Page 1 R135 R135 (EU) Form No. R135 X-Series 50940193 DP0415 English R150 Revision D R150 (EU) R150 X-Series R165 R165 (EU) R165 X-Series Skid-Steer Loaders...
Page 2 6. Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment. No agent, employee or representative of Gehl has any authority to bind Gehl to any warranty except as specifically set forth herein. 204927/AP0407 ®...
Page 3 R135, R150, R165 Skid-Steer Loader Operator’s Manual TABLE OF CONTENTS Introduction ........1 Safety .
Page 4 Equipment), 2006/42/EC (Machinery) and 2000/14/EC (Noise Emission), as amended by 2005/88/EC. In accordance with EN/ISO Standards: EN ISO 3450:1996, ISO 6165 Category: EARTH-MOVING MACHINERY/ LOADERS/COMPACT Models: R135, R150, R165 10. Directive/Conformity Assessment Procedure/Notified Body: 2004/108/EC Type-test Self-certification 97/23/EC Self-certification ---------- 2006/42/EC...
Page 5: Introduction
CHAPTER 1 INTRODUCTION Safety Symbol and Signal Words Manitou Americas, in cooperation with the Society of Automotive Engineers, has adopted this: Safety Alert Symbol This symbol identifies potential safety hazards, which, if not properly avoided, could result in injury. When you see this symbol in this manual or on the machine, you are reminded to BE ALERT! Your personal safety is involved! Signal Words...
Page 6: Safety
Follow the instructions in the Operator’s Manual Safety, Operation and Maintenance chapters, concerning accident prevention regulations, safety and occupational regulations, and machine and traffic regulations. Manitou Americas is not liable for injury or damage resulting from the failure to follow these regulations. Improper operation, inspection and maintenance CAUTION of the machine can cause injury or death.
Page 7 Machine Orientation “Right” and “left”, as described in this manual, are determined from a position sitting in the operator’s seat and facing forward. 1. Attachment Bracket 7. Lift Arm Support Device 13. Fuel Cap Cover 14. Seat Plate (according to ISO 2.
Page 8: Service And Registration
Proper Machine Use Improper use of the machine can result in property WARNING damage, injury or death. The machine is designed only for moving earth, coarse gravel or ballast and rubble. Use with approved attachments is also allowed – See “Fields of Application” on page 6. Use in any other way is considered as contrary to the intended use.
Page 9 Model and Serial Numbers Machine Model Number ____________________________________ Machine Serial Number ____________________________________ Engine Model Number ____________________________________ Engine Serial Number ____________________________________ 50940193/DP0415...
Page 10: Fields Of Application
Fields of Application Note: Refer to “Payloads/Capacities” on page 186 for specific bucket rated payload capacities. The attachments determine how the machine is used. Contact CEA Attachments at: http:// WARNING www.ceattachments.com/ContactUs.aspx for information about available attachments approved for use with the machine.
Page 11 0.40 m Bucket w/Spillguard (61.5 in.) (24.1 in.) (31.8 in.) (14.1 ft. 1372 mm 597 mm 983 mm 0.43 m R135 (54 in.) (23.5 in.) (38.7 in.) (15.0 ft. 1524 mm 597 mm 983 mm 0.48 m Light Material Bucket (60 in.)
Page 12 Table 1: Fields of Application Model Attachment Width Height Depth Capacity 1524 mm 505 mm 983 mm 0.31 m (60 in.) (19.9 in.) (38.7 in.) (11.0 ft. Dirt / Construction 1562 mm 505 mm 983 mm 0.32 m Bucket (61.5 in.) (19.9 in.) (38.7 in.) (11.3 ft.
Page 13: Vibration Information
Vibration Information Compact construction equipment is generally used in harsh environments. This type of usage can expose an operator to uncomfortable levels of vibration. It is useful to understand exposure to vibration levels when operating compact equipment and what can be done to reduce vibration exposure.
Page 14 If the assessment concludes that vibration level exposure is too high, one or more of the following actions may be necessary: 1. Train operators: • Perform operations (accelerating, steering, braking, etc.) in a smooth manner. • Adjust the controls, mirrors and seat suspension for comfortable operation. Do not make adjustments when the machine is in use.
Page 15 Fire Extinguisher Location An installation location for a fire extinguisher is shown in Figure 1. Important: Installation of a fire extinguisher according to DIN-EN 3 must be performed by an authorized dealer. Note: A fire extinguisher is neither included as standard equipment nor available as an option from Manitou Americas, Inc.
Page 16: Indicator And Operation Symbols
Indicator and Operation Symbols Safety Hazard Parking Brake High-Speed Float Hydraglide™ Pre-Heat Intake Hydraulic Oil Hydraulic Oil Elevated EGT Fasten Seat Belt Charging Fault Restriction Filter Warning Temp Warning Temp DPF Regen DPF Regen Regen Oil Pressure DPF Regen Engine Oil Accept Inhibited Maintenance...
Page 17 CHAPTER 2 SAFETY This safety alert symbol means ATTENTION! ALWAYS BE ALERT! YOUR SAFETY IS INVOLVED! This symbol is used throughout this operator’s manual and on the decals on the machine. The word “DANGER” indicates an imminently DANGER hazardous situation, that, if not avoided, will result in serious injury or death.
Page 18: Safety Equipment
Different applications may require optional safety equipment, such as a back-up alarm, mirror, strobe light or an impact-resistant front door. Be sure you know the job site hazards and equip the machine as needed. Remember that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause permanent injuries.
Page 19: Operation
• The machine is designed and intended for use only with Manitou attachments or Man- itou-approved attachments. To avoid possible personal injury, equipment damage and/ or performance problems, use only approved attachments that are within the operating capacity of the machine. Contact your dealer or Manitou Americas for information about attachment approval and compatibility with specific machine models.
Page 20: Additional Safety Equipment
• Machine stability is affected by: • The load being carried. • Height of the load. • Machine speed. • Abrupt control movements. • Driving over uneven terrain. DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE MACHINE TO TIP, WHICH COULD THROW THE OPERATOR OUT OF THE SEAT OR MACHINE, AND COULD RESULT IN DEATH OR SERIOUS INJURY.
Page 21 • Operator visibility is limited in certain areas; ROPS/FOPS posts, attachments, the lift arm, items in the cab, etc., can obstruct the operator's view and could mask hazards or people in the area around the machine. It is very important the operator is aware of these masked visibility areas before operating the machine, especially on busy work- sites.
Page 22 • Do not drive into materials at high speeds to avoid being thrown forward and injured. • Do not use the machine to lift or transport people. Never carry riders. Do not allow others to ride on the machine or attachments. •...
Page 23: Maintenance
• Never allow anyone under a raised lift arm. Lowering the lift arm or a falling load can result in death or serious personal injury. • Slow down the work cycle and use slower travel speeds in congested or populated areas.
Page 24 Parking the Machine • Never leave the operator's seat without lowering the lift arm/attachment flat on the ground or engaging the lift arm support device(s), and then stopping the engine and removing the ignition key. • When shutting the machine down for the day, plan ahead so the machine will be on a firm, level surface away from traffic and away from high walls, cliff edges and any area of potential water accumulation or runoff.
Page 25 Maintenance • Only trained and authorized personnel, with a full awareness of safe procedures, should be allowed to operate or perform maintenance or service on the machine. • Use warning tag/control lockout procedures during service. Alert others that service or maintenance is in progress by tagging the operator’s controls —...
Page 26 • Use solid support blocking. Never rely on jacks or other inadequate supports when maintenance work is being done. Never work under any equipment supported only by jacks. • Do not use the lift or tilt hydraulics to lift or support the machine for maintenance or service.
