Gehl R190 Operator's Manual
  1. Manuals
  2. Brands
  3. Gehl Manuals
  4. Compact Loader
  5. R190
  6. Operator's manual

Gehl R190 Operator's Manual

Skid-steer loaders
Hide thumbs
Table of Contents

Advertisement

Quick Links

R190
Form No.
50950106
R220
AP0313
English
R260
Skid-Steer Loaders

Advertisement

Table of Contents
loading

Related Manuals for Gehl R190

Summary of Contents for Gehl R190

  • Page 1 R190 Form No. 50950106 R220 AP0313 English R260 Skid-Steer Loaders...
  • Page 2 WRONG Manitou Americas, Inc., in cooperation with the Society of Automotive Engineers, has adopted this Safety Alert Symbol to pinpoint precautions which, if not properly followed, can create a safety hazard. When you see this symbol in this manual or on the machine itself, you are reminded to BE ALERT! Your personal Never use loader safety is involved!

  • Page 3: Table Of Contents

    INDEX ........121 Loader Model Number Loader Serial Number Engine Serial Number Hydraloc and Hydraglide are trademarks of Manitou Americas, Inc. Gehl, Powerview, All-Tach and Power-A-Tach are registered trademarks of Manitou Americas, Inc.

  • Page 5: Introduction

    The Gehl dealership network stands ready to provide any assistance that may be required, including providing genuine Gehl service parts. All service parts should be obtained from your Gehl dealer. Provide complete information about the part and include the model and serial numbers of the machine.
  • Page 6 Loader Identification 1. Attachment Bracket 6. Tires 2. Restraint Bar 7. Lift Arm Support Device (in stowed position inside 3. Front Work Lights loader arm) 4. Tilt Cylinders 8. Auxiliary Couplers 5. Lift Arm 1. Roll-Over/Falling Object 4. Rear Work Lights Protective System 5.
  • Page 7 Control/Indicator Symbols Electrical Power Power Off Power On Engine Start Battery Charge Worklight w/Tail Worklight Safety Alert Hazard Flasher Fasten Seatbelt Lights Horn Read Operator’s Volume – Full Volume – Half Full Volume – Empty Manual High – Low Neutral Forward Reverse Parking Brake...
  • Page 8 Control/Indicator Symbols, cont. DPF Service Exhaust Gas DPF Regen Temperature Acknowledgement 50950106/AP0313...

  • Page 9: Safety

    CHAPTER 2 SAFETY This safety alert symbol means Attention! Become alert! Your safety is involved! It stresses an attitude of safety consciousness and can be found throughout this Operator’s Manual and on the decals on the machine. Before operating this machine, read and study the following safety information. Be sure that everyone who operates or works with this machine, whether family member or employee, is familiar with these safety precautions.

  • Page 10: Mandatory Safety Shutdown Procedure

    To ensure safe operation, replace damaged or worn-out parts with genuine Gehl service parts.  Gehl loaders are designed and intended 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.
  • Page 11 SEAT OR LOADER, RESULTING IN DEATH OR SERIOUS INJURY. Therefore: ALWAYS operate with the seatbelt fastened and the restraint bar lowered. Do not exceed the machine’s Rated Operating Capacity. Carry the load low. Move the controls smoothly and gradually, and operate at speeds appropriate for the conditions.

