Gehl R190 Operator'S Manual Download Page 128

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50950106/AP0313

New Decal Application. . . . . . .   8
No-Text Decals . . . . . . . . . . .   13
Text Decals . . . . . . . . . . . . . . .   9

Safety Interlock System . . . . . . . . 20
Safety Reminders . . . . . . . . . . . . . . 6
Seatbelt

Upper-Torso Restraint . . . . . . 20

Seat Switch. . . . . . . . . . . . . . . . . .   21
Self-Leveling . . . . . . . . . . . . . . . . .   52
SERVICE  . . . . . . . . . . . . . . . . . . .   67
Service Locations . . . . . . . . . . . . .   74
Settings Menu - Information Center
Electronic Display . . . . . . . . . . . . .   31
Sliding Side Window

Removal Procedure. . . . . . . . 67

SPECIFICATIONS . . . . . . . . . . . 107
Specifications

Capacities and Ratings . . . . 114
Common Materials and

Densities . . . . . . . . 116

Dimensional Specifications .   114
Loader Specifications  . . . . .   107
Optional Features  . . . . . . . .   110
Standard Features. . . . . . . .   114

Speed Control. . . . . . . . . . . . . . . .   25
Speed Limit Protection During
     A Cold Start . . . . . . . . . . . . . . .   49
Standard Features  . . . . . . . . . . .   110
Standard-Flow Auxiliary
     Hydraulic Control . . . . . . . . . . .   43
Standard-Flow Auxiliary
     Hydraulics  . . . . . . . . . . . . . . . .   52
Starting the Engine . . . . . . . . . . . .   47

Before Starting

the Engine . . . . . . . . 47

Stationary Regeneration Abort
     Procedure  . . . . . . . . . . . . . . . .   63
Stationary Regeneration
     Procedure  . . . . . . . . . . . . . . . .   63
Stationary Regeneration Safety . .   62
Stopping the Loader . . . . . . . . . . .   49

T-Bar Controls . . . . . . . . . . . . . . . . 41

Auxiliary Hydraulic

System . . . . . . . . . . . 43

Tilting Back the ROPS/FOPS. . . . . 71
Tires . . . . . . . . . . . . . . . . . . . . . . . . 91

Checking Tire Pressure. . . . . . 91

TORQUE SPECIFICATIONS . . . . 119
Transporting the Loader . . . . . . . . . 57
TROUBLESHOOTING . . . . . . . . . . 95
Troubleshooting

Electrical System. . . . . . . . . . . 95
Engine . . . . . . . . . . . . . . . . . . . 97
Hydraulic System . . . . . . . . . . 99
Hydrostatic Drive System . . . . 98

Two-Speed Transmission. . . . . . . . 25

WARRANTY. . . . . . . . . . . . . . . . . 120
Wheel Nuts. . . . . . . . . . . . . . . . . . . 88
Work Lights . . . . . . . . . . . . . . . . . . 24

Summary of Contents for R190

Page 1: ...Skid Steer Loaders Operator s Manual Form No 50950106 AP0313 English R190 R220 R260 ...

Page 2: ...nal safety is involved Operators must have instructions before running the machine Untrained operators can cause injury or death Read Operator s Manual before using machine CORRECT Always fasten seatbelt snugly Always keep feet on the floor pedals when operating loader CORRECT Never use loader without ROPS FOPS Never modify the ROPS FOPS structure WRONG Never use the loader to lift personnel WRONG...

Page 3: ...7 Torque Specifications 119 Warranty 120 INDEX 121 R190 R220 R260 Skid Steer Loader Operator s Manual TABLE OF CONTENTS Hydraloc and Hydraglide are trademarks of Manitou Americas Inc Gehl Powerview All Tach and Power A Tach are registered trademarks of Manitou Americas Inc Loader Model Number Loader Serial Number Engine Serial Number ...

Page 4: ......

Page 5: ... attachment to learn how to safely maintain and operate the equipment Be sure the machine is suit ably equipped for the type of work to be performed Do not use this machine for any applications or purposes other than those described in this manual or those applicable for approved attachments If the machine is to be used with special attachments or equipment other than those approved by Manitou Ame...

Page 6: ...ylinders 5 Lift Arm 6 Tires 7 Lift Arm Support Device in stowed position inside loader arm 8 Auxiliary Couplers 1 2 5 4 3 3 6 7 8 1 Roll Over Falling Object Protective System ROPS FOPS 2 Lift Cylinder 3 Engine Cover 4 Rear Work Lights 5 Tail Lights Position Lights 6 Rear Grille 7 Fuel Cap 2 6 3 5 1 5 7 4 4 ...

Page 7: ...arking Brake Engine Air Filter Engine Oil Engine Oil Filter Engine Oil Pressure Fuel Filter Engine Temperature Hydraulic System Hydraulic Oil Temperature Hydraulic Oil Filter Grease Lubrication Point Glow Indicator Lamp Diesel Fuel Chaincase Oil Clockwise Rotation Counterclockwise Rotation Fast Slow Ride Control Engine Malfunction Shutdown Bucket Float Bucket Rollback Bucket Dump Lift Arm Lower Li...

Page 8: ...4 50950106 AP0313 Control Indicator Symbols cont DPF Service Exhaust Gas Temperature DPF Regen Acknowledgement ...

Page 9: ...ose for which it is not intended or designed Manitou Americas ALWAYS considers the operator s safety when designing its machinery and guards exposed moving parts for the operator s protection How ever some areas cannot be guarded or shielded in order to assure proper opera tion This Operator s Manual and decals on the machine warn of additional haz ards and they should be read and observed closely...

Page 10: ... to be used only with Gehl attach ments and approved attachments To avoid possible personal injury equip ment damage and performance problems use only attachments that are approved for use on and within the operating capacity of the machine Con tact your dealer or Gehl Service Department for information on attachment approval and compatibility with specific machine models Manitou Americas cannot b...