Page 27: Battery Hazards
• Keep fuel and other fluid reservoir caps tight. Do not start the engine until caps have been secured. Battery Hazards • Sparks and open flames can set off explosive battery gas from incidental contact or static discharge. Turn off the engine and all switches when working on batteries. Keep battery terminals tight.
Page 28 • Static electricity can produce dangerous sparks at the fuel-filling nozzle. 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 electric- ity.
Page 29: Loading And Transporting The Machine
• Fasten the rigging equipment so the machine is level when it is lifted. • Attach the rigging equipment only at the lift points on the properly attached lift kit. Lift the machine according to “Lifting the Machine Using a Crane or Hoist” on page 115.
Page 30 ANSI-Style Safety and Information Decals LEFT RIGHT FRONT OPERATOR’S POSITION Figure 2 – ANSI-Style Safety and Information Decal Locations 50940193/DP0415...
Page 31 Note: Refer to Figure 2 on page 26 for decal locations. Located on the front panel below the door, behind the attachment hitch. DANGER DANGER: AVOID INJURY OR DEATH AVOID INJURY OR DEATH • Keep out from under work tool, unless lift Keep out from under work tool, unless lift arm is supported.
Page 32 Note: Refer to Figure 2 on page 26 for decal locations. WARNING Located on the side of the ROPS/FOPS. WARNING: Crush Hazard • Be sure lock mechanism is securely engaged before working under ROPS/ FOPS. Read instructions for use in Operator’s Manual. USE PROPER HYDRAULIC FLUID ONLY! Located near the hydraulic fluid reservoir filler neck.
Page 33 Note: Refer to Figure 2 on page 26 for decal locations. Located inside the engine compartment. WARNING WARNING: HOT SURFACE • Do not touch hot engine or hydraulic system parts. Located on the right door pillar, facing the operator. WARNING AVOID INJURY OR DEATH WARNING: AVOID INJURY OR DEATH Always follow "Mandatory...
Page 34 Note: Refer to Figure 2 on page 26 for decal locations. Located on the bottom of the ROPS/FOPS operator enclo- sure. WARNING: Crush Hazard • Be sure lock mechanism is securely engaged before working under ROPS/FOPS. • Read instructions for use in Operator’s Manual. Located behind the operator’s seat above rear window WARNING: AVOID INJURY OR DEATH...
Page 35 Note: Refer to Figure 2 on page 26 for decal locations. Located on attachment bracket (power hitch only) 50354137 Located on attachment bracket (manual hitch only) DANGER Hose removal or coponent failure can cause lift arm to drop. Always use lift arm support device when leaving lift arm raised for service. 137637 Located on the left lift arm near the lift arm support.
Page 36 ISO-Style (Used Internationally) Safety and Information Decals LEFT RIGHT FRONT OPERATOR’S POSITION Figure 3 – ISO-Style (Used Internationally) Safety and Information Decal Locations 50940193/DP0415...
Page 37 Note: Refer to Figure 2 on page 26 for decal locations. Located on the front panel below the door, behind the attachment hitch. DANGER: AVOID INJURY OR DEATH A) Keep out from under work tool, unless lift arm is supported. B) No riders! Never use work tool as work platform.
Page 38 Note: Refer to Figure 2 on page 26 for decal locations. Located on the side of the ROPS/FOPS. WARNING: Crush Hazard • Be sure lock mechanism is securely engaged before working under ROPS/ FOPS. Read instructions for use in Operator’s Manual. USE PROPER HYDRAULIC FLUID ONLY! Located near the hydraulic fluid reservoir filler neck.
Page 39 Note: Refer to Figure 2 on page 26 for decal locations. Located on the right door pillar, facing the operator. DANGER: AVOID INJURY OR DEATH A) Crush hazard: Keep out from under lift arm unless lift arm is supported. B) Crush hazard: Hose removal or component failure can cause lift arm to drop.
Page 40 Note: Refer to Figure 2 on page 26 for decal locations. Located on the left door pillar, facing the operator. SAFETY ALERT A) Check machine before operation according to Operational Checks starting on page 81. Contact dealer (or manufacturer) for information and service parts.
Page 41 Note: Refer to Figure 2 on page 26 for decal locations. Located on the front of the lift arm cross- member. WARNING: AVOID INJURY OR DEATH • Before operating with attachment, check engagement of loader attachment bracket locking pin to the attachment. Located on attachment bracket (power hitch only) 50354137 Located on attachment bracket (manual hitch only)
Page 42 Product and Component Plate Locations Product and Component Plates 1. Operator protective system plate: with, e.g., model, certification and operator 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.
Page 43 CHAPTER 3 SAFETY EQUIPMENT Become familiar with all safety devices on the WARNING machine before starting. Know how to stop the machine before starting it. The machine is designed and intended to be used only with Manitou Americas-approved attachments or accessories. Manitou Americas cannot be responsible for operator safety if the machine is used with unapproved attachments.
Page 44: Seat Belt
Seat suspension Seat suspension can be adjusted as necessary to compensate for the drivers weight and preferred seat suspension stiffness. Mechanical suspension: While sitting in the operator’s seat, rotate knob (Z, Figure 5) as necessary to adjust seat suspension so weight indicator (X) is set to the approximate weight of the operator.
Page 45 Upper Torso Restraint (Option) Always wear the upper-torso restraint (J, Figure 6) WARNING when operating in high speed. The seat belt should always be fastened during operation. Important: Inspect the seat belt(s) for damage before use, and replace if damaged. Keep seat belt(s) clean.
Page 46 Safety Interlock System (Hydraloc™) NEVER attempt to bypass or defeat the safety WARNING interlock system. Serious personal injury or death could result. The Hydraloc™ safety interlock system provides for operator safety. The interlock system: • Prevents the engine from starting unless the operator is sitting in the operator’s seat with the restraint bar lowered.
Page 47: Parking Brake
Parking Brake The machine is equipped with a spring- applied, hydraulically-released parking brake. The parking brake is automatically applied when the restraint bar is lifted, the operator’s seat is not occupied, or the engine is shut off. The brake can also be applied manually by pressing button (K, Figure 9) on the control keypad on the right door pillar.
Page 48: Lift Arm Support
Lift Arm Support The lift arm support prevents the raised lift arm from lowering unexpectedly. The lift arm support must be applied whenever the lift arm is left in the raised position. A falling lift arm could result in severe injury or WARNING death.
Page 49: Disengage Lift Arm Support
7. Use the lift control to raise the lift arm until lift arm support (T, Figure 12) drops over the end of the lift cylinder and around the cylinder rod. 8. Slowly lower the lift arm until the free end of the support device contacts the top end of the lift cylinder (U).
Page 50 To prevent damage to the lift cylinder, do not lower CAUTION lift arm until the lift arm support is secured in the storage position. Battery Disconnect Switch (Option) The optional battery disconnect switch is located in the engine compartment. Turning the switch to the OFF position disconnects the battery from the electrical system.
Page 51 CHAPTER 4 INDICATORS AND CONTROLS Become familiar with all controls before operating WARNING the machine. Know how to stop the machine before starting it. The machine is designed and intended to be used only with Manitou-approved attachments or accessories. Manitou cannot be responsible for operator safety if the machine is used with unapproved attachments.
Page 52 Control Keypad Control Keypad Indicators Note: Control panel indicators are visible only when the indicator lamps are activated. Figure 16 – Control Keypad Indicators Table 2: Control Keypad Indicators Indicator Description Details High-Speed Travel Range Indicates high-speed travel range is activated. Indicator Lift Arm Float Indicator Indicates lift arm float is activated.
