End
Rod End
then reverse 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.
Locknut Rod End
Fig. 6-9 Left Dual Hand control handle (other side

similar).

40 SERIES CONTROLS
Control Handle Position Adjustment

Control handles are adjusted two ways for proper
operation; vertically straight appearance and handle
orientation.
Wire Tie
Pivot Assembly
Control Rod Control Rod

WARNING
Fig. 6-10 Left T-Bar control handle. device.
1. Left control handles:
CONTROLS
Tilt Rod a. T-Bar: Adjust two control rod lengths
connected at the pivot assembly, so the bracket
on pivot assembly is oriented 90° to the chassis.
Figs. 6-10, 6-14
b. Hand/Foot and Dual Hand: Adjust by
Lift Rod changing length of one control rod. Figs. 6-12,
6-14
2. Right control vertical orientation:
Fig. 6-11 Right T-Bar control handle view underneath
crossmember looking forward. a. T-Bar: Change lift control rod length attached
to bottom of pivot assembly. Fig. 6-11
b. Hand/Foot and Dual Hand: Change control
rod length attached to bottom of handle
assembly. Fig. 6-12
3. Right control handle orientation:
a. T-Bar: Change tilt control rod length attached
to handle above pivot assembly. Adjust tilt rod
length until oriented 90° to chassis. BE SURE
adjustment allows for full activation of control
valve in both directions of handle operation.
Figs. 6-11, 6-14
Control Rod b. Dual Hand: Change the cable length in the
lower handle, connected at the grip assembly.
Remove capscrew on rod end, loosen jam nut
Fig. 6-12 Right Dual Hand control handle (Hand/Foot and adjust until the handle is properly oriented,
controls are similar).
retighten the jam nut and reinstall the capscrew.
BE SURE adjustment allows for full activation

CONTROLS 40 SERIES
of the control valve in both directions of handle Rod End

operation. Fig. 6-13
c. Hand/Foot: Properly adjusted, control handle
is straight up when fully activated outward.
Jam Nut
Control Handle Tracking Adjustment,

Drive Controls (Fig. 6-15)
Tracking adjustment is performed above neutral
centering mechanisms with two capscrews and locknuts Cable
secured to travel stop assembly on crossmember. Set Screw
When to Adjust:
With control handle(s) engaged FORWARD, loader Fig. 6-13 Handle grip orientation for Dual Hand and
turns slightly to right or left (won’t drive in straight line). Hand/Foot models are similar.
WARNING
device.
Fig. 6-14 A level can be used to help adjust the handle 90°
1. Remove control cover per the procedure in the to the chassis.
Mainframe chapter.
2. Decide which capscrew to adjust. If loader turns
right, left side speed must be reduced and vice versa.
Travel Arms
DO NOT attempt to increase speed of either side, it
may cause control arm assemblies to overtravel,
resulting in damage to hydrostatic pumps.
3. If loader is turning right, loosen locknut on left
capscrew. In a counterclockwise motion, unscrew
capscrew ½ turn and retighten nut.
4. If loader is turning left, loosen locknut on right
capscrew. In a counterclockwise motion, unscrew
capscrew ½ turn and retighten nut.
5. Lower and secure ROPS. Start loader. Test loader
tracking, repeat adjustment as needed. After correct Fig. 6-15 Tracking adjustment capscrews and hex nuts
adjustment, reinstall control cover. located underneath the crossmember. (View is
from back looking forward.)

40 SERIES CONTROLS
T-Bar Control Handle Assembly

Assembly Procedure
The left T-Bar control handle operates the traction
functions for the left and right side of the skid-steer
loader. There is also a button switch for the horn in the
grip assembly. On two-speed models, a button switch in
the grip assembly controls the speed of the loader.
Bronze Bearing
The right T-Bar control handle operates the lift and tilt
functions for the skid-steer loader. There is also a button
switch for the Hydraglide™ Ride Control option in the
grip assembly.
NOTE: The left T-Bar is identical to the right T-Bar
Fig. 6-16 The left and right control handle pivots are except that a different lower pivot is used on each.
identical.
1. Slide boot up T-Bar control handle.
2. Press or drive two bronze bearings into holes on
pivot. Use a bearing driver, if available. Fig. 6-16
3. Place top half of pivot and three washers on control
handle, then slide handle through pivot. Fig. 6-17
4. Place T-Bar stop between washers: Figs. 6-17, 6-18,
CONTROLS
6-19
a. Left T-Bar: Secure to pivot with capscrew and
locknut. Press pivot assembly on bottom of
control handle and secure with roll pin.
b. Right T-Bar: Secure with studded rod end,
placed in recessed area, and jam nut. Install
spacers above and below lift control rod end and
secure in control handle with a capscrew.
Fig. 6-17 Location of three washers on right T-Bar pivot.
Washer location is same on left T-Bar pivot. 5. Attach elastomeric rod ends to sides of pivot with
capscrews, washers and locknuts. Fig. 6-20
T-Bar Stop
Roll Pin
Pivot Assembly
Rod End Spacers
Fig. 6-18 Location of capscrew used to secure the t-bar Fig. 6-19 Capscrew secures rod end and spacers at bottom
stop on the left T-Bar pivot. of right T-Bar control handle.

CONTROLS 40 SERIES
6. Control Rods:
a. Left T-Bar: Attach studded rod ends to each
side of pivot assembly. Attach control rods to
studded rod ends. Fig. 6-23
b. Right T-Bar: Attach tilt control rod to studded
rod end. Attach lift control rod to rod end.
7. Insert grip into grip bracket at top of control handle
and secure with roll pin. Orientate grip at a 45° angle
to chassis. Fig. 6-21
8. Run electrical cord through an opening below grip
bracket and out another opening above T-Bar pivot.
The same for both handles, insert four wire
terminals into electrical connector housing noted on Fig. 6-21 Grip inserted into grip bracket is secured with
step 2 of “Control Handle Removal and roll pin.
Installation” procedure previous in this chapter.
Fig. 6-22
9. Install control handle on crossmember per the
procedure in the this chapter.
10. With control handle attached to crossmember, test
the handle’s operation.
Fig. 6-22 Location of hole in control rod where the

electrical cable threads through.
Elastomeric
Rod End
Elastomeric
Rod End
Fig. 6-20 Attach elastomeric rod ends to both sides of the Fig. 6-23 Location of control rods attached to pivot
pivot with capscrew, washer and locknut. assembly on the left T-Bar control handle.

40 SERIES CONTROLS
Hand/Foot Control Handle Assembly

Assembly Procedure
The left Hand/Foot control handle operates traction
Lever Assembly
functions for left side of skid-steer loader. There is a
button switch for horn in grip assembly. On two-speed
models, a button switch in grip assembly controls loader
speed.
Right Hand/Foot control handle operates traction
functions for right side of skid-steer loader and auxiliary
hydraulics. There is a button switch for Hydraglide™
Ride Control (option) in the grip assembly.
1. Install set screw in lower handle.
Fig. 6-24 Attach elastomeric rod ends to both sides of the
lever assembly. 2. Slide boot onto lever assembly.
3. Attach elastomeric rod ends on lever assembly sides
with washers, capscrews and locknuts. Fig. 6-24
4. Attach studded rod end to bottom hole of lever
assembly from inside out with locknut. Fig. 6-33
5. Attach control rod with jam nut to studded rod end.
CONTROLS
6. Insert lever assembly from below into lower handle
and secure with set screw. Fig. 6-35
Pivot Spacer 7. Install two bearings and one pivot spacer in grip
mount. Slip grip mount into lower handle. Fig. 6-25
8. Insert grip assembly:
Bronze Bearing a. Left Handle: Route electrical cable through
large inside opening. Secure grip assembly to
grip mount with roll pin. Figs. 6-26, 6-27, 6-28,
Fig. 6-25 Press two flanged bearings and one pivot spacer 6-30
into each grip mount.
b. Right Handle: Run auxiliary hydraulics cable
through large inside opening. Run electrical
Grip Mount
Fig. 6-26 Location of electrical cable routing through the

right control handle grip mount. Left control Fig. 6-27 Press grip into the grip mount and secure with a
handle electrical cable can route through the roll pin.
larger center opening beside it.
CONTROLS 40 SERIES
cable through smaller inside opening and along

side of lever assembly. Secure grip assembly to
grip mount with socket head capscrew. Figs.
6-26, 6-27, 6-28,
9. Secure grip mount to lower handle:
a. Left Handle: Use four capscrews and locknuts.
Fig. 6-31
b. Right Handle: Use two capscrew (apply
Loctite® 242 to capscrews). Fig. 6-29
Lower Handle
11. With control handle attached to crossmember, test
Fig. 6-29 One of two (1 of 2) capscrews that secure the grip
the handle’s operation.
mount to the lower handle.
Dual Hand Control Handle Assembly

Assembly Procedure
The left Dual Hand control handle operates traction
functions for the left side of the skid-steer loader, and lift
functions. There is a button switch for the horn in the
grip assembly. On two-speed models, a button switch in
the grip assembly controls the speed of the loader.
The right Dual Hand control handle operates the traction
functions for the right side of the skid-steer loader, and
the tilt functions. There is a button switch for the
Hydraglide™ Ride Control option in grip assembly.
1. Install set screw in lower handle.
2. Slide boot onto lever assembly. Fig. 6-30 View of electrical cable routed through bottom
of the left Hand/Foot control handle.
3. Attach elastomeric rod ends on lever assembly sides
with washers and capscrews. Fig. 6-24
Electrical Cable
Fig. 6-28 Location of roll pin securing the grip to the grip Fig. 6-31 Capscrews and locknuts on left Hand/Foot
mount. control handle securing grip mount to lower
handle.

40 SERIES CONTROLS
4. Attach studded rod end to bottom hole of lever

assembly from inside out with locknut. Fig. 6-33
5. Attach control rod with jam nut to studded rod end.
6. Insert lever assembly from below into lower handle
and secure with set screw. Fig. 6-35
7. Install two bearings and one pivot spacer in grip
mount. Slip grip mount into lower handle. Fig. 6-25
8. Secure grip mount to lower handle with two
capscrews. Fig. 6-29
9. Run electrical cord through smaller opening in
lower handle and along side of lever assembly. Figs.
6-26, 6-34
Fig. 6-32 Right Hand/Foot control handle auxiliary
hydraulics ON/OFF positioner is a capscrew and 10. Insert grip assembly and electrical cord in top of
locknut. Shown in OFF position. grip mount. Secure grip assembly to grip mount
with a roll pin. Figs. 6-27, 6-28
12. Control Cables: Figs. 6-33, 6-34
a. Left Handle: Thread lift control cable through
CONTROLS
lower handle from bottom opening. Tighten
cable jam nut to secure cable to lower handle.
b. Right Handle: Thread tilt control cable
through lower handle from bottom opening.
Tighten cable jam nut to secure cable to lower
handle.
13. Connect control cable rod end to grip mount with
capscrew, hex nut and two washers. Fig. 6-35
Fig. 6-33 View of control cable routing in Dual Hand
control handles. Both sides similar. View is from 14. With control handle attached to crossmember, test
back looking forward. the handle’s operation.
Lower Handle
Elec. Cable
Fig. 6-34 Location of control cable jam nut. View of Fig. 6-35 Circle highlights cable rod attachment location.
electrical cable routing in Dual Hand control
handles. Both sides same.

CONTROLS 40 SERIES
Drive Control Components - T-Bar Models
9
26
7 4
1 5
29 14
3 34 19
7 4
34
25 17
36
25
32
13 11 D 25
17
34 36
4 15
4 34
29 19 25 4
33
6
21
27 18
7 3
1
2
22 36
7
35
30 25
17 13 26
15 36
31 20
16 17
28 34 4
SEE NOTE 3
30 16
31 9
10
24 30 32
7
1
23
8 34
SEE NOTE 1& 2

4
NOTES:
1) ROUTE ELECTRICAL WIRS BEFORE INSTALLING TERMINALS INTO CONNECTORS
3 2) INSERT RED WIRE INTO PIN 1, GRAY INTO 2, BLUE INTO 3, AND BLACK INTO 4.
12 3) INSERT WEDGE AFTER TERMINALS ARE INSTALLED
25
1 WASHER/FLAT 13 ARM/ASSEMBLY 25 NUT/TOP LOCK FLANGED

2 BOOT/CONTROL LEVER 14 TUBE ASSEMBLY/PIVOT 26 NUT/CENTER LOCK FLANGED
3 PIN/ROLL 15 DAMPER 27 SCREW/CAP
4 ROD END/FEMALE 16 ROD END/ELASTOMERIC 28 SCREW/CAP
5 STUD/CONTROL ROD 17 NUT/LOCK 29 SCREW/CAP
6 SHAFT/PIVOT 18 NUT/LOCK 30 SCREW/CAP
7 BUSHING/PIVOT 19 ARM ASSEMBLY/CONTROL 31 SCREW/CAP
8 STOP/T-BAR 20 PIVOT/T-BAR 32 BOLT/CARRIAGE
9 BRACKET/PIVOT 21 GRIP 33 PIN/ROLL
10 ROD 9-1/4 22 LEVER/LEFT CONTROL 34 NUT/JAM
11 ROD 4-3/4 23 PLUG/4-PIN 35 WASHER/FLAT
12 ASSEMBLY/PIVOT 24 WEDGE/4-PIN 36 NUT/HEX
Fig. 6-36 Exploded view of T-Bar drive control.

40 SERIES CONTROLS
Drive Control Components - Hand/Foot and Dual Hand Models
11
6
8 27
24 10 32 19
6 15
1
13
14
17
4
10 35
17 35
2 23 32
32 6 33 23
3 31 5 6
7 19
22 32
5 27
23
29
30 9
21
18
10 1 4
17 14
16 35
CONTROLS
30 25
28
12 33 1
34
34 10
16 28 24
22
17 30 17 35
28
23 20
34 26 3 11
6
30
16
32 31
28
23
16
34
1 WASHER/FLAT 13 ROD 4-3/4 25 SCREW/CAP

2 NUT/LOCK HEX 14 ASSEMBLY/LEVER 26 SCREW/CAP
3 BOOT/CONTROL LEVER 15 TUBE ASSEMBLY/PIVOT 27 SCREW/CAP
4 PIN/ROLL 16 END/ROD ELASTOMERIC 28 SCREW/CAP
5 ROD END/FEMALE 17 NUT/LOCK 29 SCREW/CAP
6 ROD END/FEMALE STUDDED 18 NUT/LOCK 30 SCREW/CAP
7 SPACER 19 ARM ASSEMBLY/CONTROL 31 BOLT/CARRIAGE
8 STUD/CONTROL ROD 20 LEVER ASSEMBLY/LEFT 32 NUT/JAM
9 SHAFT/PIVOT 21 LEVER ASSEMBLY/RIGHT 33 WASHER/FLAT
10 BEARING/SINTERED BRONZE 22 DAMPER 34 WASHER/FLAT
11 BAR/BEARING PIVOT 23 NUT/TOP LOCK FLANGE 35 NUT/HEX
12 ROD 9-1/4 24 NUT/CENTER LOCK FLANGE
Fig. 6-37 Exploded view of Hand/Foot and Dual Hand wheel drives controls.

CONTROLS 40 SERIES
Pivot Tube Removal and Installation -

T-Bar, Hand/Foot and Dual Hand
Pivot Bracket
Pivot tube exploded views are a good reference for pivot
tube’s removal/installation procedures. Refer to views
for names of components and locations in assemblies.
Pivot Tube
Removal Procedure
WARNING
q Raise liftarm, engage liftarm support Fig. 6-38 Remove/install takeup rods from the pivot tube
device. that had connected to the control arm assemblies.

Neutral Centering Devices
1. Remove the control cover per the procedure in the

Mainframe chapter.
2. Remove the crossmember per the procedure in the
Mainframe chapter.
NOTE: If loader is equipped with a backup alarm,
remove two machine screws and locknuts securing
alarm switch bracket to crossmember. Set them aside.
NOTE: It’s recommended that good notes be taken to Fig. 6-39 Remove/install 9.25” (23.50cm) and 4.75”
aid in reassembly. If necessary, mark holes on levers. (12.01cm) rods from pivot tube assembly.
3. Remove one control rod from pivot tube, and one
from arm assembly. Figs. 6-38, 6-39
4. Remove two front hex nuts on two centering
devices. Allow centering devices to hang from their
brackets.
5. Remove two bolts on right control bracket. Slide
control brackets, two washers and arm assembly off
pivot shaft. Bronze bearings are pressed into control
brackets, if not, remove from pivot shaft. Fig. 6-42
6. Pull pivot tube assembly out of left control bracket.
Slide washer off. Bronze bearing is pressed into
control bracket, if not, remove from pivot shaft. Fig.
6-40
7. Remove pivot tube assembly from crossmember.
Fig. 6-41 Fig. 6-40 Remove/install the neutral centering devices at
the pivot tube assembly.

40 SERIES CONTROLS
8. Disassemble pivot tube assembly on a workbench to

replace parts as needed. Refer to exploded views for
correct positioning of pivot tube parts.
Left Control Bracket
NOTE: BEFORE installing the pivot tube assembly,
refer to the exploded views to determine the correct
orientation of pivot tube levers prior to installation.
1. Maneuver pivot tube assembly up and under
crossmember.
2. BE SURE bronze bearing is pressed into left control
bracket. Slide washer on end of pivot shaft.
Fig. 6-41 Left side view of pivot tube assembly. 3. Lift pivot tube assembly up and push shaft in left
control bracket.
4. Slide one washer on right end of pivot tube shaft. BE
SURE bronze bearings are pressed into right control
Carriage Bolts bracket(s). Slide control brackets onto pivot shaft.
5. Slide second washer and arm assembly onto pivot
shaft.
6. Secure right control bracket to crossmember with
CONTROLS
carriage bolts. HAND TIGHTEN ONLY.
7. Push on right end of pivot tube assembly and
bearing bracket (to obtain correct amount of
end-play, (see NOTE), then tighten the carriage
bolts.
NOTE: There should be 0.03" - 0.06" end-play (0.8-1.5
mm) on pivot tube shaft to allow correct operation of
control handles. Fig. 6-43
Fig. 6-42 Right side view of pivot tube assembly, hand
controls unit. Hand/Foot or Dual Hand controls 8. Attach all control rods and centering devices to
unit shown. appropriate levers on pivot tube assembly.
9. Install crossmember per the procedure in the
Mainframe chapter.
10. Install control cover per the procedure in the
Mainframe chapter.
End play 0.03” to 0.06” (0.8 to 1.5mm)
Fig. 6-43 Pivot tube shaft end-play diagram.

CONTROLS 40 SERIES
Neutral Centering Device Adjustment

40 Series skid-steer loaders have two neutral centering
devices underneath crossmember. Neutral centering
devices allow control handles and control arm
assemblies to automatically return to NEUTRAL when
operator releases the control handles.
WARNING
Fig. 6-44 Location of two rod ends attached to hydrostatic
q Raise and block the loader so tires are control arms (pump arms). T-Bar model shown.
off the ground.
device.
(For detailed instructions, refer to the Safety Jam Nut
1. Remove one hex nut on each rod end attached to

hydrostatic control arms. Loosen jam nuts on rod
ends. Fig. 6-44
NOTE: Pump arms and neutral centering devices
automatically return to NEUTRAL, needing no
adjustment.
2. Twist rod ends on control rods until they slip in Fig. 6-45 Location of two rod ends attached to hydrostatic
pump arm holes without pump arm or centering control arms (pump arms). Hand/foot or Dual
devices moving. Tighten rod ends to pump arms and Hand controls unit shown.
jam nuts to rod ends. Fig. 6-45
3. Test operation of control handle(s), push control
handle(s) forward and backward and allow
centering devices to return control handle to the
NEUTRAL position.
IMPORTANT
BE SURE control levers still contact tracking
adjustment capscrews (Fig 6-46). If they DO
NOT contact capscrews, extend capscrews
counterclockwise to prevent overtravel of
control arms, which may cause pump
damage. See “Control Handle Tracking
Adjustment” procedure in this chapter. Fig. 6-46 Location of neutral centering devices on left
inside chassis chaincase. Circle encompasses
tracking adjustment capscrews and wheel drive
(traction) control paddles.
40 SERIES CONTROLS
Control Arm Assembly Removal and

Installation
Removal Procedure
WARNING
device.
Locknut
Fig. 6-47 Rod end securing control rod to control arm q Roll ROPS back until lock engages.
assembly.
1. Remove the locknut on each rod end attached to the

two control arm assemblies and slide rod ends out of
the control arms. Fig. 6-46 and 6-47
CONTROLS
2. Remove the capscrew and locknut that clamps the
control arm assembly to the hydrostatic pump shaft.
Fig. 6-48
Control Arm
Assembly 3. Slide the control arm assembly off the hydrostatic
pump shaft. Take the small key off the shaft (use
caution not to lose it). Fig. 6-48

then reverse the removal steps.*
Fig. 6-48 Removal/installation of control rod from control
arm assembly. * It may be necessary to perform the neutral centering
device adjustment to locate “true neutral” after
installation of the control arms, BUT, if the control rods’
lengths were not altered and the rod ends slip right in, or,
if only a very slight adjustment is made to fit the rod end
Capscrew
in the control arm assembly, no adjustment should be
necessary.
Locknut
Key Shaft
Fig. 6-49 Remove/install pump arm to hydrostatic pump

shaft. Retain the keys when lifting control arm
off the pump shaft.

CONTROLS 40 SERIES
Lift/Tilt Control Removal and Installation
WARNING Tilt Control

Elastomeric
q Raise liftarm, engage liftarm support Elastomeric
Rod End
device. Rod End
q Shut off the engine. Lift Control

chapter of this manual.) Fig. 6-50 Lift and tilt control rod connections on the right
T-Bar control handle.
Removal Procedure - T-Bar Controls
Mainframe chapter.
2. Remove two capscrews, washers and locknuts
securing T-Bar pivot to two elastomeric rod ends at
the front of the crossmember. Fig. 6-50
3. Remove clevis pin and cotter pin on lift control rod
at main control valve. Fig. 6-51
4. Remove clevis pin and cotter pin on tilt control rod
at main control valve. Fig. 6-51
5. Disconnect electrical connector at bottom of each
control handle. Fig. 6-52
6. Pull control handle assembly forward and out.
Fig. 6-51 Location of clevis assemblies to disconnect at
Installation Procedure - T-Bar Controls - Follow all the main control valve.
warnings first, then reverse the removal steps.
Fig. 6-52 Location of electrical connector to disconnect.

Other control handle is similar.

40 SERIES CONTROLS
Removal Procedure - Hand/Foot Controls
Pivot Ass’y
WARNING
device.
Pedal Ass'y q Roll ROPS back until lock engages.
Fig. 6-53 Location of capscrews and locknuts to be chapter of this manual.)
removed on the right side of the right foot pedal.
1. Remove one capscrew and locknut on pivot
assembly and one capscrew and locknut on tilt
control rod at the pedal assembly. Figs. 6-53, 6-54
2. Remove the floor cover per the procedure in the
Mainframe chapter.
Pilot Valve
3. On left side of left foot pedal, remove two carriage
CONTROLS
bolts and locknuts securing foot pedal bracket to
floor plate. Fig. 6-55
4. Pull or tap out entire foot pedal assembly out of right
pedal bracket.
5. Lift foot pedal assembly out of chassis.
6. To reassemble, refer to exploded view as a guide.
Installation Procedure - Hand/Foot Control - Follow

Fig. 6-54 Tilt control rod is attached to the pilot valve.
all warnings first, then reverse the removal steps.
Bracket
Fig. 6-55 Location of capscrews securing the left bracket

on the left pedal assembly.

CONTROLS 40 SERIES
Removal Procedure - Dual Hand Controls
WARNING
Control Cable
device.
Set Screw
chapter of this manual.) Fig. 6-56 Location of the female rod end in the Dual Hand
control handle. Same on other handle.
Mainframe chapter.
2. Disconnect female rod end on control cable in base
of grip mount by removing one capscrew and
locknut and two washers. Fig. 6-56
3. Disconnect electrical connector at bottom of each
control handle. Fig. 6-57 Control Cover
4. Loosen set screw at lower handle base and lift off the
lower handle with grip on each side.
5. Disconnect four screws on two cable brackets
securing two control cables in front of the main
control valve. Fig. 6-58
6. Disconnect cotter pin on both control cables at main
control valve yoke ends. Fig. 6-58 Fig. 6-57 Location of electrical cable on left Dual Hand
7. Thread and pull control handles up and out. control handle. Similar on other handle. View is
from underneath crossmember.
Installation Procedure - Dual Hand Control - Follow
all warnings first, then reverse the removal steps.
Cotter Pin
Cable Bracket
Fig. 6-58 Location of control cable bracket screws

attached to main control valve. Cotter pin
attaches control cable to main control valve.

40 SERIES CONTROLS
Lift/Tilt Control Adjustment

Lift Control
Tilt Control
WARNING
Jam Nut
device.
Jam Nut
Fig. 6-59 Lift and tilt control rods on Hand/Foot models. chapter of this manual.)
Adjustment Procedure - T-Bar Controls

The lengths of lift and tilt control rods can be adjusted to
obtain proper position of the T-Bar. Refer to “Control
Handle Position Adjustment” procedure in this chapter.
The “Self-leveling Valve Adjustment” procedure in the
Hydraulic System chapter is also related to correct
CONTROLS
operation of the lift and tilt controls. Refer to this
procedure as needed.
2-3/4” (70mm)
Adjustment Procedure - Hand/Foot Controls

Basic lift and tilt adjustment involves changing the
lengths of the control rods. The procedure applies to
both foot pedal levers.
Fig. 6-60 Measure the distance between the heel of the foot
pedal and the floor plate on Hand/Foot models. 1. Loosen jam nuts and disconnect capscrews and
locknuts on rod ends attached to pedal levers. Fig.
6-59
2. Turn rod ends right or left to adjust each pedal’s
height until approximately 2.75" (70 mm) of space
exists between bottom of foot pedal heel and floor
plate. Fig. 6-60
Jam Nut
3. Reinstall rod end assemblies and tighten jam nuts.
Adjustment Procedure - Dual Hand Controls

Cable length through control handles can be adjusted to
obtain proper position of Dual Hand control handles.
Refer to the “Control Handle Position Adjustment”
procedure in this chapter as needed. Fig. 6-61
Fig. 6-61 The control cable inside Dual Hand models
adjusts the control handle position.

CONTROLS 40 SERIES
Auxiliary Hydraulics Control - T-Bar and Dual Hand Components
14
2
18
5
17
8 4 17
10
15
12 8
16
19
13
15
1
20
6
3 16
21 9
5 7
18 11
4
2
1 NUT/LOCK 8 NUT/LOCK 15 SCREW/CAP

2 END/YOKE 9 BUSHING/PIVOT 16 NUT/LOCK
3 NUT/HEX 10 PIN/CLEVIS 17 PIN/COTTER
4 PIN/SPRING CLEVIS 11 ASSEMBLY/PEDAL 18 NUT/HEX
5 CLAMP/CONDUIT 12 SUPPORT ASSEMBLY/PEDAL 19 SCREW/CAP
6 JOURNAL/PIVOT 13 BAR/PEDAL SUPPORT 20 WASHER/FLAT
7 CABLE/CONTROL 14 LEVER/AUXILIARY VALVE 21 WASHER/FLAT
Fig. 6-62 Exploded view of the auxiliary hydraulics controls for T-Bar and Dual Hand control models.

40 SERIES CONTROLS
Auxiliary Hydraulics Control - Hand/Foot Components
20
8
10
2
15 NOTE 1
4
4
NOTE 1 15
1
3
18
17
1
19
1 NUT/LOCK
2 SPACER/PIVOT 7
3 ROD END/FEMALE
4 BEARING/FLANGED
5 NUT/LOCK 8
20
6 HANDLE/LOWER 14
CONTROLS
7 HANDLE/LOWER
8 GRIP
9 MOUNT/GRIP
10 MOUNT/GRIP
11 PLUG 4-PIN
12 WEDGE 4-PIN 13
13 CABLE 54"
14 SCREW/SET 9
15 SCREW/CAP
16 SCREW/CAP
17 WASHER/FLAT
18 SCREW/CAP
19 SCREW/CAP 11 SEE NOTES 2 & 3 5
20 PIN/ROLL
16
16
SEE NOTE 4 12
6
NOTES:
14
1) APPLY LOCTITE 242
2) ROUTE ELECTRICAL WIRES BEFORE INSTALLING

3) INSERT RED WIRE INTO PIN LOCATION 1, GRAY

INTO 2, BLUE INTO 3, AND BLACK INTO 4
4) INSERT WEDGE AFTER ALL TERMINALS ARE INSTALLED

Fig. 6-63 Exploded view of the auxiliary hydraulics controls for Hand/Foot control models.

CONTROLS 40 SERIES
Electric Auxiliary Hydraulics Control - Hand/Foot Components
1
6
2
6
1 NUT/LOCK
2 HANDLE/LOWER
3 GRIP 7
4 MOUNT/GRIP
5 SCREW/SET
6 SCREW/CAP
7 PIN/ROLL
4
1
6
Fig. 6-64 Exploded view of the electric auxiliary hydraulics controls for Hand/Foot control models.

40 SERIES CONTROLS
Auxiliary Hydraulics Cable Removal and

Installation - T-Bar and Dual Hand
Refer to the exploded view as a reference in identifying
parts and components.
Removal Procedure
Control Valve Lever
Yoke End WARNING

Fig. 6-65 Location of u-bolt on auxiliary hydraulics device.
control cable attached to valve lever on main
control valve. q Shut off the engine.
1. Disconnect auxiliary clevis pin on control valve
CONTROLS
lever. Fig. 6-65
2. Remove u-bolt securing cable to cable bracket. Fig.
6-65
3. Remove toe plate cover at front of chassis. Fig. 6-66
4. Disconnect rod end on cable from auxiliary pedal
Toeplate Access
assembly. Fig. 6-67
5. Loosen control cable jam nut securing the cable to
Fig. 6-66 The auxiliary cable routing underneath the floor the welded bracket. Fig. 6-67
plate.
6. Remove cable. If replacing cable, remove clevis
pin, rod end and jam nuts from old cable.
Installation Procedure - T-Bar and Dual Hand Con-

trols - Follow all warnings first, then reverse the re-
moval steps.*
U-Bolt * For cable adjustment, refer to “Auxiliary Hydraulics
Cable Adjustment” procedure in this chapter.
Fig. 6-67 Yoke end of auxiliary hydraulics control cable

attached at auxiliary hydraulics pedal.

CONTROLS 40 SERIES
Auxiliary Hydraulics Cable Adjustment -

T-Bar and Dual Hand
The auxiliary hydraulics cable should be adjusted so that
the hydraulic control valve is engaged when the foot
pedal is locked open with the lock bar. Refer to the
exploded view for identifying parts and components.
WARNING
perform the following SAFETY procedures: Fig. 6-68 Location of jam nut on auxiliary hydraulics
q Raise liftarm, engage liftarm support cable.
device.
Auxiliary
(For detailed instructions, refer to the Safety Hydraulics Pedal
1. Sit in seat, pull restraint bar down and turn key to

ON or ACCESSORY position (DO NOT START
ENGINE) to release the electrical detent on the
auxiliary valve spool. Fig. 6-70
2. Pivot auxiliary pedal assembly to right and lock it in
place with lock bar. Fig. 6-69
3. Turn key back to the OFF position.
Note: Roll ROPS back until lock engages. (For
detailed instructions, refer to the Safety chapter of this Fig. 6-69 Location of lock bar on auxiliary hydraulics
manual.) pedal that locks the hydraulics open.
4. Loosen the jam nut on the control valve end of the

auxiliary hydraulics cable. Remove the spring
clevis pin from the yoke end securing the cable to
the valve lever. Fig. 6-68
5. While holding auxiliary hydraulics valve spool
lever in full-engaged position on control valve, twist
yoke end on cable until its holes line up with hole on
spool lever. Figs. 6-65, 6-68 Auxiliary Hydraulics Valve Spool
6. Install clevis pin on yoke end. Tighten jam nut to

secure adjustment.
Fig. 6-70 Location of the electric detent on the auxiliary

valve spool of the main control valve. View is
from rear looking forward.