Page 11: ...ay from bystanders Practice with the controls until the loader can be operated safely and efficiently Wear safety goggles and head protection while operating the machine Oper ator must wear protective clothing when appropriate Exhaust fumes can kill Do not operate this machine in an enclosed area unless there is adequate ventilation When parking the machine and before leaving the seat check the re...

Page 12: ...zzle Do not wear polyester or polyester blend clothing while fueling Before fueling touch the metal surface of the machine away from the fuel fill to dissipate any built up static electricity Do not re enter the machine but stay near the fuel filling point during refueling to minimize the build up of static electricity Do not use cell phones while fueling Make sure the static line is connected fro...

Page 13: ...in 3 point contact during entry and exit Inspect work area avoid all hazards Look in direction of travel Keep children and bystanders away Start and operate machine only from the operator s seat Never carry riders Do not lift personnel in bucket Operate only in well ventilated area Keep away from electric power lines avoid contact Do not wear loose clothing while operating or servicing machine Wea...

Page 14: ...crossmember 132166 Located on rear window emergency exit 137755 Located on attachment bracket manual hitch loaders only Before operating with attachment check engagement of loader attachment bracket locking pin to the attachment AVOID INJURY OR DEATH 139101 Located on attachment bracket power hitch loaders only ...

Page 15: ...S FOPS and on the lift arm support device 50352637 Located on the ROPS FOPS locking mechanism Be sure lock mechanism is securely engaged before working under ROPS FOPS Read instructions for use in Operator s Manual 184214 50352637 Be sure lock mechanism is securely engaged before working under ROPS FOPS Read instructions for use in Operator s Manual ...

Page 16: ... ROTATING FAN Keep hands out or stop engine 50352529 50352528 HOT SURFACE Do not touch hot engine or hydraulic system parts 137657 Located on the right riser 50352529 Located on fan shroud inside engine compartment 50352528 Located on fan shroud inside engine compartment ...

Page 17: ... right instrument panel Safety alert Always follow Mandatory Safety Shutdown Procedure in Operator s Manual 1 Lower equipment to ground 2 Reduce throttle stop engine 3 Apply parking brake remove key 4 Check safety interlocks 242590 Located on left instrument panel Safety alert A Check machine before operating Service per Operator s Manual Contact dealer or manufacturer for information and service ...

Page 18: ...form Crush hazard Before operating with attachment check engagement of hitch locking pin to the attachment A Incorrect attachment engagement C Lock hitch lever B Correct attachment engagement D Unlock hitch lever A B A B C D Before operating with attachment check engagement of loader attachment bracket locking pin to the attachment AVOID INJURY OR DEATH 139101 Located on hitch power hitch loaders ...

Page 19: ...al 50352631 Located on the left side of the ROPS FOPS and on the lift arm support device 50352566 Located on the ROPS FOPS locking mechanism A B C A B C A Crush hazard Keep out from under lift arm unless lift arm is supported B Secure lift arm support device C Read instructions for use in Operator s Manual A Crush hazard Be sure lock mechanism is securely engaged before working under ROPS FOPS B S...

Page 20: ...hydraulic leaks Escaping oil under pressure can be invisible and penetrate skin Use a piece of cardboard to find leaks E Burn hazard Allow radiator to cool before removing cap Loosen cap slowly to avoid burns F Suffocation hazard Operate only in a well ventilated area A B C D E F 50352527 Located on the fan shroud inside engine compartment A Cutting Hazard Fan The fan rotates at extreme speed B Ke...

Page 21: ...protective system serial number 2 Seat plate according to ISO 7096 3 Product plate with Product Identification Number and e g model type designation 4 Engine plate with e g type designation product and serial numbers 5 Component plate hydrostatic pump with e g product and serial numbers 6 Component plate drive motor with e g product and serial numbers 1 4 6 2 3 5 ...

Page 22: ...18 50950106 AP0313 Notes ...

Page 23: ...der unless all factory installed guards and shields are properly secured in place Operator Restraint Bar Lower the operator restraint bar after entering the operator s compartment and sitting in the seat The restraint bar is securely anchored to the ROPS FOPS The operator must be seated with the restraint bar in its lowered position to start or operate the skid steer loader Refer to Safety Interlo...

Page 24: ...replace if dam aged Keep seatbelt s clean Use only soap and water to wash seatbelt s Cleaning solvents can cause damage to seatbelt s Safety Interlock System Hydraloc NEVER defeat the safety interlock system by mechanically or electrically bypassing any switches relays or solenoid valves An interlock system is provided on the loader for operator safety Together with solenoid valves switches and re...

Page 25: ...leshoot and correct the problem Contact your dealer if necessary ROPS FOPS The ROPS FOPS Roll Over Falling Object Protective Structure is designed to provide protection for the operator from falling objects and in a tip over accident if the operator is secured inside the operator s compartment by the seatbelt and restraint bar Never operate the loader with the ROPS FOPS removed or locked back Park...

Page 26: ...der to engage the support device Important With the key switch OFF and the solenoid valve working properly the lift arm will stay raised when the lift control is moved to lower the lift arm If the valve does not hold the lift am and it begins to lower do not leave the operator s compartment Instead lower the lift arm and exit the machine Then contact your Gehl dealer immediately to determine why t...

Page 27: ...e the operator s compartment Instead lower the lift arm and exit the machine Then contact your Gehl dealer immediately to determine why the lift arm lowers while the key switch is OFF To return the lift arm support device to its storage position 1 Start the engine 2 Raise the lift arm fully 3 Stop the engine 4 Verify that the lift arm is being held in the raised position by the safety inter lock s...

Page 28: ...ure 5 1 Fan Speed Control Controls the air flow 2 Temperature Control The potentiometer switch is a rotary dial for control of heat functions Heater and Air Conditioner optional Loaders with the combination heater air conditioner have two control knobs on the left instrument panel for controlling fan speed and heater air conditioner tempera ture 1 Fan Speed Control Controls the air flow 2 Temperat...