  • Page 12: Safety Decals

    These decals must be kept legible. If missing or illegible, they must be replaced promptly. Replacements can be obtained from your Gehl dealer. If there is a decal on a part that is to be replaced, be sure that the decal is applied to the replacement part.
  • Page 13 ANSI-Style Safety Decals inside the ROPS/FOPS AVOID INJURY OR DEATH Maintain 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;...
  • Page 14 ANSI-Style Safety Decals on the outside of the Loader 137655 – Located on front of loader and crossmember 132166 – Located on rear window emergency exit 137755 – Located on attachment bracket (manual hitch loaders only) AVOID INJURY OR DEATH Before operating with attachment, check engagement of loader attachment bracket locking pin...
  • Page 15 ANSI-Style Safety Decals on the outside of the Loader Be sure lock mechanism is securely engaged before working under ROPS/FOPS. Read instructions for use in Operator's Manual. 184214 184214 – Located under the ROPS/ FOPS 137637 – Located on the left side of the ROPS/FOPS and on the lift arm support device Be sure lock mechanism is securely engaged before working under ROPS/FOPS.
  • Page 16 ANSI-Style Safety Decals in the Engine Compartment 137657 – Located on the right riser ROTATING FAN HOT SURFACE Keep hands out Do not touch hot engine or or stop engine. hydraulic system parts. 50352528 50352529 50352528– Located on fan shroud 50352529 –...
  • Page 17 ISO-Style (used Internationally) Safety Decals inside the ROPS/FOPS Safety alert: Always follow “Mandatory Safety Shutdown Procedure” in Operator’s Manual. 1 – Lower equipment to ground. 2 – Reduce throttle, stop engine. 242568 – Located behind 3 – Apply parking brake; remove operator’s left shoulder key.
  • Page 18 ISO-Style (used Internationally) Safety Decals on the outside of the Loader 137844 137844 – Located on front of loader and crossmember A – Crush hazard: Keep out from under work tool unless lift arm is supported. B – Fall hazard: No riders. Never use work tool as work platform. 132166 –...
  • Page 19 ISO-Style (used Internationally) Safety Decals on the outside of the Loader 184711 – Located under the ROPS/FOPS Crush hazard: Be sure lock mechanism is securely engaged before working under ROPS/FOPS. Read instructions for use in Operator’s Manual. 50352566 50352631 50352566 – Located on the ROPS/ FOPS locking mechanism 50352631 –...
  • Page 20 ISO-Style (used Internationally) Safety Decals in the Engine Compartment 137845 137845 – Located on the right riser A – Safety alert: Keep safety devices in place and in working order. Keep guards, screens and windows in place. B – Fire hazard: Do not smoke while fueling or servicing machine. Clean debris from engine compartment daily to avoid fire.
  • Page 21 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 22 Notes 50950106/AP0313...

  • Page 23: Controls And Safety Equipment

    Know how to stop loader operation before starting it. This Gehl loader is designed and intended to be used only with Gehl attachments or Manitou Americas-approved referral attachments or accessories. Manitou Americas cannot be responsible for operator safety if the loader is used with non- approved attachments.

  • Page 24: Safety Interlock System

    Operator’s Seat The seat is mounted on rails for rearward and forward repositioning. A spring- loaded lever unlocks the seat position adjustment mechanism. Suspension seat (optional): A weight adjustment knob is provided for indi- vidual operator adjustment. Air Suspension Seat (optional): Adjust air suspension seat by pushing in the knob on the air seat to increase the amount of sus- pension.

  • Page 25: Restraint Bar

    Note: The auxiliary hydraulic circuit can be detented in the “ON” position for continuous operation with the restraint bar raised and operator out of the seat. (See Auxiliary Hydraulic Controls, page 43.) Testing the Safety Interlock System Before exiting the machine, check the safety interlock system for proper opera- tion: Restraint Bar With the engine running, raise the restraint bar.
  • Page 26 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.

  • Page 27: Accessory Plug

    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.

  • Page 28: Work Lights

    Work Lights Loaders have two sets of work lights. The front work lights are located at the top of the ROPS/FOPS. The rear work lights are located at the top of the rear grille. Heater (optional) Loaders with the optional heater have two control knobs on the left instrument panel for controlling fan speed and heater temperature (see Figure 5).