40 SERIES CONTROLS
Auxiliary Hydraulics Cable Removal and

Installation - Hand/Foot
Rod End
Removal Procedure - Hand/Foot Controls
WARNING
device.
Fig. 6-71 Location of the two jam nuts on the auxiliary q Roll ROPS back until lock engages.
hydraulics cable in the control handle.
1. Remove capscrew, locknut and two washers on rod

end inside control handle. Loosen jam nut on rod
end and remove rod end from cable. Fig. 6-71
CONTROLS
2. Remove jam nut on cable in lower handle of control
handle. Fig. 6-71
3. Pull auxiliary cable down through control handle.
Fig. 6-72
4. At control valve, loosen jam nut on cable mount.
Fig. 6-73
5. Remove two hex head machine screws on cable
mount. Fig. 6-73
Fig. 6-72 Location of cable in lower handle.
6. Remove cotter pin securing auxiliary hydraulics
cable to auxiliary spool valve. Fig. 6-73
7. Remove auxiliary control cable from loader.
Jam Nut
Cotter Pin
Installation Procedure - Hand/Foot Control - Follow
all warnings first, then reverse the removal steps.*
* For cable adjustment, refer to the “Auxiliary
Hydraulics Cable Adjustment” procedure in this
chapter.
Fig. 6-73 Location of hex head machine screw securing

cable mount to control valve.

CONTROLS 40 SERIES
Auxiliary Hydraulics Cable Adjustment - in place, and cable attached to main control valve
Hand/Foot should completely open auxiliary hydraulics spool
valve. Readjust if necessary.
Hand/Foot operated loaders are equipped with
mechanically-controlled auxiliary hydraulics. Follow 9. Retighten jam nut. Tighten locknut on capscrew.
the procedure below to adjust the cable. Refer to 10. Check operation of auxiliary cable by using an
assembly drawings as a reference in adjusting the appropriate attachment.
mechanical auxiliary cable.
Adjustment Procedure - Hand/Foot Controls

The auxiliary hydraulic cable of a skid-steer loader
needs to be adjusted when either two things occur: 1) the
auxiliary hydraulics are not fully engaged because the
cable is too loose, or 2) the cable is too tight to allow the
handle to be locked in the vertical auxiliary-open
position.
WARNING
device.
1. Sit in seat, pull restraint bar down and turn key to

ON or ACCESSORY position (DO NOT START
ENGINE) to release the electrical detent on the Fig. 6-74 To test, open Hand/Foot control handle to a
nearly vertical position.
auxiliary valve spool.
2. On right control handle, lock open auxiliary
hydraulics circuit. Figs. 6-74, 6-75
3. Turn key back to the OFF position.
Note: Roll ROPS back until lock engages. (For
detailed instructions, refer to the Safety chapter of this
manual.)
4. Remove capscrew, washers and locknut securing
auxiliary cable to grip assembly.
5. Loosen jam nut on auxiliary cable. Fig. 6-71
6. Twist rod end clockwise to tighten auxiliary cable
or counterclockwise to loosen auxiliary cable.
7. Attach capscrew, washers and locknut securing
cable to grip assembly, but do not tighten. Fig. 6-75 With other hand, slide the capscrew up and allow
the handle grip mount to rest against it, securing
8. Test control handle in the locked open-auxiliary
the auxiliary hydraulics in an open position.
position. There should be no problem in getting lock

40 SERIES CONTROLS
Throttle Components - T-Bar and Dual Hand Components
SL4640 Models
1
1 GRIP 7 WASHER/FLAT 13 ASSY/PEDAL

2 CLAMP/CABLE 8 WASHER 14 BRACKET
3 CLEVIS 9 BUSHING/PIVOT 15 CLIP/SPRING
21
4 NUT/HEX 10 LEVER/THROTTLE 16 NUT/LOCK
4 8 5 STUD 11 CABLE 17 SPRING
6 PIN/CLEVIS 12 SPACER/PIVOT 18 CLIP/RETAINING
24
10 29
18 31
(TORQUE 8 FT-LBS)
18 3
28
14 16
19 25
6
23
27
11
2
28
3 15
22
20 9 17
26
12 19 ROD/CONTROL 24 SCREW/CAP 29 WASHER/FLAT

5
9
20 CLEVIS/HALF 25 WASHER/LOCK 30 WASHER/FLAT
CONTROLS
13 7 21 HANDLE 26 PIN/COTTER 31 SCREW/CAP
30 16
22 SCREW/MACH. 27 NUT/HEX
23 SCREW/CAP 28 NUT/HEX
1
SL4840, 5640, 6640 Models
1 GRIP/FLAT HANDLE 10 LEVER/THROTTLE

8 20 2 CLAMP/CABLE 11 SPACER/PIVOT
3 CLEVIS/ROD END 12 CLIP/SPRING (TORQUE 8 FT-LBS) 29
4 NUT/HEX 13 NUT/LOCK
27
4
22 5 STUD 14 SPRING
10
17
6 PIN/CLEVIS SPRING 15 PEDAL ASSY/FOOT
7 WASHER/FLAT 16 CABLE/THROTTLE 3
17
8 WASHER/BELLEVILLE 17 CLIP/RETAINING 26
23
18
9 BUSHING/PIVOT 18 ROD/CONTROL
6
25 21
2
16
26
3
19 24
12 19 CLEVIS/HALF 25 NUT/HEX
9
14 20 HANDLE/THROTTLE 26 NUT/HEX
6 21 SCREW/MACHINE 27 WASHER/FLAT
22 SCREW/CAP 28 WASHER/FLAT
15
7 23 WASHER/LOCK 29 SCREW/CAP
28
11
13 24 PIN/COTTER
5
9
Fig. 6-76 Exploded view of throttle assembly components for T-Bar and Dual Hand control handle types.

CONTROLS 40 SERIES
Throttle Components - Hand/Foot Components
SL4640 Models
14 1 GRIP/FLAT HANDLE
2 CLAMP/CABLE
6 3 CLEVIS/ROD END
4
20 4 NUT/HEX
19 5 END/ROD
6 WASHER/BELLEVILLE
6 17
7 PIN/CLEVIS
6 8 LEVER/THROTTLE
5 9 CABLE/CONTROL 22 8
20 10 BRACKET/CABLE 20
7
21
12 11 NUT/LOCK 10 23
13
12 NUT/LOCK 11
13 BRACKET/CABLE 19
18 23
14 HANDLE 16 3 21
15 SCREW/MACHINE 20
16 SCREW/CAP
9
17SCREW/CAP 2
18 SCREW/CAP
15
19 WASHER/LOCK 22 PIN/COTTER
20 NUT/HEX 23 SCREW/CAP
21 WASHER/LOCK
SL4840, 5640, 6640 Models

1 GRIP/HANDLE 8 LEVER/THROTTLE 15 SCREW/CAP
12
2 CLAMP/CABLE 9 NUT/LOCK 16 WASHER/LOCK
6 3 CLEVIS/ROD END 10 BRACKET/CABLE 17 NUT/HEX
17 4 NUT/HEX 11 CABLE/THROTTLE 18 WASHER/LOCK
16 5 END/ROD 12 HANDLE 19 PIN/COTTER
4 6 WASHER 13 SCREW/MACHINE 20 SCREW/CAP
14 7 PIN/CLEVIS 14 SCREW/CAP
5 8
17 19
18
7
10 20
9 16
(TORQUE 8 FT-LBS)
17
15 18
3
17
16
11
2
13
Fig. 6-77 Exploded view of throttle assembly components for Hand/Foot control handle type.

40 SERIES CONTROLS
Hand Throttle Lever Hand Throttle, Rod and Cable Removal

and Installation - T-Bar and Dual Hand
Removal Procedure
Throttle Cable
WARNING
Spring
Throttle Rod q Shut off the engine.
Fig. 6-78 Location of hex nut and capscrew securing chapter of this manual.)
throttle lever to welded throttle bracket.

Mainframe chapter.
2. Disconnect throttle cable and spring from foot
throttle. Remove yoke on throttle cable. Loosen two
nuts on throttle cable bracket. Figs. 6-78, 6-80
CONTROLS
3. Remove two retaining clips securing throttle rod to
hand throttle. Remove hex nut and capscrew on
hand throttle securing it to chassis. Figs. 6-78, 6-79
4. At the engine’s throttle lever, disconnect clevis pin
from yoke end at throttle lever. Disconnect cable
clamp on cable bracket and remove throttle cable
from loader. Figs. 6-81

Fig. 6-79 Location of retaining clips on hand throttle. then reverse the removal steps.*
* Perform “Throttle Adjustment” procedure found in
this chapter after the installation is complete.
Engine Throttle Lever
Cable Clamp
Yoke End
Fig. 6-80 Location of two throttle cable nuts to loosen.
Fig. 6-81 Throttle cable secured to engine throttle lever.

CONTROLS 40 SERIES
Foot Throttle Removal and Installation -

T-Bar and Dual Hand
Removal Procedure
WARNING
device.
q Roll ROPS back until lock engages. Fig. 6-82 Removed spring and throttle cable from foot
pedal assembly.
1. Remove the floor cover per the procedure in the

Mainframe chapter. Cotter Pin on Rod
2. Remove clevis pin on throttle cable and spring

attached to the foot throttle pedal. Fig. 6-82
3. Remove cotter pin and washer securing throttle rod
to foot throttle pedal. Fig. 6-83
4. Remove locknut and washer securing the foot pedal
to the chassis. Figs. 6-83, 6-84
5. Slide the foot pedal assembly off the pivot spacer
and remove from loader. Fig. 6-84
Installation Procedure - Follow all warnings first, Fig. 6-83 Location of locknut and washer securing foot
then reverse the removal steps.* pedal to the chassis.
Pivot Spacer
Fig. 6-84 View of the foot throttle pedal assembly

disconnected from the throttle cable with floor
cover removed.

40 SERIES CONTROLS
Hand Throttle Tension Adjustment

Hand throttle tension should be tight enough to maintain
a desired engine RPM, but loose enough to allow easy
operation. The hand throttle tension can be
INCREASED or DECREASED.
Adjustment Procedure (Figs. 6-85, 6-86, 6-87)
WARNING
Fig. 6-85 Location of Belleville-type washers on Hand q Raise liftarm, engage liftarm support
and Foot units. device.
CONTROLS
NOTE: The Belleville-type washers must be installed
properly to provide tension against the hand throttle.
1. To INCREASE TENSION tighten locknut
securing hand throttle pivot assembly to chassis.
2. To DECREASE TENSION loosen locknut
securing hand throttle pivot assembly to chassis.
Fig. 6-86 Location of Belleville-type washers on T-Bar or

Dual Hand units. )View is directly above hand
throttle.)
Belleville Washers
Fig. 6-87 Orientation illustration of Belleville-type

washers on the hand throttle.

CONTROLS 40 SERIES
Hand Throttle and Throttle Cable Removal

and Installation - Hand/Foot
Removal Procedure Lock Nut
WARNING Capscrew
device.
q Roll ROPS back until lock engages. Fig. 6-88 Location of rod end attached to throttle lever.

1. Disconnect the rod end from the throttle lever. Fig.

6-88
2. Loosen the two jam nuts holding the throttle cable to
the cable bracket. Disconnect the rod end from the
throttle cable. Remove the throttle cable from the
bracket. Fig. 6-89
3. Remove one capscrew and locknut from the hand
throttle lever that attaches the lever to the throttle
bracket. Remove the hand throttle lever. Fig. 6-88
4. Disconnect the yoke end and clevis pin from the rear
throttle lever attached to the engine. Remove two
machine screws, nuts, and lock washers from the Fig. 6-89 Location of jam nuts securing throttle cable to
clamp. Remove the clamp. Remove the throttle throttle cable bracket.
cable. Fig. 6-90

Engine Throttle Lever
Yoke End
Fig. 6-90 Location of throttle cable clamp on Hand and

Foot units.

40 SERIES CONTROLS
Hand Throttle Adjustment - Hand/Foot

The hand throttle is adjusted at the factory to provide a
full range of engine speed adjustment, from IDLE to
FULL throttle.
The hand throttle can be adjusted at three different
locations; at the rod end attached to the throttle lever
(Fig. 6-91) , at the throttle cable on the cable bracket
(Fig. 6-92) and the yoke end attached to the engine (Fig.
6-90).
Fig. 6-91 One place to adjust the hand throttle.

WARNING
CONTROLS
NOTE: DO NOT attempt to adjust hand throttle lever
at the two fuel injection pump adjustment screws.
1. Test the throw of the hand throttle to determine if
cable needs shortening or lengthening. When the
hand throttle and fuel injection pump are at low idle
simultaneously, proper adjustment is achieved. Be
sure that the throttle lever does not interfere with the
rod end attached to it.
Fig. 6-92 One place to adjust the hand throttle.
2. If the cable needs adjustment, choose a location:
a. Loosen the jam nut on the yoke end or throttle
cable or rod end.
b. Remove the clevis spring pin on the yoke end or
the lockwasher and hex nut on the rod end.
c. Twist the yoke end or rod end to shorten or
lengthen the throttle cable as needed. If
adjusting at the throttle cable bracket, pull or
push throttle cable through it’s protective
sheath until correct length is achieved.
d. Reattach the yoke end or rod end. If adjusting at
the throttle cable bracket tighten the jam nut.
Next, push the hand throttle to check for correct
operation. Repeat as needed.
3. Tighten the jam nut against the yoke end or rod end
to secure the adjustment.

CONTROLS 40 SERIES
Foot Throttle Adjustment - T-Bar and Dual

Hand
Loaders with T-Bar and Dual Hand controls include a
foot throttle to control the engine RPM to match
Throttle Rod
increased power requirements. The foot throttle is
coupled to the hand throttle through a foot throttle rod
assembly. The foot throttle is at proper adjustment when
pushing the hand throttle FULL FORWARD causes the
Half Clevis
foot pedal to be pressed flush against the floor plate.
WARNING Fig. 6-93 Hand throttle shown in IDLE position.

device.
1. With hand throttle pulled back to an IDLE position,

remove cotter pin and washer to disconnect half
clevis from foot throttle assembly. Fig. 6-93
2. Push down on foot pedal until it is flush with floor
plate. Fig. 6-94 Location of jam nut on throttle rod.
3. Loosen jam nut on half clevis and adjust half clevis
so hand throttle lever is at high idle. Fig. 6-94
4. With foot pedal down and hand throttle pulled back,
the clevis pin should just touch top of slot in lever
assembly. Fig. 6-95
Half Clevis Pin
Slot
Fig. 6-95 Illustration of correct foot throttle adjustment.

40 SERIES HYDROSTATIC SYSTEM
Introduction
This chapter covers troubleshooting, testing, removal, allowing complete flexibility in forward, reverse,
installation, and adjustment procedures for the gradual, pivot and spin turns.
hydrostatic system components on Gehl 40 Series For detailed information on hydrostatic pump or drive
skid-steer loaders. motor internal repair, consult the Gehl Service
In this system, a hydrostatic pump assembly coupled to Department and/or the hydrostatic component
the engine provides hydrostatic power to the two manufacturer’s service manual. Other related hydraulic
fixed-displacement hydrostatic drive motors. The drive components are covered in the Hydraulic System
motors drive the wheels on each side of the loader chapter of this manual.
through a chain and sprocket system. The hydrostatic
pumps and drive motors are controlled individually
Hydrostatic System - SL4640 and SL4840 Single-Speed Model Components

APPLY LOCTITE 242
TORQUE TO 55 FT-LBS
36
G 17
10 1 14
2 1 FITTING/STRAIGHT
9
2 FITTING/90°
26
3 FITTING/STRAIGHT
12
2 7
4 FITTING/45°
12 5 FITTING/90°
26 12 6 CAP/37° FLARE
F 7 FITTING/45°
A E
22
1 4 8 FITTING/TEE
26 26
B
9 FITTING/90°
24 10 TUBE/CHARGE
25 C
HYDROSTATIC
13 5
5 20 32 N 11 CLAMP/TUBE
D D 37
G
12 FITTING/STRAIGHT
C 11
38
13 PLUG
19 L E 16 14 HOSE
H
15 SWITCH/TEMP
31
33 5 16 NUT/LOCK
3
H 30
17 WASHER/FLAT
18 21
6 18 HOSE
N M 19 WASHER/FLAT
J 34
35 20 HOSE
15
23
M 8 21 HOSE
K
29 22 PUMP/TANDEM
23 SCREW/CAP
L
31 24 MOTOR
K 1
6 24 25 ADAPTER/45°
27 F
28 26 HOSE
19
38
27 TUBE ASSY/DRAIN
25 J 28 TUBE ASSY/DRAIN
29 TUBE ASSY/BRAKE
13
30 TUBE ASSY/BRAKE
MAIN IN -10 ORB (B,D) B 5
DRAIN -8 ORB (K,L) 31 HOSE
CASE FLUSH-DRAIN -8 ORB 32 VALVE/SOLENOID
A 25
33 PLATE/SPACER
BRAKE -6 ORB (H,J)
34 TUBE/BRAKE VALVE
35 MANIFOLD
36 SCREW/CAP
37 SCREW/CAP
DRAIN -8 ORB 38 SCREW/CAP
MAIN OUT -10 ORB (A,C)
DRIVE MOTOR PORT REFERENCE
SINGLE SPEED (STANDARD) WITHOUT SHUTTLES
Fig. 7-1 Exploded view of the SL46/4840 hydrostatic single-speed system.

HYDROSTATIC SYSTEM 40 SERIES
Hydrostatic System - SL4840 Two-Speed Model Components
9 2 APPLY LOCTITE 242

13 TORQUE TO 55 FT-LBS
38 16
2 12
26
2 4
11
G 34
F
26 11
N
26 10
B D
E
A
21 C
26 32
5
7 37
G 19 3
36 5
J D 15
20
39 33
18 H E J
H
C L
29 M
25 N 30
23 K
6
17
M 24
22
35 F 6
14 18
39
7
25
L
31
B
K
A
28
36
27
MAIN IN -12 ORB (B,D)
2-SPEED -08 ORB (J,K)

BRAKE -08 ORB (H,L)
CASE FLUSH-DRAIN -10 ORB (G)
1 FITTING/STRAIGHT 11 FITTING/STRAIGHT 21 PUMP/TANDEM 31 TUBE/MOTOR RIGHT

2 FITTING/90° 12 HOSE 22 SCREW/CAP 32 MANIFOLD/VALVE
3 FITTING/TEE 13 HOSE 23 MOTOR/TWO-SPEED 33 PLATE/SPACER
4 FITTING/45° 14 SWITCH/TEMP 24 MOTOR/TWO-SPEED 34 HOSE
5 FITTING/90° 15 NUT/LOCK 25 ADAPTER 45° 35 MANIFOLD
6 CAP/37° FLARE 16 WASHER/FLAT 26 HOSE 36 FITTING/STRAIGHT
7 FITTING/STRAIGHT 17 HOSE 27 TUBE/BRAKE LEFT 37 SCREW/CAP
8 FITTING/90° 18 WASHER/FLAT 28 TUBE/MOTOR LEFT 38 SCREW/CAP
9 TUBE/CHARGE 19 HOSE 29 TUBE/BRAKE RIGHT 39 SCREW/CAP
10 CLAMP/TUBE 20 HOSE 30 TUBE/MOTOR RIGHT
Fig. 7-2 Exploded view of the SL4840 hydrostatic two-speed system.

Hydrostatic System - SL5640 Single-Speed Model Components
APPLY LOCTITE 242

25 TORQUE TO 55 FT-LBS
1 41
11 37 16
12
18
10
40
24 O
1
18 1
3
18
19
A L
24
35 6
B 24 N
8 D
23 13
N 33
5 C
14 4
31
42
K F
F 21
34
G L
42
15
M
O 4
32
2
38
28
22
20
B
J K
30 36
HYDROSTATIC
26 E
7
20 43
G A
17
E
39
29
43
17 BRAKE -8 ORB (E,J)
27 MAIN IN -12 ORB (B,D)

20
D
39
J
M MAIN OUT -12 ORB (A,C)

CASE FLUSH-DRAIN -10 ORB (G,M)
C DRIVE MOTOR PORT REFERENCE

SINGLE SPEED WITH SHUTTLES
20
1 FITTING/90° 12 TUBE/CHARGE 23 SCREW/CAP 34 MANIFOLD

2 FITTING/TEE 13 HOSE/PRESSURE 24 HOSE/PRESSURE 35 PUMP/TANDEM
3 FITTING/45° 14 SWITCH/TEMP. 25 HOSE/PRESSURE 36 TUBE/BRAKE VALVE
4 FITTING/90° 15 NUT/LOCK 26 HOSE/PRESSURE 37 TUBE/TANDEM PUMP
5 CAP/37° FLARE 16 WASHER/FLAT 27 MOTOR/DRIVE 38 HOSE/PRESSURE
6 FITTING/45° 17 WASHER/FLAT 28 MOTOR/DRIVE 39 FITTING/STRAIGHT
7 FITTING/TEE 18 FITTING/STRAIGHT 29 TUBE/BRAKE LEFT 40 FITTING/TEE
8 CLAMP/HOSE 19 HOSE/PRESSURE 30 TUBE/BRAKE RIGHT 41 SCREW/CAP
9 FITTING/STRAIGHT 20 FITTING/45° 31 VALVE/SOLENOID 42 SCREW/CAP
10 ADAPTER/90° 21 HOSE/PRESSURE 32 TUBE/DRAIN MOTOR 43 SCREW/CAP
11 FITTING/90° 22 HOSE/PRESSURE 33 HOSE/PRESSURE
Fig. 7-3 Exploded view of the SL5640 hydrostatic single-speed system.


APPLY LOCTITE 242
TORQUE TO 55 FT-LBS
45
12 26 17
19
25 13 41
11
44
O
1
1
A 20
19
B
L 25
7
39
37
24 25 D
9 P C
6 14
N
38 5 34
K
16
15 P 22 46
L O
M 27 5 4
3
36
42 N
G 33
H
23
31
8 2
J K
F 35
29
B 10 40
F 21
8
32
A
47
G
21
E 18
43
E
47 30
18
2-SPEED -08 ORB (F,H)
21
28 10
D
43
J M
BRAKE -08 ORB (E,J)
H
43 DRIVE MOTOR PORT REFERENCE
21
C
1 FITTING/90° 13 TUBE/CHARGE 25 HOSE/PRESSURE 37 HOSE/PRESSURE

2 FITTING/TEE 14 HOSE/PRESSURE 26 HOSE/PRESSURE 38 MANIFOLD
3 FITTING/STRAIGHT 15 SWITCH/TEMP. 27 HOSE/PRESSURE 39 PUMP/TANDEM
4 FITTING/45° 16 NUT/LOCK 28 MOTOR/TWO-SPEED 40 TUBE/BRAKE VALVE
5 FITTING/90° 17 WASHER/FLAT 29 MOTOR/TWO-SPEED 41 TUBE/TANDEM PUMP
6 CAP/37° FLARE 18 WASHER/FLAT 30 TUBE/BRAKE LEFT 42 HOSE/PRESSURE
7 FITTING/45° 19 FITTING/STRAIGHT 31 TUBE/BRAKE RIGHT 43 FITTING/STRAIGHT
8 FITTING/TEE 20 HOSE/PRESSURE 32 TUBE/TWO-SPEED 44 FITTING/TEE
9 CLAMP/HOSE 21 FITTING/45° 33 TUBE/TWO-SPEED 45 SCREW/CAP
10 FITTING/STRAIGHT 22 HOSE/PRESSURE 34 MANIFOLD/VALVE 46 SCREW/CAP
11 ADAPTER/90° 23 HOSE/PRESSURE 35 TUBE/VALVE 47 SCREW/CAP
12 FITTING/90° 24 SCREW/CAP 36 TUBE/DRAIN MOTOR

Hydrostatic System - SL6640 Single-Speed Model Components

12 25
18 1 1 APPLY LOCTITE 242
TORQUE TO 55 FT-LBS 16
18 41
11 37
24 10
G
40
18
24
19 1
B 43 6 L
17 35 18
20
27 33
24
D D
F
39 J
C 42
M 4 32 42 3
21
9 L
G
23
C
20 5
N
15
4
8 N 2
34 38 22
30
14 K 13 J K
F
31
M
7 36
28 E
20
HYDROSTATIC
B
17
9 43
26
20
E
A
39 29
BRAKE -8 ORB (E,J)

SINGLE SPEED WITH SHUTTLES
1 FITTING/90° 12 TUBE/CHARGE 23 SCREW/CAP 34 MANIFOLD

2 FITTING/TEE 13 HOSE/PRESSURE 24 HOSE/PRESSURE 35 PUMP/TANDEM
3 FITTING/45° 14 SWITCH/TEMP. 25 HOSE/PRESSURE 36 TUBE/BRAKE VALVE
4 FITTING/90° 15 NUT/LOCK 26 HOSE/PRESSURE 37 TUBE/TANDEM PUMP
5 CAP/37° FLARE 16 WASHER/FLAT 27 MOTOR/DRIVE 38 HOSE/PRESSURE
6 FITTING/45° 17 WASHER/FLAT 28 MOTOR/DRIVE 39 FITTING/STRAIGHT
7 FITTING/TEE 18 FITTING/STRAIGHT 29 TUBE/BRAKE LEFT 40 FITTING/TEE
8 CLAMP/HOSE 19 HOSE/PRESSURE 30 TUBE/BRAKE RIGHT 41 SCREW/CAP
9 FITTING/STRAIGHT 20 FITTING/45° 31 TUBE/DRAIN MOTOR 42 SCREW/CAP
10 ADAPTER/90° 21 HOSE/PRESSURE 32 VALVE/SOLENOID 43 SCREW/CAP
11 FITTING/90° 22 HOSE/PRESSURE 33 HOSE/PRESSURE
Fig. 7-5 Exploded view of the SL6640 hydrostatic single-speed system.

APPLY LOCTITE 242

1 26 TORQUE TO 55 FT-LBS
13 45
17
O
1
41 44
11
25 12 1
19
47 20
4
18 A
L
25
19
B 7
39
D N
5 36
21
J 25
H 22
L
43 37 C
D O
3 46
P
C N 42 5
9 33
M
10 2
24 6 16
J 23
28 14 8
38 H
K
K
31
F 34
MAIN IN -12 ORB (B,D) P 29
15 40
27
E 8
8 ORB (F,H) 35
M 18
G
47
G B
A 10
21
F
IN OUT -12 ORB (A,C) BRAKE -08 ORB (E,J) E
CASE FLUSH-DRAIN -10 ORB (G,M) 32

43 30
1 FITTING/90° 13 TUBE/CHARGE 25 HOSE/PRESSURE 37 HOSE/PRESSURE

2 FITTING/TEE 14 HOSE/PRESSURE 26 HOSE/PRESSURE 38 MANIFOLD
3 FITTING/STRAIGHT 15 SWITCH/TEMP. 27 HOSE/PRESSURE 39 PUMP/TANDEM
4 FITTING/45° 16 NUT/LOCK 28 MOTOR/TWO-SPEED 40 TUBE/BRAKE VALVE
5 FITTING/90° 17 WASHER/FLAT 29 MOTOR/TWO-SPEED 41 TUBE/TANDEM PUMP
6 CAP/37° FLARE 18 WASHER/FLAT 30 TUBE/BRAKE LEFT 42 HOSE/PRESSURE
7 FITTING/45° 19 FITTING/STRAIGHT 31 TUBE/BRAKE RIGHT 43 FITTING/STRAIGHT
8 FITTING/TEE 20 HOSE/PRESSURE 32 TUBE/TWO-SPEED 44 FITTING/TEE
9 CLAMP/HOSE 21 FITTING/45° 33 TUBE/TWO-SPEED 45 SCREW/CAP
10 FITTING/STRAIGHT 22 HOSE/PRESSURE 34 TUBE/VALVE 46 SCREW/CAP
11 ADAPTER/90° 23 HOSE/PRESSURE 35 TUBE/DRAIN MOTOR 47 SCREW/CAP
12 FITTING/90° 24 SCREW/CAP 36 MANIFOLD/VALVE

Troubleshooting Guide
The following troubleshooting guide lists potential
hydrostatic system problems, as well as possible causes
and remedies, for Gehl 40 Series skid-steer loaders. IMPORTANT
DO NOT attempt to service or repair major
When a problem occurs, don’t overlook simple causes.
hydrostatic system components, such as the
A malfunction can be caused by something as simple as hydrostatic pumps or drive motors, unless
low oil level. After a mechanical failure has been authorized to do so by your Gehl dealer. Any
corrected, be sure to locate and correct the cause of the unauthorized repair will void the warranty.
problem.
Problem Possible Cause Remedy

No response from the Hydraulic oil viscosity is too high. Allow longer warm-up or replace oil with
hydrostatic drive or the the proper viscosity oil.
lift/tilt systems.
Hydraulic oil supply is too low. Check for low oil level in reservoir. Add
oil as needed.
Hydrostatic pump drive is disconnected. Check for broken or worn pump Drive
Drive coupling failure. Coupling and replace, as needed.
HYDROSTATIC
Traction drive will not Parking brake is engaged. Disengage parking brake.
operate in either 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
mechanisms. Reconnect linkage.
Low or no charge pressure. See hydrostatic pump manual.
Hydrostatic pump relief valves are Inspect and clean the relief valves.
malfunctioning. Replace them as needed.
Drive wheels do not turn in High pressure hydraulic hoses between Reconnect hoses to proper ports on the
proper direction for T-Bar hydrostatic pump and drive motors are drive motors. Refer to schematic and
movement. connected wrong. figures in hydrostatic chapter.


Neutral is difficult to Rod ends loose on centering mechanism Check and tighten or replace components.
maintain. or servo rod.
Neutral centering mechanism(s) out of Adjust neutral centering mechanism(s).

adjustment. See Controls chapter for procedure.
Clamping bolt is loose. Tighten clamp bolt.
Hydrostatic pump out of adjustment. See hydrostatic pump manual.

Sluggish response to Air in the hydraulic system. Cycle the lift and tilt cylinders to maximum
acceleration. stroke and maintain pressure for a short
time to clear air from system. Check
hydraulic oil reservoir, fill as needed.
Hydraulic oil supply is too low. Check hydraulic oil reservoir. Add oil, if
necessary.
Low hydrostatic system charge pressure. See hydrostatic pump manual.
Drive motor(s) or hydrostatic pump(s) Refer to component manufacturer’s

have internal damage or leakage. service manual.
Engine is not responding under load. Troubleshoot engine.

Hydrostatic drive is Drive system overloaded continuously. Improve efficiency of operation.
overheating.
Lift and tilt system overloaded Improve efficiency of operation.
continuously.
Drive motor(s) or hydrostatic pump(s) Refer to component manufacturer’s

have internal damage or leakage. service manual.
Oil cooler is plugged with debris. Clean oil cooler fins.
Loader being operated in a high Reduce duty cycle and improve air
temperature area with no air circulation. circulation.