Page 29: ...to exceed 7 5 mph 12 0 km h up to a maximum speed of 12 5 mph 20 km h When the loader is in High H an H icon on the Indicator and Warning Light Display page 27 will illuminate Press the button once to activate and again to deactivate Note Speed varies slightly with tire size When two speed drive is activated down shifting to single speed drive while traveling at full speed is not recommended and d...

Page 30: ...gage the latch pins Rotate the lever as viewed from the front all the way to the right to disengage the latch pins Refer to page 51 for more information To prevent unexpected release of the attach ment from the hitch be sure to secure the latch pins by rotating the lever all the way to the hitch Power A Tach System A three position momentary rocker switch is used to operate the Power A Tach System...

Page 31: ...e lamp and notifying the operator that the warming circuit is on To deactivate the warming circuit push the switch to the neutral middle posi tion Also when retracting the pins the warming circuit will deactivate and stay off until activated again Note It is safe to operate the loader with the warming circuit on or off it won t affect the performance of the loader Indicator and Warning Lamp Displa...

Page 32: ...ow pressure During normal operation this indicator should be OFF 5 Engine Coolant Temperature Lights if the engine coolant is too hot warn ing the operator to stop the engine and determine and correct the cause of the high temperature During normal operation this indicator should be OFF 6 High Speed Lights when two speed optional is engaged 7 Hydraglide Ride Control System Lights when the ride con...

Page 33: ... associated with the DPF modes When pressing any button once a dynamic pop up menu appears The menu contains function icons aligned above the associated button The user selects the required function from the displayed menu After a few seconds the menu will be hidden If the LCD is broken care must be taken with any leaking fluid If LCD fluid gets onto your skin wipe with a cloth and wash the area w...

Page 34: ...displays the associated parameter icon and units To change to dual screen mode press the left wrench button This will bring up an option screen with the top line dis play mode will be highlighted Press the center arrow button to change the screen display to dual multi or DTC screen Press the left wrench button to return to the main display Multi Screen The Multi Screen mode is used to monitor a li...

Page 35: ...gnal from the dis crete sensor input In this mode the local information is also broadcast on the J1939 network to other nodes In Network mode the device reads the fuel signal from the associated PGN on the J1939 network Contrast Backlight Contrast and backlight commands according to the user s preferences Supported Parameters The following three pages list the sup ported parameters of the informat...

Page 36: ...32 50950106 AP0313 Information Center Electronic Display cont ...

Page 37: ...50950106 AP0313 33 Information Center Electronic Display cont ...

Page 38: ...the operator that the engine is in an emergency condition where ash cleaning is required See the ash cleaning mode description on page 60 for more details Elevated EGT Exhaust Gas Temperature The EGT icon is used to notify the operator of high exhaust temperatures during an active reset stationary regeneration Parking Brake The parking brake icon is used to remind the operator that the parking bra...

Page 39: ...ft side for reverse flow To disengage push and release either side of the switch or raise the restraint bar Turning off the machine and restarting the engine will also reset the high flow to neu tral 7 Light Switch Master control of the lights Push the right side of the rocker switch to activate front and rear lights or to the left side for deactivation of the front and rear lights It also provide...

Page 40: ...ng the operator that the regen request allow switch is being activated Regen Cancel The right side of the toggle switch is used for delaying or cancelling a reset or stationary regeneration Regen Cancel Lamp The lamp is used for notifying the operator that the reset sta tionary regeneration is in a standby mode 6 Keyswitch In a clockwise rotation the positions are OFF Position With the key verti c...

Page 41: ... movement of the left joystick To go forward push the drive control forward for reverse pull the control rear ward To turn right push the control right to turn left push the control left To go forward and left move the control for ward and left To go forward and right move the control forward and right To move back and left move the control back and to the right To move back and right move the con...

Page 42: ...m into the float position push and hold the left button on the right joystick This mode allows the lowered lift arm to follow the ground con tour while traveling over changing ground conditions An indicator lamp in the indicator and warning lamp display will blink when float is activated Never push the float control button with the attachment raised because this will cause the lift arm to lower ve...

Page 43: ...andle farther forward than the right handle For sharp turns move the handles in opposite directions Be sure the controls are in neutral before starting the engine Operate the controls gradually and smoothly Excessive speed and quick control move ments without regard for conditions and circumstances are haz ardous and could cause an accident Moving the handles farther from neutral increases the spe...

Page 44: ... tilt motion is directly proportional to the amount of pedal movement and engine speed To place the lift arm into the float position push and hold the left button on the right hand control This mode allows the lowered lift arm to follow the ground contour while traveling over changing ground conditions An indicator lamp in the indicator and warning lamp display will blink when float is activated N...

Page 45: ...ard For sharp turns turn the control clockwise or counter clockwise Moving the T bar farther from neutral increase the speed steadily to the max imum travel speed Tractive effort decreases as speed increases To get maximum tractive effort move the T bar only slightly away from the neutral position The engine will stall if the control is moved too far forward when loading the bucket Be sure the con...

Page 46: ...e The speed of the lift tilt motion is directly proportional to the amount of T bar movement and engine speed To place the lift arm into the float position push the right control handle fully forward to detent This mode allows the lowered lift arm to follow the ground contour while traveling over changing ground conditions An indicator lamp in the indicator and warning lamp display will blink when...

Page 47: ...her direction and push the trigger button located on the front of the grip for five sec onds and release To cancel continuous operation push the button or move the black switch in either direction High Flow Auxiliary Hydraulic Control Optional In addition to a standard flow auxiliary hydraulic system loaders may be equipped with a reversible high flow aux iliary hydraulic system The couplers are l...

Page 48: ...nary regeneration 3 Regen Request Allow Lamp The lamp prompts the operator to implement a stationary regeneration It is used for notifying the operator that the regen request allow switch is being activated 4 Regen Cancel The right side of the toggle switch is used for delaying or cancelling a reset or stationary regeneration 5 Regen Cancel Lamp The lamp is used for notifying the operator that the...

Page 49: ...ch An electrical battery disconnect switch is located inside the engine compartment on the left side and forward of the fuse panel Turn the switch to the OFF position to disconnect the battery from the electrical system Figure 20 Battery Disconnect Switch ...