  • Page 29: Engine Speed Control

    Engine Speed Control An engine speed control (Figure 6) is pro- vided for setting the engine speed. Move the control clockwise to increase the engine speed, and counter-clockwise to decrease the engine speed. Engine speed may be limited while diagnostic trouble codes (DTC’s) are active or during a cold start.
  • Page 30 Float Control Dual joystick and hand/foot loaders use the left button on the right control handle for shifting between normal mode and float mode. For T-Bar loaders push the right control handle fully forward to detent the float control. This mode allows the lowered lift arm to follow the ground contour while traveling over changing ground conditions.
  • Page 31 To extend the hitch pins: Press down on the Power-A-Tach switch in the right instrument panel and the switch will detent to the ‘on’ position. To prevent unexpected release of the attach- WARNING ment from the hitch, be sure the latch pins are secure by verifying that the pin flags have moved fully to the out- side of the hitch.
  • Page 32 Indicator and Warning Lamp Display 1. Battery – Lights if the charging voltage is too high or too low. During normal operation this indicator should be OFF. 2. Engine Air Filter – Lights when a restriction in the engine air filter is detected, warning the operator to clean or replace the element in the engine air cleaner.
  • Page 33 Information Center Electronic Display Figure 10 Information Center Electronic Display The information center electronic display module is a three-button liquid crystal display (LCD) display located above the right instrument panel and it affords the operator a real time informational display of numerous engine, coolant, fuel, bat- tery and environmental parameters.
  • Page 34 Display Modes - Information Center Electronic Dis- play The information center is used to dis- the screen display to dual, multi or play live parameters and diagnostic DTC screen. Press the left “wrench” trouble codes available on the J1939 button to return to the main display. bus.
  • Page 35 Settings Menu - Information Center Electronic Display Language The user can select various supported languages for interface display. Fuel Level Source With Input mode selected, the device reads the fuel level signal from the dis- crete sensor input. In this mode, the local information is also broadcast on the J1939 network to other nodes.
  • Page 36 Information Center Electronic Display (cont.) 50950106/AP0313...
  • Page 37 Information Center Electronic Display (cont.) 50950106/AP0313...
  • Page 38 Information Center Electronic Display (cont.) Engine Stop The engine stop icon is used to notify the operator that the engine is in “backup” or “limp” mode. See the backup mode description on page 60 for more details. Engine Water Temp Overheat Warning The engine water temperature overheat icon is used to notify the operator of high engine coolant temperature.

  • Page 39: Left Panel

    Instrument Panels Left Panel 1. Indicator and Warning Lamp Display – See page 27. 2. Rotating Beacon/Strobe Switch (optional) – Controls the warning lamp (strobe or bea- con). 3. Hazard/Flasher Switch (optional) – Con- trols hazard/flasher. 4. High/Low Beam Switch (optional) – Con- trols road head lights between main/upper beams and dimmed/lower beams.
  • Page 40 Right Panel 1. Information Center Electronic Dis- play – See page 29. 2. Parking Brake Switch – Used to manu- ally apply the parking brake. Lights when the parking brake is applied. 3. Front Wiper/Washer (optional) 4. Rear Wiper/Washer (optional) 5.
  • Page 41 Note: The engine cannot be started unless the operator is sitting in the seat and the restraint bar is lowered. 7. Power-A-Tach ® System Switch – A three-position momentary rocker switch is used to actuate the Power-A-Tach® System. Press the top of the switch to retract (release) the hitch pins;...
  • Page 42 Lift/Tilt Control Moving the lift arm and tilting the attachment are accomplished by movement of the right joystick. To raise the lift arm, pull the control straight rearward; to lower the lift arm, push the control straight forward. To tilt the attachment for- ward and downward, move the control to the right;...
  • Page 43 Hand/Foot Controls The loader may be equipped with hand/foot controls (Figure 15). The handles control the drive and the foot pedals control the lift/tilt. Drive Controls Forward, reverse, speed and turning maneuvers are accom- plished by movement of the con- trol handles.
  • Page 44 Lift/Tilt Controls Moving the lift arm and tilting the attachment are accomplished by movement of the foot pedals. The left pedal raises and lowers the lift arm; the right pedal tilts the attachment. To raise the lift arm, push down on the back of the left pedal with your left heel;...
  • Page 45 T-Bar Controls The loader may be equipped with T-bar controls (Figure 16). The left T-bar controls the drive, and the right T-bar controls the lift/ tilt. Drive Controls Forward, reverse, speed and turning maneuvers are accom- plished by movement of the left T-bar.
  • Page 46 Lift/Tilt Control Moving the lift arm and tilting the attachment are accomplished by movement of the right T-bar. To raise the lift arm, pull the control straight rearward; to lower the lift arm, push the control straight forward. To tilt the attachment forward and downward, twist the control clockwise;...
  • Page 47 Auxiliary Hydraulic System Auxiliary hydraulics are used with attachments that have a mechanism requiring hydraulic power. Note: When ignition power is interrupted, auxiliary hydraulic function (both standard and high-flow) are reset to OFF. Standard-Flow Auxiliary Hydraulic Control Loaders are equipped with a standard-flow auxiliary hydraulic system with flat- face couplers.
  • Page 48 DPF (Diesel Particulate Filter) Regeneration The Gehl R190, R220 and R260 series skid-steer loaders utilize a DPF (diesel particulate filter) regeneration system on the engine to meet the Tier 4 emission requirements.
  • Page 49 Electrical Battery Disconnect Switch 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 50950106/AP0313...
  • Page 50 Notes 50950106/AP0313...