Hydrostatic (drive) Hydraulic oil viscosity is too high. Allow longer warm-up or replace existing oil
system is noisy. with the proper viscosity oil.
Drive motor(s) or hydrostatic pump(s) have Refer to component manufacturer’s service

internal damage or leakage. manual.
Air in hydraulic system. Cycle lift and tilt cylinders to maximum

stroke and maintain pressure for a short
time to clear air from system. Check oil
level in reservoir, fill as needed.
Right side doesn’t Excessive internal leakage in right drive Perform “Case Drain Test” on right drive
drive in either motor. motor. Repair or replace as needed. Refer
direction. Left side to motor manufacturer’s service manual.
operates normally.
Excessive leakage in engine-end Refer to the pump manufacturer’s manual

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

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

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

Servo controller malfunctioning. service procedures. Repair or replace rear
pump as needed.
Lift/tilt controls fail to Hydraulic oil viscosity is too heavy. Allow longer warm-up or replace with
respond. proper viscosity oil.
Hydraulic oil level is low. Check oil level in reservoir. If oil is low,
check for an external leak. Repair and add
oil.
Solenoid valve(s) malfunctioning. Check electrical connections to lift solenoid

and repair.
Restraint bar or seat switch malfunction. Check switches.


Left side doesn’t drive in Excessive internal leakage in left drive Perform “Case Drain Test” on left drive
either direction. Right motor. motor. Repair or replace as needed. Refer
side operates normally. to motor manufacturer’s service manual.
Excessive leakage in gear-end hydrostatic Refer to pump manufacturer’s manual for

pump. service procedures. Repair or replace the
front pump as needed.
Relief valves on gear-end hydrostatic Switch valves with those on rear

pump malfunctioning. hydrostatic pump. See “Hydrostatic Pump
Relief Valves” information in this chapter;
problem should switch to the right side.
Replace defective relief valve as needed.
Servo controller malfunctioning. Refer to the pump manufacturer’s manual

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

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

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

service procedures. Repair or replace

Charge Pressure Test and Adjustment

Before performing the following test, run loader until
hydraulic oil is at normal operating temperature.
NOTE: This test requires a minimum 500 PSI (34.5
bar) pressure gauge.
Test Procedure (Figs. 7-7, 7-8, 7-9)
WARNING
BEFORE beginning this Service procedure,
Fig. 7-7 Location of rear left charge pressure port. This
pressure port is the preferred pressure check
location (no hoses or tubes to remove). q Roll ROPS back until lock engages.
1. Install pressure gauge on a charge pressure port.

Fig. 7-7
2. Start engine and check pressure reading on gauge.
The gauge should read as follows:
a. All models - 250 - 300 PSI (17 - 21 bar)
HYDROSTATIC
3. If the pressure reading on the gauge is either lower
or higher than specified, see the manufacturer’s
service manual for the hydrostatic pump.
4. Remove the pressure gauge and replace plug, hose
Fig. 7-8 Location of front left charge pressure port. or tube, depending on where pressure was
measured.
Add or remove shims on charge relief valve (next
section) to adjust charge pressure. Add shims to increase
charge pressure. Remove shims to lower charge
pressure.
Fig. 7-9 Location of front and rear right charge pressure

ports.

Hydrostatic Pump Relief Valves

Relief Valve Components
Each hydrostatic pump is equipped with two high
pressure relief valves making a total of four hydrostatic
pump relief valves in the hydrostatic drive system (Figs. 1
7-10 and 7-11). The two front relief valves on the
hydrostatic pump assembly control the front hydrostatic
2
pump, which drives the left side of the skid loader. The
two rear relief valves on the hydrostatic pump assembly
control the rear hydrostatic pump, which drives the right
side of the loader. Refer to the manufacturer’s
manual for service procedures.
Hydrostatic Pump Removal / Installation

Removal Procedure
WARNING 2
BEFORE beginning this Service procedure, 1

device. Fig. 7-10 Pump relief valve exploded view.
1. Relief valve
q Shut off the engine. 2. Shim

1. Drain oil from hydraulic reservoir. Refer to the

Hydraulic System chapter for that procedure.
NOTE: Hydraulic hoses and fittings should be
capped/plugged after they are disconnected to prevent
contaminants from entering the hydraulic system.
2. R e m o v e c o n t r o l c o v e r , f l o o r c o v e r a n d
crossmember per procedures in the Mainframe
chapter.
3. Disconnect hoses at gear pump. Fig. 7-12
4. Support pump. Remove two capscrews securing
gear pump to hydrostatic pump. Pull gear pump
Fig. 7-11 Location of the top hydrostatic pump relief
forward and up, out of chassis. Figs. 7-13 valves. There is another located directly
5. Disconnect and label hydraulic hoses connected to underneath the top relief valves, for a total of
hydrostatic pump. Plug or cap hoses and tubes to four relief valves, two per side.
prevent hydraulic fluid loss or contaminants from
entering hydraulic system.
6. Position a hoist above hydrostatic pump. Attach
lifting strap around pump and raise hoist just enough

to remove slack from strap. The hoist should now be

prepared to support weight of pump.
7. 3-Cylinder Engines Only: Unbolt the pump
support bracket from underneath, two capscrews
and washers at mid-pump and four capscrews
attaching pump support to the engine flywheel
cover. Fig. 7-15
8. Remove two capscrews (55 ft-lbs)(73 N•m)
securing hydrostatic pump to flywheel housing. Lift
pump slightly to remove capscrews. Pull pump out
of flywheel housing. Figs. 7-14, 7-16
9. Lift and maneuver hydrostatic pump out of loader.
Fig. 7-12 Hoses to remove off gear pump for pump Installation Procedure - Follow all warnings first,
removal.
then reverse the removal steps..
HYDROSTATIC
Fig. 7-13 Capscrews securing gear pump to hydrostatic Fig. 7-15 Location of capscrews to remove on the pump
pump. support bracket of 3-cylinder engines.
Pump Hoist
Flywheel Cover
Fig. 7-14 One of two capscrews securing hydrostatic Fig. 7-16 With a suitable hoist, remove the hydrostatic
pump to engine flywheel cover. pump from the flywheel housing.

Hydrostatic Pump Drive Coupling

Removal Procedure
WARNING
device.
q Roll ROPS back until lock engages. Fig. 7-17 Remove 11 capscrews securing the flywheel
housing to the engine. When installing, torque to
(For detailed instructions, refer to the Safety 28 ft-lbs (37 N•m).
1. Remove the hydrostatic pump per the procedure in

this chapter.
2. Remove 11 capscrews securing the flywheel Flywheel
housing to the engine. Fig. 7-18 Coupling
3. Remove six capscrews attaching flywheel coupling

plate to flywheel. Fig. 7-19

Fig. 7-18 Remove six capscrews on the flywheel coupling

plate.

Drive Motor Removal and Installation

Removal Procedure
WARNING
Front Floor Plate perform the following SAFETY procedures:
device.
Fig. 7-19 Location of capscrews securing the front floor
plate to the chassis. (View is from underneath q Raise and securely block the loader so
looking forward.) all four tires are off the ground.
1. Remove two capscrews securing front floor plate,

then remove floor plate from chassis. Fig. 7-19
2. Remove drive chains per the procedure in the Wheel
Drives chapter. Figs. 7-20, 7-21
3. If necessary, drain oil from hydraulic reservoir per
HYDROSTATIC
the procedure in the Hydraulic System chapter. Fig.
7-22
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
Fig. 7-20 Remove chaincase cover to access drive chains hoses and tubes should be plugged to prevent
on both sides of the loader.
contaminants from entering the hydraulic system.
Fig. 7-21 Remove drive chains from drive motor at the Fig. 7-22 Location of hydraulic oil reservoir drain plug
connector links. behind right rear tire.

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
(hoses/tubes can then be correctly reattached during
installation).
5. Disconnect four hydraulic hoses on each single
speed drive motor. Disconnect five hydraulic hoses
on each two-speed drive motor. Figs. 7-23, 7-24
6. Remove six hex nuts and washers attaching the
drive motor to the chaincase. Remove the drive
motor with a suitable hoist. Figs. 7-25, 7-26

then reverse the removal steps.* Fig. 7-24 Disconnect all hoses and tubes on the left drive
motor. (View is through front floor plate.)
* Scrape off old gasket material and apply new sealant
to mating surface of the drive motor before reassembly
to the chassis.
Fig. 7-25 Remove six hex nuts (five nuts visible in this
photograph) and washers securing the drive
motor to the chassis.
Fig. 7-23 Disconnect all hoses and tubes on the right drive Fig. 7-26 Use a suitable hoist to lift the drive motor out of
motor. (View is through front floor plate.) the chassis.

40 SERIES HYDRAULIC SYSTEM
Introduction and Troubleshooting Guide

This chapter covers troubleshooting, testing, removal, The following troubleshooting guide lists potential
installation, and adjustment procedures for hydraulic hydraulic system problems, as well as possible causes
system components on Gehl 40 Series skid-steer and remedies, for Gehl 40 Series skid-steer loaders.
loaders. Primary hydraulic system components in this If you cannot locate a particular hydraulic system
chapter are shown below and on following pages. problem in this chart, you should also consult the
Power for the liftarm functions and auxiliary hydraulics Hydrostatic System chapter troubleshooting chart.
is provided by a gear pump attached to the front of the When a problem occurs, don’t overlook simple causes.
hydrostatic pumps. A malfunction could be caused by something as simple
Standard and high-flow models include a standard-flow as low fluid level in the hydraulic reservoir. After a
auxiliary hydraulics system with connections on the mechanical failure has been corrected, be sure to locate
liftarm for attachment hookup. High-flow models are the cause of the problem.
equipped with high-flow hydraulics, which includes a
connectors on the right side of the liftarm, for operating
attachments that require higher hydraulic flow.
Information on recommended hydraulic fluids, IMPORTANT
capacities and filter change intervals is in the DO NOT attempt to service or repair major
Lubrication chapter. For detailed information on gear hydraulic system components, such as the
pump or control valve internal repair, consult the Gehl gear pump, unless authorized to do so by
Service Department and/or the hydraulic component your Gehl dealer. Any unauthorized repair
manufacturer’s service manual. Hydraulic components will void the warranty.
related to the drive system are covered in the
Hydrostatic System chapter.
Lift/tilt controls fail to Hydraulic oil viscosity is too heavy. Allow longer warm-up or replace with
respond. proper viscosity oil.
HYDRAULICS
Solenoid valve(s) malfunctioning. Check electrical connections to lift
solenoid and repair connections as
needed. Perform “Solenoid Valve
Test”. Replace solenoid as needed.
check for an external leak. Repair and
add oil.
Hydraulic oil flow to the gear pump is Inspect suction hose. Clean or replace
blocked. as needed.
System relief valve is malfunctioning. Adjust or replace relief valve as

needed.
Drive is disconnected. Check for broken or worn pump drive

coupling and replace as needed.
Sheared spline or broken shaft in Check splined shaft of pump closest to

hydrostatic pump assembly. engine. Replace shaft if broken or if
splines are sheared.
Sheared spline or broken shaft in gear Remove gear pump from hydrostatic
pump. pump, inspect the splined shaft and
coupler. Replace components as
needed.
Restraint bar switch or seat switch not Check switches and wiring. Replace as
closing. needed.

HYDRAULIC SYSTEM 40 SERIES

Hydraulic cylinder action is Low engine speed. Operate engine at higher speed.
slow for lift/tilt functions.
Hydraulic oil viscosity is too heavy. Allow longer warm-up or replace existing
oil with proper viscosity oil.
Hydraulic oil leaking past cylinder Perform “Tilt Cylinder Test” and /or “Lift
piston seals. Cylinder Test”. Replace cylinder seals
and o-rings as needed.
Lift/tilt control is not fully activated. Perform “Lift/tilt Control Adjustment”

procedure in Controls chapter.
Lift or tilt solenoid valve Check electrical connections to lift

malfunctioning. solenoid and repair connections as
needed. Perform “Solenoid Valve Test”.
Replace solenoid as needed.
Control linkage is restricted. Check control linkage, readjust for full

spool travel.
check for an external leak. Repair and
add oil.
Liftarm does not raise, bucket Lift solenoid valve malfunctioning. Check electrical connections to lift
tilt works properly. solenoid and repair connections as
Lift spool in control valve not Check hose or tube connection to valve.
actuated or leaking. Check pressure and flow.
Jerky liftarm and bucket action. Restraint bar switch or seat switch Check electrical connections to the
malfunction. switch. Replace switch as needed.
Air in the hydraulic system. Cycle lift and tilt cylinders to maximum
stroke and maintain pressure for short
time to clear air from system.
Oil in hydraulic reservoir low. Check and add oil to reservoir as

needed.
Standard-flow auxiliary Control linkage misadjusted. Check linkage, readjust for full spool
hydraulics function slowly. travel.
Low engine speed. Operate engine at higher engine speed.
Hydraulic oil level low. Add oil to reservoir.
Hydraulic oil viscosity is too heavy. Allow long warming period.


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

fittings between control valve and fittings as needed. Replace hoses or
cylinders. tubes as needed.
Liftarm will not lower or raise. Lift cylinder liftarm support device Raise liftarm and disengage the liftarm
engaged. support device.
Lift solenoid valve is malfunctioning. Perform “Solenoid Valve Test”. Check

electrical connections to solenoid.
Repair or replace as 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.
Bucket drifts downward with Oil leaking past tilt cylinder seals Perform “Tilt Cylinder Test”. Check
tilt control in NEUTRAL. (external or internal). cylinder tube bore condition. Replace
seals, o-rings, or cylinder as needed.
Self-leveling valve is malfunctioning. Repair or replace as needed.
Leaking hydraulic hoses, tubes, or Inspect hoses and tubes, tighten

fittings between control valve and fittings as needed. Replace hoses or
cylinders. tubes as needed.
Liftarm will not raise a heavy Lift port relief in the control valve is Replace lift port relief or contact the
load or any load at all. malfunctioning. Gehl Service Department.
HYDRAULICS
Slow or no response for Pilot control lines have air in them. Bleed the pilot control line from the
bucket tilt, lift works properly main control valve.
(Hand/Foot units only)
Low charge pressure. See hydrostatic pump manual.
Linkage misadjusted. Readjust for full travel without

restriction. Perform “Lift/Tilt Control
Adjustment” in the Controls chapter.
Standard-flow auxiliary Restraint bar is raised. Lower the restraint bar.
hydraulics do not function.
Spool lock solenoid malfunctioning. Check electrical connections to lock
solenoid, repair as needed.
Restraint bar switch or seat switch Replace the malfunctioning switch.

malfunctioning.


No downward pressure on Control valve in “float” position. Take control out of “float” position.
the bucket.
Tilt cylinders are malfunctioning. Perform “Tilt Cylinder Test”. Also
check condition of cylinder tube bore.
Replace seals, O-rings, and/or cylinder
tube as needed.
Bucket does not level on Self-leveling valve misadjusted or Perform “Self-Leveling Valve
the lift cycle. malfunctioning. Adjustment”. If adjustment fails to
correct problem, repair or replace
self-leveling valve as needed.
Bucket will not tilt; liftarm Tilt solenoid valve is malfunctioning. Check electrical connections to tilt
works properly. solenoid and repair connections as
Tilt spool in control valve not actuated or Check hose or tube connection to
leaking. Valve. Check pressure and flow.
High-flow auxiliary does Solenoid on high-flow valve malfunctioning. Check electrical connections to
not function. solenoid. Repair or replace solenoid
Restraint bar is raised. Lower the restraint bar.
Restraint bar switch or seat switch Replace the malfunctioning switch.

malfunctioning.
Standard auxiliary or Control linkage misadjusted. Check linkage, readjust for full spool
high-flow auxiliary travel.
functions slowly.
Low engine speed. Operate engine at higher speed.
Hydraulic oil level low. Add oil to reservoir.
Hydraulic oil viscosity is too heavy. Allow for longer warming period.

Hydraulic System - Chassis Components - SL4640, SL4840 and SL5640
41 5
Oil Filter
25 part #131838
38 38
6
4 6
4
12
7 24 8
35
38
10 26
42
9
17
2 39 6
32 20 8
6 33
8 34 11
40
16 3
3
4
36
7
3 20
6
1 31
2
2 15 32
18 28 23 30
6 27
19
4 7
3
37 21
HYDRAULICS
38
7
29
14 38
22 3
1 FITTING/90° 12 FITTING/90° 23 TUBE/AUX. FRONT 34 TUBE/LIFT FRONT

2 NUT/HEX 5/16 13 ASSEMBLY/FILTER 24 TUBE/TILT SOLENOID 35 SCREW/CAP
3 FITTING/90° 14 NUT/LOCK 25 TUBE/TILT 36 SCREW/CAP
4 FITTING/STRAIGHT 15 NUT/LOCK 26 TUBE/TILT 37 SCREW/CAP
5 FITTING/TEE 16 TUBE/TILT 27 TUBE/SELF LEVEL 38 SCREW/CAP
6 PLATE/TWIN COVER 17 TUBE/TILT 28 TUBE/LIFT 39 SCREW/CAP
7 CLAMP/TUBE 18 NUT/LOCK 29 TUBE/LIFT 40 SCREW/CAP
8 CLAMP/TUBE 19 FITTING/90° 30 TUBE/TILT FRONT 41 SCREW/MACHINE
9 FITTING/TEE 20 STRAP 31 TUBE/TILT REAR 42 WASHER/FLAT
10 PLUG 21 VALVE/SELF LEVEL 32 VALVE/SOLENOID
11 FITTING/STRAIGHT 22 TUBE/AUX. REAR 33 TUBE/LIFT REAR
Fig. 8-1 Exploded view of the SL46/48/5640 chassis hydraulics.

Hydraulic System - Chassis Components - SL6640
48 6
15
16
7
27 8
14
7 10
7
49 2 28
24 49 2 41
43 33
21
26 31
4 47
19
7 39
42 24 34
20 3 25
44 8 11
22 46 46
7 8 13
3
2 7 19
4 38 7
3 35 2 32
46 42
7
2 10
40 37 3
7 47 43
22 8 36
8 7 2
3 7
23
7
49
1 4
30 2 49
9 45
30 29
8
7
2
5
1 FITTING/90° 14 FITTING/90° 27 TUBE/TILT 40 HOSE

2 NUT/HEX 15 HOSE/SUCTION 28 TUBE/TILT 41 TUBE/RETURN
3 FITTING/90° 16 ASSEMBLY/FILTER 29 TUBE/AUXILIARY 42 VALVE/SOLENOID
4 FITTING/STRAIGHT 17 NUT/LOCK 30 TUBE/LIFT 43 SCREW/CAP
5 FITTING/90° 18 PLUG/POWER 31 TUBE/LIFT REAR 44 SCREW/CAP
6 FITTING/TEE 19 NUT/LOCK 32 TUBE/SELF LEVEL 45 SCREW/CAP
7 PLATE/TWIN COVER 20 TUBE/TILT 33 TUBE/LIFT FRONT 46 SCREW/CAP
8 CLAMP/TUBE 21 TUBE/TILT 34 TUBE/TILT 47 SCREW/CAP
9 FITTING/45° 22 NUT/LOCK 35 TUBE/AUXILIARY 48 SCREW/MACHINE
10 CLAMP/TUBE 23 FITTING/90° 36 TUBE/LIFT 49 WASHER/FLAT
11 FITTING/TEE 24 STRAP 37 TUBE/LIFT
12 PLUG 25 VALVE/SELF LEVEL 38 TUBE/LIFT
13 FITTING/STRAIGHT 26 TUBE/TILT SOLENOID 39 TUBE/TILT REAR
Fig. 8-2 Exploded view of the SL6640 chassis hydraulics.

Hydraulic System - Standard Auxiliary Components - SL4640 and SL4840
12
11
5 8
2
10
17
18
9
4 3 15
7 13
HYDRAULICS
16 6
14
1 FITTING/90° 10 HOSE/PRESSURE
2 WASHER/FLAT 11 TUBE/RETURN
3 O-RING 12 TUBE/SUCTION
4 FITTING/90° 13 CLAMP/TUBE
5 NUT/SERRATED LOCK 14 HOSE/SUCTION
6 NUT/HEX 1/4 15 PLATE/TUBE CLAMP
7 FITTING/45° 16 SCREW/CAP
8 CLAMP/HOSE 17 BOLT/CARRIAGE
9 PUMP/GEAR 18 SCREW/CAP
Fig. 8-3 Exploded view of the SL46/4840 standard auxiliary hydraulic system.

Hydraulic System - Standard Auxiliary Components - SL5640 and SL6640
8
7
3 5
1 FITTING/90°
2 2 FITTING/90°
9 3 FITTING/45°
4 HOSE/SUCTION
6 5 O-RING
6 PUMP/GEAR
7PRESSURE HOSE
8 TUBE/RETURN
9 SCREW/CAP
Fig. 8-4 Exploded view of the SL56/6640 standard auxiliary hydraulic system.

Hydraulic System - High-Flow Auxiliary Components - SL4640 and SL4840
24
25
27
35 6
15
16
40
21
28
11
19 36 17 33
13 4 29
12 4
18
9
39
1
11 23 37
22
38
3 2 32
10 14
HYDRAULICS
31
3
30 5
34 8
1 WASHER/FLAT 11 NUT/LOCK 21 ROD/CONTROL 31 CLAMP/TUBE

2 O-RING 12 PLUG/POWER 22 FITTING/TEE 32 PLATE/TUBE CLAMP
3 FITTING/90° 13 BRACKET/VALVE 23 HOSE/PRESSURE 33 SCREW/CAP
4 NUT/LOCK 14 HOSE/PRESSURE 24 TUBE/HIGH FLOW 34 SCREW/CAP
5 NUT/HEX 15 TUBE/INLET 25 TUBE/HIGH FLOW 35 SCREW/CAP
6 FITTING/STRAIGHT 16 CLEVIS 26 VALVE/HIGH FLOW 36 SCREW/CAP
7 FITTING/TEE 17 CLEVIS 27 TUBE/OUTLET 37 BOLT/CARRIAGE
8 FITTING/45° 18 BOX/LEVER PIVOT 28 TUBE/RETURN 38 SCREW/CAP
9 CLAMP/HOSE 19 LEVER/HAND 29 TUBE/SUCTION 39 NUT/HEX
10 PUMP/DOUBLE GEAR 20 SPACER 30 HOSE/SUCTION 40 NUT/HEX
Fig. 8-5 Exploded view of the SL46/4840 high-flow auxiliary hydraulic system.

Hydraulic System - High-Flow Auxiliary Components - SL5640
1 FITTING/STRAIGHT
2 FITTING/90°
3 FITTING/TEE
4 FITTING/45°
5 HOSE/SUCTION
6 NUT/LOCK
29 23
7 PLUG/POWER BEYOND
8 O-RING 19
9 BRACKET/VALVE
10 TUBE/INLET 20 3
11 NUT/LOCK
12 CLEVIS 1
13 CLEVIS 27
14 BOX/LEVER PIVOT
15 LEVER/HAND 9
16 SPACER
12 11 24
32
26 6
10
30
15
31
22
7
14
13
17
5
8 17 FITTING/TEE
18 PUMP/DOUBLE GEAR
6 19 TUBE/HIGH FLOW
20 TUBE/HIGH FLOW
4 21 VALVE/HIGH FLOW
22 HOSE/
23 TUBE/OUTLET
24 TUBE/RETURN
2 25 HOSE
26 ROD/VALVE CONTROL
27 SCREW/CAP
2 28 SCREW/CAP
28 18 29 SCREW/CAP
30 SCREW/CAP
31 NUT/HEX
25 32 NUT/HEX
Fig. 8-6 Exploded view of the SL5640 high-flow auxiliary hydraulic system.

Hydraulic System - High-Flow Auxiliary Components - SL6640
1 FITTING/STRAIGHT
2 FITTING/90°
3 FITTING/TEE
4 NUT/LOCK
5 PLUG/POWER BEYOND
6 O-RING
7 BRACKET/VALVE
8 TUBE/INLET
9 NUT/LOCK
10 CLEVIS 25
11 CLEVIS
17
12 BOX/LEVER PIVOT
3
13 LEVER/HAND 18
14 SPACER
15 FITTING/TEE 21
16 PUMP/GEAR
17 TUBE/HIGH FLOW 8 1
18 TUBE/HIGH FLOW
19 VALVE/HIGH FLOW 19
20 ROD/CONTROL 10
21 TUBE/OUTLET
28
7
20 9
23
4 5
7
26 27
13
12
HYDRAULICS
11 6 15
4 16
22 HOSE
24
23 SCREW/CAP
24 SCREW/CAP
22 25 SCREW/CAP
26 SCREW/CAP
27 NUT/HEX
28 NUT/HEX
Fig. 8-7 Exploded view of the SL6640 high-flow auxiliary hydraulic system.

Hydraulic System - Liftarm Hydraulics Components - SL4640 and SL4840
37 43
10 TO TOP OF HYDRAULIC RESERVOIR
3 21 21
19 14
8
39 29
37
7 22
15 22
1
18 7 2
6
3 16
45 4
6 20
14 1
23 23 41
7 42
34 35 43
33 32
6 7 1
15 19
44 41
26 GREASE TAPER 17 1 37
OF PINS 40
20
40 31
6 3
11 6 6 8
5
28 39 29
12 42
24 9 18
11
37
25 36
26 9 5 3
44 13
38 28
24
NOTES:
30 1. DO NOT OVERTIGHTEN CAP SCREWS 650545,
30 650568, AND 650547.
2. APPLY LITHIUM GREASE TO PINS 134522 AND 134523.
27 3. APPLY LOCTITE 242 TO CAP SCREWS 651366 AND
25 TORQUE TO 80FT-LBS.
3
27
1 FITTING/STRAIGHT 16 TUBE/LIFT CYLINDER RIGHT 31 TUBE WITH TEE

2 NUT/HEX 17 TUBE/LIFT CYLINDER LEFT 32 TUBE/AUX OUTER UPPER
3 NUT/HEX 18 PIN 33 TUBE/TILT OUTER
4 CLAMP/HOSE 19 PIN 34 TUBE/TILT INNER
5 CAP/37° 20 HOSE 35 TUBE/AUX INNER UPPER
6 PLATE/TWIN COVER 21 HOSE 36 TUBE WITH TEE
7 CLAMP/TUBE 22 HOSE 37 FITTING/GREASE
8 CLAMP/HOSE 23 HOSE 38 SCREW/CAP
9 CLAMP/TUBE 24 HOSE 39 SCREW/CAP
10 PLUG 25 HOSE 40 SCREW/CAP
11 TUBE/TILT 26 WASHER/FLAT 41 SCREW/CAP
12 COUPLER/MALE 27 PIN 42 SCREW/CAP
13 COUPLER/FEMALE 28 PIN/TILT CYLINDER 43 SCREW/CAP
14 SPACER/TILT TUBE 29 CYLINDER/LIFT 44 SCREWCAP
15 TUBE/LIFT CYLINDER BASE 30 CYLINDER/TILT 45 WASHER/FLAT
Fig. 8-8 Exploded view of the SL46/4840 liftarm hydraulic system.

Hydraulic System - Liftarm Hydraulics Components - SL5640
41
36 11 TO TOP OF HYDRAULIC RESERVOIR
24 12
12
3
8
18
37 34
36
10
19
1 43
1 2
25
20 7
3 7
4
6 6
30 35
10 39 40
14 18
13 31
32 35
7 7
6 21 1
39 1
5 41
38 33 19
38 24
42
6 28 6 8
22
15 3 36
34
16
26 37
40
29 25
9 15
6 17
26
9 36
3
22
GREASE TAPER 42
OF PINS 37 13
14
NOTES:
27 1. DO NOT OVERTIGHTEN CAP SCREWS 650545,
650568, AND 650547
HYDRAULICS
23 23 2. APPLY LITHIUM GREASE TO PINS 135301 AND 135302
3. APPLY LOCTITE 242 TO CAP SCREWS 651366 AND
TORQUE TO 80FT-LBS
3
27
1 FITTING/STRAIGHT 16 PLUG 31 TUBE/TILT OUTER

2 NUT/HEX 17 HOSE 32 TUBE/TILT INNER
3 CAP/37° FLARE 18 HOSE 33 TUBE/AUXILIARY INNER
4 PLATE/TWIN COVER 19 HOSE 34 TUBE WITH TEE
5 CLAMP/TUBE 20 HOSE 35 TUBE WITH TEE
6 CLAMP/HOSE 21 TUBE/TILT 36 TUBE/AUXILIARY OUTER
7 TUBE/LIFT CYLINDER BASE 22 COUPLER/MALE 37 FITTING/GREASE
8 TUBE/LIFT CYLINDER RIGHT 23 COUPLER/FEMALE 38 SCREW/CAP
9 TUBE/LIFT CYLINDER LEFT 24 SPACER/TILT TUBE 39 SCREW/CAP
10 CLAMP/TUBE 25 WASHER/FLAT 40 SCREW/CAP
11 HOSE 26 PIN 41 SCREW/CAP
12 HOSE 27 PIN 42 SCREW/CAP
13 HOSE 28 PIN/TILT CYLINDER 43 SCREW/CAP
14 HOSE 29 CYLINDER/LIFT
15 HOSE 30 CYLINDER/TILT
Fig. 8-9 Exploded view of the SL5640 liftarm hydraulic system.

Hydraulic System - Liftarm Hydraulics Components - SL6640
40 11 TO TOP OF HYDRAULIC RESERVOIR
35 10 10
29
23
29
3
8
36
34
10 10
2
35 18
1
17
24 4
19 7
3 42
7
30
6 29
1
38
17 6
32 29
31 39
7 7
12 1
6 18 40
20 1
33
13 38 23
27
5
41 37 6 35
21 37
15 8 3
6 34
14 6 39
36
25
28 24
9 14 5
16
12
25 35
9 3
21
GREASE TAPER 41
OF PINS
36 13
NOTES:
26 36
1. DO NOT OVERTIGHTEN CAP SCREWS 650545,
22 650568, AND 650547
22
2. APPLY LITHIUM GREASE TO PINS 135301 AND 135302
3
3. APPLY LOCTITE 242 TO CAP SCREWS 651366 AND
TORQUE TO 80FT-LBS
3
26
1 FITTING/STRAIGHT 15 HOSE 29 TUBE/TILT INNER

2 NUT/HEX 16 HOSE 30 TUBE/AUXILIARY INNER
3 NUT/HEX 17 TUBE/TILT 31 TUBE WITH TEE
4 CLAMP/HOSE 18 COUPLER/MALE 32 TUBE WITH TEE
5 CAP/37° FLARE 19 COUPLER/FEMALE 33 TUBE/AUXILIARY OUTER
6 PLATE/TWIN COVER 20 SPACER/TILT TUBE 34 HOSE
7 CLAMP/TUBE 21 WASHER/FLAT 35 FITTING/GREASE
8 CLAMP/HOSE 22 PIN 36 SCREW/CAP
9 TUBE/LIFT CYLINDER BASE 23 PIN 37 SCREW/CAP
10 TUBE/LIFT CYLINDER RIGHT 24 PIN 38 SCREW/CAP
11 TUBE/LIFT CYLINDER LEFT 25 PIN/TILT CYLINDER 39 SCREW/CAP
12 CLAMP/TUBE 26 CYLINDER/LIFT 40 SCREW/CAP
13 HOSE 27 CYLINDER/TILT 41 SCREW/CAP
14 PLUG 28 TUBE/TILT OUTER 42 WASHER/FLAT
Fig. 8-10 Exploded view of the SL6640 liftarm hydraulic system.