Page 53 Table 2: Control Keypad Indicators Indicator Description Details Indicates engine air filter requires service. See “Engine Engine Air Filter Restriction Air Cleaner” on page 139. During normal operation this Indicator indicator should be OFF. Indicates hydraulic oil filter requires service. Hydraulic Oil Filter Warning See“Changing Hydraulic Oil Filter”...
Page 54 Control Keypad Buttons Figure 17 – Control Keypad Buttons Table 3: Control Panel Buttons Button Description Function Parking Brake Engages / disengages parking brake. Activates optional beacon, position, and/or work lights. Beacon / Position / Work Lights See “Beacon/Position/Work Lights” on page 74. Cancels self-leveling function.
Page 55 Accessory Keypad Indicators/Buttons Heat Indicator: is lit when cab heat is activated Figure 18 – Accessory Keypad Indicators/Buttons Table 4: Accessory Keypad Buttons Button Description Function Turns cab heat/cool on/off. Low, medium and high HVAC Button settings are available. See “HVAC (Option)” on page 74.
Page 56 Optional Lights/Lockout Keypad Indicators/Buttons Figure 19 – Road Lights/Lockout Keypad Indicators/Buttons Table 5: Optional Road Lights/Lockout Keypad Buttons Button Description Function Operates optional road lights, and works with main control keypad to control the beacon and position lights. If all lights are off, one press activates the beacon and all position lights;...
Page 57 Information Center Electronic Display The information center electronic display is located on the right door pillar. It provides the following functionality: • Displays operational status such as engine fuel tank level, engine RPM, coolant tem- perature, service hours and system voltage. •...
Page 58 O. Regen/Return Button – Used for different functions depending upon screen and context: • Switches to the Regen display mode if the R. Regen Inhibit Button (DPF models) – Press for symbol is displayed on the screen. Also initiates 5 seconds to inhibit DPF reset regeneration. DPF regeneration if all appropriate conditions Displays the symbol.
Page 59 Table 6: Symbols Descriptions Symbol Description Symbol Description Diesel Particulate Filter (DPF) regeneration inhibit (DPF Models). See “Diesel Particulate Filter (DPF) Regeneration Procedures (DPF Percentage of engine power based Models)” on page 116. on load. Note: Strike-through line through the symbol is displayed in red when DPF regeneration is inhibited.
Page 60 Information Center Electronic Display Screens Note: Values may not display for all parameters, depending upon installed options and equipment. Table 7: Status, Maintenance and Error Code Screens Display Mode Description Status Screens Dual Gauge Display A. Fuel level. B. Engine coolant temperature. C.
Page 61 Table 7: Status, Maintenance and Error Code Screens Display Mode Description Single Gauge Display Displays single real time operating parameters. Switch between parameters using the navigation button (M, Figure 20). Used for various functions, depending upon screen and context. 1234.5 n/min Regeneration Screens (DPF Models) These screens are associated with Diesel Particulate...
Page 62 Table 7: Status, Maintenance and Error Code Screens Display Mode Description UNITS Units Screen Press the top/bottom of navigation rocker button (M, Figure 20) to switch between SAE or metric units for values displayed in screens. LANGUAGE Language Screen ENGLISH The press the top/bottom of navigation rocker button (M, Figure 20) to switch between English or Spanish language for values displayed in screens.
Page 63 Table 7: Status, Maintenance and Error Code Screens Display Mode Description DIAGNOSTICS INPUTS Input Status Alternator Float KP Ingnition Run Hydro Glide Displays input information from electronic control KP Ignition Start High Gear modules, showing real-time machine component/ KP Seat Switch Aux Detent control state.
Page 64: Throttle Controls
Throttle Controls On machines equipped with throttle knob (Q, Figure 22), engine speed is controlled with throttle knob and optional foot throttle (P, Figure 24), if installed. Throttle knob (Q) is the primary throttle control. The throttle is set with the knob to the desired idle/run position.
Page 65 Travel Drive, Lift and Tilt Controls Skid-Steer loaders are equipped with one of three control systems: • T-Bar Controls: see “T-Bar Controls” on page 61. • Joystick Controls: see “Joystick Controls” on page 64. • Hand and Foot Controls: see “Hand and Foot Controls” on page 67. T-Bar Controls On T-bar-equipped machines, the left T-bar controls the travel drive, and the right T-bar controls the attachment lift and tilt.
Page 66 On machines equipped with T-bar controls, the left T-bar controls the drive, and the right T-bar controls the lift/tilt. Drive Control (Left T-Bar) Forward, reverse, travel speed and turning maneuvers are controlled using the left T- bar (Figure 26): A. To go forward, push the left T-bar forward.
Page 67 Lift/Tilt Control (Right T-Bar) Lift arm raise and lower, and attachment tilt are controlled using the right T-bar (Figure 27): A. To lower the lift arm, push the right T-bar straight forward. B. To raise the lift arm, pull the right T-bar straight rearward.
Page 68 Joystick Controls On joystick-equipped machines, the left joystick controls the travel drive, and the right joystick controls the attachment lift and tilt. Left Joystick Right Joystick Figure 28 – Joystick Hand Controls Table 9: Joystick Controls Ref. Control Description Controls drive forward, reverse, turn, and speed. See Left Joystick “Drive Control (Left Joystick)”...
Page 69 Drive Control (Left Joystick) Forward, reverse, travel speed and turning maneuvers are controlled using the left joystick (Figure 29): A. To go forward, push the left joystick forward. B. To go in reverse, pull the left joystick rearward. C. To turn right, push the left joystick to the right.
Page 70 E. To lower the lift arm while tilting the attachment forward and down, move the right joystick forward and to the right. F. To lower the lift arm while tilting the attachment up and back, move the right joystick forward and to the left. G.
Page 71 Hand and Foot Controls On hand and fool controlled-equipped machines, the hand controls are used to control the travel drive, and the foot controls are used to control the attachment lift and tilt. Left Hand Control Right Hand Control Foot Controls Figure 31 –...
Page 72 Table 10: Hand and Foot Controls Ref. Control Description Auxiliary Hydraulics Rocker Controls auxiliary hydraulics flow direction and amount. Switch See “Auxiliary Hydraulic System” on page 79. Works with Auxiliary Hydraulics Rocker Switch to latch/ Auxiliary Hydraulics Continuous unlatch auxiliary hydraulics continuous flow. See “Auxiliary Flow Latch Trigger Hydraulic System”...
Page 73 Moving the hand controls farther from neutral increases the speed steadily to the maximum travel speed. Tractive effort decreases as wheel speed increases. For maximum tractive effort, move the hand controls only slightly away from the neutral positions. The engine will stall if the hand controls are moved too far forward when loading the bucket. Lift/Tilt Control (Foot Controls) Lift arm raise and lower, and attachment tilt are controlled using the foot controls...
Page 74 Press button (C, Figure 34) to switch between Left T-Bar high and low two-speed drive ranges. When the high-speed two-speed drive range is activated, the high-speed indicator ( ) on the control pad is lit. Left Joystick Left Hand Control Figure 34 –...
Page 75 Lift Arm Float Make sure the attachment is lowered to the ground WARNING before activating the lift arm float. Activating float with the lift arm raised will cause the lift arm and attachment to fall to the ground, which can cause severe injury or death. .The float mode WARNING Right T-Bar...
Page 76 2. To place the lift arm in the detent (“float”) position, use your toes to push the left pedal all the way down (A) into the detent. This position allows the lowered lift arm to “float” while traveling over changing ground conditions. 3.
Page 77 Hydraglide™ Ride Control System (Option) When Hydraglide™ ride control is activated, the lift WARNING arm may drop slightly without a load, or several inches with a heavy load. Do not use Hydraglide™ when using pallet forks. WARNING Hydraglide™ cushions lift arm loads during Right T-Bar transport.