  • Page 51: Operation

    CHAPTER 4 OPERATION Before starting the engine and operating the WARNING loader, review and comply with all safety rec- ommendations in the Safety chapter of this manual. Know how to stop the loader before starting it. Also, be sure to fasten and prop- erly adjust the seatbelt(s) and lower the operator restraint bar.
  • Page 52 4. Turn the key to the START position. Note: If temperature is below 32°F (0°C), see Cold-Starting Procedure, on page 48. Important: Do not engage the starter for longer than 15 seconds at a time. Longer use can overheat and damage the starter. If the engine fails to start within 15 seconds, return the key to the OFF position or check for engine error codes.

  • Page 53: Stopping The Loader

    Cold Start Aids  At an ambient temperature of 32° F (0° C) or below, no starting aids are required. However, as with any diesel vehicle, using the recommended engine oil, maintaining a healthy battery and installing an engine block heater are sound practices to improve cold-starting performance and prolonging starter life.
  • Page 54 Parking the Loader Park the loader away from traffic on level ground. If this is not possible, park the loader across the incline and block the tires to prevent movement. Jump-starting If the battery becomes discharged or does not have enough power to start the engine, use jumper cables and the following procedure to jump-start the engine.
  • Page 55 Changing Attachments To prevent unexpected release of the attach- WARNING ment from the hitch, be sure to properly secure the hitch latch pins by rotating the latch lever fully (manual ® All-Tach hitch), or by verifying that the pin flags moved fully to ®...
  • Page 56 Connecting Auxiliary Hydraulic Couplings Note: With the engine off, key in the ON position and the restraint bar down, the auxiliary hydraulic control can be moved to relieve any pressure in the hydraulic system. Because the auxiliary hydraulics system is controlled using pilot pressure stored in an accumulator, the engine must have been run recently.

  • Page 57: Driving On An Incline

    Self-Leveling Cancel (optional) The self-leveling cancel option allows for the deactivation of the self-leveling feature. To deactivate self-leveling, press the top of the self-leveling cancel switch. To restore self-leveling, press the bottom of the self-leveling cancel switch. Using a Bucket Always maintain a safe distance from electric WARNING power lines and avoid contact with any elec-...

  • Page 58: Loading A Bucket

    Loading a Bucket Approach the pile with the lift arm fully lowered and the bucket tilted slightly for- ward until the edge contacts the ground. Drive forward into the pile, lifting the lift arm and tilting back the bucket to fill it. Back away from the pile (Figure 23).

  • Page 59: Scraping With A Bucket

    Scraping with a Bucket For scraping, the loader should be oper- ated in the forward direction. Position the lift arm down against the loader frame. Tilt the bucket cutting edge forward at a slight angle to the surface being scraped. While traveling slowly forward with the Figure 25 Scraping bucket in this position, material can flow...
  • Page 60 Storing the Loader If the skid-steer loader is to be stored for a period in excess of two months, the following procedures are suggested: 1. Fully inflate the tires. 2. Lubricate all grease zerks. 3. Check all fluid levels and replenish as necessary. (Review and follow the engine manufacturers recommendations from the Engine Operator’s Manual.) 4.
  • Page 61 Transporting the Loader Park the truck or trailer on a level surface. Be WARNING sure the vehicle and its ramps have the weight capacity to support the loader. Make sure the vehicle sur- face and its ramps are clear of debris and slippery material that may reduce traction.