9
10
11
4
12
15
8
13
3
14
6
5
4
15
7
8
14
10
11
4
12
13
15
9
14
4
7
6 15
9
3
8
2
14

NOTES

Pressure Tests, Control Valve and High

Flow
The control valve on the skid loader controls lift and tilt
functions of the liftarm and auxiliary hydraulics. It is
located on the right side of the chassis. The relief valve
inside the control valve can be tested by taking a
pressure reading at a port on the control valve, but there
is another way to perform this procedure for high-flow
units and the standard auxiliary hydraulics. (See
NOTE and photographs at end of this procedure.)
Test Procedure
Fig. 8-13 Location of the main control valve in the skid

loader.
WARNING
device.
q Relieve hydraulic system pressure.
NOTE: To prevent contamination, ALWAYS clean
HYDRAULICS
the area around the hydraulic fittings before
Fig. 8-14 Location to install a pressure gauge on main disconnecting any hydraulic plug, hose or tube.
control valve to measure system pressure. 1. What you’ll need: an assistant, a high pressure
hydraulic hose and 90° fitting, and a minimum 5000
PSI (345 bar) pressure gauge.
2. Remove plug from top of inlet section of the control
valve and attach the 90° fitting. Fig. 8-14
3. Attach the pressure gauge hose to the fitting. A hose
between the gauge and control valve may be
required to allow lowering of the ROPS.
4. Lower the ROPS, climb into operator’s seat, lower
the restraint bar, and start loader engine. For the test,
engine should be running at low idle. Have an
assistant read the pressure gauge.
5. Using the tilt control handle, roll the bucket all the
way back. Hold the tilt control handle in this
Fig. 8-15 Loosen the locknut on the relief valve adjuster position.
screw.

6. Have assistant observe the pressure reading on the

gauge. The pressure reading on your respective
loader should be,
a. SL46/4840 Models; at least 2700 PSI (186 bar),
but NOT more than 2800 PSI (193 bar),
b. SL56/6640 Models; at least 2950 PSI (203 bar),
but NOT more than 3050 PSI (210 bar).
7. If the pressure reading is NOT between the
abovementioned pressures, adjust pressure as
follows:
WARNING Fig. 8-16 Use an Allen wrench to increase or decrease

system pressure.
chapter in this manual.)
a. Loosen the locknut on the relief valve adjuster

screw. Fig. 8-15
b. With an Allen wrench, turn the adjuster screw
IN to increase pressure or OUT to decrease
pressure. Fig. 8-16
c. Repeat steps 4 through 6.
d. Once the pressure is within the correct PSI Fig. 8-17 Alternate system pressure test location.
optimum setting, tighten the locknut on the
control valve adjuster screw to secure the
adjustment.
8. If, after the adjustment, there is NO CHANGE in the
pressure reading, this indicates a defective
hydraulic gear pump or relief valve cartridge (on the
control valve). To determine which is the cause, first
replace the relief valve cartridge. If the pressure
reading still does not change, the hydraulic gear
pump should be repaired or replaced.
NOTE: It is also possible to perform the pressure
reading test at the auxiliary hydraulic couplers located
on the left liftarm and the high-flow couplers located on
the right liftarm of high-flow auxiliary loaders. Install
the pressure gauge in the end of the male coupler and
activate the auxiliary hydraulic (or turn on high-flow) to
Fig. 8-18 System pressure test location on high-flow
pressurize the line. Figs. 8-17 and 8-18
hydraulic couplers.

Tilt Cylinder Test

If the bucket (or attachment) settles down with the tilt
control in the NEUTRAL position, first check the tilt
cylinders for external leakage. If external leakage is
evident, a new seal kit should be installed in the leaking
cylinder(s). If no external leakage is evident, check the
tilt cylinders for internal leakage according to the
following procedure.
NOTE: When checking the bucket for settling, the
ignition key MUST BE in the ON position, operator in
the seat, and the restraint bar lowered. The maximum
allowable tilt cylinder circuit settling with a loaded
bucket is 0.4" (10 mm) of cylinder extension in 15
Fig. 8-19 For the tilt cylinder test, load a bucket with dirt,
gravel or sand to begin the test. minutes.
Test Procedure
WARNING
1. Load the bucket and allow it to rest on the ground.
HYDRAULICS
Fig. 8-19
Fig. 8-20 Location of the lower hydraulic hose on the left
tilt cylinder. Right tilt cylinder is the same. NOTE: To prevent contamination, ALWAYS clean
the area around the hydraulic fittings before
disconnecting any hydraulic hose or tube.
2. Checking one tilt cylinder at a time, remove the
lower hydraulic hose from the cylinder being tested,
and cap or plug the hose and cylinder port. Caps
MUST BE able to withstand full hydraulic pressure.
Fig. 8-20
WARNING
BEFORE raising a loaded bucket, BE SURE
no personnel are near the loader. Serious
personal injury can result if bucket should
drop suddenly or its contents spill out.
3. Climb back into the operator’s seat, lower the

restraint bar, and start the engine.

4. Raise the liftarm enough for the bucket (or

attachment) to clear the ground. NOTES
5. Shutoff the engine, turn the ignition key to the ON

position (engine OFF) and operate the tilt control in
both directions.
6. If the bucket settles, the blocked tilt cylinder has
leaking seals. If it DOES NOT settle, lower the
liftarm and reconnect the hydraulic hose to the
cylinder. Then test the other tilt cylinder in the same
way, repeating steps 2-5.
7. Once both tilt cylinders have been tested, be sure the
hydraulic hoses are reconnected.
NOTE: If both tilt cylinders have good seals, and the
bucket still settles, the fault could be in either the control
valve or the self-leveling valve. Continue the procedure
with step 8 below. Also, refer to the troubleshooting
guide in this chapter.
8. To determine if either the control valve or
self-leveling valve is faulty and causing the bucket
to settle, perform the “Self-Leveling Valve Test”

Self-Leveling Valve Test

Test Procedure
WARNING
device.
Fig. 8-21 Location of the self-leveling valve, bolted onto
the left inside chassis. (For detailed instructions, refer to the Safety
1. With the engine OFF and the ROPS raised and

locked, loosen the jam nut on the self-leveling valve
adjuster screw. Figs. 8-21, 8-22
NOTE: For step 2, BE SURE to count and write down
the number of turns so the adjuster screw can be returned
to its original setting after the test.
2. With a flexible Allen wrench, turn the adjuster
screw in (clockwise) until it bottoms out. The
self-leveling valve is now disabled and will not
effect tilt operations. Figs. 8-22, 8-23
3. Lower the ROPS and perform steps 3-5 in the “Tilt
HYDRAULICS
Cylinder Test” procedure. If the bucket no longer
Fig. 8-22 Loosen jam nut on the self-leveling valve settles, the self-leveling valve is defective. If the
adjuster screw. bucket continues to settle, the control valve is
defective and in need of repair or replacement.
4. Refer to the “Self-Leveling Valve Adjustment”
procedure in this chapter for correct adjustment of
self-leveling valve.
Fig. 8-23 Self-leveling valve adjusted with an Allen

wrench.

Lift Cylinder Test

If the liftarm settles with the lift control in NEUTRAL
position, and the ignition key is OFF, first check the lift
cylinders for external leakage. If external leakage is
evident, a new seal kit should be installed in the leaking
cylinder(s). If no external leakage is evident, check the
lift cylinders for internal leakage according to the
following procedure.
NOTE: When checking liftarm for settling, BE SURE
the ignition key is in the OFF position. The maximum
allowable lift cylinder settling is 0.75" (19 mm) of
cylinder extension in 15 minutes.
Test Procedure Fig. 8-24 Mechanical lock engaged and contacting the lift
cylinder.
1. Remove the bucket or attachment from the liftarm
attaching system.
2. Raise the liftarm to maximum height. Then release
the lift cylinder liftarm support device and lower the
liftarm to engage the device. Fig. 8-24
WARNING
chapter in this manual.) Fig. 8-25 Clamp securing the hydraulic tubes to the lift
cylinder.
3. Remove the clamp securing the hydraulic tubes to
the lift cylinder on the side being tested. Fig. 8-25
NOTE: To prevent contamination, ALWAYS clean
around hydraulic fittings before disconnecting any
hydraulic lines.
4. Disconnect the hydraulic tube from the rod end port
of the lift cylinder to be tested. Fig. 8-26
5. Install a plug on hydraulic tube. Attach a hose to rod
end port of the cylinder and run other end of hose
into a container. Lower the ROPS. Fig. 8-27 Rod End Tube Port
6. Climb back into the operator’s seat, lower the

restraint bar, and start the engine.
7. Hold the lift control in the RAISED position. If the
seals in the cylinder are defective and leaking, oil Fig. 8-26 Hydraulic tube port on the rod end of the lift
will come out of the rod end port. cylinder.

Rod End Tube Port 8. Lower the liftarm support device back against the
lift cylinder. Shut off the engine and move the lift
control back and forth (up and down) to relieve
hydraulic pressure.
9. Reconnect the hydraulic tube to the cylinder, then
Plugged Port Fitting reattach the clamp around the hydraulic tubes and
cylinder.
NOTE: If neither lift cylinder shows signs of external
or internal leakage, and the liftarm still settles, the
Hose to Bucket problem could be due to leaking hydraulic hose fittings
between the control valve and the lift cylinders. Check
all hydraulic hose fittings thoroughly. The fault could
also be in either the control valve or the self-leveling
Fig. 8-27 Attachment up and rolled forward for the valve. Continue the procedure with step 11. Also refer to
solenoid valve test. the Troubleshooting Guide in this chapter.
10. The other lift cylinder may be checked in the same
manner.
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.
Solenoid Valve Test - Tilt, Lift, Brake and

Two-Speed
During normal operations, the solenoid valves should
prevent operation of the liftarm and drive functions if
any of the safety interlocks are open, for example:
HYDRAULICS
Fig. 8-28 Location of the tilt solenoid. 7 Operator not sitting on loader seat.
7 Restraint bar not lowered in front of operator.
7 Optional front door is open.
Test Procedure
1. Climb into the operator’s seat, lower the restraint
bar and start the engine.
2. Using the lift control, raise the liftarm off the ground
enough so that the attachment can be tilted.
3. Raise the restraint bar, then use the lift and tilt
controls (one at a time) to see if either function will
operate.
a. If the liftarm can be raised or lowered, the lift
solenoid is malfunctioning. Figs. 8-29, 8-31
b. If the attachment can be tilted, the tilt solenoid is
Fig. 8-29 Location of the lift solenoid (SL6640 Models).
malfunctioning. Fig. 8-28
4. Lower the restraint bar, BE SURE the parking brake
on the instrument panel is in the OFF position.
5. Raise the restraint bar, then use the drive controls

(one at a time) to see if the tires will operate.
a. If the skid loader moves forward or backward,
the brake solenoid is malfunctioning. Fig. 8-30
6. If any solenoid in the above tests appears to be
malfunctioning, test that solenoid coil as follows:
WARNING
perform the following SAFETY procedure: Tracking Screws
device. Fig. 8-30 Location of the brake solenoid (one coil) or the
brake/two speed solenoid (two coils), just behind
(For detailed instructions, refer to the Safety the tracking adjustment capscrews, left inside
chapter of this manual.) chassis.
a. Have an assistant sit on operator’s seat, lower

the restraint bar and turn the keyswitch to ON.
DO NOT start the engine.
b. Using a thin strip of steel (such as a pocket
ruler), check the suspected solenoid by moving
the steel strip close by the solenoid coil. Fig.
8-32
c. 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 Fig. 8-31 Location of the lift solenoid (SL46/48/5640
Reassembly” procedure in this chapter. Models).
Fig. 8-32 Solenoid test with metal pocket ruler.

Hydraulic Oil Filter Element Replacement

Gehl 40 Series skid-steer loaders have one hydraulic oil
filter. The hydraulic oil filter needs to be replaced when
the restriction indicator shows red.
NOTE: When reading the restriction indicator, run the
engine at HIGH idle with the hydraulic oil temperature
at 70°F (21°C) or warmer. Fig. 8-34
WARNING
Fig. 8-33 Location of drain plug on hydraulic oil tank. BEFORE beginning this service procedure,
1. Open the engine access cover and rear grille.

Restriction Indicator 2. Remove hydraulic reservoir drain plug and drain oil
(into a suitable container) to a level BELOW the
point where the filter attaches to reservoir. Fig. 8-33
3. Reinstall the drain plug.
4. Using a filter wrench, turn the filter element
counterclockwise to remove it from the filter head.
5. Install correct filter element (refer to GEHL Parts
HYDRAULICS
manual). BEFORE installation, apply a light coat of
Fig. 8-34 Location of the hydraulic filter. Replace this oil to gasket, then install it on filter head. Fig. 8-35
filter when the restriction indicator shows, or
reads, red. 6. Hand tighten element until gasket contacts filter
head. Turn element another 3/4 turn to seat gasket.
7. Refill the hydraulic reservoir. Refer to the
Oil Seal Lubrication chapter in this manual for hydraulic
fluid requirements and specifications.
WARNING
NEVER use your hands to search for
hydraulic fluid leaks. Use a piece of
cardboard or paper. Escaping fluid
under pressure can be invisible and
penetrate the skin causing serious injury. If
any fluid is injected into your skin, see a
doctor at once. Injected fluid MUST be
Fig. 8-35 Apply a light coat of new oil to the rubber seal on
the new filter element before installing in the
skid-steer loader.

surgically removed by a doctor familiar with

this type of injury or gangrene may result. NOTES
WARNING
ALWAYS wear safety glasses when
checking for hydraulic fluid leaks.
Escaping fluid under pressure can be
invisible and can cause permanent eyesight
damage if safety glasses are not worn.
8. ALWAYS check for hydraulic fluid leaks after

assembling components of the hydraulic system.

Tilt Cylinder Removal and Installation

Removal Procedure
NOTE: Refer to “Liftarm Removal/Disassembly”
procedure in Mainframe chapter for help on removing
the complete liftarm group including the tilt cylinders.
1. Remove bucket or attachment.
2. With the engine running, lower the liftarm until it is
in contact (or near contact) with the liftarm stops (on
front of chassis).
Fig. 8-36 Location of upper and lower tilt cylinder hoses. WARNING
3. First, disconnect the upper and lower tilt cylinder

hoses from the tubes on top of the crossmember. BE
SURE to install plugs in the hoses and cap the
fittings to prevent fluid loss and contamination of
the hydraulic system. Fig. 8-36
4. While supporting the weight of the tilt cylinder,
HYDRAULICS
remove the capscrew and locknut securing the lower
Fig. 8-37 Capscrew and locknut securing the lower tilt tilt cylinder pivot pin. Then drive the pivot pin out to
cylinder pivot pin. release the lower end of the tilt cylinder. Figs. 8-37,
8-38 and 8-39
5. Loosen the capscrew on the end of the upper tilt
cylinder pin by two to three counterclockwise turns.
Strike the bolt head to drive the pin into the liftarm to
break the pin free of the taper. Remove the capscrew
All-Tach
and flat washer. Remove the upper tilt cylinder pin
while supporting the tilt cylinder. Figs. 8-40 and
8-41
6. Remove upper and lower hoses from the cylinder.
Fig. 8-38 Supporting the All-Tach™ attachment.

1. Connect upper and lower cylinder hoses to the
cylinder.
2. Install the upper end of the tilt cylinder in position
on the liftarm and insert the pivot pin. Use Loctite®
242 or equivalent on the capscrew before
reinstalling and torque to 80 ft-lbs (108 N•m). Figs.
8-40 and 8-41
3. 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. Figs. 8-37, 8-38 and 8-39
NOTE: The grease fitting on the rod end of the tilt Fig. 8-39 Remove the lower tilt cylinder pin.
cylinder should face inward as installed.
4. Remove plugs/caps and attach the upper and lower
tilt cylinder hoses to the cylinder and then connect
the hoses to the tubes on top of the crossmember.
Fig. 8-36
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 hydraulic fluid requirements and
specifications.
WARNING
hydraulic fluid leaks. Use a piece of Fig. 8-40 Location of capscrew and washer securing the
upper tilt cylinder pin to the liftarm.
paper or cardboard. Escaping fluid
under pressure can be invisible and pene-
trate the skin causing serious injury. If any
fluid is injected into your skin, see a doctor at
once. Injected fluid MUST be surgically re-
moved by a doctor familiar with this type of
injury or gangrene may result.
invisible and cause permanent eyesight

Fig. 8-41 The upper tilt cylinder pin and tilt cylinder.

Lift Cylinder Removal and Installation

Removal Procedure
1. Remove any bucket or attachment connected to the
hitch.
WARNING
q Shutdown the engine.
Fig. 8-42 Location of clamp securing hydraulic tubes to
the lift cylinder. (For detailed instructions, refer to the Safety
2. Attach a suitable hoist to the hitch and raise liftarm

to a position where access to tubes and hoses on the
lift cylinder is maximized.
3. Remove the clamp that secures the hydraulic tubes
to the lift cylinder. Fig. 8-42
NOTE: To aid in correct reassembly of hydraulic
hoses/tubes, mark the hoses/tubes to be removed
BEFORE disassembly in step 3.
4. Disconnect two hydraulic hoses from two hydraulic
tubes on cylinder. BE SURE to install plugs/caps in
the hoses/tubes to prevent fluid loss and
HYDRAULICS
contamination of the hydraulic system. Fig. 8-43
Fig. 8-43 Location of hoses connected to the lift cylinder 5. Remove the capscrew and locknut securing the front
tubes. lift cylinder pivot pin. Then drive the pivot pin out to
release the rod end of the lift cylinder. Figs. 8-44
and 8-45
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. Figs. 8-46 and 8-47
Fig. 8-44 Location of rod end lift cylinder pin.

1. Attach a suitable hoist to the hitch and raise liftarm
to a position where access to tubes and hoses on the
lift cylinder is maximized.
2. Install the lift cylinder on the chassis so the rod end
is facing forward and the hydraulic tube ports on the
cylinder are facing inward.
3. Insert the rear and front pivot pins through the
cylinder pivots and secure them with capscrews and
locknuts.
4. Remove plugs/caps and connect two hydraulic
hoses to two hydraulic tubes on the cylinder
according to markings made at removal. If no Fig. 8-45 Support lift cylinder and remove the pivot pin
markings were made or new parts were installed, from the rod end of the cylinder.
refer to the hydraulics exploded view.
necessary. Refer to the Lubrication chapter in this
manual for hydraulic fluid requirements and
specifications.
WARNING
penetrate the skin causing serious injury. If Fig. 8-46 Remove capscrew and washer securing the base
any fluid is injected into your skin, see a doc- end of the lift cylinder to the chassis riser.
tor at once. Injected fluid MUST be surgically
removed by a doctor familiar with this type of

6. Remove the hoist.
Fig. 8-47 Location of the capscrew and locknut securing

the lower lift cylinder pin to the chassis.

Lift Cylinder Components
1 NU/LOCK
2 2 TUBE/LIFT CYLINDER
8 3 ROD/LIFT CYLINDER
4 PISTON
5 GLAND/HEAD
1
4 6 CAP/GLAND
7 7 KIT/SEAL*
8 BUSHING
7
5
6
8
3
8
Fig. 8-48 Exploded view of the lift cylinder components.
* One seal kit per cylinder
Tilt Cylinder Components
HYDRAULICS
3
1 NUT/LOCK
8
1 2 PISTON
2 3 TUBE/TILT CYLINDER
7 4 GLAND/HEAD
5 CAP/GLAND
6 ROD/TILT CYLINDER
7 KIT/SEAL*
8 BUSHING
9 ZERK/GREASE
7
4
9
5
8
6
8
Fig. 8-49 Exploded view of the tilt cylinder components.
* One seal kit per cylinder

Lift/Tilt Cylinder Disassembly / Assembly

1. Remove cylinder from loader. See “Lift Cylinder
Removal” or “Tilt Cylinder Removal” in this
chapter.
2. Purge oil from cylinder by facing ports downward,
pumping cylinder rod back and forth several times.
3. Use an Allen wrench to loosen the set screw on the
cylinder collar. Fig. 8-50
4. Clamp a shaft in a vise and slide cylinder onto shaft
to prevent cylinder tube from turning. Fig. 8-53
5. Use a clamp wrench to thread the collar from the Fig. 8-50 Loosen set screw on the cylinder collar with an
cylinder tube. Fig. 8-51 Allen wrench.
6. Remove the rod assembly and inspect both the

cylinder rod and tube for dents or nicks that may
cause damage to the o-rings and seals. Fig. 8-52
7. Loosen and remove locknut that secures head gland,
seal kit, and piston on the cylinder rod. Fig. 8-53
8. Remove piston assembly. Fig. 8-54
9. Slide head gland, seals, and o-rings off the cylinder
rod and inspect for wear. Figs. 8-54 and 8-55
10. Change the seals as needed. Refer to the lift or tilt
cylinder exploded views for reassembly order. Chain Clamp Wrench
NOTE: Soaking seals in warm water prior to

installation will make them pliable and easier to install.
However, BE SURE to dry them and coat with hydraulic
oil for proper installation. Fig. 8-51 Remove the cylinder collar with a chain clamp
wrench after securing the cylinder on a shaft in a
Assembly Procedure vise.
1. Slide collar onto cylinder rod (threaded end of collar

should face threaded end of cylinder rod). Fig. 8-52
2. Slide head gland, larger diameter first, onto cylinder
rod. Fig. 8-54
Collar
3. Install the piston on the cylinder rod. Fig. 8-54
4. Secure the head gland and piston on the cylinder rod
with a locknut. The locknut should be torqued to 350 Cylinder Tube
ft-lbs (474 N•m). Fig. 8-53 Cylinder Rod
5. Install the cylinder rod into the tube. Fig. 8-52
6. Slide collar down to the cylinder tube, thread it onto
the tube and tighten with a chain clamp wrench.
Tighten set screw on collar. Figs. 8-50 and 8-51
Fig. 8-52 Remove the cylinder rod and components.
7. Install cylinder on loader. See “Lift Cylinder
Installation” or “Tilt Cylinder Installation”
procedures in this chapter.
NOTES
Fig. 8-53 Remove the locknut securing the piston, seal kit,
and head gland on the cylinder rod.
Piston
Head Gland
HYDRAULICS
Fig. 8-54 Inspect o-rings and seals for damage.
O-Ring
Piston
Head Gland
Fig. 8-55 Components found in the cylinder.

Gear Pump Removal and Installation

Removal Procedure
WARNING
device.
q Shutdown the engine.
Fig. 8-56 Location of hoses to remove from the gear pump.
q Roll ROPS back until lock engages. Single speed gear pump shown. Optional
(For detailed instructions, refer to the Safety high-flow gear pump has three hoses to remove
chapter in this manual.) from pump.
1. Remove the hydraulic reservoir drain plug and drain

hydraulic oil into a suitable container.
2. Remove the control cover and floor cover per their
procedures found in the Mainframe chapter.
3. Remove the crossmember per the procedure found
in the Mainframe chapter.
4. Disconnect hydraulic hoses from fittings on gear
pump. The two-speed gear pump has an additional
hose to remove. Fig. 8-56
NOTE: Cap or plug hydraulic hoses and fittings to
prevent fluid loss/contamination of hydraulic system. Fig. 8-57 Location of two capscrews and washers securing
5. Remove two capscrews and washers attaching the the gear pump to the hydrostatic pump.
gear pump to the hydrostatic pump. Fig. 8-57
6. Pull gear pump forward and out of hydrostatic
pump. BE CAREFUL not to lose the o-ring. Fig.
8-58
1. Install o-ring on the mating surface of gear pump.
Fig. 8-58
2. Attach gear pump to the hydrostatic pump (BE
SURE the gear pump shaft engages the splined
coupler). Install two capscrews with Loctite® 242
applied to secure gear pump to the hydrostatic
pump. Fig. 8-57
3. Remove the caps/plugs and connect the hydraulic
hoses to the gear pump. Fig. 8-56 Fig. 8-58 O-Ring on the gear pump.
4. Install crossmember, floor cover and control cover

per their procedure found in the Mainframe chapter.
5. Replace the hydraulic oil drained out of the

NOTES reservoir in step 1.
necessary. Refer to the Lubrication chapter for
hydraulic fluid requirements and specifications.
WARNING

HYDRAULICS

Self-Leveling Valve Removal and

Installation
Removal Procedure
WARNING
device.
q Relieve hydraulic system pressure. Fig. 8-59 The self-leveling valve is located on the left
inside chassis.
NOTE: Cap or plug hydraulic hoses and fittings after

disconnecting to prevent fluid loss and contamination of
the hydraulic system.
1. Disconnect four hydraulic tubes from hydraulic
fittings on the self-leveling valve. Figs. 8-60, 8-62
a. Hydraglide™ Ride Control Models Only:
Disconnect two hydraulic tubes from the
bottom of the self-leveling valve at a tee fitting.
Fig. 8-61
2. Remove two capscrews and locknuts securing
self-leveling valve to chassis side. Fig. 8-63 Fig. 8-60 Remove hydraulic tubes from fittings on the
self-leveling valve at four locations.
3. Remove the self-leveling valve.
necessary. Refer to the Lubrication chapter for fluid
requirements and specifications.
Fig. 8-61 Hydraglide Models "tee" into the bottom of the

self-leveling valve. Remove two hydraulic tubes
from the tee fitting.


assembling any components of the hydraulic
system.
WARNING
Fig. 8-62 Location of hydraulic tube found at the rear of fluid is injected into your skin, see a doctor at
the self-leveling valve.
HYDRAULICS
Fig. 8-63 One of two locknuts securing the self-leveling
valve to the side of the chassis.

Self-Leveling Valve Adjustment

1. Raise and lower the liftarm several times to insure
there is no air in the hydraulic system.
2. Lower the liftarm completely then fully retract the
tilt cylinders (roll back).
3. Raise the liftarm to its maximum height, then lower
it to the ground.
4. Measure how far tilt cylinder rod extends from tilt
cylinder. The distance should be between 8 and
8-1/4” (203-210 mm). If measurement is outside
this range, self-leveling valve needs to be adjusted Fig. 8-64 Tilt cylinder rod extension should be between 8”
according to steps 5 - 9 of this procedure. Fig. 8-64 and 8-1/4” (203 mm - 210 mm) in length.
WARNING
device.
WARNING Fig. 8-65 Location of adjustment

self-leveling valve.
locknut on the
Surfaces inside the engine

compartment may be extremely hot,
particularly the engine muffler and
exhaust pipes. Serious injury may
occur from touching components that have
become hot while the engine was running.
5. The self-leveling valve can be accessed from the

right side of the chassis with the ROPS rolled back.
6. Loosen adjuster screw locknut on self-leveling
valve. Fig. 8-65
7. Insert a flexible Allen wrench into the adjuster
screw on the self-leveling valve and adjust the
valve. Turn the screw IN (clockwise) to shorten the
cylinder extension. Turn the screw OUT
Fig. 8-66 Use an Allen wrench on the self-leveling
(counterclockwise) to lengthen the cylinder adjuster screw.
extension. Fig. 8-66

8. To check for proper operation, lower the ROPS,

climb into the operator’s seat, lower the restraint bar
and start the engine. Disengage the liftarm support
Control Valve device and secure it to the liftarm.
9. Repeat steps 2 through 4 above to check for proper
operation of the self-leveling valve. If further
adjustment is needed, perform the safety procedures
again and repeat steps 5 through 7.
10. Once adjustment is complete, tighten the adjuster
screw locknut. Fig. 8-65
Safety Lock Valves - Removal and

Fig. 8-67 One electrical and two hydraulic disconnect Installation
points on the tilt safety lock valve.
GEHL 40 Series skid-steer loaders have separate
electric solenoid safety lock valves for the lift and tilt
functions of the hydraulic system. The lift safety lock
valve is located on the left side of the chassis near the
self-leveling valve. The tilt safety lock valve is located
on the right side of the chassis above the main control
valve. The brake or brake/two-speed solenoid valve is
located forward and below the self-leveling valve.
Removal Procedure
WARNING
HYDRAULICS
Fig. 8-68 Location of the lift safety lock in SL46/48/5640
skid-steer loaders. )The lift safety lock in
SL6640 skid-steer loaders is located just forward device.
of the self-leveling valve.) q Shut off the engine.
1. Tilt Solenoid Removal: Disconnect the electrical

connector from the solenoid coil. Disconnect two
hydraulic tubes on the solenoid. Remove two
capscrews and locknuts that secure the solenoid to
the chassis. Fig. 8-67
2. Lift Solenoid Removal: Disconnect the electrical
Fig. 8-69 Two electrical and four hydraulic disconnect connector from the solenoid coil. Disconnect two
points on the brake/two-speed solenoid valve hydraulic tubes on the solenoid. Remove two
(two coils). capscrews, straps, and locknuts securing the
solenoid to valve bracket (or chassis). Fig. 8-68
3. Brake Solenoid Valve Removal: (Fig. 8-69)

NOTES
a. Single Speed: Disconnect one electrical
connector on the solenoid coil. Remove one
tube and two hoses on the lock valve. Remove
two capscrews and locknuts securing the lock
valve to the chassis.
b. Two Speed: Disconnect two electrical
connectors on the dual solenoid coils. Remove
two hoses and tubes on the lock valve. Remove
two capscrews and locknuts securing the lock
valve to the chassis.
NOTE: Cap or plug ALL hydraulic hoses, tubes,
fittings, and control valve ports immediately after they
are disconnected to prevent fluid loss and contamination
of the hydraulic system.

necessary. Refer to the Lubrication chapter for
assembling any component of the hydraulic system.
WARNING

Solenoid Coil
Lift and Tilt Solenoid Valve - Disassembly
and Assembly
Coil
Retaining Lift and tilt solenoid valves can be removed from the
Nut loader for parts replacement, but may not be necessary.
If it is necessary, refer to the procedure in this chapter.
1. Remove the nut that secures the coil to the cartridge.
Cartridge The coil can then be removed from the cartridge.
Fig. 8-70
2. Unscrew cartridge from the valve body. Fig. 8-71
3. Install seal kit (or other new parts). Assemble
Fig. 8-70 Safety lock valve components. solenoid valve in reverse order of disassembly. Fig.
8-72
IMPORTANT
DO NOT torque coil retaining nut more than
45 in-lbs (5.1 N•m). Fig. 8-70
4. If removed from the loader, install the lift or tilt

solenoid on the hydraulic system. Refer to the
Valve Body
HYDRAULICS
Fig. 8-71 Solenoid cartridge removed from the valve
body.
O-Ring
Backup Rings
Fig. 8-72 Detailed drawing of backup rings and o-rings on

solenoid valve cartridge.

Control Valve Removal and Installation

The main hydraulic control valve is located on the right
side of the chassis, in front of the engine. The control
valve ports have been numbered for reference.
Removal Procedure
WARNING
perform the following SAFETY procedures: Port #1

device. Fig. 8-73 View of T-Bar control valve. Disconnect the
assemblies attached to control valve spools.
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 Port #1
hydraulic reservoir. BE SURE to plug/cap ALL
hydraulic hose and tube fittings to prevent
contamination of the hydraulic system.
Fig. 8-74 View of Dual Hand control valve. Disconnect
2. Disconnect all items attached to the control valve the assemblies attached to control valve spools.
spools. On T-bar models disconnect two control
rods (lift and tilt) and auxiliary hydraulics control
cable. On Mechanical Auxiliary Hand/foot 1
models disconnect one lift rod, auxiliary cable and
2
two pilot valve hoses. On Dual Hand models 3 5
disconnect two control cables and the auxiliary
control cable. Figs. 8-73, 8-74 and 8-76
3. Disconnect the electrical connector attached at the
auxiliary spool lock solenoid. Fig. 8-77
4
NOTE: To aid in reassembly of hydraulic hoses and
tubes, mark hoses and tubes to be removed BEFORE
disassembly. Fig. 8-75
6 7
4. Port 1: Disconnect the gear pump hose at the 90°
8
fitting. 9
5. Ports 2 and 3: Disconnect the lift tubes from Fig. 8-75 Control valve port reference numbers.
straight fittings on control valve.