Page 78 Beacon/Position/Work Lights The optional beacon, the rear red position lights. and the front and rear work lights are all operated using button (Z). Note: The rear work lights and red position lights are located at the top of the rear door. The front work lights are located at the top front corners of the ROPS/FOPS.
Page 79 Windshield Wiper/Washer All skid loaders are equipped with a wiper and washer on the rear window, machines equipped with a cab door are equipped with an additional wiper and washer on the front windshield. A. Windshield Wiper: Controls the front windshield wiper on machines equipped with a cab door.
Page 80: Accessory Plug
When the ignition is on, the light is activated by rotating it to either side (T, Figure 40); the light is deactivated by rotating it to the center. If the light is centered, the light will activate when the ignition is turned off. Note: The light will deactivate after approximately 10 seconds, if the ignition is turned on, or if the light is rotated by pressing on either side (T, Figure 40) of the light.
Page 81 Attachment Mounting The machine is equipped with either the standard manual All-Tach® hitch or optional Power-A-Tach® system hitch for mounting a bucket or other attachments. All-Tach® Hitch A manual latch lever (E, Figure 43) engages the latch pins, which lock the attachment onto the hitch.
Page 82 Power-A-Tach® System Buttons (G and H, Figure 45) on the control keypad are used to operate the Power-A- ® Tach System hitch. Refer to “Connecting Attachments” on page 96 for more information. Note: The Power-A-Tach® system hitch will not operate if the parking brake is engaged and/or the operator restraint bar is in the raised position.
Page 83 Locking pins (F) must be fully extended through the holes in the attachment frame before using the attachment. The attachment could fall off if it is not locked on the hitch and cause serious injury or death. Figure 47 – Hitch Locking Pins Auxiliary Hydraulic System Auxiliary hydraulics are used with attachments requiring hydraulic power.
Page 84 Auxiliary Hydraulics Control Rocker switch (F, Figure 49) controls the Right T-Bar direction and amount of auxiliary hydraulics flow. Auxiliary hydraulics control is proportional: the farther switch (F) is moved from center, the higher the flow through the auxiliary circuit. Flow direction is reversed when rocker switch (F) is moved in the opposite direction.
Page 85: Before Starting The Engine
CHAPTER 5 OPERATION Before Starting the Engine Before starting the engine and operating the WARNING machine: • Review and comply with all safety recommendations in the Safety chapter of this manual. • Know how to stop the machine before starting it. •...
Page 86: Checks During Operation
Table 11: Pre-Start Checks Check Refer To: Overall machine condition (including attachments) for bends, cracks, broken, loose or missing parts, etc. Engine cover securely closed and latched? Rags, tools, debris and other loose objects removed? (check especially after maintenance) Approved warning triangle, hazard warning light and first aid kit in the machine? Perform safety interlock system test See “Safety Interlock System Test”...
Page 87 Cab Entry and Exit Use only WARNING steps (A, Figure 50) and handles (B) on the machine when entering/exiting. Keep the steps and the handles clean to ensure a secure hold at all times. Never use the controls as hand holds. Remove dirt (oil, grease, earth, snow and ice) from handles (B), steps (A) and your shoes before entering the cab.
Page 88 Operate the door latch inside the cab using lever (D, Figure 52) located along the interior door frame. Figure 52 – Cab Interior Door Han- Important: If the door is removed for any reason, make sure to re-connect the door electrical connection (E, Figure 53) when the door is replaced.
Page 89: Starting The Engine
Starting the Engine Be familiar with the “Mandatory Safety Shutdown WARNING Procedure” on page 14 before starting the machine. Always perform this procedure before exiting the machine. Note: The machine cannot be push- or tow-started. Attempting to push/tow start the machine may damage the drive systems of both the machine and the push/tow vehicle.
Page 90 Important: The recommended limit of continuous starter engagement is 15 seconds, and the starter must never be energized for more than 30 seconds. If the starter is energized for 20-30 seconds, the ignition should be turned off for one minute or longer.
Page 91: After Starting
After Starting 1. Check that the charge ( ) and oil pressure ( ) indicators go out after the engine starts. Important: If the charge ( ) and/or the engine oil pressure ( ) indicators do not go out when the engine is running, shut down the engine immediately and correct the problem.
Page 92: Stopping The Machine
Warm Up Do not operate the machine until the hydraulic WARNING system reaches operating temperature. When cold, hydraulic response is slow and can be unpredictable, presenting an unsafe condition. Damage to the machine can also result. 1. After starting, allow the engine to run at low idle with no load for a minimum of 5 minutes without operating the drive, lift, tilt or auxiliary functions.
Page 93 Parking the Machine Park the loader away from traffic on firm, level ground. If this is not possible, park the loader across the incline and block the tires to prevent movement. After performing the “Mandatory Safety Shutdown Procedure” on page 14, perform the following: •...
Page 94 6. Tow the machine for short distances only, such as towing it onto a trailer. Depending on the internal leakage rate of the travel motors, the machine may roll easily with the brake release activated, or the tires may skid until the oil is forced from the motors. 7.
Page 95 1. Turn the ignition keyswitches of both machines to the OFF position. Be sure the controls in both machines are in the neutral position and the machines are NOT touching each other. If the machine with the booster battery has a drive transmission, place the transmission into neutral and apply the parking brake.
Page 96: Travel Drive Operation
Do not connect the other end of the negative WARNING jumper cable clamp to the negative terminal (-) on the discharged battery. Gas emerging from the battery may ignite if sparks are formed. 7. Start the machine with the discharged battery. See “Starting the Engine” on page 85. If the engine does not start immediately, stop cranking after 10 seconds and repeat starting procedure after approximately 30 seconds.
Page 97: Driving On An Incline
Driving on an Incline When traveling on an incline, travel with the heavy end pointing uphill. Driving over Rough Terrain When traveling over rough terrain, activate the Hydraglide™ ride control system and drive slowly with the bucket lowered in the transport position (“Attachment Transport Position”...
Page 98: Lift Arm Operation
Lift Arm Operation Refer to lift and tilt control information starting on page 61. Do not lift loads exceeding rated operating WARNING capacity. See “Payloads/Capacities” on page 186. The float mode can be used where the engine has WARNING stopped, is unable to be started, and lowering the lift arm is necessary to allow the operator to exit the loader.
Page 99 Float allows the lowered lift arm to follow the ground contour while traveling over changing ground conditions. It is useful when grading surfaces while driving the machine in reverse. Note: Lift arm float is not effective if the lift arm is lowered against the loader frame. See “Lift Arm Float”...
Page 100 Changing Attachments To prevent unexpected release of the attachment WARNING from the hitch, make sure the attachment is fully locked onto the hitch before using the attachment. On manual All-Tach® hitches, rotate the latch levers fully. On Power-A-Tach® hitches, verify that the pin flags are all the way to the outside of the hitch.
Page 101 6. Place the attachment lock into the locked Manual Attachment Hitch In position (Figure 62): Locked Condition • All-Tach® system manual hitch: Perform the “Mandatory Safety Shut- down Procedure” on page 14 and move hitch lock lever all the way to the left (G).
Page 102: Disconnecting Attachments
Disconnecting Attachments Position the attachment so that after WARNING disconnecting, the attachment will stand safely and not tip over. Serious injury can occur if an attachment tips over onto a person. 1. Empty the attachment and drive to an open, level area to disconnect the attachment. 2.
Page 103 Connecting Auxiliary Hydraulic Couplings Important: Connect hydraulically-powered attachment hoses to the auxiliary circuits after the attachment is secured to the hitch. Disconnect hydraulically-powered attachment hoses from the auxiliary circuits before removing the attachment from the hitch. 1. Empty the attachment and lower it to the ground. 2.