Page 50: ...46 50950106 AP0313 Notes ...

Page 51: ...while fueling Before fueling touch the metal surface of the machine away from the fuel fill to dissipate any built up static electricity Do not re enter the machine but stay near the fuel filling point during refueling to minimize the build up of static electricity Do not use cell phones while fueling Make sure the static line is connected from the machine to the fuel truck before fueling begins U...

Page 52: ...and hydraulic fluid before operating the loader A block heater is recommended for starting in temperatures of 14 F 10 C or lower See your dealer for heater options Cold Starting Procedure Do not use starting fluid ether with pre heat systems An explosion can result which can cause engine damage injury or death 1 Turn the key to the RUN position If the preheat lamp symbol on the indicator and warni...

Page 53: ...ld starts Speed Limit Protection During A Cold Start Depending upon coolant temperature 14 F 10 C or below the max imum engine speed allowable is 1500 rpm This 1500 rpm limit remains in effect for approximately 10 seconds or less If a throttle command above 1500 rpm is requested during this 10 second time frame the oper ator must return the throttle to a command less than 1500 rpm before returning...

Page 54: ...ery 1 Turn the keyswitches of both vehicles to OFF be sure the vehicles are in neutral and NOT touching each other 2 Connect the positive jumper cable to the positive battery terminal on the disabled loader first DO NOT allow the positive clamps to touch any metal other than the positive battery terminals 3 Connect the other end of the positive jumper cable to the jumper vehicle s battery positive...

Page 55: ...the top edge of the hitch is below the flange on the back side of the attachment and centered between the vertical plates 5 Slowly drive the loader forward and at the same time tilt the hitch back to engage the flange on the back side of the attachment 6 Stop forward travel when the flange is engaged but continue to tilt the hitch back to lift the attachment off the ground 7 Manual hitch Exercise ...

Page 56: ...r coupler is for the case drain Only connect high flow attachment couplers to the high flow auxiliary couplers Removing Attachments 1 Tilt the hitch back until the attachment is off the ground 2 Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE page 6 3 With the engine off leave the operator s compartment and disconnect the auxiliary hydraulic hoses 4 Manual hitch Rotate the latch lever to the righ...

Page 57: ...ting to dig Driving over Rough Terrain When traveling over rough terrain activate the ride control system and drive slowly with the bucket lowered Driving on an Incline When traveling on an incline travel with the heavy end pointing uphill Digging with a Bucket Approach the digging site with the lift arm slightly raised and the bucket tilted forward until the edge contacts the ground Dig into the ...

Page 58: ...r Hopper Carry the loaded bucket low and approach the vehicle or hopper Stop as close to the side of the truck or hopper as pos sible while allowing for clearance to raise the lift arm and loaded bucket Next raise the lift arm until the bucket clears the top of the truck or hopper and move the loader ahead to position the bucket over the inside of the truck or hopper Dump the material and then bac...

Page 59: ...e to the surface being leveled Then place the lift arm into float position and drive the loader rear ward dragging the dirt and at the same time leveling it Figure 26 Note For information on how the float detent is activated see page 26 Check that the work area is clear of people and obstacles Always look in the direction of travel Highway Travel If it becomes necessary to move the loader a long d...

Page 60: ...n a cool dry location 6 Protect against extreme weather conditions such as moisture sunlight and temperature Removing Loader from Storage 1 Check the tire air pressure and inflate the tires if they are low 2 Connect the battery and check that the electrical battery disconnect switch is turned to its ON position 3 Check all fluid levels engine oil transmission hydraulic oil engine coolant and any a...

Page 61: ...er Safety Regulations Section 392 Ensure that the hauling vehicle meets all safety requirements before loading the skid steer loader 1 Block the front and rear of the hauling vehicle s tires 2 If the loader has an attachment lift it slightly off the ground 3 Back the loader slowly and carefully up the ramp onto the vehicle 4 Lower the loader attachment to the vehicle deck turn off the engine and r...

Page 62: ...with attach ments other than those stated Lift equipment used and its installation is the responsibility of the party con ducting the lift All rigging MUST comply with applicable regulations and guidelines 1 Using suitable lift equipment hook into the lift eyes Adjust the length of the slings or chains to lift the loader level Note The loader my be slightly off level 10 degrees max when lifted 2 C...

Page 63: ...n request allow switch is being activated 4 Regen Cancel The right side of the toggle switch is used for delaying or cancelling a reset or stationary regeneration 5 Regen Cancel Lamp The lamp is used for notifying the operator that the reset stationary regeneration is in a standby mode Note During regeneration there may be a change in sound due to the intake throttle and the EGR Exhaust Gas Recirc...

Page 64: ...eneration is a 100 hour recurring event unless other factors such as engine load and effective PM levels determine otherwise Note The operator can improve the effectiveness of the reset regen by oper ating the skid steer loader at a middle to high throttle position during the reset regen Stationary Regeneration This DPF regen mode includes engine speed control for a more effective and complete DPF...

Page 65: ... more details Elevated EGT Exhaust Gas Temperature The EGT icon is used to notify the operator of high exhaust temperatures during an active reset stationary regeneration Parking Brake The parking brake icon is used to remind the operator that the parking brake switch must be engaged prior to a stationary regeneration DPF Regeneration Acknowledgement The DPF regeneration acknowledgement icon is us...

Page 66: ...from that of a conventional diesel engine This is not a fault The different odor is generated because the exhaust gas is purified by the catalyst integrated in the DPF Other Stationary Regeneration Topics Besides the safety concerns listed above the operator must also be aware of these additional stationary regen topics Extended duration of engine idling will rapidly increase soot levels in the DP...

Page 67: ...re takes approximately 25 to 30 minutes to per form 6 When the above time has passed the engine speed gradually decreases to the low idle speed and the DPF regen acknowledgement lamp and the EGT lamp turn off Stationary regen is completed Note When stationary regen starts the DPF regen required lamp turns off the DPF acknowledge lamp briefly appears and the EGT lamp illuminates Stationary Regenera...