6. Ports 4 and 5: Disconnect the tilt tubes from 90°

fittings on the control valve.
7. Ports 6 and 7: Disconnect the auxiliary tubes from
Pilot Hose
straight fittings on the control valve.
8. Port 8 (High-Flow only): Disconnect the return
tube and valve filter tube from the tee fitting on the
side of the valve.
9. Port 9: Disconnect the valve inlet tube from the 90°
fitting at bottom of the control valve.
10. Remove two capscrews and locknuts securing the
control valve from the welded mounting bracket.
Fig. 8-80
Fig. 8-76 View of Hand/Foot control valve. Disconnect
11. Lift the control valve out. Removal may require
the assemblies and two pilot control valve hoses
attached to control valve spools.
loosening the opposite ends of some of the
disconnected tubes.
fittings and control valve ports immediately after being
disconnected to prevent fluid loss and contamination of
Spool Lock
Electrical Connector
1. Secure the control valve to the welded bracket with
two capscrews and locknuts. If straight fittings are
not in the control valve, install them at this time. Fig.
Port #9
8-80
HYDRAULICS
2. Port 9: Connect the valve inlet tube to the 90°
fitting at bottom of the control valve.
Fig. 8-77 Location of second pilot valve hose connected at
the rear of the control valve. 3. Port 8 (High-Flow only): Connect the return tube
and valve filter tube to the tee fitting on the side of
the valve.
4. Ports 6 and 7: Connect auxiliary tubes to straight
fittings on the control valve.
5. Ports 4 and 5: Connect tilt tubes to 90° fittings on
Port #3 the control valve.
Port #2
6. Ports 2 and 3: Connect lift tubes to straight fittings
Port #4
on control valve.
Port #7 7. Port 1: Connect the gear pump hose to the 90°
Port #6 fitting.
Port #8
8. Connect all items attached to the control valve
spools. On T-bar models connect two control rods
(lift and tilt) and auxiliary hydraulics control cable.
Fig. 8-78 Tubes on straight fittings on port #2 and port #3. On Mechanical Auxiliary Hand/Foot models
connect one lift rod, auxiliary cable bonnet and two
pilot valve hoses. On Dual hand models connect

two control cables and the auxiliary control cable.

Figs. 8-73, 8-74 and 8-76
9. Reconnect the auxiliary spool lock electrical Port #5
connector to its connector on the wiring harness.
10. Install hydraulic reservoir drain plug and refill with
correct type of hydraulic oil. Refer to Lubrication
chapter for hydraulic oil requirements and
specifications.
WARNING Fig. 8-79 Location of the port #5 on main control valve.

any fluid is injected into your skin, see a doc-
invisible and cause permanent
eyesight damage if safety glasses are not
worn.
Fig. 8-80 Location of two of four capscrews and locknuts

securing the main control valve to the chassis.
1
2
3 5
6 7
8
9
Fig. 8-81 Control valve port reference numbers.

Control Valve Components
Dual Hand / T-Bar Section #8
2
8
5
6
HYDRAULICS
10
Hand/Foot Section #8
9
1 - Outlet Section
2 - Inlet Section
3 - Relief Valve
4 - Load Check Poppet
1
5 - Spring
6 - Work Port Relief Valve
7 - Lift Section
8 - Tilt Section
9 - Auxiliary Section
10 - Spool Lock
Fig. 8-82 Exploded view of the main control valve components.

High-Flow Manifold Valve Removal and

Installation (High-Flow models)
GEHL 40 series skid-steer loaders are equipped with a
high-flow manifold valve that is part of the high-flow
auxiliary hydraulics system.
Removal Procedure
WARNING
q Raise liftarm, engage liftarm support Fig. 8-83 Location of micro switch at rear of high-flow
device. valve.

1. Disconnect the microswitch from the high-flow

valve. Fig. 8-83
2. Disconnect four hydraulic tubes from the high-flow
valve. Fig. 8-84
3. Disconnect the pivot box from the high-flow valve
at the high-flow valve end. Fig. 8-85
4. Remove two capscrews and locknuts securing the Fig. 8-84 Four hydraulic tubes to remove from high-flow
manifold valve to the chassis. valve.

component in the hydraulic system, ALWAYS check High-Flow Valve
the level of the hydraulic fluid in the reservoir. Add fluid
if necessary. Refer to the Lubrication chapter for
Fig. 8-85 Location of clevis assembly that connects the

high-flow valve to the high-flow pivot box.

High-Flow Manifold Valve Disassembly

and Assembly (High-Flow models)
The high-flow manifold valve has a relief valve which
can be removed for service. The complete manifold
valve should be removed from the loader for repair or
replacement of components.
1. To remove the relief valve, place it in vise and
Detent Assembly
unscrew it from the manifold valve body. Figs.
8-86, 8-87 and 8-88
Assembly Procedure - Reverse the disassembly step

Fig. 8-86 Place the high-flow manifold in a sturdy vise. AND include the step below:
IMPORTANT
Torque relief valve cartridges to 70 ft-lb (95
N•m). Torque nut retaining solenoid coil to 45
in-lb (5.1 N•m).
HYDRAULICS
Fig. 8-87 Use a wrench to loosen the relief valve.
Fig. 8-88 Remove the relief valve.

Pilot Valve Removal and Installation -

Hand/Foot Models
Gehl Hand/Foot skid-steer loaders have a pilot valve
attached to the tilt control rod for smoother actuation and
lower foot efforts.
Removal Procedure
WARNING
q Raise liftarm, engage liftarm support device. Fig. 8-89 Four hydraulic hoses to remove off the pilot
q Shut off the engine. valve.

1. Remove the control cover per the procedure in the

Mainframe chapter.
2. Disconnect four hydraulic hoses from the pilot
valve and cap or plug them. Fig. 8-89
3. Remove two retaining clips on the tilt control rod at
the pilot valve. Disconnect the tilt control rod. Fig.
8-90
4. Remove two capscrews securing the pilot valve
Fig. 8-90 Remove two retaining clips with a needle-nosed
bracket to the chassis. Fig. 8-91 plier.
5. Remove the pilot valve and bracket from the loader.
Installation Procedure - Follow the four steps in the

Removal Procedure WARNING above, then the
steps below.
1. Attach the pilot valve to the bracket.
2. Install two capscrews securing the pilot valve
bracket to the chassis. Fig. 8-91
3. Install two retaining clips on tilt control rod at pilot
valve. Connect the tilt control rod. Fig. 8-90
4. Connect four hydraulic hoses to the pilot valve. Fig.
8-89
5. At the main control valve, find two hoses that
connect to the bottom of the pilot valve. Fig. 8-89
Fig. 8-91 Location of two capscrews securing the pilot
6. Loosen one of the hoses ½ turn. valve bracket to the chassis.

IMPORTANT
Pilot valve lines require bleeding after
service(ing). Loosen one hose at a time to
remove trapped air out of the hydraulic line
and pilot valve.
7. Actuate the tilt control foot pedal in both directions

to remove any air in the hydraulic hose. Fig. 8-92
Tilt Control Foot Pedal
8. Retighten the hose on the main control valve. Fig.
8-93
9. Repeat steps 6-8 for the second hydraulic hose.
Fig. 8-92 Location of the tilt control rod attached at the tilt
control foot pedal. 10. Install the control cover per the procedure in the
Mainframe chapter.
WARNING
HYDRAULICS
Fig. 8-93 Location of pilot valve hoses connected at the under pressure can be invisible and pene-
main control valve. trate the skin causing serious injury. If any

Control Valve Disassembly and Assembly

The main control valve is made up of serviceable spool
sections. These sections may be removed for service.
The control valve also contains load-sense shuttles that
may be cleaned during this procedure, and that
procedure follows this procedure on the next page.
1. Remove main control valve per the procedure in this
chapter.
2. Remove three hex nuts on outlet spool section of the
control valve. The valve stack bolts move freely
inside the spools. Fig. 8-94 Fig. 8-94 The valve stack bolts move freely through the
3. Pull spool sections off the three long valve stack spool sections.
bolts. Fig. 8-95
4. Lift each section off valve stack bolts as needed,
being sure to account for o-rings and springs. Fig.
8-96
5. Check condition of o-rings on each section
removed.
Assembly Procedure - Reverse the disassembly steps.
Relief Valve Removal and Installation

An anti-cavitation relief valve is integrated within the
control valve and activates when oil pressures inside the
valve reach unacceptable levels; to relieve that pressure
and prevent damage to valve and hydraulic system. Fig. 8-95 Sections can be separated from each other.
Removal Procedure
WARNING
Spring
q Relieve hydraulic system pressure. O-Ring
q Roll back ROPS until lock engages.
1. Loosen and remove the anti-cavitation relief valve

from the main control valve. Fig. 8-97 Fig. 8-96 Main control valve (removed from loader for
clarity of procedure.)
2. Check condition of o-rings and clean off any debris.
Fig. 8-98

then reverse removal steps
Spool Lock Solenoid Removal and

Installation
The control valve contains one spool lock solenoid. The
spool lock is for auxiliary hydraulics use. The spool
locks activate when the operator raises the restraint bar
or leaves the seat locking the auxiliary hydraulics.
Removal Procedure
Fig. 8-97 Location of the anti-cavitation relief valve on the

main control valve. WARNING
q Roll back ROPS until lock engages.
1. Loosen and remove spool lock solenoid from the

control valve. Fig. 8-99
2. Check condition of o-ring and locking cylinder,
HYDRAULICS
clean off any debris. Fig. 8-100
Fig. 8-98 Relief valve removed from control valve. Installation Procedure - Follow all warnings first,
(Control valve removed from loader for clarity
then reverse removal steps
of procedure.)
Fig. 8-99 Loosen spool lock using a hand wrench. (Control Fig. 8-100 View of spool lock removed from control valve.
valve removed from loader for clarity of (Control valve removed from loader for clarity
procedure.) of procedure.)

Hydraglide™ Ride Control Components - SL4640 and SL4840
1 FITTING/STRAIGHT 7 PLATE/SPACER
2 FITTING/90° 8 TUBE/MANIFOLD
3 FITTING/TEE 9 TUBE/MANIFOLD 3
4 NUT/LOCK 10 HOSE
5 ASSEMBLY/MANIFOLD 11SCREW/CAP
6 ACCUMULATOR 9
8

10
4 1
BLK
BRN
6 7
11
Fig. 8-101 Exploded view of the SL46/4840 Hydraglide™ ride control.
Hydraglide™ Ride Control Components - SL5640
1 FITTING/STRAIGHT 7 ASSEMBLY/MANIFOLD
2 FITTING/90° 8 ACCUMULATOR
3 FITTING/TEE 9 PLATE/SPACER 3
4 NUT/LOCK 10 HOSE
5 TUBE/MANIFOLD 11 SCREW/CAP
6 TUBE/MANIFOLD 6
10

4
1
BLK
BRN
9
8
11
7
Fig. 8-102 Exploded view of the SL5640 Hydraglide™ ride control.

Hydraglide™ Ride Control Components - SL6640

2
11
7
5 3
4
6
BLK
BRN
8
12
HYDRAULICS
9
1 10
1 FITTING/90° 5 NUT/LOCK 9 ACCUMULATOR

2 FITTING/TEE 6 TUBE/MANIFOLD 10 PLATE/SPACER
3 FITTING/TEE 7 TUBE/MANIFOLD 11 HOSE
4 FITTING/STRAIGHT 8 ASSY/MANIFOLD 12 SCREW/CAP
Fig. 8-103 Exploded view of the SL6640 Hydraglide™ ride control.

Hydraglide™ Ride Control Accumulator

The Gehl 40 Series skid-steer loaders offer as an option a
ride control system. This system includes a
hydraulically-driven accumulator that is electrically
controlled in the right control handle and has its own
solenoid.
Removal Procedure
WARNING
BEFORE beginning this service procedure, Fig. 8-104 Location of the left interior fender. Remove this
perform the following SAFETY procedures: fender to access the accumulator and its
q Raise liftarm, engage liftarm support device. manifold.

1. Remove three machine screws securing the left

interior fender (ROPS filler panel) to the side of the
chassis. The machine screws can be accessed from
outside the chassis. Fig. 8-104
Manifold
2. Disconnect three electrical connectors on the
manifold from the wire harness. Fig. 8-105
Fig. 8-105 Location of three electrical connectors on the
3. Remove two hydraulic tubes from straight fittings accumulator manifold valve.
on the manifold. Fig. 8-106
fittings and control valve ports immediately after being
disconnected to prevent fluid loss and contamination of
4. Remove one hydraulic hose from 90° fitting at the
bottom of the manifold. Fig. 107
Locknut
5. Remove two locknuts on capscrews securing
manifold (with accumulator attached) to chassis and
remove both from the loader. Fig. 106
6. Place the manifold in a vise. Use a wrench and
remove the accumulator from the manifold. Locknut
Fig. 8-106 Location of two hydraulic tubes attached to

straight fittings on the accumulator manifold.


Manifold hydraulic fluid requirements and specifications.
WARNING
Fig. 8-107 Location of the hydraulic hose line attached at NEVER use your hands to search for
90° fitting on bottom of manifold. hydraulic fluid leaks. Use a piece of
HYDRAULICS
Fig. 8-108 Overall view of the Hydraglide™ ride control
accumulator set-up in the skid-steer loader.

2900 PSI
56-6640 OPTIONAL
HIGH FLOW
2500 PSI
46-4840
917002/AP0704
2 SPEED
SOLENOID
(OPTION)
TILT
CYLINDERS
SELF
HYDRAULIC SYSTEM
LEVEL
VALVE
OPTIONAL HIGH
FLOW PUMP B A
C D
5500 PSI 5500 PSI
379 BAR 379 BAR
R1
R2
R3
PORT RELIEF 1A 1B 2A 2B 3A 3B
3500 PSI
3000 PSI
56-6640
8-56
2750 PSI
46-4840
Hydraulic/Hydrostatic System Schematic, 40 Series
5500 PSI 5500 PSI

379 BAR 379 BAR
R2
R1
30 CU IN
800 PSI
PRECHARGE
LIFT CYLINDERS AC
4 G
HEAT 2
EXCHANGER
1A
OPTIONAL
HYDROGLIDE 3 A
B
1 5
T
PRINTED IN USA
40 SERIES
40 SERIES ELECTRICAL SYSTEM
Introduction
Description of Operation - Right and Left
Instrument Panels
Right Instrument Panel
Hourmeter The right instrument panel for Gehl 40 Series skid-steer
loaders includes a bank of four circuit breakers.
The following items describe the normal operation of
electrical system components on the 40 Series skid-steer
loaders.
Fuel Level 1. When the operator is in the seat, the restraint bar is
Gauge
down, and the keyswitch is turned to the “ON”
position the following indicator lamps will light:
Engine q Glow Indicator (momentary above 81°F,
Oil
27°C) (Longer light time below 81°F, 27°C)
Temperature
Gauge q Fasten Seat Belt (momentary)
q Engine Oil Pressure
Fasten Seat Belt
q Battery
Engine Oil Engine Oil q Fasten Seat Belt Buzzer will sound for five
Temperature Pressure seconds.
Battery NOTE: Timed buzzer is separate from engine glow
Hydraulic Oil Glow Indicator cycle.
Temperature Lamp NOTE: The glow plugs automatically cycle ON and
OFF when the key is ON. Glow plugs WILL NOT cycle
if ambient temperature is above 81°F (27°C). Refer to
glow control module operation in this chapter.
Light 2. The keyswitch can then be turned to the START
Switch
position.
ELECTRICAL
q The engine oil pressure and battery lamps will
On go out after the engine starts.
Off 3. The lift and tilt safety lock valves should be
Start energized when the operator is on the seat, the
Key
Switch 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, after the keyswitch is turned to
ON, raise the restraint bar or lift body off the seat. Either
Four action should prevent the engine from cranking with the
Circuit
Breakers keyswitch turned to START.
Fig. 9-1 Right instrument panel.

ELECTRICAL SYSTEM 40 SERIES
Left Instrument Panel

The left instrument panel for Gehl 40 Series skid-steer
loaders holds the manual parking brake switch indicator
and light. Optional switches, power outlet and light
indicators are also on this panel.
1. Two-Speed Indicator Lamp - it lights when
skid-steer loader’s two-speed HIGH option is
engaged.
2. Parking Brake Indicator Lamp - it lights when
skid-steer loader's parking brake switch is engaged.
3. Electric Float Indicator Lamp - it lights when
skid-steer loader's electric float option is engaged.
4. Hydraglide™ Ride Control Indicator Lamp - it
lights when loader’s ride control option is engaged.
5. Fan Switch - controls the (optional) fan on heater
and/or air conditioning package.
6. HVAC Switch - controls the selection of heat or air
conditioning option.
7. Electric Auxiliary Hydraulics Switch, Hand/Foot
Models only - a three-position detented switch
option used for continuous operation.
8. 12 VDC Power Outlet - a plug-in outlet with rubber Two-Speed Control Ride Control
boot used for external electrical connections. (Optional) (Optional)
Electric Float
9. P o w e r - A - T a c h ™ S w i t c h - c o n t r o l s t h e Parking Brake
(Optional)
electrically-driven attachment engagement system
option.
Power-A-Tach™
10. Parking Brake Switch - used to manually apply the Switch (Optional)
parking brake.
Parking Brake
Switch
Fan Switch
(Optional)
HVAC Selector
Switch (Optional)
Electric Auxiliary
Hydraulics Switch
(Optional)
12 VDC Power
Outlet
Power-A-Tach and Hydraglide are trademarks of the

Gehl Company. Fig. 9-2 Left instrument panel.


Entire electrical system Battery disconnect switch is “OFF”. Turn battery disconnect switch to “ON”.
does not function.
Circuit breaker(s) are 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 are loose or Clean battery terminals and cables and
corroded. tighten them.
Battery is faulty. Test battery and replace as needed.

No instrument panel lamps Circuit breaker is tripped. Consult wiring diagram, check circuit and
light with keyswitch turned locate trouble before resetting breaker.
to “ON”.
No glow indicator lamp Ambient temperature above 81°F Proceed with starting engine.
with keyswitch turned to (27°C).
“ON”.
Bulb is burned out. Replace bulb.
Faulty glow module. Check connection and voltage, replace as
needed.
Seat belt buzzer indicator Plugged or obstructed buzzer. Clean out buzzer.
not sounding when key
turned to “ON”, indicator Faulty buzzer. Replace Interlock Control Module.
lamps work properly.
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 Faulty sender. Replace temperature sender.
does not work.
Loose wiring/terminal connections. Verify wiring connections.
ELECTRICAL
Faulty temperature gauge. Replace temperature gauge.
Hourmeter does not work. Loose wiring/terminal connections. Verify wiring connections.
Faulty alternator. Repair or replace alternator.
Faulty hour meter. Replace hour meter.


Starter will not engage Seat or restraint bar switch malfunctioning Operator is in the seat with the restraint
when key is turned to or not activated. bar down. Replace switches as needed.
“START”.
Poor connections to starter relay in Verify relay connections.
instrument panel.
Faulty starter relay in the panel. Test starter relay. Replace as needed.
Battery discharged or defective. Recharge or replace battery.
Starter solenoid in chassis malfunctioning. Troubleshoot circuit per wiring diagram,

locate trouble. Replace starter solenoid.
Ignition wiring, seat switch, restraint bar switch, Check wiring for poor connections, broken
etc. loose or disconnected. leads; repair wiring or connection.
Starter or pinion faulty. Remove starter; repair/replace as needed.
Faulty connections to Interlock Control Module. Check diagnostic lights on Interlock

Control Module for proper inputs. Refer to
the Truth Table (Fig. 9-20) in this chapter.
Battery will not Battery terminals or cables are loose or Clean battery terminals and cables and
recharge. corroded. tighten them. Replace cables as needed.
Battery or alternator is defective. Test battery and alternator. Replace.
Work lights not Single light doesn’t work: Light bulb Check and replace light bulb as needed.
functioning properly. burned out, faulty wiring. NOTE: When changing the halogen bulb,
DO NOT directly touch the light bulb. Use
a clean rag to handle the bulb. Check
wiring connection to light.
No lights at all: Circuit breaker #2 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 Propel Wiring to solenoids disconnected; faulty. Refer to wiring diagram, locate trouble and
Lock Solenoids do not repair as needed.
work.
Faulty seat or restraint bar switch. Replace seat and/or restraint bar switches
as needed.
Faulty solenoid valve coil. Perform “Solenoid Valve Test” in Hydraulic

System chapter. Replace solenoid valve
coil(s) as needed.
Faulty hydraulic solenoid relay in Test relay, replace as needed.

instrument panel.

Chassis Electrical Components
27 14
14 11
15 17
13 24
TO WORK, TAIL LIGHTS TO AIR FILTER SWITCH OPTION
21
TO MAIN ROPS HARNESS
TO FLASHER TO 2-SPEED, RIDE
15 OPTION CONTROL MODULE OPTION
25 TO GLOW RELAY
7
TO GLOW MODULE
11 14
14 TO GLOW TO HORN RELAY OPTION
14 TO START
SOLENOID CIRCUIT BREAKER
11 15 25 29
21 14
14 21 TO MASTER TO GLOW ELEMENT 22
CIRCUIT BREAKER
31 7 21
TO ENGINE TEMP
28
SWITCH & SENDER
14 TO HORN OPTION 23
7 TO ALTERNATOR
3
TO H-F HYD
TO HYD TILT SPOOL LOCK 20 14
LOCK SOLENOID 31 TO FUEL SENDER
3 3
2 TO FUEL SHUT-OFF SOLENOID
TO LOW OIL PRESURE SWITCH
TO EXTRA START
TO AUX HYD FUEL SOLENOID
SPOOL LOCK 6
TO HYD LIFT
TO STARTER LOCK SOLENOID 30
TO ENGINE
20 GROUND 9
20 1 4
TO RIGHT
CONTROL HANDLE 33
34 34
TO HYD TEMP SWITCH 16 10
TO 2-SPEED SOLENOID OPTION TO CHASSIS GROUND 35
26 16
TO PARK BRAKE SOLENOID 5
8
TO LEFT CONTROL 14 14
HANDLE 3 11
18
31
32 4
33
TO STARTER
TO RIDE CONTROL
TO KEYED POWER SOLENOID OPTION 28
11 19
TO BACK-UP ALARM OPTION 31 8
START SOLENOID GLOW RELAY 12
2-SPEED, RIDE CONTROL MODULE OPTION

HORN RELAY OPTION
GLOW MODULE
ELECTRICAL
ELECT. PANEL DETAIL VIEWS
GLOW CIRCUIT BREAKER
MASTER CIRCUIT BREAKER
1 CABLE/BATTERY 10 ANGLE/HOLDDOWN 19 CABLE/BATTERY 28 BUSHING

2 TIE/WIRE 11 CLAMP/TUBE 20 CLAMP/TUBE 29 SCREW/CAP
3 CLAMP 12 BATTERY 12 VDC 21 NUT/SERRATED 30 SCREW/CAP
4 NUT/HEX 13 SOLENOID/START 22 PLATE/MODULE 31 SCREW/CAP
5 CLAMP/TUBE 14 NUT/LOCK 23 MODULE/GLOW 32 BOLT/CARRIAGE
6 CABLE/BATTERY 15 NUT/LOCK 24 RELAY 33 WASHER/FLAT
7 CLAMP/HOSE 16 NUT/LOCK 25 BREAKER/CIRCUIT 34 WASHER/LOCK
8 ROD/HOLDDOWN 17 WASHER/LOCK 26 HARNESS/CHASSIS 35 SCREW/CAP
9 COVER/TERMINAL 18 CONDUIT/CABLE 27 BRACKET/ELECTRICS
Fig. 9-3 Exploded view of the chassis electrical components.

ROPS Electrical Components

15 6
14
16
16 4 16
9 16 7 10 7
17
9
18 16
10
5
13
KEYED POWER
TO KEY SWITCH KEYED POWER
20
21 TO FLASHER
OPTION
20 12
20
TO DOOR
SWITCH
19
19
LEFT INSTRUMENT PANEL DETAIL
RIGHT INSTRUMENT PANEL DETAIL
1 TIE/WIRE
2 GROMMET
3 NUT/LOCK
TO RADIO OPTION
4 HOURMETER
5 SWITCH/LIGHT
TO DOME LIGHT
6 RELAY SPDT
7 HOUSING/DISPLAY
2 8 CLAMP/TUBE
2
TO WORK LIGHT
TO STROBE LIGHT OPTION 9 BULB/LAMP
10 GASKET/LAMP
2 11 CONNECTOR 12 V
TO WORK LIGHT
12 COVER 12 V
13 SWITCH/PARKING BRAKE
TO RESTRAINT BAR 14 MODULE/INTERLOCK
TO MAIN CHASSIS
3 HARNESS
8
1
15 RELAY/POWER
1 16 NUT/SERRATED
17 GAUGE/FUEL LEVEL
18 GAUGE/ENGINE TEMP/OIL
TO SEAT SWITCH
19 HARNESS/PANEL
20 BREAKER/CIRCUIT
19
22
21 BREAKER/CIRCUIT
TO SEAT
PAN GROUND 22 WASHER/LOCK
Fig. 9-4 Exploded view of the ROPS’s electrical components.

Ignition Switch Electrical Components
6 5
1
1
8
7 4 8
1 1
8 8
1 1
1 8 8 1
8 8
ELECTRICAL
2
1 NUT/SPEED
2 TAG/KEY
3 SWITCH/IGNITION
4 DECAL/RIGHT INSTRUMENT PANEL
5 PANEL/RIGHT INSTRUMENT
6 PANEL/LEFT INSTRUMENT
7 DECAL/LEFT INSTRUMENT PANEL
8 SCREW/PHILLIPS
Fig. 9-5 Exploded view of the ignition switch electrical components.

Module and Relay Test and Operation START SOLENOID GLOW RELAY
Gehl 40 Series skid-steer loaders utilize many types of

modules and relays in the electrical system to maximize
the efficiency of engine, hydraulic, power and electrical
operations. Following in this section are test procedures.
Master Circuit Breaker/Glow Circuit Breaker Test

The following procedure can be used to test the master GLOW CIRCUIT BREAKER
circuit breaker and glow circuit breaker located on the
right engine electrical panel inside the chassis.
MASTER CIRCUIT BREAKER

WARNING Fig. 9-6 Illustration of right side electrical panel.
q Shut off the engine. Starter Relay Glow Relay
1. Circuit breakers are accessible with rear grille

Glow Circuit Breaker
locked open and engine cover fully extended.
2. Using a volt/ohm multimeter, confirm the following
conditions with the wiring connected and the
keyswitch in the OFF position. Master Circuit Breaker
u There should be 12 VDC on copper colored
stud (#1 red wire from battery supply). If 12
VDC cannot be measured at the copper stud
check for disconnected or damaged wiring.
Fig. 9-7 View of the right side engine electrical panel
A dead battery may be the cause. inside the chassis.
u If 12 VDC is present at copper colored stud,
then check for 12 VDC at the silver colored
stud. If 12 VDC is measured at silver stud,
the breaker is good. If 12 VDC cannot be
measured at the silver stud, the breaker
should be replaced.
NOTE: The battery supply wires (#1 red) must be
connected to the copper colored stud of the circuit
breaker.
Alternate test:
1. Disconnect negative battery cable or, if equipped,
turn battery disconnect switch to OFF position.
2. Disconnect wiring from circuit breaker.
3. Check for continuity between copper colored and
silver colored terminals. If there is continuity, the
circuit breaker is good.

Power Relay Test

The following procedure can be used to test the power
relay located inside the right instrument panel.
87
30 WARNING
85 BEFORE beginning this service procedure,
86 q Shut off the engine.
Fig. 9-8 Illustration of the power relay terminals.

1. Remove four Phillips head screws securing right
instrument panel to ROPS. It should then be
possible to expose wiring and relay without
disconnecting any wires from panel.
SPDT Relays
2. Using a volt/ohm multimeter, confirm the following
conditions with wiring plug connected to relay
Power Relay terminals #85 and #86 and wires disconnected from
screw terminals #30 and #87.
u With the keyswitch in OFF position, there
should not be continuity between terminals
#30 and #87.
u Turning keyswitch to ON position should
provide 12 VDC to terminal #86 and
produce an audible “click” from the relay.
There should be continuity between
terminals #30 and #87.
Fig. 9-9 Locations of the power relay and the SPDT relay
inside the left and right instrument panels. u If 12 VDC cannot be measured at terminal
#86, check for disconnected or damaged
ELECTRICAL
wiring. A dead battery may also be the
cause. If the relay does not pass the above
test conditions, it should be replaced.
u Relay Coil Test: Using a volt/ohm
multimeter with all wires disconnected,
measure the resistance across terminals #85
and #86. There should be 46 ohms +/- 5
ohms. There should be no continuity
between terminals #30 and #87.
Fig. 9-10 Voltage test on the power relay.

ISO SPDT Interlock Relay and Horn Relay Test

1. For horn relay, 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.
u Relay coil test: Using a volt/ohm
Fig. 9-11 Location of the horn relay on the left side engine
Starter Solenoid Test electrical panel.
The following procedure can be used to test starter relay
located on right side engine electrical panel in chassis.
87
WARNING
perform the following SAFETY procedure: 87a
(For detailed instructions, refer to the Safety 86 85
1. Starter relay is accessible with rear grille locked 30

open and engine access cover fully extended.
2. Using volt/ohm multimeter, confirm the following Fig. 9-12 Illustration of the interlock relay/horn relay
conditions with white “S” wire disconnected. terminals.
u With keyswitch in OFF position, there

should be 12 VDC on large copper stud with
#1 red wire.
u Turning keyswitch to START position
should provide 12 VDC on “S” terminal
(#21 green wire) of solenoid and produce an
audible “click” from solenoid. There should
be 12 VDC on the other large copper stud
(the one that the white wire was removed STARTER BATTERY
from) and on the “I” terminal (#41 yellow
wire). Relay should release when keyswitch STARTER SW IGN COIL
is returned to ON or OFF position.

u If 12 VDC cannot be measured at large stud
with #1 red wire, check for disconnected or
damaged wiring. A dead battery may also Fig. 9-13 Illustration of the starter solenoid/relay and its
be the cause. If the solenoid does not pass electrical path. Arrows point to continuity and
the above test, it should be replaced. voltage test locations.