Page 104 Disconnecting Auxiliary Hydraulic Couplings 1. Empty the attachment and lower it to the ground. 2. Shut off the engine, but do not turn off the ignition. Move the auxiliary hydraulics control rocker switch (F, Figure 67) on the right T-bar, joystick or hand control back and forth to relieve pressure in the auxiliary hydraulics circuit.
Page 105 Self-Leveling (Option) Self-leveling automatically keeps the tilt angle Self-Leveling of the attachment constant, relative to the Operates When Lift ground plane, when the lift arm is raised (A, Arm is Raised Figure 68). This feature is especially useful when using pallet forks. Important: Self-leveling operates only when the lift arm is raised: when the lift arm is lowered (B), self-leveling is not activated.
Page 106 Self-Leveling Cancel The self-leveling cancel option allows deactivation of the self-leveling feature when equipped with this option. To deactivate self-leveling, press the self-level cancel button (E, Figure 69) on the control pad. To restore self-leveling, press button (E) again. Note: If equipped with this option, self- leveling is activated by default.
Page 107: Digging With A Bucket
Always carry the loaded bucket with the lift arm in the transport position. See “Attachment Transport Position” on page 94. For additional stability when operating on inclines, always travel with the heavier end of the loader toward the top of the incline. Make sure you have a good view of the material you are digging, and of the area you will be working in.
Page 108: Loading A Bucket
Loading a Bucket 1. (Figure 71) Lower the bucket to the ground. 2. Tilt the bucket slightly forward so the bucket cutting edge is pointing slightly down into the ground. 3. Drive forward until the bucket is filled with material. Adjust the bucket tilt as needed to remove an even layer of ground and to reduce...
Page 109 Never push the “float” button with the bucket or WARNING attachment raised, because this will cause the lift arm to fall to the ground, which can cause severe injury or death. Loading Trucks (or Hoppers) Important: When the self- leveling feature is on, the tilt angle of the attachment is kept constant, relative to the ground plane, when the lift arm is...
Page 110 Backfilling Holes and Embankments Do not drive too close to an excavation or ditch. Be WARNING sure the surrounding ground has adequate strength to support the weight of the loader and the load. 1. (Figure 75) Lower the bucket a few inches from the ground.
Page 111: Scraping With A Bucket
Scraping with a Bucket Important: Always scrape in the forward direction. 1. (Figure 27) Lower the lift arm down against the loader frame. 2. Tilt the bucket forward until the cutting edge is at a slight angle to the surface being scraped.
Page 112 Grading Using Float Make sure the bucket is lowered to the ground WARNING before activating the lift arm float. Activating float with an attachment raised will cause it to fall to the ground, which can cause severe injury or death. Do not drive the loader forward with the lift arm float activated.
Page 113 Using Pallet Forks Safety Instructions When Working with Pallet Forks Read the “Safety” section in this manual, starting WARNING on page 13, before working with pallet forks. Pay special attention to the “During Operation” information, starting on page 16. Follow all instructions in the Operator's Manual provided with the pallet forks.
Page 114 DO NOT push, pull or shove the fork arms, or move them in at a slanting angle; the resulting lateral forces can damage the fork arms. DO NOT pull loads off the fork arms, or allow loads to fall onto the forks arms.
Page 115: Transporting Loads Using Pallet Forks
Transporting Loads Using Pallet Forks Important: When the self-leveling feature is on, the tilt angle of the attachment is kept constant, relative to the ground plane, when the lift arm is raised. When the lift arm is lowered however, self-leveling is not activated. Refer to “Self-Leveling (Option)” on page 101 for more information about the self-leveling feature.
Page 116 15. Raise the pallet forks slightly above where the load will be placed. 16. Tilt the pallet forks as needed to level the fork arms. 17. Carefully drive slowly forward until the load is positioned precisely above where the load will be placed. Use care when aligning the load with a stack. 18.
Page 117: Loading And Transporting The Machine On A Transport Vehicle
Loading and Transporting the Machine on a Transport Vehicle Park the transport vehicle on a level surface. Be WARNING sure the vehicle and its ramps have the weight and size capacity to support the skid loader. Make sure the driver of the transport vehicle knows the overall height, width and weight of the vehicle, including the loaded skid loader, before starting transport.
Page 118 4. Slowly and carefully drive the skid loader in reverse up the ramp onto the transport vehicle. Important: Do not adjust travel direction while traveling on the ramps. Instead, drive down off of the ramps, and re-align the machine with the ramps. 5.
Page 119 Lifting the Machine Using a Crane or Hoist Note: Single-point and four-point lift kits are available for lifting the machine. Contact you dealer for more information. Contact your dealer for available lift kits for the WARNING machine. Do not lift the machine without an approved lift kit installed.
Page 120 Diesel Particulate Filter (DPF) Regeneration Procedures (DPF Models) The Diesel Particulate Filter (DPF) treats exhaust emissions in compliance with Tier 4 emission standards. The DPF filter relies on high exhaust temperatures. Periodic DPF maintenance (regeneration) is required, dependent upon machine operation load / temperature.
Page 121 Reset Regeneration Important: Reset regeneration can be prevented from occurring. See “Reset Regeneration Inhibit” on page 117. Reset regeneration occurs automatically (unless inhibited) approximately every 100 hours of operation. Note: Reset regeneration effectiveness is improved if the machine is operated at mid- to high-throttle settings while regeneration is in progress.
Page 122 Stationary Regeneration Stationary regeneration may be periodically required to reduce DPF soot build-up. The frequency of stationary regeneration is dependent upon machine operation and engine load. n/min The machine cannot be used during stationary regeneration and cannot be moved without interrupting the stationary regeneration process.
Page 123 3. When all three checkmarks (A, B & C) are displayed on the Stationary Regeneration screen, press and hold the button (Z) until the Stationary Regeneration In-Progress screen displays (Figure 84) 22 % Note: Stationary regeneration can be interrupted at any time by releasing the parking brake, advancing the throttle, or stopping the engine.
Page 124 DPF Maintenance DPF soot filter replacement is required when the DPF (Diesel Particulate Filter) Service Screen (Figure 86) displays. Note: Contact your dealer when the DPF Service screen displays. Figure 86 – Stationary Regenera- tion In-Progress Screen 50940193/DP0415...
Page 125 CHAPTER 6 MAINTENANCE Read and understand the “Safety” Chapter in this WARNING manual, starting on page 15, before servicing the machine. Follow all applicable warnings and instructions. Check for correct function after performing maintenance. Failure to follow instructions can result in injury or death. BEFORE performing any maintenance, perform the “Mandatory Safety Shutdown Procedure”...
Page 126 NEVER weld on the machine without consulting WARNING the manufacturer. Special metals may be used, which require special welding techniques or parts may be designed so that they should not be welded. NEVER cut or weld on fuel lines or tanks.
Page 127 Maintenance Schedules Table 13: Inspection, Checks and Cleaning Maximum Interval Service Procedure 10 Hours 500 Hours 250 Hours (or Daily) (or Annually) Remove foreign material (page 129). Check engine air cleaner restriction indicator (page 139). Check for loose or missing parts; repair/replace if necessary.
Page 128 Table 14: Leakage Check Maximum Interval Service Procedure 10 Hours 500 Hours 250 Hours (or Daily) (or Annually) Check engine for oil/coolant leaks. Check cooling system for leaks. Check hydraulic system for leaks. Table 15: Lubrication and Filter Changes Maximum Interval 250 Hours Service Procedure 10 Hours...
Page 129: Maintenance Log
Maintenance Log Log maintenance when it is performed in the following table. Table 17: Maintenance Log Date Hours Maintenance Procedure 50940193/DP0415...