Page 68: ...o Normal Opera on Sta onary Regen is not allowed Sta onary Regen is allowed Sta onary Regen See Sta onary Regen Procedure for complete details DPF SWITCH Press and hold Sta onary Regen Request switch for 10 seconds release then hold for an addi onal three seconds These icons will appear on the Electronic display during the Sta onary Regen mode E ECU returns to Normal Opera on ...

Page 69: ...DPF switch DPF SWITCH During the three hour Reset Standby mode se ng the DPF switch back to the center AUTO posi on allows the Reset Regen mode to become available and then ac ve as necessary depending upon PM DPF SWITCH Keeping the DPF switch in the CANCEL posi on for three hours or if there is excessive soot levels in the DPF the E ECU automa cally prompts the E ECU to request a Sta onary Regen ...

Page 70: ...e If a Stationary Regen Mode is requested by the ENGINE ECU DPF SWITCH When these icons are ac ve the E ECU is reques ng a Sta onary Regen DPF SWITCH DPF REGEN ACKNOWLEDGE Electronic Display See Sta onary Regen Procedure for complete details DPF SWITCH Press and hold Sta onary Regen Request switch for three seconds These icons will appear on the Electronic display during the Sta onary Regen mode E...

Page 71: ...g center for disposal Do not pour onto the ground or down the drain Dealer Services The following areas of component service replacement and adjustments require special tools and knowledge for proper servicing and should be performed only by your authorized Gehl skid steer loader dealer hydrostatic drive components hydraulic system pumps valves hydraulic cylinders electrical components other than ...

Page 72: ...econdary inner R190 184195 Air Cleaner Element Primary outer R220 R260 50352454 Air Cleaner Element Secondary inner R220 R260 50352455 Hydraulic Oil Filter Element All Models 074830 Engine Oil Filter Element All Models 195568 Fuel Filter Element All Models 50352551 Fuel Separator Element All Models 50352550 Fresh Air Intake Filter heater option 195660 Recirculation Air Filter heater option 242832 ...

Page 73: ...nd 2 Using a jack or hoist capable of lifting the fully equipped weight of the loader with all attached options lift the rear of the loader until the rear tires are off the ground 3 Stack wooden hard plastic or metal blocks under the flat part of the loader chassis They should run parallel with but not touch the rear tires 4 Slowly lower the loader until its weight rests on the blocks If the tires...

Page 74: ...til the front tires are resting on the ground 4 Repeat steps 1 through 3 for the rear of the loader When the procedure is finished all four tires will be on the ground and the blocks removed from under the loader Engine Compartment Access To open the engine compart ment lift the engine cover Then pull the rear grille latch up Figure 32 and carefully swing open the rear grille There is another rear...

Page 75: ...e ROPS FOPS is in a rolled back position To lower the ROPS FOPS return the lock mechanism to the unlocked position flipper up Lower the ROPS FOPS slowly onto the chassis Reinstall the anchor bolts washers and locknuts Refer to the Torque Specifica tions chart page 119 for torque informa tion Never operate the loader with the ROPS FOPS removed or tilted back Be sure the lock mechanism is securely e...

Page 76: ...ed daily of dirt and other foreign materials in the following areas around the lift cylinders at the front of the loader on the hitch especially around tilt cylinder around the hydraulic oil reservoir breather in the engine compartment in the operator s compartment Important Build up of foreign materials in these areas can interfere with the operation of the loader cause component damage or become...

Page 77: ...a recycling center for disposal Do not pour onto the ground or down the drain System Lubricant Hydraulic System Oil Use Petro Canada HVI60 Mobil DTE 15M or equivalent which contain anti rust anti foam and anti oxidation additives and conforms to ISO VG46 Entire System Capacity R190 11 U S gallons 41 6 L Entire System Capacity R220 12 U S gallons 45 4 L Entire System Capacity R260 12 U S gallons 45...

Page 78: ...Lift Arm Pins page 73 Check Oil Level in Chaincases page 75 Change Engine Oil and Filter page 80 Change Hydraulic Oil Filter page 87 Change Hydraulic Oil page 88 Change Chaincase Oil page 75 Check and Drain Water Separator page 81 Replace Filter in Water Separator page 81 50 250 250 10 50 500 500 250 Figure 36 Service Locations see Maintenance Chart on page 103 Perform the initial procedure at 50 ...

Page 79: ...Figure 37 Remove this plug The oil level should be at the plug level or no more than 1 4 in 6 mm below the plug 3 If the oil level is low add oil through the check and fill plug until the oil level reaches the check plug hole Reinstall the plug Draining Oil 1 Park the loader on a level surface or on a sloping surface with the loader facing downhill and the tires blocked 2 At the front of the loade...

Page 80: ... page 69 2 Remove the tire from the axle to be adjusted 3 Loosen but DO NOT remove the bolts holding the axle to the chaincase 4 Front Chain Tension To tighten the front chain move the front axle assembly toward the front of the loader To loosen the chain move the front axle assembly toward the rear of the loader Rear Chain Tension To tighten the rear chain move the rear axle assembly rearward To ...

Page 81: ...uter element should be replaced only when the restriction indicator lamp lights The inner element should be replaced every third time the outer element is replaced unless the outer element is damaged or the inner element is visibly dirty Along with a daily check of the restriction indicator check that the air cleaner intake hose and clamps and the mounting bracket hardware are properly secured Acc...

Page 82: ...he inner element from the housing clean out any dirt built up in the housing Leave the inner element installed during this step to pre vent debris from entering the engine intake manifold 2 Remove the inner element Reinstallation 1 Check the inside of the housing for any damage that may interfere with the elements 2 Be sure that the element sealing surfaces are clean 3 Insert the element s making ...

Page 83: ...0 Engine Service Components 1 Muffler 2 Air Cleaner 3 Coolant Bottle 4 Engine Radiator 5 Hydraulic Cooler 6 Hydraulic Filter 7 Remote Engine Oil Filter 8 Water Separator 9 Fuel Filter 10 Remote Engine Oil Drain 11 Engine Oil Fill Cap 12 Engine Oil Dipstick 13 Starter 14 Alternator R220 R260 Models R190 Models ...