Glow Control Module
GREEN LED INDICATORS

TYP (2)
PIN DESCRIPTIONS:
3 4
1. RED - 12VDC IN
+12VDC 21 5
6
2. YEL - STARTER SIGNAL IN
GLOW OUTPUT
3. +12VDC = GLOW CYCLE 1
GROUND = GLOW CYCLE 2
6 PIN DEUTSCH NC = GLOW CYCLE 3
PN DT15-06PA
4. PNK - GLOW RELAY OUTPUT
(5 AMP OUTPUT)
5. BLU - GLOW LIGHT OUTPUT
6. BLK - GROUND
MATING CONNECTOR:
DEUTSCH PN DT06-06S
Fig. 9-14 Illustration of the glow control module.
Glow Control Module Time/Temp Cycle

200
180
LEGEND
160
AFTER-GLOW
140 PRE-GLOW
ELECTRICAL
SECONDS
120
SPECS:
100 1. TEMP 2 C
80 2. TIME 10%
60 3. GLOW ON DURING
START IF TEMP
40 LESS THAN 27C.
4. 1 SEC. LAMP TEST
20 AT POWER-UP.
0 5. LAMP OUTPUT ON
-40 -30 -20 -10 0 10 20 30 DURING PRE-GLOW.
TEMPERATURE CELSIUS 6. LAMP OUTPUT OFF
DURING START AND
TIME/TEMP CYCLE 1 (PIN 3 = +12 VDC) AFTER-GLOW.
TYPICAL APPLICATION: DEUTZ 2011 SERIES ENGINE
- GRID HEATER PROTOCOL
Fig. 9-15 Glow control module time and temperature chart.

Glow Control Module Test

The glow control module, located on the left engine
2-SPEED, RIDE CONTROL MODULE OPTION
electrical panel, is a timed control module that powers
the glow relay, located on the right engine electrical HORN RELAY OPTION
panel. The timing cycle varies relative to ambient GLOW MODULE
temperature. The glow relay cycles power ON and OFF
to the glow element on the engine.
1. Turn keyswitch to ON position. Check green LED
indicator on module labeled “+12 VDC” to verify it
is ON. If indicator light is not ON, check for 12 VDC
across terminals #1 (13 red) and #6 (0 black) on
harness connector to module.
2. The glow indicator lamp in the right instrument
Fig. 9-16 Illustration of the left side engine electrical
panel will come on momentarily (approximately 1 panel.
sec) each time the keyswitch is turned to the ON
position to test the lamp. If ambient temperature is
below 81 F (27 C), glow indicator lamp in right
instrument panel will come on while glow element
is activated for pre-glow cycle. After indicator lamp
goes out, then crank engine to start.
87
3. The green LED indicator on module labeled “Glow
Output” will be ON when the module is activating
the glow relay for both pre-glow and after-glow
cycles. 86 85
4. If “Glow Output” indicator is on but glow element
on engine is not activated, check function of glow
relay on right engine electrical panel.
30
5. Glow control module is restarted by returning
keyswitch to OFF position and back to ON position. Fig. 9-17 Illustration of the glow relay terminals.
Glow Relay Test

The following procedure can be used to test the glow
relay mounted on the engine electrical panel located
inside the chassis on the right side.
WARNING
1. The glow relay is accessible with the rear grille

locked open and the engine access cover fully
extended.
2. Using volt/ohm multimeter, confirm the following

NOTES condition with wiring plug disconnected from relay.
There should be 100 ohms +/- 5 ohms resistance
between terminals #85 and #86. There should not be
continuity between terminals #87 and #30.
3. Using volt/ohm multimeter, confirm the following
conditions with wiring plug connected to relay.
With keyswitch ON and Glow Control Module
Output ON (ambient temperature below 81 F, 0 C)
there should be 12 VDC on terminal #86 (#44 Pink
wire from control module) to turn relay ON. There
should also be 12 VDC on terminal #87 (#2 red wire
from battery supply) and #30 (#3 Blue wire to glow
element).
4. If 12 VDC cannot be measured on terminals #86 and
#87, check for disconnected or damaged wiring. A
dead battery may be the cause. If relay does not pass
above test conditions, it should be replaced.
u Relay coil test: Using a volt/ohm

ELECTRICAL

Interlock Control Module Test

The following procedure can be used to test interlock
control module inside the left instrument panel.
WARNING
Fig. 9-18 Location of the interlock control module.

1. Remove four Phillips-head screws securing left
instrument panel to ROPS. It should be possible to
expose wiring and interlock control module without In” should light, output LED “Fuel
disconnecting any wires from panel. Solenoid” should light, and internal seat
2. Most module troubleshooting can be done by belt alarm should sound for five seconds.
observing green diagnostic LED indicators. u Example 2 (low engine oil pressure
u Disconnect 12-pin and 6-pin connectors condition): At initial keyswitch ON, allow
and inspect terminals. Be sure no pins are seat belt alarm condition to time out. Input
bent on module and no sockets are damaged LED “12 VDC In” and “Oil Pressure
on harness. Replace damaged components Switch” should be lit. In output section,
and reconnect harness to control module. internal “Engine Shut Down Alarm” will
sound intermittently and output LED “Fuel
3. Refer to truth table (Fig. 9-20) to analyze Solenoid” will shut OFF after 30 seconds.
functionality of module. The module controls
operation of components listed in OUTPUTS 4. The truth table section “Diagnostic LED States”
section of truth table. The ON or OFF state of specifies active (ON) state of each input and output.
various outputs is determined by ON or OFF state of u Example: Active (ON) state of engine oil
various input conditions listed in INPUTS section of pressure switch input (connector #1, pin #8)
truth table. The keyswitch must be in ON position. is a low or grounded input. Active state of
u Example 1 (initial keyswitch ON): At seat switch input (connector #1, pin #3) is a
initial keyswitch ON, input LED “12 VDC high or 12 VDC input.
GREEN LED
DIAGNOSTIC
INDICATORS (15)
SEE NOTE 3
OUTPUT PIN DESCRIPTIONS: INPUT PIN DESCRIPTIONS:
1. BLUE - PARK BRAKE SOLENOID, 1. RED - KEYED POWER

(5 AMP MAX CONTINUOUS) 2. BLACK - GROUND
BRAKE SOL OUT
AUTO-GLOW TIME IN
+12VDC IN
PARK BRAKE LT OUT
ENG TEMP SW IN
SEAT BELT LT OUT
OIL PSI SW IN
FUEL SOL OUT
START RELAY OUT
DOOR SW IN
HYD RELAY OUT
HYD TEMP SW IN
PARK BRAKE SW IN
SEAT SW IN
RESTRAINT BAR SW IN
2. YELLOW - HYD RELAY, 3. WHITE - SEAT SWITCH

(3 AMP MAX CONTINUOUS) 4. GREEN - RESTRAINT BAR SWITCH
3. BROWN - SEAT BELT LIGHT, 5. PURPLE - PARK BRAKE SWITCH
(2 AMP MAX CONTINUOUS) 6. GRAY - HYD TEMP SWITCH
4. GREEN - PARK BRAKE LIGHT, 7. ORANGE - ENG TEMP SWITCH
(2 AMP MAX CONTINUOUS) 8. PURPLE - OIL PSI SWITCH
5. RED - FUEL SOLENOID, 9. WHITE - DOOR SWITCH
(5 AMP MAX CONTINUOUS) 10. BLUE - AUTO-GLOW TIME
6. PINK - START RELAY, 11. NC
(3 AMP MAX CONTINUOUS) 12. NC
ALARM BUZZER MATING CONNECTOR: MATING CONNECTOR:

DEUTSCH PNB DT06-06S DEUTSCH PNB DT06-12S
OUTPUT CONNECTOR INPUT CONNECTOR
6 PIN DEUTSCH 12 PIN DEUTSCH
DT15-06 DT15-12PA
Fig. 9-19 Illustration of the interlock control module.

2
n) n) n) ID #
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40 SERIES
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(
INPUTS (12 Pin Connector #1.X) OUTPUTS (6 Pin Connector #2.X)
Function Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 INTERNAL INTERNAL NOTES
Seat Belt Warning
AT POWER ON ON X ON FOR ON ON FOR Light and Intermitent
5 SEC 5 SEC Chirp Alarm
HYD OVER TEMP Intermitent Alarm Sounds
ON X ON ON when Input Signal is
WARNING Present or until Power Off
Engine Shut Down Timer
AUTO-GLOW TIME ON X ON ON and Alarm Disabled
During Auto-Glow
ENGINE OVER TEMP OFF Fuel Solenoid Shut Down
ON X ON AFTER ON and Intermitent Alarm
SHUT DOWN 30 SEC Sounds Until Power Off
ENGINE LOW OIL OFF Fuel Solenoid Shut Down
PSI ON X ON AFTER ON and Intermitent Alarm
Interlock Control Module Truth Table
SHUT DOWN 30 SEC Sounds Until Power Off

PARK BRAKE Solenoid "ON" Releases
Fig. 9-20 Truth table for the interlock control module.

RELEASE ON X ON ON ON ON OFF Hyd Brake to Allow
SOLENOID ON Loader Movement
PARK BRAKE OFF Seat Switch has
RELEASE ON X AFTER OFF ON 1 Second Delay for
SOLENOID OFF 1 SEC Park Brake Function
9-15
PARK BRAKE Instantaneous,
RELEASE ON X OFF OFF ON Park Brake Stops
SOLENOID OFF Loader Movement
PARK BRAKE Instantaneous,
RELEASE ON X OFF OFF ON Park Brake Stops
SOLENOID OFF Loader Movement
SAFETY RELAYS Instantaneous, Hydraulics
ON X ON ON OFF ON ON and Start Functions are
ENABLE Able to Operate
ON X OFF OFF OFF and Start Functions are
DISABLE Disabled
ON X OFF OFF OFF and Start Functions are
DISABLE Disabled
ON X ON OFF ON and Start Functions are
DISABLE Disabled
DIAGNOSTIC LED STATES

LED Title Pin No. Type of Active Input/Output LED State
+12VDC (IN) 1.1 HIGH (12VDC) ON
Brake Sol (OUT) 2.1 HIGH (12VDC) ON INTERLOCK CONTROL MODULE TRUTH TABLE
Fuel Sol (OUT) 2.5 HIGH (12VDC) ON
Start Relay (OUT) 2.6 HIGH (12VDC) ON
Hyd Relay (OUT) 2.2 HIGH (12VDC) ON
Seat Belt Lt (OUT) 2.3 LOW (GND) ON
Park Brake Lt (OUT) 2.4 LOW (GND) ON
Restraint Bar Sw (IN) 1.4 HIGH (12VDC) ON
Door Sw (IN) 1.9 HIGH (12VDC) ON
Seat Sw (IN) 1.3 HIGH (12VDC) ON
Park Brake Sw (IN) 1.5 HIGH (12VDC) ON
Hyd Temp Sw (IN) 1.6 LOW (GND) ON
Engine Temp Sw (IN) 1.7 LOW (GND) ON
Oil PSI Sw (IN) 1.8 LOW (GND) ON
Auto-Glow Time (IN) 1.10 LOW (GND) ON
917002/AP0704
ELECTRICAL SYSTEM
ELECTRICAL
917002/AP0704
TWO-SPEED, RIDE CONTROL MODULE TRUTH TABLE
y
tro
p
mp
tar
La
e n
Lam
ELECTRICAL SYSTEM
ch
p
rol
r
G
itch
e
nt
wit l
Sw ear
ea
S
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Lam
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t
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gle ntro
en
en ear
itch m
en
o
l
loa
Fl
Flo
Rid
Hig
Rid
Hig
Low
F
Rid
Sw at Mo
Sol t/Rid
Tog /High
S
Sol Con
Tog e Co
ACTION COMMENTS
At Power Up 0 0 0 0 0 0
Toggle High 1 1 Momentary press toggles
Gear ON high gear.
Toggle High 0 0
Gear OFF
Fig. 9-21 Truth table for the two-speed, right control module.
9-16
Toggle Ride Momentary press toggles
Two-Speed, Ride Control Module Truth Table
Control ON 1 1 1
ride control.
Toggle Ride 0
0 (after 0
Control OFF .25 sec
delay)
1 0 0 1 Float is activated only as long
Activate Float 1 as switch is pressed.
(moment (after Lamp blinks at 2Hz rate.
.25 sec Float action has priority over
hold) ride control.
delay) If ride control is ON when float
is pressed, ride control solenoid
has .25 sec. OFF delay.
Ride control output returns to
prior state when float is
de-activated.
Float Hold ON 1 Lamp blinks at 2Hz rate for
(hold 1 0 0 1 5 sec. then locks to continuous
for ON state. Solenoid output
5 sec) locks ON after 5 sec.
Toggle Float OFF Lamp and solenoid turn OFF.
0 0 0 0 Ride control output returns to
prior state when float is
de-activated.
PRINTED IN USA
40 SERIES
Two-Speed, Ride Control Module Test u Disconnect 12-pin connector and inspect
The following procedure can be used to test the terminals. Be sure no pins are bent on the
module and no sockets are damaged on the
two-speed, ride control module mounted on the engine
harness. Replace any damaged components
electrical panel located inside the chassis on the left side.
and reconnect harness to control module.
3. Refer to truth table (Fig. 9-21) to analyze
WARNING functionality of module.
BEFORE beginning this service procedure, u With keyswitch ON, press #1 button on left
perform the following SAFETY procedure: control handle. The “High/Low Toggle”
LED should be lit while button is depressed.
q Raise liftarm, engage liftarm support The “High Gear Sol” LED should toggle
device. ON (light) and OFF with alternate pushes of
q Shut off the engine. button.
q Roll ROPS back until lock engages. u With keyswitch ON, press #2 button on
right control handle. The “Ride Ctrl
Toggle” LED should be lit while button is
depressed. The “Ride Ctrl Sol” LED should
toggle ON (light) and OFF with alternate
1. The two-speed, ride control module is accessible pushes of button.
with the rear grille locked open and the engine
access cover fully extended.
2. Most troubleshooting of the two-speed, ride control
module can be done by observing the green
diagnostic LED indicators on the module.
Two-Speed, Ride Control Module
GREEN LED MATING CONNECTOR:

DIAGNOSTIC DEUTSCH PNB DT06-12S
INDICATORS (7)
ELECTRICAL
HIGH GEAR SOL
FLOAT/RIDE SOL
PIN DESCRIPTIONS: 7. BLU RIDE CONTROL LAMP

1 6 1. BLK GROUND 8. BRN RIDE CONTROL SOLENOID
12 7
2. TAN FLOAT LAMP (5 AMP OUTPUT)

3. GRY RIDE CONTROL TOGGLE 9&10. YEL FLOAT/RIDE SOLENOID
4. PNK FLOAT SWITCH (10 AMP OUTPUT)
12 PIN DEUTSCH
PN DT15-12PA 5. RED +12VDC 11. ORG HIGH GEAR LAMP
6. WHT LOW/HIGH GEAR TOGGLE 12. PUR HIGH GEAR SOLENOID
(5 AMP OUTPUT)
Fig. 9-22 Illustration of the two-speed, ride control module.

Control Handle Actuation Buttons - Two-Speed and Ride Control Module
SWITCH 1 SWITCH 2 SWITCH 1 SWITCH 2

Two-Speed Horn OPEN Ride Control
LEFT RIGHT
CONTROL CONTROL
HANDLE HANDLE
SWITCH 1 SWITCH 2
BLACK
GRAY
BLUE
RED
SWITCH SCHEMATIC
Fig. 9-23 Illustration of control handle buttons and their functions.

Seat Switch Removal and Installation

Removal Procedure
WARNING
Fig. 9-24 Location of capscrews on standard seat. 1. Remove seat from loader per the procedure found in
the Mainframe chapter. Turn the seat over.
2. Seat switch removal: Figs. 9-24, 9-25
a. Standard Seat: Remove two capscrews and
nuts securing seat switch to seat. Press three
tabs to separate dome from base. Press two tabs
to remove switch from base.
b. Deluxe Seat: Press two tabs, one on each side of
seat switch. Push switch through bracket and
pull out of seat.
WARNING
DO NOT attempt to operate the loader without
the seat switch installed.
Fig. 9-25 Location of seat switch on a deluxe seat. There is
a release tab on each side of the switch. Installation Procedure - Follow all warnings first,
ELECTRICAL
* Install seat on loader as per procedure in Mainframe
chapter.

Restraint Bar Components
22
8
12
6
18
6
10
3 6 22
12
27
12 15 6
6
1 9 8 12
1
6
23
7
11 3
24 27 10
20 5 6 19
6 26 1 6
25 1
D 12
21 20
9
1 14
6
20
2
7 25
21 26
16
13 11 24 1 20
23
4
6
17
2
1 RING/EXTERNAL RETAINING 10 ROD/SPRING GUIDE 19 COVER/LEFT

2 NUT/LOCK 11 NUT/HEX NYLON INSERT 20 SCREW/CAP
3 SPRING/COMPRESSION 12 CLIP/RETAINING 21 BOLT/CARRIAGE
4 ACTUATOR 13 BAR/RESTRAINT W/PAD 22 SCREW/PHILLIPS
5 SWITCH/RESTRAINT BAR 14 BRACKET/PIVOT LEFT 23 WASHER/FLAT
6 BEARING/BRONZE 15 BRACKET/PIVOT RIGHT 24 NUT/JAM
7 BUMPER 16 BRACKET/PIVOT RIGHT 25 WASHER/FLAT
8 PIN/PIVOT 17 BRACKET/PIVOT LEFT 26 WASHER/FLAT
9 PIN/PIVOT GROOVED 18 COVER/RIGHT 27 WASHER/FLAT
Fig. 9-26 Exploded view of the restraint bar.

Restraint Bar Switch Removal and

Installation
Removal Procedure
WARNING
Rubber Stop BEFORE beginning this service procedure,
Fig. 9-27 Location of the restraint bar switch on the right
rear inside of the restraint bar assembly. 1. Remove restraint bar assembly per the procedure in
the Mainframe chapter.
2. Remove two washers and hex nuts that secure
restraint bar switch to pivot assembly bracket. Figs.
9-27, 9-28, 9-29
3. Remove switch from bracket.
Restraint Bar Switch
WARNING
DO NOT attempt to operate loader without the
restraint bar switch installed.
Pivot Assembly Bracket Installation Procedure - Follow all warnings first,

Fig. 9-28 View of switch orientation on the pivot * Adjust position of restraint bar switch and actuator so
assembly. they are aligned with each other when restraint bar is
down against the rubber stops.
ELECTRICAL
* Install restraint bar according to procedure in the
Mainframe chapter.
Fig. 9-29 Remove two hex nuts and washers on restraint

bar switch securing the switch to the pivot
assembly bracket.

Engine Disconnect Switch - Remote

Battery Terminal Removal and Installation
Battery
Gehl 40 Series skid-steer loaders have, as an option, an
electrical engine disconnect switch located underneath
Switch Plate Jam Nut
the battery at the rear of the loader.
Removal Procedure
Switch Plate
WARNING
q Shut off the engine. Fig. 9-30 Location of screw securing the disconnect
switch knob to the switch.
q Turn engine disconnect switch to OFF.
1. Raise engine access cover and lock open the rear

grille.
2. On switch, find a small screw securing switch knob
to the switch. Remove screw from switch and
remove knob. Fig. 9-30
3. Remove switch plate jam nut securing switch plate
and switch into mounting hole. Fig. 9-30
4. Unbolt capscrews and locknuts securing disconnect
switch to the battery tray. Fig. 9-30
5. On back of disconnect switch, remove two nuts
Fig. 9-31 A hand or socket wrench can be used to remove
attaching cables. Pull disconnect switch rearward the engine disconnect switch cables from the
and out of loader. Fig. 9-31 engine disconnect assembly.
NOTE: Keep a record of the cable connections for
reinstallation.


Electrical Lights Components
11
10
8
6
6
3 4 8
3 5
3 2
12
3
3 2
5
9 2
13 3
4
1
9
1
ELECTRICAL
7
1 TIE/WIRE 8 LAMP/TAIL NO BEZEL

2 CLAMP 9 GROMMET/PANEL FASTENER
3 NUT/LOCK 10 LIGHT/DOME
4 CLIP/SINGLE 11 SCREW/PHILLIPS
5 CLIP/DOUBLE 12 CLIP/MIDDLE
6 LAMP/WORK NO BEZEL 13 HARNESS/REAR LIGHTS
7 LAMP/WORK BEZEL
Fig. 9-32 Exploded view of the electrical lights.

Front Work Light Bulb Replacement

Removal Procedure
WARNING
1. Remove four screws on work light. Fig. 9-33 Fig. 9-33 Location of four screws securing front work light
to ROPS.
2. Detach the electrical connector.
3. Release bulb retaining clip and remove bulb. Figs.
9-34, 9-57
IMPORTANT
Halogen bulbs SHOULD NOT be touched with
bare fingers; they can fail prematurely. Wear
clean gloves or use a clean rag if you must
handle the halogen bulbs.
4. Replace the used 55 W H3 bulb with the new 55 W

H3 bulb.

then reverse the removal steps. Fig. 9-34 Release bulb retaining clip to get at the halogen
bulb.
Rear Work Light Bulb Replacement

Removal Procedure
WARNING
1. Raise engine access cover. Fig. 9-36

2. Detach electrical connector on halogen bulbs. Fig. 9-35 Halogen bulb removed from the work/tail light.
3. Release bulb retaining clip and remove bulb. Figs.
9-34, 9-35

IMPORTANT
Halogen bulbs SHOULD NOT be touched with
bare fingers; they can fail prematurely. Wear
clean gloves or use a clean rag if you must
handle the halogen bulbs.
4. Replace the used bulb (either 55 W H3 bulb in white

lens or 35 W H3 bulb in red lens) with a new H3
bulb.

Fig. 9-36 Rear work lights in the engine access cover.
Cover shown removed from loader for clarity.
Dome Light Bulb Replacement
Removal Procedure
WARNING
1. Climb into ROPS and find dome light assembly on

ceiling of ROPS.
Fig. 9-37 Pop the lens cover off the dome light to gain
access to the bulb. 2. Find notches and pop dome light lens cover out of
recessed base with a flat-tipped screwdriver. Fig.
ELECTRICAL
9-37
3. Replace used bulb with a new GE168 bulb.

Electrical System Schematic - ROPS/FOPS
LEFT STROBE RIGHT

FRONT RADIO DOME FRONT
WORK (OPT) LIGHT
(OPT) LIGHT WORK
LIGHT 1 2 3 LIGHT
0 BK 43 OR 0 BK 0 BK 0 BK 0 BK
11 RD 11 RD 43 OR
16 RD
2 RD
5 RD 2 RD
29 YL 12 RD 86 87
+
33 PK 20 BR
85 30
86 87 86 87 -
+ 87a + 87a
7 RD
0 BK
#1 #2
85 30 85 30
- - HOURMETER
0 BK 0 BK 35 BU
34 YL 0 BK
21 GN
9 52 WH
ROPS ELECTRICAL 12 RD
8 14 PU SCHEMATIC 12 RD
(I)
0 BK
33 PK FUEL
6 7 31 OR
S
29 YL 2 6 40 GY 25 BR
12 RD
51 RD SAFETY
5 3 10 WH
INTERLOCK
36 BU 1 CONTROL 4 17 GN
MODULE 12 RD 0 BK
15 BR (I)
3 10 4 BU ENG TEMP
37 GN 4 5 30 PU S
22 GN
1 12 RD
2 0 BK
12 RD 12 RD
FILTER
BELT
SEAT
AIR
19 WH 15 BR
12 RD 12 RD
TEMP
ENG
PSI
OIL
31 OR 14 PU
CONTROL
2 SPEED
12 RD 12 RD 12 RD 12 RD
FILTER
HIGH
RIDE
HYD
BATT
23 OR 24 BU 32 GN 34 YL
12 RD 12 RD 12 RD 12 RD
FLOAT
BRAKE
GLOW
PARK
TEMP
HYD
37 GN 87 TN 40 GY 4 BU
LIGHT SW
11 RD 1
PARK BRAKE
48 WH 6
SWITCH
43 OR 5
30 PU 3
3
42 GN 2
2 12 RD 11 RD 4
FLASHER
[ OPT. ]
IGNITION SW
50 WH
5 RD AC
48 WH
OFF
20 BR 17 ON
ST
CB4 KEYED POWER SEAT RESTRAINT 2 RD 30
BAR
A 13 RD SWITCH
SWITCH
B B A
0 BK
10 WH
12 RD
17 GN
12 RD
CB3 KEYED POWER CB 1

12 RD 7 RD
20
A 16 RD
B ROPS
GROUND CB 2
0 BK 11 RD 7 RD
30
0 BK
ACCESSORY CB 3
PLUG 16 RD 7 RD
20
0 BK 16 RD CB 4
13 RD 7 RD
20
TO EU LIGHTS
11 RD A
0 BK B
TO WIPER/WASHER/
DOOR SWITCH
16 RD
A
52 WH B
0 BK C
32 GN
22 GN
21 GN
42 GN
19 WH
50 WH
23 OR
31 OR
43 OR
40 GY
51 RD
13 RD
24 BU
36 BU
35 BU
14 PU
25 BR
87 TN
34 YL
4 BU
NC
NC
NC
NC
2 RD
2 RD
0 BK
0 BK
18
23
17
24
11
10
16
22
21
20
19
15
12
13
14
6
5
4
7
3
1
2
9
A B A B
2 PIN 2 PIN
METRIPACK 480 METRIPACK 480
TOWER TOWER
24 PIN
DEUTSCH PLUG
DRC 16-24SA

Electrical System Schematic - Chassis
24 PIN
DEUTSCH FLANGE RECEPTACLE
DRC 12-24PA
2 PIN 2 PIN
METRIPACK 480 METRIPACK 480
SHROUD SHROUD
A B A B
2 RD
2 RD
18
23
17
24
11
10
16
22
21
20
19
15
12
13
14
0 BK
0 BK
6
5
4
7
3
1
2
9
8
32 GN
22 GN
19 WH
21 GN
42 GN
23 OR
31 OR
50 WH
40 GY
43 OR
NC
NC
NC
51 RD
13 RD
24 BU
14 PU
25 BR
36 BU
35 BU
86 TN
34 YL
4 BU
NC
CHASSIS ELECTRICAL
SCHEMATIC
RIDE/ 1 39 YL
FLOAT
CONTROL
2 0 BK LEFT CONTROL RIGHT CONTROL
SOLENOID
HANDLE SWITCHES HANDLE SWITCHES
RIDE/ 1 39 YL
FLOAT
CONTROL 2 0 BK 13 RD 1 4 26 WH 13 RD 1 4 85 PK 85 PK
SOLENOID RD BK RD BK ELECTRIC
FLOAT
RIDE 1 86 BR 85 PK
ENABLE
CONTROL 2 RD 2 3 6 OR 13 RD 2 3 27 GY
0 BK GY BU GY BU
SOLENOID 2
KEYED POWER
A 13 RD
B 0 BK
40 GY
HYD TEMP
38 PU SWITCH
2 SPEED 1
SOLENOID 2 0 BK
13 RD A BACKUP 49 GN A BACKUP
ALARM ALARM
SWITCH 49 GN B SWITCH
PARK 1 36 BU 49 GN B
(OPT) (OPT)
35 BU A
AUX HYD
BRAKE
0 BK 0 BK B SPOOL
SOLENOID 2 LOCK
HYD 1 35 BU 35 BU 1 HIGH
TILT FLOW
0 BK 0 BK 2 SPOOL
SOLENOID 2 LOCK
35 BU 1 HYD
LIFT
0 BK 2
13 RD 5 SOLENOID
7 24 BU
26 WH 6 2 SPEED SHIFT, 8 86 BR
13 RD 1 4 44 PK
27 GY 3 RIDE CONTROL & 9 39 YL GLOW
FLOAT CONTROL 41 YL 2 CONTROL 5 4 BU 32 GN HYD FILTER
6 OR 85 PK 4 MODULE 2 86 TN RESTRICT
13 RD 3 MODULE SWITCH
2 RD (OPTION) 6 0 BK (OPT)
23 OR 11 10 NC
38 PU 12 1 0 BK
86 87
+ 87a
HORN
RELAY
#1
85 30
-
0 BK
8 OR
STARTER RELAY
GLOW RELAY 21 GN 0 BK
GLOW
BREAKER
44 PK 86 87 2 RD 2 RD 1 RD S
+
HORN 50 AMP I 41 YL
0 BK - 3 BU 1 RD S WH
85 30
MASTER
BREAKER
2 RD 1 RD
25 BR
FUEL 50 AMP
ELECTRICAL
SENDER 0 BK
14 PU LOW GLOW
AIR ELEMENT
FILTER A 19 WH OIL
PRESSURE 3 BU
RESTRICT SWITCH
SWITCH B 0 BK
(OPT)
S WH
31 OR I
ENGINE
TEMP 1 RD
22 GN SWITCH STARTER
AND
TEMP
SENDER
RED BATTERY CABLE
+ -
BATTERY 51 RD 1 FUEL
SHUTOFF
0 BK 2
SOLENOID
BLACK BATTERY CABLE
W
BATTERY 0 BK
DISCONNECT 21 GN EXTRA D+
SWITCH START
34 YL
(OPT) BLACK BATTERY CABLE FUEL
ALTERNATOR
SOLENOID B+
ENGINE 1 RD
GROUND
RED BATTERY CABLE
TO FLASHERS
50 WH A
0 BK B
43 OR
43 OR
42 GN
49 GN
42 GN
0 BK
0 BK
0 BK
0 BK
0 BK
REAR A B REAR
TAIL WORK BACKUP WORK TAIL
LIGHT ALARM LIGHT
LIGHT (OPT) LIGHT

HVAC Schematic
YELLOW
RED ORANGE
L M H
FAN SPEED
B C SWITCH
RED
BLUE
HEAT OFF AC
AC/HEATER
PRESET COLD SWITCH
CONTROL SWITCH
IN HEATER HOUSING
RED
BLUE
BLUE B BLUE TO 12VDC KEYED
B RED A
BLUE A A
BLUE A #16 RED POWER IN RIGHT
BLACK B B BLACK INSTR PANEL
(CIRCUIT BREAKER 3)
2 PIN WEATHERPACK
CONNECTOR PAIR AT 2 PIN WEATHERPACK
HEATER HOUSING CONNECTOR PAIR IN
LEFT INSTR PANEL
BLACK
WHITE
BLUE
RED
ORANGE
YELLOW
BLACK
RED
C
A
D
C
D
A
B
4 PIN WEATHERPACK
CONNECTOR PAIR AT
HEATER HOUSING 4 PIN WEATHERPACK
CONNECTOR PAIR AT
HEATER HOUSING HIGH SPEED
BLOWER FUSE
RED RED
+ TO BATTERY
40 AMP BLACK TERMINAL
C
D
A
B
- POSTS
C
D
A
BLACK
B
RED
WHITE
BLUE
QUICK DISCONNECT
YELLOW
BLACK
ORANGE
RED
TERMINAL PAIR AT
HEATER HOUSING
RED
BLUE BLUE
86 87
+ 87a
COMPRESSOR HIGH SPEED
MAGNETIC BLOWER RELAY
85
- 30
CLUTCH BINARY PRESSURE
SWITCH IN
ACCUMULATOR/DRYER BLACK
BRIDGE -
RED
AC
RECTIFIER
PACKAGE AC
+
YELLOW
RED
BLACK B B BLACK
BLUE A A RED ORANGE BLACK
L M H
2 PIN WEATHERPACK
CONNECTOR PAIR AT RESISTOR BLOCK BLOWER MOTOR
CONDENSOR HOUSING IN HEATER HOUSING IN HEATER HOUSING
WHITE
86 87 BLACK
+ 87a
CONDENSOR ELECTRIC ENG
FAN RELAY NC
BLACK BLUE COOLANT FLOW
85
- 30 RED CONTROL VALVE
BLACK
FAN MOTOR
CONDENSOR
IN CONDENSOR
FAN FUSE
HOUSING RED RED TO BATTERY
+
TERMINAL
40 AMP
POST

Heater Schematic
L M H FAN SPEED
SWITCH
B C
RED #16 RED TO 12VDC

A A KEYED POWER
BLACK GROUND (CIRCUIT
B B
BREAKER 3)
2 PIN WEATHERPACK
CONNECTOR PAIR IN
LEFT INSTR PANEL
ORANGE
YELLOW
BLACK
RED
C
D
A
B
4 PIN WEATHERPACK
CONNECTOR PAIR AT
HEATER HOUSING
HIGH SPEED
BLOWER FUSE
RED RED
+ TO BATTERY
40 AMP TERMINAL
BLACK POSTS
-
C
D
A
B
ORANGE
RED
QUICK DISCONNECT
BLACK
YELLOW
TERMINAL PAIR AT
HEATER HOUSING
ELECTRICAL
RED
86 87
+ 87a
HIGH SPEED
BLOWER RELAY
85 30
-
AC -
BRIDGE
RED
RECTIFIER
PACKAGE
+ AC
YELLOW
RED
ORANGE BLACK
L M H
RESISTOR BLOCK BLOWER MOTOR

IN HEATER HOUSING IN HEATER HOUSING

NOTES

40 SERIES ENGINE
Introduction
This chapter covers troubleshooting, removal, engine. If Gehl parts are required, they can be ordered
installation, and adjustment procedures for engine from the Gehl Company.
components on Gehl 40 Series skid-steer loaders. The
primary engine system components are shown below
and on following pages. The following troubleshooting guide lists potential
The skid loaders are equipped with either a Deutz engine problems, as well as possible causes and
F3M2011F/F4M2011F naturally-aspirated diesel or a remedies, for Gehl 40 Series skid-steer loaders.
Deutz BF3M2011F/BF4M2011F turbocharged diesel When a problem occurs, don’t overlook simple causes.
engine. The three-cylinder engines are 142 cubic inch A malfunction could be caused by something as simple
displacement (2,3 L) engines. The four-cylinder engines as an empty fuel tank. After a mechanical failure has
are 190 cubic inch displacement (3,1 L) engines. The been corrected, be sure to locate the cause of the
non-turbo engine compression ratio is 18.5:1 and the problem. For further troubleshooting information, refer
turbo engine compression ratio is 17.5:1. The to the engine manufacturer’s manual.
three-cylinder engines are direct injection four-stroke
engines with a firing order of 1, 2, 3. The four-cylinder
engines are direct injection four-stroke engines with a
firing order of 1, 3, 4, 2.
IMPORTANT
A “full-flow” oil filter is used in the lubrication system. DO NOT attempt to service or repair major
As in any engine, clean oil, fuel, and air are critical to components, such as the fuel injector pump,
satisfactory performance and long engine life. If unless authorized to do so by your Gehl
properly maintained, this engine will provide thousands dealer. Any unauthorized repair will void the
of hours of trouble-free operation. warranty.
When ordering engine parts, always check the Gehl
Parts Manual to see if a special part has been fitted to the
Starter will not crank engine Battery terminals or cables corroded Clean battery terminals and cables
or loose. and secure them tightly.
Battery discharged or defective. Recharge or replace battery.
Starter solenoid not functioning. Troubleshoot circuit per wiring

diagrams to locate trouble and repair
or replace starter solenoid.
Seat switch or restraint bar switch Sit on seat and lower restraint bar; if
malfunctioning. engine still doesn’t start, troubleshoot
circuit and replace faulty switch as
needed.
ENGINE
Wiring to and from ignition, seat Check wiring for poor connections or
switch, restraint bar switch, etc. is broken leads and repair wiring or
loose or disconnected. connection.
Starter or pinion faulty. Remove starter and repair or replace

as needed.
Engine turns over but will not Engine cranking speed too slow. Battery requires recharging or
start. 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,

(below 81° F - (27°C)) replace as needed.