Page 130 Table 17: Maintenance Log Date Hours Maintenance Procedure 50940193/DP0415...
Page 131 Table 17: Maintenance Log Date Hours Maintenance Procedure 50940193/DP0415...
Page 132: General Lubrication
General Lubrication Important: Use of lubricants not corresponding to manufacturer recommendations may invalidate warranty claims. Always dispose of waste lubrication oils and hydraulic fluids according to environmental laws or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain. See “Fluid Capacities/Lubricants”...
Page 133 Removing Foreign Material Remove dirt and other foreign matter from the following areas daily before operating the machine: • Around the lift cylinders. • At the front of the machine. • On the attachment hitch, especially around the tilt cylinder. •...
Page 134 3. Tilt the ROPS/FOPS up and back, moving the control handles out of the way. Tilt the ROPS/FOPS back slowly, until locking mechanism (B, Figure 88) locks the ROPS/FOPS in the raised position. Note: A gas-charged spring helps balance the ROPS/FOPS as it tilts. A self-actuating lock mechanism engages to lock the ROPS/FOPS in the tilted position.
Page 135 Important: Be sure the lifting apparatus is of sufficient capacity for the weight of the machine. Refer to “Weights” on page 93. If lifting the machine, refer to “Lifting the Machine Using a Crane or Hoist” on page 115. 3. Stack blocks or place jackstands under the flat part of the loader chassis.
Page 136: Engine Maintenance
Engine Maintenance Engine Access 1. Lift the engine cover and pull the rear door latch (Z, Figure 91) up. 2. Carefully swing open the rear door. Note: Rear door prop (Y) near the top hinge pin of the door is used to secure the door open.
Page 137 Engine Mounting Hardware Inspection Perform the Mandatory Safety Shutdown WARNING Procedure. Allow hot engine and hydraulic system components to cool before servicing. All bolts that secure the engine mounting brackets to the engine and the loader frame should be checked and re-tightened as necessary. Checking Engine Oil Level Check the engine oil level daily before starting the machine, or after every 10 hours of use.
Page 138 2. Perform “Mandatory Safety Shutdown Procedure” on page 14. 3. Wait until the engine has cooled, but is not completely cold. Note: Oil drains faster and more completely when warm. 4. All machines except model R165: Remove the rear belly pan to access engine oil drain plug (X, Figure 94).
Page 139: Adding Fuel
10. Clean the area around oil fill cap (E, Figure 93). Remove oil fill cap (E) and add the recommended type and amount of oil. See “Fluid Capacities/Lubricants” on page 183. Replace and tighten oil fill cap (E) after the oil is added. Note: Oil capacity listed is approximate.
Page 140 3. Using the ignition key to unlock fuel cap (F, Figure 97) and remove the fuel cap from the fuel filler neck. Note: On Model R135, fuel cap (F) is located under the engine cover. 4. Fill the fuel tank by adding fuel through the fuel filler neck opening.
Page 141 3. Inspect the water separator (Figure 98) for the presence of water: • If the indicator ring (M) is at the bot- tom of the cup, no action is required. • If the indicator ring (M) is floating off the bottom of the cup, water is present and needs to be drained.
Page 142: Changing Fuel Filter
7. Prime the fuel system by turning the ignition key to the ON position without starting the engine for 30 seconds. Repeat this step 3 times to ensure the fuel system is completely primed. Do not use the starter motor to crank the engine to CAUTION prime the fuel system.
Page 143: Engine Air Cleaner
Do not use the starter motor to crank the engine to CAUTION prime the fuel system. Damage to the engine starter motor, coils, pinion/ring gear could result. 8. Start the engine and check for leaks. Engine Air Cleaner Important: Failure to follow proper air filter servicing instructions could result in catastrophic engine damage.
Page 144 8. Check the inside of the housing for damage. 9. If applicable, install a new inner filter element (H). Make sure the sealing surfaces are clean and the new element is properly seated. 10. Install a new outer filter element (G). Make sure the sealing surfaces are clean and the new element is properly seated.
Page 145: Cooling System
Cooling System Important: Check the cooling system every day to prevent overheating, loss of performance or engine damage. Checking Coolant Level 1. Park the machine on a level surface. 2. Perform the “Mandatory Safety Shutdown Procedure” on page 14. 3. Wait until the engine has cooled. Do not remove radiator cap when the coolant is WARNING hot.
Page 146: Hydraulic System
Draining/Flushing Cooling System 1. Perform the “Mandatory Safety Shutdown Procedure” on page 14. 2. Wait until the engine has cooled. Do not remove WARNING radiator cap when the coolant is hot. Serious burns could result. 3. Slowly loosen radiator cap (P, Figure 105) and allow pressure to escape.
Page 147 The oil level should be in the middle (A) of the sight gauge. Models R135 • Model R135: Remove the hydraulic tank filler/dipstick cap (H). Important: Slowly remove the hydraulic oil fill cap (H). Allow the pressure to escape before completely removing the cap.
Page 148 5. If the hydraulic oil level is low, remove the hydraulic tank filler cap (H, Figure 108), located in the left engine compartment wall. Important: Slowly remove the hydraulic oil fill cap (H). Allow the pressure to escape before completely removing the cap. 6.
Page 149 Changing Hydraulic Oil The hydraulic oil must be replaced if it becomes contaminated, after major repairs, and after 1000 hours or one year of use. 1. Perform the “Mandatory Safety Shutdown Procedure” on page 14. 2. Wait until the engine has cooled. 3.
Page 150: Hydraulic Hose Maintenance
Hydraulic Hose Maintenance Hydraulic hoses and connections must be WARNING inspected by a trained technician before the first use of the machine, and at least annually thereafter, for leaks and/or damage. Leakages and damaged pressure hose/lines must be immediately repaired or replaced by an authorized service center. Never use your hands to check for suspected hydraulic leaks.
Page 151 Chaincases The chaincase contains the drive sprockets and drive chains. There are two plugs in each chaincase. One is to drain the oil and the other is to check the oil level. Refer to the “Maintenance Schedules” on page 123 for change intervals. See “Fluid Capacities/ Lubricants”...
Page 152: Bucket Cutting Edge
Drive Chain Tension Drive chains are located in the chaincase on each side of the machine. See “Maintenance Schedules” on page 123 for chain tension check interval. Checking Chain Tension 1. Raise the loader according to the “Lifting the Machine” on page 130. 2.
Page 153: Wheel Nuts
Wheel nut torque must be checked before initial operation and every two hours until the wheel mounting hardware torque stabilizes at the following recommended settings: • Model R135: 161-175 Nm (120-130 lb.-ft) • Models R150/165: 244 Nm (180 lb.-ft) Check wheel nut torque every 250 hours thereafter.
Page 154: Checking Tire Pressure
Checking Tire Pressure Table 18: Tire Inflation Pressures Inflation Pressure Tire Size 10.00 x 16.5 10-Ply Severe Duty 10.00 x 16.5 8-Ply Flotation 12.00 x 16.5 10-Ply Flotation 27 x 10.50 x 15 8-Ply Correct tire pressure should be maintained for all tires to enhance operating stability and extend tire life.
Page 155 Fuses, Relays and Diodes Important: Blown fuses indicate electrical system malfunctions. Determine what caused the fuse to blow and repair the problem before replacing the fuse. The fuse, relay and diode boxes are located in the engine compartment, just behind the cab, on the right side of the machine.
Page 156 Table 20: Fuse Locations (Figure 115) Rated Rated Current / Current / Fuse Circuit Fuse Circuit Resistance Resistance Ω Ω (A / (A / Control Keypad Windshield wiper, Door Electronic Control Unit Cab blower fan (ECU) Note: if required Dome light, Radio Horn, Alarm Exhaust Gas Recirculation Operator’s seat switch/...