Page 84: ...rs Important Always dispose of waste lubricating oil according to local regulations or take to a recycling center for disposal do not pour onto the ground or down the drain The remote engine oil filter is located behind the engine above the battery Raise the engine cover and lock open the rear grille to access the oil filter Figure 41 Access for draining the engine oil is located behind the left r...

Page 85: ...om of the separator bowl Important Water in the fuel system can cause severe engine damage Drain water from the water separator anytime water is present To change the water separator filter turn the plastic petcock located on top of the water separator a 1 4 turn to stop fuel flow Unscrew the separator bowl from the housing and pull down on the existing filter to release it from the housing Replac...

Page 86: ...82 50950106 AP0313 Engine Diagnostic Chart ...

Page 87: ...50950106 AP0313 83 Engine Diagnostic Chart cont ...

Page 88: ...84 50950106 AP0313 Engine Diagnostic Chart cont ...

Page 89: ...50950106 AP0313 85 Engine Diagnostic Chart cont ...

Page 90: ...86 50950106 AP0313 Engine Diagnostic Chart cont ...

Page 91: ...hydraulic oil fill tube Refer to the Lubri cation chart page 73 Replace the fill cap Changing Hydraulic Oil Filter The hydraulic filter element is located to the right of the radiator cooler against the side of the chassis To change hydraulic filter element 1 Park the loader on a level surface Shut off the engine and remove the key 2 Open the reservoir drain plug located on the inside bottom of th...

Page 92: ...all the drain plug 4 Change the oil filter 5 Refill the reservoir Refer to the Lubrication chart page 73 6 Start the engine and operate the hydraulic controls 7 Stop the engine and check for leaks at the filter and reservoir drain plug 8 Check the fluid level and add fluid if needed Bucket Cutting Edge The bucket cutting edge should be replaced when it is worn to within 1 in 25 mm of the bucket bo...

Page 93: ... the Cooling System Allow sufficient time for the oil radiator to cool before working on or near it Parts get extremely hot during operation and can burn you The radiator assembly is mounted between the engine and the hinged rear grille When operating correctly air is blown through the openings between the fins by the engine fan During operation dust and debris can build up on the engine side of t...

Page 94: ... on the radiator Figure 49 and drain the coolant into a suitable container Note Coolant must be drained from the radiator and the engine 6 Close the drain cock Note Protect the cooling system by adding premixed 50 water and 50 ethylene glycol to the system 7 Fill the radiator fully and the coolant tank to half full 8 Reinstall the radiator cap and run the engine until it is at operating tempera tu...

Page 95: ... 35 psi 240 kPa to seat the beads If the beads have not seated by the time the pressure reaches 35 psi 240 kPa deflate the assembly reposition the tire on the rim lubricate both parts and re inflate Inflation pressure beyond 35 psi 240 kPa with unseated beads may break the bead or rim with explosive force sufficient to cause death or serious injury After seating the beads adjust the inflation pres...

Page 96: ...ing ventilating and air conditioning housing mounted on the upper rear corner of the cab Remove the threaded knobs on both sides of the cover to access the filter Recirculation Air Filters Located behind the covers in the headliner directly above the rear window The access remove the screws on either side of the covers Important Keeping the cab clean will reduce need for service and help ensure pr...

Page 97: ...els in the Operator s Compartment A C HEAT 20A BACK UP ALARM 5A REAR WORK LIGHTS 15A SAFETY START FLASHER 10A KEY POWER 15A REGEN INTERLOCK REAR WIPER WASHER 15A POWER ALL TACH 10A SOL LOCK PILOT SOL LOCK PILOT 15A ACCESSORY CHASSIS 20A ACCESSORY CAB 30A FUEL PUMP 5A RIDE 2SP 10A OPEN FRONT WORK LIGHTS 15A SEAT COMPRESSOR 20A INTERLOCK 10A FRT WIPER WASHER 15A OPEN HORN 10A AUX HYD CONTROL 10A GAU...

Page 98: ...n a battery is in use or being charged Keep flames and sparks away from the battery area ALWAYS charge the battery in a well ventilated area Never lay a metal object on top of a battery because a short circuit can result Battery acid is harmful on contact with skin or fabrics If acid spills follow these first aid tips 1 Immediately remove any clothing on which acid spills 2 If acid contacts the sk...

Page 99: ...heck main harness connectors Battery terminals or cables are loose or corroded Clean battery terminals and cables and retighten them Starter will not engage when key is turned to START Battery terminal or cables loose or corroded Clean terminal cables and retighten Battery discharged or defective Recharge or replace battery Seat or restraint bar switch malfunctioning or not actuated Contact your d...

Page 100: ...ght switch es or poor ground Check ground wire connections Replace light switch Lift Tilt and or drive solenoids do not work Wiring to solenoids disconnected or faulty Troubleshoot circuit repair Restraint bar or seat switch malfunction Contact your dealer Faulty solenoid valve coil Contact your dealer Solenoid relay malfunctioning Verify relay is working properly replace Faulty fuse Verify relay ...

Page 101: ...rect Engine not warm enough Install block heater Ambient temperature too low Install block heater Fuel filter plugged Replace filter Fuel pump not working Contact your dealer Engine overheats Crankcase oil level too low or too high Add or remove oil as required Fan air circulation blocked or restricted With engine off remove blockage or restriction Fan belt loose Tighten fan belt Grade of oil impr...

Page 102: ... Sluggish acceleration Air in hydraulic system Cycle lift and tilt cylinders to maximum stroke and maintain pressure for short time to clear air from system Also check for low oil level in reservoir fill as needed Hydraulic oil level too low Check for low oil level in reservoir add oil Hydrostatic system charge pressure low Contact your dealer Drive motor s or hydrostatic pump s have internal dama...