ENGINE 40 SERIES

Engine turns over but will not Fuel shutoff solenoid not energizing. Check electrical connections and
start. voltage to shutoff solenoid.
Engine oil not warm enough. Cycle glow plug; check glow plug
wiring connections.
Ambient temperature is 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.
High-flow or 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 stop,
restricted. remove blockage or restriction.
Fan shroud improperly positioned. Perform “Fan Shroud Adjustment”

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 is restricted. Replace the filter(s).
Oil cooler flow restricted. Flush cooler inside and out.

40 SERIES ENGINE
Engine Components - SL4640 3-Cylinder, Turbocharged and Naturally Aspirated
25
12
MOUNT SUPPLIED WITH ENGINE 17
12
20 11
22
33 TORQUE 110 FT-LBS
34
13
TORQUE 108 FT-LBS
SEE NOTE 3 34
2
13
13
TO SUPPORT ASSEMBLY- 27
ORIENTATION AS SHOWN
(REF TANDEM PUMP) 35 21
14 TORQUE 110 FT-LBS 2
10
13 6
TORQUE 14 FT-LBS
31 SEE NOTE 3 37 16
12 MOUNT SUPPLIED WITH ENGINE
TORQUE 110 FT-LBS
33
15
12 9
2 26 13
SEE NOTE 1
TORQUE 28 FT-LBS
29
39 13 34 TORQUE 108 FT-LBS
SEE NOTE 3
SEE NOTE 3
32 2 35 TORQUE 110 FT-LBS
SEE NOTE 3 NOTES 1,5 27
40 19 SEE NOTE 4
38
TORQUE 55 FT-LBS 2
SEE NOTE 3 32 18 28
32 36 SEE NOTE 1 2
12 SEE NOTE 1
4 7
24 30
32 5 SEE NOTE 2
TORQUE 28 FT-LBS
32 SEE NOTE 3 8
NOTES: 1
40 3
TORQUE 55 FT-LBS 1. DO NOT OVERTIGHTEN
12 SEE NOTE 3
2. APPLY PIPE THREAD SEALANT
MOUNT SUPPLIED WITH ENGINE 3. APPLY LOCTITE 242
35 4. RE-USE COPPER WASHER SUPPLIED
12 TORQUE 110 FT-LBS WITH DEUTZ ENGINE OIL DRAIN PLUG
5. LOOM/SLEEVE FUEL LINE-REF ENGINE MOUNT
23
33
TORQUE 110 FT-LBS
12
1 CLAMP/HOSE 15 HOUSING/FLYWHEEL 29 HOSE/FUEL

2 CLAMP/HOSE 16 COUPLING/FLYWHEEL 30 FITTING/90°
ENGINE
3 TIE/NYLON 17 FAN/17” 31 SCREW/CAP
4 CLAMP/TUBE 18 FILTER/IN-LINE FUEL 32 SCREW/CAP
5 HOSE/FUEL 19 SLEEVE/NYLON 33 SCREW/CAP
6 HOSE/FUEL 20 STARTER 34 SCREW/CAP
7 PLUG 21 BRACKET/MOUNT RIGHT 35 SCREW/CAP
8 NUT/LOCK 22 ENGINE/DEUTZ 3-CYLINDER 36 SCREW/CAP
9 FILTER/OIL 23 SUPPORT/MOUNT 37 SCREW/CAP
10 FILTER/FUEL 24 SUPPORT 38 WASHER/LOCK
11 BELT/FAN 25 ALTERNATOR 39 SCREW/CAP
12 NUT/LOCK 26 BRACKET/MOTOR MOUNT 40 SCREW/CAP
13 WASHER/FLAT 27 HOSE/FUEL
14 SUPPORT/PUMP 28 HOSE/OIL DRAIN
Fig. 10-1 Exploded view of the three cylinder turbocharged and naturally-aspirated engine.

ENGINE 40 SERIES
Engine Components - SL4840 and SL5640 4-Cylinder, Naturally Aspirated
21
19
20 15
35
9
30 12
35
14 33 SEE NOTE 1 6
3
34 3 3
3
13
33
35 10
6
SEE NOTE 5 37 28
4 25
SEE NOTE 3 7 11
18
32 23 3 SEE NOTE 1
SEE NOTE 6 3 17
7
SEE NOTE 4 & 5 31 SEE NOTE 1
SEE NOTE 3
4
36
SEE NOTE 7
24 36
SEE NOTE 3 7 9
1 3
4 2 SEE NOTE 1 26
SEE NOTE 2
36 SEE NOTE 3
27 31 SEE NOTE 4 & 5 7 32 SEE NOTE 6
4
16
29
SEE NOTE 6 32
4 8
2 36
2
4 4
22 NOTES
29 36
29
1. DO NOT OVERTIGHTEN
ENGINE RPM SPECIFICATIONS SEE NOTE 6 32 4
2 2. PIPE THREAD SEALANT
1. LOW IDLE (NO LOAD) 1000 50 RPM
2. HIGH IDLE (NO LOAD)2778 RPM REF. 3. 110 FT-LBS.
29
3. EU UNITS ONLY - HIGH IDLE 2600 25 RPM 4. APPLY LOCTITE 242
5. 28 FT-LBS
6. 108 FT-LBS
7. RE-USE COPPER WASHER SUPPLIED
WITH DEUTZ ENGINE OIL DRAIN PLUG
1 CLAMP 20 ENGINE/DEUTZ
2 MOUNT/ISOLATOR 21 ALTERNATOR
3 CLAMP/HOSE 22 PLATE/MOTOR REAR
5 CLAMP/HOSE 24 MOUNT/MOTOR FRONT
6 HOSE/FUEL 25 HOSE/FUEL
7 NUT/HEX 26 FITTING/BARB
8 PLUG 27 SCREW/SET
10 FILTER/ENGINE OIL 29 BOLT/SQUARE NECK
11 FILTER/FUEL 30 SCREW/CAP
12 BELT/FAN 31 SCREW/CAP
13 STARTER 32 SCREW/CAP
14 HOUSING/FLYWHEEL 33 SCREW/CAP
15 COUPLING/FLYWHEEL 34 SCREW/CAP
16 FAN/17” BREEZA 35 WASHER/LOCK
17 HOSE ASSEMBLY/OIL DRAIN 36 WASHER/LOCK
18 HOSE/FUEL 37 SCREW/CAP
19 FILTER/IN-LINE FUEL
Fig. 10-2 Exploded view of the four cylinder naturally-aspirated engines.

40 SERIES ENGINE
Engine Components - SL5640 and SL6640 4-Cylinder Turbocharged
20 22
NOTES
12
1. DO NOT OVERTIGHTEN
18
2. PIPE THREAD SEALANT
3. 110 FT-LBS. 19
4. APPLY LOCTITE 242
5. 28 FT-LBS
6. 108 FT-LBS
7. RE-USE COPPER WASHER SUPPLIED
WITH DEUTZ ENGINE OIL DRAIN PLUG
5
35 PART 081841, 137794, & 186068
MAY BE SUPPLIED WITH THE ENGINE
30 9
ENGINE RPM SPECIFICATIONS
1. LOW IDLE (NO LOAD) 1000 50 RPM
2. HIGH IDLE (NO LOAD) 2778 RPM REF.
3. EU UNITS ONLY - HIGH IDLE 2600 25 RPM 6
14 3
35
34
25 3 3
13 SEE NOTE 133
28
35 33 17 11
SEE NOTE 5 37
3 10
SEE NOTE 3 7
3 23 3 SEE NOTE 1
32 4 SEE NOTE 1
SEE NOTE 6 16
7
SEE NOTE 3
SEE NOTE 3 7
36 4 SEE NOTE 7
4 26
31 24 36 9
1 SEE NOTE 2
2 3 SEE NOTE 1
36
32 SEE NOTE 6
31 SEE NOTE 4 & 5 4
27 29 32 SEE NOTE 6 15
36
SEE NOTE 4 & 5 SEE NOTE 6 32 4
8
2
2 4
36 21
4 29
29
2
SEE NOTE 632 4
29
1 CLAMP 20 ALTERNATOR
2 MOUNT/ISOLATOR 21 PLATE/MOTOR REAR
3 CLAMP/HOSE 22 FAN/19" CROWLEY
5 CLAMP/HOSE 24 MOUNT/MOTOR FRONT
6 HOSE/FUEL 25 HOSE/FUEL
7 NUT/HEX 26 FITTING/BARB
ENGINE
8 PLUG 27 SCREW/SET
10 FILTER/ENGINE OIL 29 BOLT/SQUARE NECK
11 FILTER/FUEL 30 SCREW/CAP
12 BELT/FAN 31 SCREW/CAP
13 STARTER 32 SCREW/CAP
14 HOUSING/FLYWHEEL 33 SCREW/CAP
15 COUPLING/FLYWHEEL 34 SCREW/CAP
16 HOSE ASSEMBLY/OIL DRAIN 35 WASHER/LOCK
17 HOSE/FUEL 36 WASHER/LOCK
18 FILTER/IN-LINE FUEL 37 SCREW/CAP
19 ENGINE/DEUTZ
Fig. 10-3 Exploded view of the four cylinder turbocharged engine.

ENGINE 40 SERIES
Air Cleaner and Exhaust Components - SL4640 Naturally Aspirated

CLAMP FURNISHED
WITH HOOD
INSTALLED ON INCLUDES:
ENGINE COVER 135261
135263
L99453
L99967
GASKET & HARDWARE

FURNISHED WITH ENGINE
27 13
26
FIBERGLASS WASHER ON TOP

6 OF MUFFLER FLANGE AND ON
TOP OF ISOLATOR MOUNT
2
DETAIL A
30
16
1
4
14 11 DETAIL B
8
B
12
5
A 28
26 4
23 27 22
NOTE B
20 15 NOTE B
3
29
21 2
25
15
20 19
25
17 10
18
24
NOTE A: ALL INTAKE COMPONENTS; SLEEVES, TUBES, 31

AND ELBOWS MUST BE ASSEMBLED SUCH THAT
ADJOINING FACES ARE PARALLEL, TIGHT, AND
SURFACE TO SURFACE. ASSEMBLE ALL COMPONENTS
PRIOR TO TIGHTENING CLAMPS. INSTALLATION
MUST ACHIEVE AIR TIGHT SEALS. 32
NOTE B: PIPE SEALANT REQUIRED (NO LOCK-TITE)
1 NUT/SERRATED LOCK 12 SLEEVE/REDUCER INLET 23 MUFFLER/SPARK ARRESTOR

2 NUT/SERRATED LOCK 13 HOOD/AIR INLET 24 ELBOW/INTAKE 90°
3 CLAMP/MUFFLER 14 HOSE/AIR INTAKE 25 CLAMP/T-BOLT
4 CLAMP/HOSE 15 CLAMP/HOSE 26 PLATE/HEAT SHIELD
5 CLAMP/HOSE 16 TUBE/FLANGED 90° 27 WASHER/FIBERGLASS
6 ISOLATOR 17 TUBE/FLEX EXHAUST 28 GAUGE/RESTRICTION
7 FILTER/AIR CLEANER 18 COBRA 4” 29 SCREW/CAP
8 CLAMP/FILTER 19 SLEEVE/INTAKE REDUCER 30 SCREW/PHILLIPS
9 COVER/ASSEMBLY 20 SLEEVE/INTAKE 31 FILTER ELEMENT/PRIMARY
10 EJECTOR/DUST 21 TUBE/INTAKE 32 FILTER ELEMENT/SECONDARY
11 TUBE/AIR CLEANER ELBOW 22 ADAPTOR 90°
Fig. 10-4 Exploded view of the SL4640 naturally aspirated engine air cleaner and exhaust components.

40 SERIES ENGINE
Air Cleaner and Exhaust Components - SL4640 Turbocharged
CLAMP FURNISHED
WITH HOOD
INSTALLED ON
ENGINE COVER
NOTE A: ALL INTAKE COMPONENTS; SLEEVES, TUBES,

INCLUDES SURFACE TO SURFACE. ASSEMBLE ALL COMPONENTS
135261 PRIOR TO TIGHTENING CLAMPS. INSTALLATION
MUST ACHIEVE AIR TIGHT SEALS.
BOLT TO ENGINE 135263
USE EXISTING L99453 NOTE B: PIPE SEALANT REQUIRED (NO LOCK-TITE)
HARDWARE L99967 NOTE C: VERIFY AND ESTABLISH FAN CLEARANCES
GASKET AND HARDWARE
FURNISHED WITH ENGINE 9
3
33
26 33
17 32 32
33
9
3 9
3 DETAIL A
A 5 37 15
32
33 11
16
10 3
2
21 NOTE B 6
5 35
18 24
19
4 8
NOTE C
31
25 36
NOTE B
12
20
27 23
29
7
31 20
13
22 14
28 NOTE C
30
7
38
13
34
39
1
1 CLAMP/HOSE 14 EJECTOR/DUST 27 TUBE/FLEX EXHAUST
ENGINE
2 NUT/SERRATED LOCK 15 TUBE/AIR CLEANER 28 TUBE/TURBO PORT
3 NUT/SERRATED LOCK 16 SLEEVE/REDUCER INLET 29 TUBE/INTAKE
4 CLAMP/MUFFLER 17 HOOD/AIR INLET 30 TUBE/INTAKE
5 CLAMP/HOSE 18 HOSE/AIR INTAKE 31 CLAMP/T-BOLT
6 CLAMP/HOSE 19 ELBOW/COBRA 90° 32 PLATE/HEAT SHIELD
7 CLAMP/HOSE 20 CLAMP/HOSE 33 WASHER/FIBERGLASS
8 CLAMP/MUFFLER 21 TUBE/FLANGED 90° 34 BAR/INTAKE SUPPORT
9 ISOLATOR 22 COBRA 4” 35 GAUGE/RESTRICTION
10 FILTER/AIR CLEANER 23 SLEEVE/INTAKE REDUCER 36 SCREW/CAP
11 CLAMP/FILTER 24 SLEEVE/INTAKE 37 SCREW/PHILLIPS
12 COVER 25 ADAPTOR 90° 38 FILTER ELEMENT/PRIMARY
13 HOSE/COUPLING 26 MUFFLER/NON-ARRESTING 39 FILTER ELEMENT/SECONDARY
Fig. 10-5 Exploded view of the SL4640 turbocharged engine air cleaner and exhaust components.

ENGINE 40 SERIES
CLAMP FURNISHED
WITH HOOD
INSTALLED ON
ENGINE COVER
INCLUDES:
135261
135263
L99453
L99967
DETAIL A
REFERENCE FILTER BRACKET

ON RIGHT SIDE OF FRAME
GASKET AND HARDWARE

FURNISHED WITH ENGINE
REFERENCE INTAKE &

EXHAUST MANIFOLDS
ISOLATOR
FIBERGLASS WASHER ON TOP
OF MUFFLER FLANGE AND ON
FILTER MOUNT TOP OF ISOLATOR MOUNT REFERENCE BRACKET ON
LEFT SIDE OF FRAME
MUFFLER
ASSEMBLE HEX NUT

TOWARDS OUTSIDE
11 9
DETAIL A
31
26
17
27 12
32
13
10
30
6 16
4 8
14 4 2 5
3
2
1
FILTER BRACKET
28
NOTE B
23
29
18
22
15 7 NOTE A: ALL INTAKE COMPONENTS; SLEEVES, TUBES,

20 AND ELBOWS MUST BE ASSEMBLED SUCH THAT
19 SURFACE TO SURFACE. ASSEMBLE ALL COMPONENTS
25 MUST ACHIEVE AIR TIGHT SEALS.
NOTE B: PIPE SEALANT REQUIRED (NO LOCK-TITE)
25
21
24
15
1 NUT/SERRATED LOCK 12 SLEEVE/REDUCER INLET 23 ADAPTER/90°

2 NUT/FLANGED LOCK 13 HOOD/AIR INLET 24 ELBOW/90°
3 CLAMP/MUFFLER 14 HOSE/AIR INTAKE 25 CLAMP/T-BOLT
5 CLAMP/HOSE 16 TUBE/FLANGED 90° 27 WASHER/FIBERGLASS
6 ISOLATOR 17 MUFFLER/ARRESTOR 28 GAUGE/RESTRICTION
7 FILTER/AIR CLEANER 18 TUBE/FLEX EXHAUST 29 SCREW/CAP
8 CLAMP/FILTER 19 INTAKE/ADAPTOR 30 SCREW/PHILLIPS
9 COVER 20 REDUCER SLEEVE/INTAKE 31 FILTER ELEMENT/PRIMARY
10 EJECTOR/DUST 21 SLEEVE/INTAKE 32 FILTER ELEMENT/SECONDARY
11 TUBE/AIR CLEANER 22 TUBE/INTAKE
Fig. 10-6 Exploded view of the SL4840 naturally-aspirated engine air cleaner and exhaust components.

40 SERIES ENGINE
DETAIL B
CLAMP FURNISHED
WITH HOOD
INSTALLED ON
ENGINE COVER
INCLUDES:
135261
135263
L99453
L99967
DETAIL A
REFERENCE FILTER BRACKET REFERENCE BRACKET ON

ON RIGHT SIDE OF FRAME LEFT SIDE OF FRAME
GASKET AND HARDWARE ASSEMBLE HEX NUT

FURNISHED WITH ENGINE TOWARDS OUTSIDE 9
DETAIL A
REFERENCE INTAKE &
EXHAUST MANIFOLDS
31
DETAIL B
23
13 32
10
16
11
30
4
12 8
26 1
27 5 7
6
2
4
3 2
28
21
29
14 NOTE B
22
19
NOTE A: ALL INTAKE COMPONENTS; SLEEVES, TUBES,
15 18 AND ELBOWS MUST BE ASSEMBLED SUCH THAT
SURFACE TO SURFACE. ASSEMBLE ALL COMPONENTS
MUST ACHIEVE AIR TIGHT SEALS.
NOTE A 20 NOTE B: PIPE SEALANT REQUIRED (NO LOCK-TITE)
NOTE C
NOTE C: VERIFY AND ESTABLISH FAN CLEARANCES
25
TO INTAKE NOTE A 17 NOTE A

24
MANIFOLD NOTE C
1 NUT/SERRATED LOCK 17 INTAKE/ADAPTOR

2 NUT/FLANGED LOCK 18 REDUCER SLEEVE/INTAKE
3 CLAMP/MUFFLER 19 SLEEVE/INTAKE
ENGINE
4 CLAMP/HOSE 20 TUBE/INTAKE
5 CLAMP/HOSE 21 ADAPTER/90°
6 ISOLATOR 22 TUBE/EXHAUST FLEX
7 FILTER/AIR CLEANER 23 MUFFLER/ARRESTOR
8 CLAMP/FILTER 24 ELBOW/90°
9 COVER 25 CLAMP/T-BOLT
10 EJECTOR/DUST 26 PLATE/HEAT SHIELD
11 TUBE/AIR CLEANER 27 WASHER/FIBERGLASS
12 SLEEVE/REDUCER INLET 28 GAUGE/RESTRICTION
13 HOOD/AIR INLET 29 SCREW/CAP
14 HOSE/AIR INTAKE 30 SCREW/PHILLIPS
15 CLAMP/HOSE 31 FILTER ELEMENT/PRIMARY
16 TUBE/FLANGED 90° 32 FILTER ELEMENT/SECONDARY
Fig. 10-7 Exploded view of the SL5640 naturally-aspirated engine air cleaner and exhaust components.

ENGINE 40 SERIES
Air Cleaner and Exhaust Components - SL5640 and SL6640 Turbocharged
DETAIL B
CLAMP FURNISHED
WITH HOOD
INSTALLED ON
ENGINE COVER
INCLUDES:
135261
135263
L99453
L99967
DETAIL A
BOLT TO ENGINE
USE EXISTING
HARDWARE
DO NOT TWIST OR
PRELOAD HOSE
REFERENCE FILTER BRACKET

ON RIGHT SIDE OF FRAME
REFERENCE TURBO
INTAKE & EXHAUST
GASKET AND HARDWARE
FURNISHED WITH ENGINE REFERENCE BRACKET ON
LEFT SIDE OF FRAME
ASSEMBLE HEX NUT 10

TOWARDS OUTSIDE
34
DETAIL A
22
DETAIL B
35
14
18
33 11
1
29 12
6 30
E 2 4
28
16 4
NOTE C 8
13 5
3
9
28 2
17
21
15
31
24 NOTE A NOTE B
23
25
NOTE A
26 32
NOTE A NOTE A: ALL INTAKE COMPONENTS; SLEEVES, TUBES,
NOTE A ADJOINING FACES ARE PARALLEL, TIGHT, AND
20 SURFACE TO SURFACE. ASSEMBLE ALL COMPONENTS
7 NOTE C PRIOR TO TIGHTENING CLAMPS. INSTALLATION
19 17 MUST ACHIEVE AIR TIGHT SEALS.
NOTE A NOTE B: PIPE SEALANT REQUIRED (NO LOCK-TITE)
NOTE C 27 NOTE C: VERIFY AND ESTABLISH FAN CLEARANCES
4
BOLT TO ENGINE
CLAMP TO TUBE
1 NUT/SERRATED LOCK 13 SLEEVE/REDUCER INLET 25 TUBE/INTAKE

2 NUT/FLANGED LOCK 14 HOOD/AIR INLET 26 ELBOW/INTAKE
3 CLAMP/MUFFLER 15 HOSE/AIR INTAKE 27 BAR/INTAKE SUPPORT
4 CLAMP/HOSE 16 ELBOW/90° 28 CLAMP/T-BOLT
6 ISOLATOR 18 TUBE/FLANGED 90° 30 WASHER/FIBERGLASS
7 CLAMP/MUFFLER 19 INTAKE/ADAPTOR 31 GAUGE/RESTRICTION
8 FILTER/AIR CLEANER 20 REDUCER SLEEVE/INTAKE 32 SCREW/CAP
9 CLAMP/FILTER 21 SLEEVE/INTAKE 33 SCREW/PHILLIPS
10 COVER 22 MUFFLER/NON-ARRESTING 34 FILTER ELEMENT/PRIMARY
11 EJECTOR/DUST 23 ADAPTER/90° 35 FILTER ELEMENT/SECONDARY
12 TUBE/AIR CLEANER 24 TUBE/FLEX TURBO
Fig. 10-8 Exploded view of the SL5640 and SL6640 turbocharged engine air cleaner and exhaust components.

40 SERIES ENGINE
Oil Cooler Components - SL4640 and SL4840 Naturally Aspirated
17
5
1
5 18
3
9 5
4
19 21
5
21
2 3
1 5
20
3
16 14 1 13
3 12 6 3
7
14 8
15
3 1
10 16
TO ENGINE PORT - FLYWHEEL END
3 TO ENGINE PORT - FAN END

11 14
7 14
22 10 3
11
ENGINE
22
1 FITTING/90° 9 HOSE/PRESSURE 17 SHROUD/TOP

2 FITTING/STRAIGHT 10 NUT/LOCK 18 SEAL/SHROUD
3 SCREW/FLANGE WHIZ LOCK 11 WASHER/FLAT 19 SHROUD/RIGHT
4 COOLER/STACKED 12 SHROUD/FAN 20 SHROUD/LEFT
5 NUT/LOCK 13 PAD/COOLER 21 SEAL/BULB
6 HOSE/PRESSURE 14 SEAL/SHROUD 22 SCREW/CAP
7 SEAL/SHROUD 15 HOSE/PRESSURE
8 HOSE/PRESSURE 16 SUPPORT/SHROUD
Fig. 10-9 Exploded view of the SL4640 and SL4840 naturally-aspirated oil cooler components.

ENGINE 40 SERIES
Oil Cooler Components - SL4640 Turbocharged
17
1
19
8 4
5 4
20
3 18
4
20
2 3
4
1 16
1 3
15 13
3 12
11 6
7 3
13
21
14
3
1
15
9
TO ENGINE PORT - FLYWHEEL END
3 TO ENGINE PORT - FAN END

10 13
7
22 13
9 3
10
22
1 FITTING/90° 10 WASHER/FLAT 19 SEAL/SHROUD

2 FITTING/STRAIGHT 11 SHROUD ASSEMBLY/FAN 20 SEAL/BULB
3 SCREW/FLANGE WHIZ LOCK 12 PAD/COOLER 21 HOSE/PRESSURE
4 NUT/LOCK 13 SEAL/SHROUD 22 SCREW/CAP
5 COOLER/STACKED TURBO 14 HOSE/PRESSURE
7 SEAL/SHROUD 16 SHROUD/LEFT
8 HOSE/PRESSURE 17 SHROUD/TOP
9 NUT/LOCK 18 SHROUD/RIGHT
Fig. 10-10 Exploded view of the SL4640 turbocharged oil cooler components.

40 SERIES ENGINE
Oil Cooler Components - SL5640 and SL6640 Naturally Aspirated
3
13
3
1 15
6
7 3
17
4 14
2 17 3
1
3
12
1
16 5
2
8 1 2
2
11
7 2
2
18
19 1
16
2 TO ENGINE PORT - FLYWHEEL END

10
TO ENGINE PORT - FAN END
9 8
2
19
10
9
ENGINE
1 FITTING/90° 11 PAD/COOLER
2 SCREW/FLANGE WHIZ LOCK 12 SHROUD/LEFT
3 NUT/LOCK 13 SHROUD/TOP
4 COOLER/STACKED TURBO 14 SHROUD/RIGHT
5 SHROUD ASSEMBLY/FAN 15 SEAL/SHROUD
7 HOSE/PRESSURE 17 SEAL/BULB
9 NUT/LOCK 19 BOLT/CARRIAGE
10 WASHER/FLAT
Fig. 10-11 Exploded view of the SL5640 and SL6640 naturally-aspirated oil cooler components.

ENGINE 40 SERIES
Oil Cooler Components - SL5640 and SL6640 Turbocharged
4 12
19
13
4
10
3 4
2 20
17 4
1 4
11
22
3 3
1
2
9 16 6
3
21
3
5 23
3 3 18 1
24 21
15
6 TO ENGINE PORT - FLYWHEEL END
TO ENGINE PORT - FAN END
3
8
8 7
14
24
3
8 7
1 FITTING/90° 13 SEAL/SHROUD
2 FITTING/STRAIGHT 14 SHROUD
3 SCREW/FLANGE WHIZ LOCK 15 SUPPORT/SHROUD
4 NUT/LOCK 16 COVER/SHROUD
5 HOSE/PRESSURE 17 HOSE/PRESSURE
7 NUT/LOCK 19 SHROUD/RIGHT
8 WASHER/FLAT 20 SEAL/BULB
9 SUPPORT/SHROUD 21 SEAL/BULB
10 RADIATOR/COOLER 22 PAD/COOLER
11 SHROUD/LEFT 23 HOSE/PRESSURE
12 SHROUD/TOP 24 BOLT/CARRIAGE
Fig. 10-12 Exploded view of the SL5640 and SL6640 turbocharged oil cooler components.

40 SERIES ENGINE
Oil Filter Element Removal and

Installation
The engine oil filter is attached low to the left side of the
engine. The filter can be replaced without an oil change,
but it is not recommended.
WARNING
device.
Fig. 10-13 Engine oil filter access point behind the left
engine side cover. q Shut off the engine and allow to cool.
Removal Procedure
1. Remove left engine side cover. Fig. 10-13
Fuel Filter
2. On left side of engine find the oil filter element.
Figs. 10-14, 10-15
3. Clean area around oil filter element.
4. Turning counterclockwise, loosen oil filter element
with a filter wrench.
5. Turn filter element by hand until it is free of oil filter
head.
Fig. 10-14 Location of engine oil filter from the access point Installation Procedure
behind the ROPS. 1. Clean oil filter mating surface of any debris before
installing new element.
2. Apply a thin film of oil to seal on filter element
before installing.
3. Hand tighten filter element, turning it clockwise,
until gasket contacts filter mating surface, then turn
ENGINE
element another 3/4 turn to seat gasket.
4. If old oil has been removed also, fill crankcase with:
a. Three-Cylinder Engines: 8.3 qts. (7,9 L) of
oil. (See Lubrication chapter.)
b. Four-Cylinder Engines: 11.5 qts. (10,8 L) of
oil. (See Lubrication chapter.)
5. Start engine and check for leaks near oil filter. Shut
off engine, recheck oil level, and fill as needed.
Fig. 10-15 Side view from front of engine looking back at
the oil filter.