  • Page 62: Lifting The Loader

    Lifting the Loader The loader can be lifted using a single-point or four-point lift kit, which are avail- able from your Gehl dealer. WARNING • Before lifting, check the lift kit for proper installation. • Never allow riders in the operator’s compartment while the loader is lifted.
  • Page 63 DPF (Diesel Particulate Filter) Regeneration The Gehl R190, R220 and R260 series skid-steer loaders utilize a DPF (diesel particulate filter) regeneration system on the engine to meet the Tier 4 emission requirements. The information center electronic display will automatically alert the user when a regeneration of the engine is required.
  • Page 64 Regeneration Terms and Definitions DPF: Diesel Particulate Filter Regen: Typically refers to the reset or stationary regeneration mode of the DPF, but could also refer to other regeneration modes, such as an assist or passive regeneration. PM: Particulate matter in the DPF Hours: Refers to the engine run-time hours E-ECU: Refers to the Engine-ECU Control Unit DTC: Diagnostic Trouble Codes...
  • Page 65 Engine Stop The engine stop icon is used to notify the operator that the engine is in “backup” or “limp” mode. See the backup mode description on page 60 for more details. DPF (Diesel Particulate Filter) Service The DPF service icon is used to notify the operator that the engine is in an emergency condition where ash cleaning is required.
  • Page 66 Stationary Regeneration Safety Before beginning a stationary regen operation there are several safety precautions to be aware of:  Do not do a stationary regeneration in a poorly ventilated location. There is the danger of carbon monoxide poisoning.  Be sure that there are no flammables near the exhaust pipes to avoid fires.
  • Page 67 Stationary Regeneration Procedure Take the following steps when performing a stationary regeneration. Refer to the DPF regen flowcharts (page 64) for a further understanding of this procedure. 1. Move to a safe location that is well-ventilated. 2. Set the acceleration of the engine to its lowest position and run the engine at idle speed.
  • Page 68 DPF Regen Flowcharts Machine Operator If a S S tationary Regen Mode is requested by How many hours since last Sta onary Regen? < 50 Hours > 50 Hours Sta onary Regen is not allowed. Sta onary Regen is allowed. Sta onary Regen See Sta onary Regen Procedure for complete details.
  • Page 69 DPF Regen Flowcharts, cont. ENGINE— ECU: If a Reset Regen Mode is ini ated by the Exhaust Gas Temp icon appears on the electronic display. Reset Regen is now ac ve See Reset Regen Descrip on for complete details. How can the operator cancel Reset Regen? Press the CANCEL side of the DPF switch.
  • Page 70 DPF Regen Flowcharts, cont. ENGINE— ECU If a Stationary Regen Mode is requested by the DPF REGEN ACKNOWLEDGE DPF SWITCH (Electronic Display) When these icons are ac ve, the E-ECU is reques ng a Sta onary Regen. A Sta onary Regen Procedure is What happens if a Sta onary required within 10 hours.

  • Page 71: Service

    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 battery, fuses or relays).
  • Page 72 241477 Belt, Alternator/Fan - R220/R260 242274 Belt, AC Compressor - All Models Note: Part numbers may change. Your Gehl dealer will always have the latest part numbers. Important: To ensure continued warranty coverage, use only genuine Gehl replacement filters. 50950106/AP0313...
  • Page 73 Loader Raising Procedure To raise the skid-steer loader so all four tires are off the ground, use the procedure below: Do not rely on a jack or hoist to maintain the WARNING raised position without additional blocking and supports. Serious personal injury could result from improp- erly raising or blocking the loader.
  • Page 74 Loader Lowering Procedure When service or adjustment procedures are complete, the loader can be lowered from the raised position. To lower the loader onto its tires: 1. Using a jack or hoist, raise the front of the loader until its weight no longer rests on the front blocks.
  • Page 75 Tilting Back the ROPS/FOPS A manual lock mechanism is used as a gas spring lock to prevent the raised ROPS/ FOPS from lowering unexpectedly. The manual lock mechanism engages to lock the ROPS/FOPS in a tilted-back position. To tilt back the ROPS/FOPS, remove two hex nuts on two anchor bolts at the front of the ROPS/FOPS.