Page 103: ...rostatic pump arm control lever loose Control rod linkage to rear hydrostatic pump disconnected Contact your dealer Tighten control lever Attach control rod linkage Right side doesn t drive in one direction Relief valve on rear hydrostatic pump malfunctioning Contact your dealer Rear hydrostatic pump malfunctioning Contact your dealer Left side doesn t drive in either direction Right side operates...

Page 104: ...eak Repair and add oil Hydraulic oil leaking past cylinder piston seals Contact your dealer Worn pump Contact your dealer Solenoid valve malfunctioning or one of the two cartridges on solenoid valve malfunctioning Control linkage restricted Check electrical connections to pilot solenoid and repair connections as needed If solenoid valve is still not functioning properly contact your dealer Readjus...

Page 105: ...es not raise bucket tilt works properly Lift spool in control valve not actuated or leaking Check tube connections to valve Lift arm does not maintain raise position with left control in NEUTRAL Oil leading past lift cylinder seals internal or external Contact your dealer Oil leaking past lift spool in control valve Contact your dealer Self leveling valve malfunctioning Contact your dealer Leaking...

Page 106: ... functions slowly Low engine speed Operate engine at higher speed Hydraulic oil level low Add oil Hydraulic oil viscosity too heavy Control linkage misadjusted Allow longer warm up or replace oil with proper viscosity oil Readjust linkage for full spool travel High flow auxiliary does not function Restraint bar raised Lower the restraint bar Pilot solenoids malfunctioning Check electrical connecti...

Page 107: ...Check Engine Oil Level page 80 Check Hydraulic Oil Level page 87 Check Tire Pressures page 91 Grease Hitch Hitch related Cylinder Pivots and Latch Pins page 73 Check Bucket Cutting Edge page 88 Test Safety Interlock System page 20 Check Coolant Level page 89 Clean Cooling System page 89 Grease Lift Arm Pins page 73 Check Drive Chain Tension page 76 Check Wheel Nuts Torque page 88 Check Oil Level i...

Page 108: ...104 50950106 AP0313 Maintenance Log Date Hours Service Procedure ...

Page 109: ...50950106 AP0313 105 Maintenance Log Date Hours Service Procedure ...

Page 110: ...106 50950106 AP0313 Maintenance Log Date Hours Service Procedure ...

Page 111: ...229 241 N m 1625 rpm Hydraulic System theoretical Main Hydraulic System Pressure 3000 psi 207 bar Standard Flow Rating 18 5 gpm 70 03 L min High Flow System Pressure 2900 psi 200 bar High Flow Rating 31 5 gpm 119 24 L min Electrical Battery 12 Volt DC 950 CCA Group 31 Starter 12 Volt DC 3 0 kW Alternator 95 amperes Capacities Chaincase each 9 5 U S qts 9 0 L Engine Oil 9 5 U S qts 9 0 L Engine Coo...

Page 112: ...ystem Pressure 3300 psi 227 5 bar Standard Flow Rating 23 5 gpm 89 L min High Flow System Pressure 3200 psi 220 6 bar High Flow Rating 35 0 gpm 132 5 L min Electrical Battery 12 Volt DC 950 CCA Group 31 Starter 12 Volt DC 3 0 kW Alternator 95 amperes Capacities Chaincase each 10 0 U S qts 9 5 L Engine Oil 11 0 U S qts 10 4 L Engine Coolant entire system 6 8 U S qts 6 4 L Fuel Tank 18 0 U S gal 68 ...

Page 113: ...System Pressure 3300 psi 227 5 bar Standard Flow Rating 23 5 gpm 89 L min High Flow System Pressure 3200 psi 220 6 bar High Flow Rating 35 0 gpm 132 5 L min Electrical Battery 12 Volt DC 950 CCA Group 31 Starter 12 Volt DC 3 0 kW Alternator 95 amperes Capacities Chaincase each 11 U S qts 10 4 L Engine Oil 11 0 U S qts 10 4 L Engine Coolant entire system 6 8 U S qts 6 4 L Fuel Tank 21 5 U S gal 81 ...

Page 114: ... Front and Rear Halogen Work Lights and Dual Tail Lights Bi directional Auxiliary Hydraulics with Flat Faced Couplers All Tach Attachment Mounting System Single Lever manual Engine Auto Shutdown System Emergency Exit Rear Window Hydraglide Ride Control System Dual Joystick and Hand Foot Foot Throttle Dual Joystick and T Bar Electrical Battery Disconnect Switch Horn Float Control Interior Dome Ligh...

Page 115: ...t Full Height 22 5 572 J Rollback at Ground 26 M Rollback Angle at Full Height 96 O Seat to Ground Height 39 991 P Wheel Base Nominal 42 1067 Q Overall Width Less Bucket1 64 5 1638 R Bucket Width Overall 66 1676 S Ground Clearance to Chassis Between Wheels 6 5 165 V Overall Length Less Bucket 94 2388 W Departure Angle 25 X Clearance Circle Front With Bucket 79 2007 Y Clearance Circle Front Less Bu...

Page 116: ...et Full Height 27 686 J Rollback at Ground 28 M Rollback Angle at Full Height 95 O Seat to Ground Height 40 1016 P Wheel Base Nominal 43 1092 Q Overall Width Less Bucket1 65 5 1664 R Bucket Width Overall 70 1778 S Ground Clearance to Chassis Between Wheels 8 0 203 V Overall Length Less Bucket 105 2667 W Departure Angle 25 X Clearance Circle Front With Bucket 87 5 2223 Y Clearance Circle Front Less...

Page 117: ... Full Height 27 686 J Rollback at Ground 28 M Rollback Angle at Full Height 95 O Seat to Ground Height 40 1016 P Wheel Base Nominal 49 5 1257 Q Overall Width Less Bucket1 65 5 1664 R Bucket Width Overall 70 1778 S Ground Clearance to Chassis Between Wheels 8 0 203 V Overall Length Less Bucket 111 5 2832 W Departure Angle 25 X Clearance Circle Front With Bucket 90 2286 Y Clearance Circle Front Less...