Page 157 Battery Before servicing the battery or electrical system, WARNING be sure the battery disconnect switch (if equipped) is in the OFF position. If not equipped with a disconnect switch, disconnect the ground (-) terminal from battery. The battery on the loader is a 12-volt, wet-cell battery. To access the battery, remove front floor panel.
Page 158 Windshield Washer Reservoir The windshield washer reservoir (E, Figure 117) is located inside the engine compartment. Check the windshield washer reservoir level daily before starting the machine and fill if necessary. Important: Fill the windshield washer fluid reservoir with clean tap water or windshield washer fluid only.
Page 159: After Storage
After Storage 1. Replace and re-connect the battery. 2. If the machine is so equipped, turn the battery disconnect switch to the on position. See “Battery Disconnect Switch (Option)” on page 76. 3. Check tire pressure; adjust to correct pressure, if necessary. See “Tires” on page 149. 4.
Page 160 Final Shutdown / Decommissioning Important: Dispose of all materials properly. Used oils/fluids are environmental contaminants and may only be disposed of at approved collection facilities. Never drain any oils/fluids onto the ground, dispose of in municipal waste collection containers, or in metropolitan sewer systems or landfills.
Page 161 Machine Disposal Make sure all materials are disposed of in an ecologically sound manner. Recycle the machine in accordance with the current state of the art at the time of recycling. Observe all accident prevention regulations. Dispose of all parts at the at the recycling sites specific to the material of the part. Take care to separate different materials for recycling.
Page 162 NOTES 50940193/DP0415...
Page 163: Troubleshooting
CHAPTER 7 TROUBLESHOOTING Engine Troubleshooting Table 23: Engine Troubleshooting Problem Possible Cause Corrective Action Check circuit and replace fuse. See “Fuses, Blown fuse. Relays and Diodes” on page 151. Charge or replace battery—see “Jump- Dead battery. starting” on page 90. Battery disconnect switch in Place battery disconnect switch into closed open position or...
Page 164 Table 23: Engine Troubleshooting Problem Possible Cause Corrective Action Check battery and charge/replace as Engine cranking speed too necessary—tighten battery terminals. slow. In cold temperatures, pre-warm the engine. Fuel tank empty. Fill tank and vent fuel system if necessary. Fuel filter plugged or restricted. Change fuel filter. Fuel paraffin separation in Use winter grade diesel fuel.
Page 165 Table 23: Engine Troubleshooting Problem Possible Cause Corrective Action Black smoke indicates poor and incomplete diesel fuel combustion, which could be caused • Incorrect timing. • Dirty or worn injectors. • Incorrect valve clearance. • Incorrect air/fuel ratio. Black smoke •...
Page 166: Indicator Lamp Troubleshooting
Indicator Lamp Troubleshooting Table 24: Indicator Lamp Troubleshooting Indicator Icon Indicator Activated Possible Cause Corrective Action Stop engine immediately; Engine oil pressure too check oil level and top off low. oil if necessary; check oil pump. Engine oil pressure Top off oil. See “Fluid Capacities/Lubricants”...
Page 167: Seal And Hose Troubleshooting
Table 24: Indicator Lamp Troubleshooting Indicator Icon Indicator Activated Possible Cause Corrective Action Adjust V-belt tension. Alternator not charging Battery voltage properly. Repair/replace alternator. Replace air filter(s). See Air filter dirty/restricted. “Changing Air Filter Elements” on page 139. Engine air filter restriction Blockage in air filter Remove blockage.
Page 168 Table 26: Hydraulic System Troubleshooting Problem Possible Cause Corrective Action Low hydraulic fluid level. Top off hydraulic fluid. Replace existing oil with proper viscosity oil. Hydraulic oil viscosity too See “Fluid Capacities/Lubricants” on page 183. heavy. Allow longer warm-up. Engine to pump coupling or hydraulic pump damaged.
Page 169 Table 26: Hydraulic System Troubleshooting Problem Possible Cause Corrective Action Oil leaking past tilt cylinder seals (internal or external). Oil leaking past lift spool in Contact dealer. Attachment tilts control valve. down with tilt control Self-leveling valve malfunction. in neutral Leaking hydraulic hoses, tubes or fittings between control valve Repair as required.
Page 170 Table 26: Hydraulic System Troubleshooting Problem Possible Cause Corrective Action Restraint bar raised. Lower restraint bar. Check electrical connections. Restraint bar switch malfunctioning. Contact dealer. Check electrical connections. Solenoid malfunctioning. Contact dealer. Auxiliary hydraulics Spool in control valve not do not function actuated or leaking.
Page 171 Hydrostatic Drive System Troubleshooting Table 27: Hydrostatic Drive System Troubleshooting Problem Possible Cause Corrective Action Parking brake is applied. Release parking brake. Top off hydraulic oil. See “Checking Hydraulic Low hydraulic oil level. Oil Level” on page 143. See “Fluid Capacities/ Lubricants”...
Page 172 Table 27: Hydrostatic Drive System Troubleshooting Problem Possible Cause Corrective Action Top off hydraulic oil. See “Checking Hydraulic Low hydraulic oil level. Oil Level” on page 143. See “Fluid Capacities/ Lubricants” on page 183 for proper oil grade. Low hydrostatic system charge pressure.
Page 173: Electrical Troubleshooting
Electrical Troubleshooting Table 28: Electrical Troubleshooting Problem Possible Cause Corrective Action Turn battery disconnect switch to the ON Battery disconnect switch is in position. See “Battery Disconnect Switch OFF position. (Option)” on page 76. Battery terminals or cables Clean battery terminals and cables and loose or corroded.
Page 174 Table 28: Electrical Troubleshooting Problem Possible Cause Corrective Action Fuel level sender malfunction. Replace fuel level sender. Loose wiring/terminal Check wiring connections. connections. Fuel gauge inoperative Check circuit and replace fuse. See “Fuses, Blown fuse. Relays and Diodes” on page 151. Fuel gage malfunction.
Page 175: Error Codes
Error Codes The tables in this section describe error codes which may be reported on the information center electronic display screens DM1 and DM2. More than one error can be reported at one time and may be display on more than one screen. See page 58. Engine Diagnostic Trouble Codes (DTC) Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item...
Page 176 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State Intake Air Temperature Intake air temperature sensor fault (high P040D Sensor voltage) Intake Air Temperature Intake air temperature sensor fault (low P040C Sensor voltage) P2230 Barometric Pressure Sensor Intermittent fault Atmospheric Pressure Atmospheric pressure sensor fault (high P2229...
Page 177 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State Fuel temperature sensor temperature P0168 Fuel Temperature Sensor abnormally high Fuel temperature sensor fault (high P0183 Fuel Temperature Sensor voltage) Fuel temperature sensor fault (low P0182 Fuel Temperature Sensor voltage) P0219 Overspeed...
Page 178 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State Injector 1 (Cylinder Number P1262 Injector 1 short circuit Injector 4 (Cylinder Number P1268 Injector 4 short-circuit Injector 1 (Cylinder Number Injector 1 open circuit (inherent location P0203 of the Injector) Injector 4 (Cylinder Number...
Page 179 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State P0634 ECU Internal Temperature Too high ECU Internal Temperature P1664 Intermittent fault Sensor 1136 ECU Internal Temperature P0669 Shorted to high source Sensor ECU Internal Temperature P0668 Shorted to low source Sensor 1202...
Page 180 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State VB power short-circuit of throttle valve P1661 Intake Throttle Drive Circuit drive H bridge output 2 2951 GND short-circuit of throttle valve drive H P1662 Intake Throttle Drive Circuit bridge output 2 DPF Inlet Temperature DPF inlet temperature sensor...