ENGINE 40 SERIES
Air Cleaner Assembly Removal and

Installation
Removal Procedure Cobra
WARNING
Fig. 10-17 Location of hose clamps to loosen at the front of
1. Open the engine access cover and rear grille. the air cleaner.
2. Clean area around the hose connections.
3. Loosen hose clamp securing the 90° elbow to air
filter assembly. Pull elbow with air intake hose off
end of air filter. Cover air cleaner hose opening to
prevent contamination. Figs. 10-16 and 10-17
4. Loosen hose clamp securing Cobra to air cleaner
assembly and pull off assembly. Cover air cleaner
opening to prevent contamination. Fig. 10-17
5. Disconnect bolt and nut on air cleaner spring clamp
to release the air cleaner canister. Fig. 10-18
6. Remove two capscrews and locknuts on filter clamp
attached to welded filter bracket. Fig. 10-19

Fig. 10-18 Unbolt air cleaner spring clamp and remove air
then reverse the removal steps. cleaner canister.
Air Intake Hose

Elbow
Intake Tube
Air Cleaner
Fig. 10-16 View of air cleaner assembly from rear of Fig. 10-19 Unbolt two capscrews and locknuts securing air
skid-steer loader. cleaner clamp to the chassis.

40 SERIES ENGINE
Air Filter Element Removal and

Installation
Spring Clip
Service the air filter element when the restriction gauge
shows in the red zone. The red zone indicates a clogged
air filter. If the gauge shows red with the engine stopped,
Spring Clip
replace the air filter element. After fitting a clean
element, push gauge reset button.
Dust Ejector
WARNING
Fig. 10-20 Pull cover off the air cleaner assembly. q Shut off the engine.
Removal Procedure
1. Open engine access cover and rear grille.
2. Release three spring clips securing cover and
remove cover. Clean out dirt build up in cover
assembly. Fig. 10-20
3. Pull primary and safety air filter from housing. Figs.
10-21, 10-22
4. Replace both air filter elements, if needed. (See
Service chapter of the Operator's Manual.)
5. Check condition of dust ejector. Fig. 10-20
Fig. 10-21 View of the primary filter element.
* Clean mating plastic body for radial seal surfaces. Fig.
10-23
ENGINE
Fig. 10-22 View of the safety filter element inside of the

primary filter element. Fig. 10-23 View of the radial seal surfaces inside the air
canister. Clean mating surfaces for good seals.

ENGINE 40 SERIES
Battery Removal and Installation

Removal Procedure
WARNING
(For detailed instructions, refer to the Safety Negative ( - ) Battery Cable
Fig. 10-24 Disconnect the negative battery cable first, then,

WARNING disconnect the positive battery cable. View is
from front of battery looking back.
Review the following safety considerations
before working on or around the battery.
q Keep sparks and flames away from
battery. Gas given off by the battery’s
electrolyte solution is extremely
explosive.
q Avoid contact with battery electrolyte;
wash off any electrolyte immediately.
q Wear safety glasses when working near
battery.
q Do not tip battery more than 45° to avoid
spilling electrolyte solution.
r To avoid injury from spark or short circuit,
Fig. 10-25 Location of the battery holddown angle.
disconnect negative (-) battery cable
before servicing electrical system.

2. First, disconnect and remove the negative (-) and
then disconnect the positive (+) battery cable from
the battery. Fig. 10-24
3. Remove two locknuts from the battery rods and the
hold down battery angle. Fig. 10-25
4. Slide battery rearward and out of chassis
5. Remove three capscrews securing battery tray to
chassis. Fig. 10-26

Fig. 10-26 Location of three capscrews securing the battery
tray to the chassis.

40 SERIES ENGINE
Starter Removal and Installation

For wiring connections to the starter and solenoid, refer
to the Electrical System chapter of this manual.
Removal Procedure
WARNING
device.
Fig. 10-27 Disconnect wires at the starter solenoid.
1. Disconnect and remove the negative (-) battery

cable from the battery. Fig. 10-24
2. Remove the nut that secures positive (+) battery
cable and two smaller wires (starter wire and main
lead wire) to starter solenoid. Fig. 10-27
3. Remove capscrews securing the starter heat shield
to the engine. Pull shield away from engine to
Plastic Plug release plastic plug from starter solenoid. Fig. 10-28
4. Remove the two capscrews securing the starter to
the engine. Fig. 10-29
Fig. 10-28 Remove capscrews and washers securing starter
heat shield to the engine. 5. Remove the starter from the engine.

Starter
ENGINE
Fig. 10-29 Location of one of two (1 of 2) capscrews

securing the starter/solenoid to the engine.

ENGINE 40 SERIES
Exhaust Assembly Removal and

Installation
Removal Procedure
WARNING
device. Exhaust Tube

(For detailed instructions, refer to the Safety Fig. 10-30 Location of muffler clamp securing muffler to
chapter of this manual.) flexible exhaust tube.
WARNING
Shut off engine. Engine components
may be extremely hot, particularly
engine muffler and exhaust pipes.
Serious injury can occur touching hot Heat Shield
components.
Isolator
2. Loosen muffler clamp securing muffler to flexible
exhaust tube. Fig. 10-30
3. Above the muffler isolators, remove four locknuts
and fiberglass washers at each corner of the muffler. Fig. 10-31 Location of locknut and fiberglass washer to
Fig. 10-31 remove from the muffler.
4. Lift muffler off the muffler support weldment.
5. If needed, remove the heat shield plate next.
6. If needed, remove the isolators from the weldment.
7. If needed, remove three nuts securing the flexible
exhaust tube to the engine. Fig. 10-32

*Tighten the mounting hardware only after checking
alignment of exhaust assembly so tailpipe is centered in
opening on tailgate when closed.
Fig. 10-32 One of three nuts securing the flexible exhaust

tube to the engine.

40 SERIES ENGINE
Fan Belt Adjustment

WARNING
Fig. 10-33 Location of alternator behind the fan shroud and 1. Open the engine access cover and the rear grille.
engine fan blade. Oil cooler removed for clarity.
2. Test fan belt tension by pushing on the belt midway
between the alternator and the engine crankshaft
pulley. The belt should deflect about ½" (13 mm)
under a load of 20 lbs (90 N). If adjustment is
needed, follow steps below.
Fan Belt
3. Loosen two bolts on alternator - one at low pivot
area and one on top in slide bracket. Fig. 10-34
4. Rotate the alternator in a clockwise direction until
correct belt tension is achieved.
5. Retighten bolts.
Fig. 10-34 Location of two capscrews to loosen prior to

adjustment of the fan belt.
ENGINE

ENGINE 40 SERIES
Oil Cooler Removal and Installation

The oil cooler is mounted on a shroud located just
behind the engine.
Removal Procedure
Straight Fitting
WARNING
chapter of this manual.) Fig. 10-35 Location one hydraulic hose at top right of oil
cooler. Turbocharged SL56/6640 connector
shown. All other hoses at this location have 90°
1. If necessary, drain oil from hydraulic reservoir per fittings.
the procedure in the Lubrication chapter.
NOTE: If hydraulic hoses are plugged after removal to
prevent oil leakage, it should not be necessary to drain
hydraulic reservoir. Hydraulic hoses should be plugged
to prevent contaminants from entering hydraulic
system.
3. Disconnect two hydraulic hoses and two engine
hydraulic hoses from the inlets and outlets of the oil
cooler. BE SURE to use two wrenches for this step,
one on the hose fitting and one on the 90° fitting (or
straight fitting), to prevent damage to the oil cooler.
Figs. 10-35, 10-36, 10-37 Fig. 10-36 Location one engine hydraulic hose at lower left
4. Remove four flange whizlock screws securing the of oil cooler.
cooler to the shroud. Figs. 10-38, 10-39

*ALWAYS check for hydraulic fluid leaks after
assembling any components of the hydraulic system.
NOTE: The smaller side of the oil cooler faces the
engine side.
Fig. 10-37 Location one engine hydraulic hose at upper left

of oil cooler.

40 SERIES ENGINE
WARNING
any fluid is injected into your skin, see a doc-
Fig. 10-38 Location of one of the flange screws securing the checking for hydraulic fluid leaks.
oil cooler to the shroud. Escaping fluid under pressure can be
* ALWAYS check for hydraulic fluid leaks after

assembling any components of the hydraulic system.
Fig. 10-39 Location of one of the flange screws securing the

oil cooler to the shroud.
ENGINE

ENGINE 40 SERIES
Fan Shroud Removal and Installation

Removal Procedure
WARNING
Fig. 10-40 Location of four flange whizlock screws

WARNING securing the shroud assembly to the shroud
supports.
DO NOT attempt to service any part of oil
cooler system until engine has been allowed
to cool down. Serious injury may result from
high temperature of oil and water or high
pressure.
1. Remove hydraulic reservoir drain plug and drain

hydraulic oil into a suitable container. Refer to the
procedure in the Lubrication chapter.
NOTE: I f h y d r a u l i c h o s e s a r e p l u g g e d a f t e r
disconnecting to prevent leakage, it should not be
necessary to drain hydraulic reservoir. Hoses should be
plugged after disconnecting to prevent contaminants
from entering hydraulic system.
2. Remove the hydraulic oil cooler per the procedure Fig. 10-41 Location of the carriage bolts, washers and
in this chapter. locknuts securing right shroud support to chassis
floor. SL56/6640 loaders bolt the carriage bolts
3. Remove four flange whizlock screws securing in from the top.
shroud assembly to shroud supports and remove
assembly. Fig. 10-40
4. Unbolt four carriage bolts, hardened washers and
locknuts securing shroud supports to the chassis
floor. Figs. 10-41, 10-42

* BE SURE and uncap/unplug the hydraulic hoses prior
to reconnecting them to the oil cooler.
Fig. 10-42 Location of the carriage bolts, washers and

locknuts securing left shroud support to chassis
floor. SL56/6640 loaders bolt the carriage bolts
in from the top.
40 SERIES ENGINE
Fan Shroud Adjustment

WARNING
Outer Ring of Fan Shroud
Fig. 10-43 View of fan flush with outer ring of the fan 1. Loosen, but do not remove, four carriage bolts and
shroud. locknuts securing shroud supports to chassis. Figs.
10-41, 10-42
2. Loosen, but do not remove, the four flange whizlock
screws on the shroud support connected to the
shroud. Fig. 10-40
3. Slide shroud assembly and mounting brackets and
supports back and forth until front edge of fan
blades (engine side of fan) are flush with outer ring
of fan shroud. Fig. 10-43
4. Partially tighten carriage bolts fastening shroud
support to chassis to secure depth adjustment.
5. Without disturbing shroud depth adjustment, slide
shroud assembly and mounting brackets and
supports sideways until fan is centered horizontally
in shroud. Tighten capscrews and locknuts securing
Fig. 10-44 When the fan blade is properly centered in the shroud support to chassis. Fig. 10-44
fan shroud, the distance from the end of each fan
blade to the shroud should be equal all around. 6. Move shroud assembly up or down until fan is
centered in shroud opening. Fig. 10-44
7. Tighten the four flange lock screws on the fan
shroud sides securing the height adjustment. Fig.
10-40
ENGINE

ENGINE 40 SERIES
Engine Removal and Installation

Fuel Inlet Line
The following procedure allows removal of diesel
engine without removing hydrostatic pump assembly.
Some hydraulic hoses need disconnecting in this
procedure, and if they cannot be capped/plugged to
prevent fluid loss, the hydraulic reservoir should be
Throttle Cable
drained BEFORE disconnecting hydraulic hoses.
Removal Procedure
WARNING
BEFORE beginning this service procedure, Fig. 10-45 Some of the disconnect locations on the engine
perform the following SAFETY procedures: prior to removing the engine from the skid-steer
q Raise liftarm, engage liftarm support loader.
device.
Ground (-) Cables
1. Drain hydraulic oil reservoir (as required).

2. Completely drain fuel tank into a clean approved
container.
3. Remove engine access covers per the procedure in
the Mainframe chapter. Fuel Return Line
4. Remove rear grille per the procedure in the
Mainframe chapter.
Fig. 10-46 Some of the disconnect locations on the engine
NOTE: The following step is not required, but it is
prior to removing the engine from the skid-steer
recommended. loader.
5. Remove the ROPS per the procedure found in the
Mainframe chapter.
6. Remove the battery and battery tray per the
Engine Oil Pan
7. Remove the air cleaner assembly per the procedure
in this chapter.
WARNING Oil Pan Heater

Remote Oil Drain
DO NOT PROCEED with the following steps
unless engine has completely cooled and is
safe to touch.
8. Remove exhaust assembly per the procedure in this Fig. 10-47 Some of the disconnect locations on the engine
chapter.
loader.
9. Remove oil cooler per the procedure in this chapter.
40 SERIES ENGINE
10. Remove fan shroud assembly per the procedure in

Oil Cooler Hose
this chapter.
11. Loosen hose clamp and disconnect and cap fuel
return hose from engine. Loosen hose clamp and
disconnect and cap fuel inlet hose. Figs. 10-46,
Fuel Return Line 10-47, 10-49
12. Remove clevis assembly at fuel injector arm on
engine to disconnect throttle cable. Fig. 10-46
NOTE: The following two steps include 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
Fig. 10-48 Some of the disconnect locations on the engine
Hydraulic System chapter for the procedure.
prior to removing the engine from the skid-steer NOTE: ALWAYS clean area around hydraulic fittings
loader. BEFORE disconnecting any hydraulic hose or tube.
13. Disconnect the following:
a. Remote Oil Drain
b. Hydraulic Lock Solenoids
c. Parking Brake Solenoid
d. Two-Speed Solenoid (optional)
e. Engine Temperature Sensors/Switch
f. Starter
g. Alternator
h. Electrical Engine Panels (2)
i. Fuel Tank Sensor
Fig. 10-49 Some of the disconnect locations on the engine j. Fuel Shutoff Solenoid
loader. k. Hydraulic Temperature/Oil Pressure Switch
l. Hydraulic Oil Filter
m. Ground Cable from Engine to Chassis
n. Instrument Panel Wiring Harness
14. Support weight of pump and support with suitable
ENGINE
blocking material:
a. Three-Cylinder Engines: Remove two
capscrews securing pump to flywheel housing
and four capscrews securing pump support
assembly to flywheel housing
b. Four-Cylinder Engines: Remove two
capscrews securing pump to flywheel housing .
15. Attach lift hooks to engine located on front and rear
Fig. 10-50 Some of the disconnect locations on the engine of head cylinder. Fig. 10-55
loader. 16. Remove one capscrew washer and hex nut (110
ft-lbs) (149 N•m) on four engine mounts. Fig. 10-54

ENGINE 40 SERIES
17. With hoist attached to engine, lift slightly and pull

engine rearward. Continue pulling engine rearward
until pump is free from drive coupling. Then remove
engine from chassis. Fig. 10-55

* If the diesel fuel was drained, add fuel, then bleed the
fuel system according to procedures found in the Deutz
Engine Manual. Also check engine oil and hydraulic oil
levels prior to starting the skid-steer loader.
* Safely check for hydraulic fluid leaks observing the
correct procedure in doing so (refer to Hydraulic System
chapter). Perform the neutral centering adjustment Fig. 10-53 Two of two electrical panels on the skid-steer
procedure found in the Controls chapter. loader. Disconnect all electrical connections
prior to removing the engine.
Fig. 10-51 Some of the disconnect locations on the engine Fig. 10-54 One of four engine mounts to disconnect prior to
prior to removing the engine from the skid-steer removing the engine.
loader.
Fig. 10-52 One of two electrical panels on the skid-steer Fig. 10-55 Location of lift hooks on engine.
loader. Disconnect all electrical connections
prior to removing the engine.

INDEX
A
Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Air Cleaner and Exhaust Components - SL4640 Naturally Aspirated . . . . . . . . . . . . . . . 10-6
Air Cleaner and Exhaust Components - SL4640 Turbocharged . . . . . . . . . . . . . . . . . . 10-7
Air Cleaner and Exhaust Components - SL5640 and SL6640 Turbocharged . . . . . . . . . . . 10-10
Air Cleaner Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Air Duct Louver Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Air Duct Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Air Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
All-Tach Hitch Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
All-Tach, Power-A-Tach Hitch Removal and Installation . . . . . . . . . . . . . . . . . . . . . 4-15
Auxiliary Hydraulics Cable Adjustment - Hand/Foot . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Auxiliary Hydraulics Cable Adjustment - T-Bar and Dual Hand . . . . . . . . . . . . . . . . . . 6-28
Auxiliary Hydraulics Cable Removal and Installation - Hand/Foot. . . . . . . . . . . . . . . . . 6-29
Auxiliary Hydraulics Cable Removal and Installation - T-Bar and Dual Hand. . . . . . . . . . . 6-27
Auxiliary Hydraulics Control - T-Bar and Dual Hand Components . . . . . . . . . . . . . . . . 6-24
Axle and Wheel Bearing Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Axle Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Axle Housing Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
B
Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
C
Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Charge Pressure Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Chassis Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Control Arm Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Control Cover Components - Hand and Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Control Cover Components - Hands Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
INDEX
Control Cover/Floor Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Control Handle Actuation Buttons - Two-Speed and Ride Control Module . . . . . . . . . . . . 9-18
Control Handle Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Control Handle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Control Handle Tracking Adjustment, Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Control Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
PRINTED IN USA Index-1 917002/AP0704

INDEX
Control Valve Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
Controls Chapter
Auxiliary Hydraulics Cable Adjustment - Hand/Foot . . . . . . . . . . . . . . . . . . . 6-30
Auxiliary Hydraulics Cable Adjustment - T-Bar and Dual Hand . . . . . . . . . . . . . 6-28
Auxiliary Hydraulics Cable Removal and Installation - Hand/Foot . . . . . . . . . . . . 6-29
Auxiliary Hydraulics Cable Removal and Installation - T-Bar and Dual Hand . . . . . . 6-27
Control Arm Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . 6-19
Control Handle Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Control Handle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Control Handle Tracking Adjustment, Drive Controls . . . . . . . . . . . . . . . . . . . 6-8
Dual Hand Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Foot Throttle Adjustment - T-Bar and Dual Hand . . . . . . . . . . . . . . . . . . . . . 6-38
Foot Throttle Removal and Installation - T-Bar and Dual Hand. . . . . . . . . . . . . . 6-34
Hand and Foot Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Hand Throttle Adjustment - Hand/Foot . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Hand Throttle and Throttle Cable Removal and Installation - Hand/Foot. . . . . . . . . 6-36
Hand Throttle Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Hand Throttle, Rod and Cable Removal and Installation - T-Bar and Dual Hand . . . . 6-33
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lift/Tilt Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Lift/Tilt Control Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Neutral Centering Device Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Pivot Tube Removal and Installation - T-Bar, Hand/Foot and Dual Hand . . . . . . . . 6-16
T-Bar Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Cooling System Drain Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
D
Description of Operation - Right and Left Instrument Panels . . . . . . . . . . . . . . . . . . . . 9-1
Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dome Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drive Chain Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Drive Control Components - Hand/Foot and Dual Hand Models . . . . . . . . . . . . . . . . . . 6-15
Drive Control Components - T-Bar Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Drive Motor Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Dual Hand Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Dual Hand Control Models - Lift and Tilt Components . . . . . . . . . . . . . . . . . . . . . . . 6-4
917002/AP0704 Index-2 PRINTED IN USA

INDEX
E
Electric Auxiliary Hydraulics Control - Hand/Foot Components . . . . . . . . . . . . . . . . . . 6-26
Electrical Lights Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Electrical System Chapter
Description of Operation - Right and Left Instrument Panels. . . . . . . . . . . . . . . . 9-1
Dome Light Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Engine Disconnect Switch - Remote Battery Terminal Removal and Installation . . . . 9-22
Front Work Light Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Module and Relay Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Rear Work Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Restraint Bar Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 9-21
Seat Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Electrical System Schematic - Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Electrical System Schematic - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Engine Access Cover - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Engine Chapter
Air Cleaner Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . 10-16
Air Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 10-17
Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Exhaust Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 10-20
Fan Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Fan Shroud Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Fan Shroud Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Oil Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 10-15
Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Engine Components - SL4640 3-Cylinder, Turbocharged and Naturally Aspirated . . . . . . . . 10-3
Engine Components - SL4840 and SL5640 4-Cylinder, Naturally Aspirated . . . . . . . . . . . 10-4
Engine Components - SL5640 and SL6640 4-Cylinder Turbocharged . . . . . . . . . . . . . . . 10-5
INDEX
Engine Disconnect Switch - Remote Battery Terminal Removal and Installation . . . . . . . . . 9-22
Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Exhaust Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20

INDEX
F
Fan Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Fan Shroud Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Fan Shroud Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Foot Throttle Adjustment - T-Bar and Dual Hand. . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Foot Throttle Removal and Installation - T-Bar and Dual Hand . . . . . . . . . . . . . . . . . . 6-34
Front Work Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Fuel Sensor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
G
Gear Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
Glow Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Glow Control Module Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Glow Control Module Time/Temp Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Glow Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Grease Fitting Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
H
Hand Throttle Adjustment - Hand/Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Hand Throttle and Throttle Cable Removal and Installation - Hand/foot . . . . . . . . . . . . . . 6-36
Hand Throttle Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Hand Throttle, Rod and Cable Removal and Installation - T-Bar and Dual Hand . . . . . . . . . 6-33
Hand/Foot Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Hand/Foot Control Models - Lift and Tilt Components . . . . . . . . . . . . . . . . . . . . . . . 6-3
Heater Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
High-Flow Manifold Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 8-46
High-Flow Manifold Valve Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . 8-47
HVAC Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Hydraglide Accumulator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
Hydraglide Ride Control Components - SL4640 and SL4840 Models . . . . . . . . . . . . . . . 8-52
Hydraglide Ride Control Components - SL5640 Models . . . . . . . . . . . . . . . . . . . . . . 8-52
Hydraglide Ride Control Components - SL6640 Models . . . . . . . . . . . . . . . . . . . . . . 8-53
Hydraglide™ Ride Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic System - Chassis Components - SL4640, SL4840 and SL5640 Models . . . . . . . . . 8-5
Hydraulic System - Chassis Components - SL6640 Models . . . . . . . . . . . . . . . . . . . . . 8-6
Hydraulic System - High-Flow Auxiliary Components - SL4640 and SL4840 Models . . . . . . . 8-9
Hydraulic System - High-Flow Auxiliary Components - SL5640 Models . . . . . . . . . . . . . 8-10

INDEX
Hydraulic System - High-Flow Auxiliary Components - SL6640 Models . . . . . . . . . . . . . 8-11

Hydraulic System - High-Flow Auxiliary Liftarm Hydraulics - SL4640 and SL4840 . . . . . . . 8-15
Hydraulic System - High-Flow Auxiliary Liftarm Hydraulics - SL5640 and SL6640 . . . . . . . 8-15
Hydraulic System - Liftarm Hydraulics Components - SL4640 and SL4840 Models . . . . . . . 8-12
Hydraulic System - Liftarm Hydraulics Components - SL5640 Models . . . . . . . . . . . . . . 8-13
Hydraulic System - Liftarm Hydraulics Components - SL6640 Models . . . . . . . . . . . . . . 8-14
Hydraulic System - Standard Auxiliary Components - SL4640 and SL4840 Models . . . . . . . . 8-7
Hydraulic System - Standard Auxiliary Components - SL5640 and SL6640 Models . . . . . . . . 8-8
Hydraulic System Chapter
Control Valve Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 8-50
Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
Gear Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
High-Flow Manifold Valve Disassembly and Assembly . . . . . . . . . . . . . . . . . 8-47
High-Flow Manifold Valve Removal and Installation . . . . . . . . . . . . . . . . . . . 8-46
Hydraglide Accumulator Removal and Installation . . . . . . . . . . . . . . . . . . . . 8-54
Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Lift and Tilt Cylinder Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . 8-32
Lift and Tilt Solenoid Valve - Disassembly and Assembly . . . . . . . . . . . . . . . . 8-41
Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Lift Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Pilot Valve Removal and Installation - Hand/Foot. . . . . . . . . . . . . . . . . . . . . 8-48
Pressure Tests, Control Valve and High-Flow . . . . . . . . . . . . . . . . . . . . . . . 8-17
Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
Safety Lock Valves - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 8-39
Self-Leveling Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Self-Leveling Valve Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . 8-36
Self-Leveling Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Solenoid Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Spool Lock Solenoid Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 8-51
Tilt Cylinder Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Tilt Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Hydraulic/Hydrostatic System Schematic, 40 Series . . . . . . . . . . . . . . . . . . . . . . . . 8-56
Hydrostatic Pump Drive Coupling Removal and Installation . . . . . . . . . . . . . . . . . . . . 7-14
INDEX
Hydrostatic Pump Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Hydrostatic Pump Removal / Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Hydrostatic System - SL4840 Two-Speed Model Components . . . . . . . . . . . . . . . . . . . 7-2
Hydrostatic System - SL4640 and SL4840 Single Speed Model Components. . . . . . . . . . . . 7-1

INDEX
Hydrostatic System - SL5640 Single Speed Model Components . . . . . . . . . . . . . . . . . . 7-3

Hydrostatic System - SL6640 Single Speed Model Components . . . . . . . . . . . . . . . . . . 7-5
Hydrostatic System Chapter
Charge Pressure Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Drive Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Hydrostatic Pump Drive Coupling Removal and Installation . . . . . . . . . . . . . . . 7-14
Hydrostatic Pump Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Hydrostatic Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
I
Ignition Switch Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Interlock Control Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Interlock Control Module Truth Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
ISO SPDT Interlock Relay and Horn Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
L
Lift and Tilt Solenoid Valve - Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . 8-41
Lift Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Lift Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Lift/Tilt Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Lift/Tilt Control Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Lift/Tilt Cylinder Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Liftarm Bushing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Liftarm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Liftarm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Liftarm Stop Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Liftarm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Liftarm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Liftarm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Lubrication Chapter
Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cooling System Drain Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

INDEX
Grease Fitting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
M
Mainframe Chapter
Air Duct Louver Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Air Duct Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
All-Tach, Power-A-Tach Hitch Removal and Installation . . . . . . . . . . . . . . . . . 4-15
Control Cover, Floor Cover Removal and Installation. . . . . . . . . . . . . . . . . . . 4-20
Crossmember Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Engine Access Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fuel Sensor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Liftarm Arm Stop Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . 4-20
Liftarm Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Liftarm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Restraint Bar Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
ROPS Rear Window Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 4-9
ROPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Seat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Seat Slide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Mandatory Safety Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Master Circuit Breaker/Glow Circuit Breaker Test . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Mechanical Auxiliary Hydraulics Control - Hand/Foot Components . . . . . . . . . . . . . . . . 6-25
Module and Relay Test and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
N
Neutral Centering Device Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
O
Oil Cooler Components - SL4640 and SL4840 Naturally Aspirated . . . . . . . . . . . . . . . 10-11
INDEX
Oil Cooler Components - SL4640 Turbocharged . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

Oil Cooler Components - SL5640 and SL6640 Naturally Aspirated . . . . . . . . . . . . . . . 10-13
Oil Cooler Components - SL5640 and SL6640 Turbocharged . . . . . . . . . . . . . . . . . . 10-14
Oil Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

INDEX
P
Pilot Valve Removal and Installation - Hand/foot Models . . . . . . . . . . . . . . . . . . . . . 8-48
Pivot Tube Removal and Installation - T-Bar, Hand/Foot and Dual Hand . . . . . . . . . . . . . 6-16
Power Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Power-A-Tach Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Pressure Tests, Control Valve and High-Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
R
Rear Grille and Engine Cover Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Rear Work Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Restraint Bar Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10, 9-20
Restraint Bar Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Restraint Bar Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Rollover & Falling Object - Protective Structure (ROPS/FOPS) Components . . . . . . . . . . . 4-1
ROPS – Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
ROPS Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
ROPS Rear Window Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
ROPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
ROPS, Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
S
Safety Chapter
Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Liftarm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Liftarm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Liftarm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
ROPS, Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
ROPS, Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Lock Valves - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

INDEX
Seat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Seat Slide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Seat Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Self-Leveling Valve Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Self-Leveling Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Self-Leveling Valve Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Solenoid Valve Test - Tilt, Lift, Brake and Two-Speed . . . . . . . . . . . . . . . . . . . . . . . 8-23
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Spool Lock Solenoid Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Starter Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
T
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-i
T-Bar Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
T-Bar Control Models - Lift and Tilt Components . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Throttle Components - Hand and Foot Components . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Throttle Components - T-Bar and Dual Hand Components . . . . . . . . . . . . . . . . . . . . . 6-31
Tilt Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Tilt Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Tilt Cylinder Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Two-Speed Control Module Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Two-Speed, Ride Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Two-Speed, Ride Control Module Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
W
Wheel Drives Chapter
Axle and Wheel Bearing Disassembly and Assembly . . . . . . . . . . . . . . . . . . . 5-6
Axle Housing Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . 5-3
Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drive Chain Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Wheel Drives Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
INDEX

PAGE LEFT INTENTIONALLY BLANK

®
Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 USA
www.gehl.com
917002/AP0704 © 2004 GEHL COMPANY PRINTED IN USA

All Rights Reserved.

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What is the purpose of this manual?

What is the purpose of this manual?

What safety procedures are outlined in the manual?

What safety procedures are outlined in the manual?

SL46/4840 Form No.

Gehl is a registered trademark of the Gehl Company.

Specifications Page 1-1

Safety Page 2-1

Lubrication Page 3-1

Mainframe Page 4-1

PRINTED IN USA i 917002/AP0704

Wheel Drives Page 5-1

Controls Page 6-1

All-Tach is a trademark of the Gehl Company.

917002/AP0704 ii PRINTED IN USA

Hydrostatic System Page 7-1

Hydraulic System Page 8-1

PRINTED IN USA iii 917002/AP0704

Specifications below apply to all 40 Series Models

Buckets and Capacities

PRINTED IN USA 1-1 917002/AP0704

1 - w/ 0.4 cu. yd. bkt., w/ 10 x 16.5 tires

917002/AP0704 1-2 PRINTED IN USA

PRINTED IN USA 2-1 917002/AP0704

917002/AP0704 2-2 PRINTED IN USA

Liftarm Support Device

Many service procedures require a raised liftarm to

Liftarm Support Device Engagement

PRINTED IN USA 2-3 917002/AP0704

Liftarm Support Device Disengagement

To return the liftarm support device to its storage

3. Before leaving the operator’s compartment, check

917002/AP0704 2-4 PRINTED IN USA

4. Remove one capscrew, three flat washers, and one

3. Reinstall the two capscrews, six flat washers and

Fig. 2-9 BE SURE the ROPS/FOPS clears the control

PRINTED IN USA 2-5 917002/AP0704

Relieving Hydraulic Pressure

3. With the operator in the seat and the restraint bar

Lift and Tilt

Lift and Tilt

Fig. 2-12 On T-Bar models, lift and tilt functions are

Loader Raising Procedure

Tie Down Support

Fig. 2-13 View of the stand placement and tie down

1. To raise and block the skid-steer loader, obtain four

Loader Lowering Procedure

PRINTED IN USA 2-7 917002/AP0704

917002/AP0704 2-8 PRINTED IN USA

Hydraulic System Chaincases Grease Crankcase Oil

PRINTED IN USA 3-1 917002/AP0704

specific grades and ratings as specified by the engine

Hydraulic Oil Reservoir

Ambient Temperature Viscosity

Below 32°F (0°C) SAE 10 or 10W-30

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

917002/AP0704 3-2 PRINTED IN USA

Change Chaincase Oil

Grease Fitting Locations