Page 118: ...19 2 ft3 1880 mm 0 54 m3 547 lbs 248 kg N A 1890 lbs 857 kg 2109 lbs 957 kg 74 in 22 8 ft3 1880 mm 0 64 m3 672 lbs 305 kg N A 1730 lbs 785 kg 2035 lbs 923 kg Dirt Construction with Spill Guard Buckets Description Weight R190 Rating R220 Rating R260 Rating 70 in 16 1 ft 3 1778 mm 0 46 m3 505 lbs 229 kg 1900 lbs 862 kg 2200 lbs 998 kg 2600 lbs 1179 kg Low Profile Grading Bucket Description Weight R1...

Page 119: ...ty 675 lbs 306 kg N A 1755 lbs 796 kg 2030 lbs 921 kg Pallet Forks 42 in 1067 mm Description Weight R190 Rating R220 Rating R260 Rating 15 75 in 400 mm Load Center per EN 474 3 500 lbs 227 kg 1405 lbs 637 kg 1653 lbs 750 kg 1928 lbs 875 kg 19 68 in 500 mm Load Center per EN 474 3 500 lbs 227 kg 1330 lbs 603 kg 1541 lbs 699 kg 1818 lbs 825 kg Pallet Forks 48 in 1219 mm Description Weight R190 Ratin...

Page 120: ...l 53 63 848 1008 Concrete 115 1840 Cinders 50 800 Coal anthracite 94 1504 Coke 30 480 Earth dry loam 70 90 1121 1442 Earth wet loam 80 100 1281 1602 Granite 93 111 1488 1776 Gravel dry 100 1602 Gravel wet 120 1922 Gypsum crushed 115 1840 Iron ore 145 2320 Lime 60 960 Lime stone 90 1440 Manure liquid 65 1040 Manure solid 45 720 Peat solid 47 752 Phosphate granular 90 1440 Potash 68 1088 Quartz gran...

Page 121: ...n bucket SAE rated heaped capacity of 16 cu ft With this bucket the R220 has a rating of 2200 lbs Multi plying the maximum density of the material by the bucket capacity 100 x 16 yields a load that weighs 1600 lbs This number is less than the machine rating and thus indicates that the loader bucket combination is safe to use in this appli cation Example 2 Granite density of 1488 1776 kg m3 is to b...

Page 122: ...118 50950106 AP0313 Notes ...

Page 123: ... 12 50 56 9 9 9 10 17 19 75 86 13 14 12 14 25 25 9 10 18 20 3 8 16 3 8 24 7 16 14 7 16 20 20 23 32 36 15 17 24 27 30 35 50 55 23 25 35 40 45 50 70 80 35 35 55 60 1 2 13 1 2 20 9 16 12 9 16 18 50 55 70 80 35 40 55 60 75 90 110 120 55 65 80 90 110 120 150 170 80 90 110 130 5 8 11 5 8 18 3 4 10 3 4 16 100 110 175 200 75 85 130 150 150 180 260 300 110 130 200 220 220 240 380 420 170 180 280 320 7 8 9 ...

Page 124: ...CONTINUE TO APPLY SOME STATES DO NOT PERMIT THE EXCLUSION OF LIMITATION OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW GEHL WARRANTY DOES NOT INCLUDE 1 Transportation to selling dealer s business location or at the option of the Original Retail Purchaser the cost of a service call 2 Used equipment 3 Components covered by their own non Gehl warranties such as tires batteri...

Page 125: ...with a Bucket 55 C Capacities and Ratings 114 Chaincases 75 Checking and Adding Oil 75 Draining Oil 75 Changing Attachments 51 Connecting Attachments 51 Connecting Auxiliary Hydraulic Couplings 52 Removing Attachments 52 Changing Engine Oil and Filter 80 Changing Fuel Filter 81 Changing Hydraulic Oil 88 Changing Hydraulic Oil Filter 87 Checking and Adding Oil 75 Checking Coolant Level 89 Checking ...

Page 126: ...ough Terrain 53 DTC Screen 30 E Electrical Battery Disconnect Switch 45 Electrical System 93 Fuse Panel 93 Emergency Exit Rear Window 22 Engagement 22 Engine Air Cleaner 77 Engine Compartment Access 70 Engine Diagnostic Chart 81 Engine Service 79 Changing Fuel Filter 81 Changing Oil and Filter 80 Checking Oil Level 80 Engine Mounting Hardware 80 Water Separator 81 Engine Speed Control 25 F Fuel 47...

Page 127: ...toring 56 Transporting 57 Loader Identification 2 Loader Specifications 107 Lubrication 73 M MAINTENANCE 103 Maintenance Interval Chart 103 Maintenance Log 104 Mandatory Safety Shutdown Procedure 6 O OPERATION 47 Operator Restraint Bar 19 Operator s Seat 20 Optional Features 110 Other Stationary Regeneration Topics 62 Outer Element 78 P Parking Brake 21 Parking the Loader 50 Potential Hazards 8 Po...

Page 128: ...14 Speed Control 25 Speed Limit Protection During A Cold Start 49 Standard Features 110 Standard Flow Auxiliary Hydraulic Control 43 Standard Flow Auxiliary Hydraulics 52 Starting the Engine 47 Before Starting the Engine 47 Stationary Regeneration Abort Procedure 63 Stationary Regeneration Procedure 63 Stationary Regeneration Safety 62 Stopping the Loader 49 T T Bar Controls 41 Auxiliary Hydraulic...

Page 129: ...raised Load unload and turn on flat level surface WRONG Never carry riders Keep bystanders away from work area WRONG Never modify equipment Use only attachments approved for model loader WRONG Never leave loader with engine running or with lift arm up To park engage parking brake and put attachment flat on the ground WRONG ...

Page 130: ...If you have any questions on proper operation adjustment or maintenance of this machine contact your dealer or the Gehl Service Department before starting or continuing opera tion Manitou Americas Inc One Gehl Way P O Box 179 West Bend WI 53095 0179 U S A www gehl com California Proposition 65 Warnings Diesel engine exhaust and some of its constituents are known to the State of California to cause...

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Gehl R190, Operator'S Manual

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