Page 181 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State Engine Fuel Rack Actuator P1224 Intermittent fault Relay Engine Fuel Rack Actuator P1223 Circuit fault B Relay 522241 Engine Fuel Rack Actuator P1222 Circuit fault A Relay P1221 Reserved P1244...
Page 182 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State High-pressure pump drive circuit (drive P062A SCV (MPROP) current [high level]) 522572 High-pressure pump drive circuit (pump P1645 SCV (MPROP) overload error) 522573 P2463 Over-accumulation (method C) 522574 P1463 Over-accumulation (method P)
Page 183 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State Y_EC (CAN message) reception time U1293 CAN 2 out error 522600 P1637 ECU Internal Malfunction SW reset (recovery) execution 3 Y_RSS (CAN message) reception time U1294 CAN 2 out error 522601 WDA/ABE shut off due to dropped...
Page 184 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State 522751 P1443 Exhaust Throttle CAN fault P1633 ECU Internal Malfunction Actuator drive circuit 2 GND short-circuit P1607 ECU Internal Malfunction WDA/ABE communication error 522994 P1615 ECU Internal Malfunction CY320 SPI communication error P1616 ECU Internal Malfunction...
Page 185 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State PLV (Common Rail Rail pressure fault (the actual rail 523489 P1668 Pressure Limit Value); Rail pressure is too high during PRV limp Pressure Sensor mode) Rail Pressure Control/ Rail pressure fault (injector B/F temp 543491 P1669...
Page 186 NOTES 50940193/DP0415...
Page 187: Specifications
CHAPTER 8 SPECIFICATIONS Fluid Capacities/Lubricants Table 30: Fluid Capacities/Lubricants Component/ Type R135 R150 R165 Application Refer to the Engine Operator’s Manual for specific engine oil recommendations. 6.7 L (7.1 qts) (w/out filter) 9.5 L (10 qts) Service Classification: API-CJ- 4 SM...
Page 188 Table 30: Fluid Capacities/Lubricants Component/ Type R135 R150 R165 Application DPF Models: ULSD ultra-low sulfur only, below 15 PPM. ASTM D975 with biodiesel content limited to 5% of DIN EN14214 type (no additives allowed!) Non-DPF Models: Diesel Fuel 62.5 L (16.5 gal.)
Page 189 Weights Table 31: Weights R135 R150 R165 2327 kg 2690 kg 2796 kg Operating Weight (without counterweight) (5130 lbs.) (5930 lbs.) (6165 lbs.) 2424 kg 2783 kg 2887 kg Operating Weight (with counterweight) (5345 lbs.) (6135 lbs.) (6365 lbs.) 2073 kg...
Page 190 Payloads/Capacities Note: Refer to “Common Materials and Densities” on page 195 for selecting the appropriate bucket. Table 32: Payloads/Capacities (General) R135 R150 R165 Rated Operating Load 612 kg (1350 lbs.) 680 kg (1500 lbs.) 748 kg (1650 lbs.) (w/o Counterweight) Rated Operating Load 680 kg (1500 lbs.)
Page 191 228 kg 651 kg (502 lbs) (1436 lbs.) (70 in./20.3 ft. a. Can be used on R135 with 8.50 or 10.50 tires, but will provide zero (0) heel clearance Table 37: Pallet Forks R135 R150 R165 SAE Tipping Load (w/o Counterweight) 418 kg (922 lbs.)
Page 192 Engine Table 38: Engine R135 R150 R165 Yanmar 4TNV98C- Yanmar 4TNV88C-KMS (DPF Models) NMS2 (DPF Models) Engine Make/Model 4TNV98-ZNMS3R Yanmar 4TNV88-BKMSR2 (Non-DPF Models) (Non-DPF Models) Design In-line 4 cylinder, 4-stroke diesel, naturally aspirated Displacement 2.19 L (133.6 in 3.3 L (201.4 in Bore and Stroke 88 ×...
Page 193 14 (-10) -4 (-20) 2.6 (10) -13 (-25) -22 (-30) -44 (-42) Hydraulics Table 40: Hydraulics R135 R150 R165 Main Hydraulic System Pressure 207 bar (3000 psi) 60.5 L/min (16.0 71 L/min (18.75 62 L/min (16.4 gpm) Auxiliary System Standard-Flow @ gpm) @ 179.3 bar...
Page 194 Minimum Reserve Capacity 115 minutes minimum 170 minutes minimum Sound Levels Table 43: Sound Power/Pressure Levels Sound Power Level (Environmental) 101 dB(A) Sound Pressure Level (Operator Ear) 85 dB(A) With sound attenuation package. R165 with Tier 4 engine; R135/R150 with interim Tier 4 engine. 50940193/DP0415...
Page 195 0.68 Air Ride Suspension 0.73 Hand-Arm Vibration Values Control Option Vibration m/s Uncertainty m/s Hand/Foot 1.60 T-Bar 1.30 Model R135 Whole Body Vibration Values Seat Option Vibration m/s Uncertainty m/s Standard Non-Suspension 0.90 Mechanical Suspension 0.81 Air Ride Suspension 0.75...
Page 196 Dimensions Table 45: Dimensions R135 R150 R165 3655 mm 3876 mm Overall Operation Height – Fully Raised (143.9 in.) (152.6 in.) 2784 mm 3023 mm Height to Hinge Pin – Fully Raised (109.6 in.) (119 in.) Overall Height – Top of ROPS 1908 mm (75.1 in.)
Page 197 Table 45: Dimensions R135 R150 R165 Departure Angle (w/o Counterweight) 25° 21° Departure Angle (with Counterweight) 21° 19° Clearance Circle – Front (with Bucket) 1842 mm (72.5 in.) 1869 mm (73.6 in.) Clearance Circle – Front (w/o Bucket) 1120 mm (44.1 in.) 1130 mm (45.4 in.)
Page 198 Bucket Bolt-On Cutting Edge Kits Two-Speed Drive (Model R165 only) Electric (Battery) Disconnect Switch Radio System Counterweight Mechanical / Air Suspension Seat Cab Enclosure a. Model R165 only. b. Not available on Model R135. c. Standard on EU Machines 50940193/DP0415...
Page 199: Common Materials And Densities
Common Materials and Densities Table 48: Common Materials and Densities Density Material lbs./ft.3 kg/m3 Ashes 35-50 560-800 Brick-common 1792 Cement 1760 Charcoal Clay, wet-dry 80-100 1280-1600 Coal 3 53-6 848-1008 Concrete 1840 Cinders Coal-anthracite 1504 Coke Earth-dry loam 70-90 1121-1442 Earth-wet loam 80-100 1281-1602...
Page 200 NOTES 50940193/DP0415...
Page 201 INDEX Connection Attachments ..96 Control Keypad ....48 Accessory Keypad ... . 51 Controls .
Page 202 Adding Fuel ... . . 135 Chaincase ....147 Maintenance ... . 135 Chaincases .
Page 203 Operator’s Position ... . 39 Rear Window Emergency Operator’s Seat ....39 Exit ....43 Seat Suspension .
Page 204 Troubleshooting ... . . 159 Drive System ... . 167 Electrical ....169 Engine Diagnostic Trouble Codes (DTC) .
Page 205 Torque Specifications Note: Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread forming and sheet metal screws) unless specified otherwise. UNIFIED GRADE 2 GRADE 5 GRADE 8 NATIONAL LUBED LUBED LUBED THREAD 8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16-24...
Page 206: California Proposition 65 Warnings
State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling battery. ® Manitou Americas, Inc., One Gehl Way, P.O. Box 179, West Bend, WI 53095-0179 U.S.A. www.gehl.com/ © 2015 MANITOU AMERICAS, INC.

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