  • Page 76: Control Handles

    Adjustments Control Handles The control handles do not require routine adjustment. Refer to the Service Manual for the initial setup procedure. Removing Foreign Material The loader should be cleared daily of dirt and other foreign materials in the following areas: •...
  • Page 77 ISO VG46. Hydraulic Entire System Capacity, R190: 11 U.S. gallons (41,6 L) System Oil Entire System Capacity, R220: 12 U.S. gallons (45,4 L) Entire System Capacity, R260: 12 U.S. gallons (45,4 L) Bare Reservoir Capacity: 8.0 U.S.
  • Page 78 50/500 50/250 Figure 36 Service Locations (see Maintenance Chart on page 103.) 10 Hours 500 Hours Lubrication Procedure (or Daily) Hours Hours (or Yearly)  Check Engine Oil Level (page 80)  Check Hydraulic Oil Level (page 87) Grease Hitch, Hitch-related Cylinder Pivots ...

  • Page 79: Checking And Adding Oil

    (Figure 38) on each chaincase and drain the oil into a suitable container. 3. Reinstall and tighten the drain plugs. 4. Refill the chaincases at the fill plugs per the procedure above. Figure 38 Drain Plug (R190 Shown) 50950106/AP0313...

  • Page 80: Drive Chains

    Drive Chains Drive chains are located in the chaincase on each side of the machine. Refer to the Maintenance Interval Chart (page 103) for tension check interval. Checking Chain Tension 1. Raise the loader following the Loader Raising Procedure (page 69). 2.

  • Page 81: Engine Air Cleaner

    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. R220/R260 R190 Figure 39 Dual-Element Air Cleaner 1. Element Housing (includes filters) 5. Restriction Indicator 2.
  • Page 82 Outer Element 1. Carefully pull the outer element out of the housing. Never remove the inner element unless it is to be replaced. 2. Clean out any dirt built up in the housing. Leave the inner element installed during this step to prevent debris from entering the engine intake manifold. 3.

  • Page 83: Engine Service

    9. Fuel Filter 3. Coolant Bottle 10. Remote Engine Oil Drain 4. Engine Radiator 11. Engine Oil Fill Cap 5. Hydraulic Cooler 12. Engine Oil Dipstick 6. Hydraulic Filter 13. Starter 7. Remote Engine Oil Filter 14. Alternator R190 Models 50950106/AP0313...
  • Page 84 Refer to the Maintenance Interval chart (page 103) for change intervals. Refer to the Replacement Parts chart (page 68) for filter part numbers. Refer to the Engine Operator’s Manual for detailed engine information. Checking Engine Mounting Hardware All bolts that secure the engine mounting brackets to the engine and the loader frame should be checked and re-torqued as necessary.

  • Page 85: Changing Fuel Filter

    Changing Fuel Filter The fuel filter is located on the left side of the engine. To begin, turn the plastic petcock located on top of the water separator (Figure 43) a 1/4 turn to stop fuel flow. Clean dirt from around the filter head. Remove the spin-on filter cartridge. Replace with a new filter cartridge.
  • Page 86 Engine Diagnostic Chart 50950106/AP0313...
  • Page 87 Engine Diagnostic Chart (cont.) 50950106/AP0313...
  • Page 88 Engine Diagnostic Chart (cont.) 50950106/AP0313...
  • Page 89 Engine Diagnostic Chart (cont.) 50950106/AP0313...
  • Page 90 Engine Diagnostic Chart (cont.) 50950106/AP0313...
  • Page 91 Hydraulic System Refer to the Maintenance Interval Chart (page 103) for service intervals. Refer to the Replacement Parts chart (page 68) for filter part numbers. Before servicing the hydraulic system, be WARNING sure the lift arm is lowered. Checking Hydraulic Oil Level Inside the engine compartment, the loader has a sight gauge located at the right rear of the chassis.

  • Page 92: Bucket Cutting Edge

    4. Replace the reservoir drain plug. 5. Clean any dirt/debris off the surface of the filter housing. 6. Spin off the old hydraulic filter ele- ment and spin on the new filter ele- ment. 7. Lubricate the seal on the new filter element with hydraulic oil before installing.

  • Page 93: Cooling System

    Cooling System Important: Check the cooling system daily to prevent overheating, loss of perfor- mance and engine damage. Drain, flush and refill coolant every year or 1,000 hours. Checking Coolant Level 1. With the engine at operating tempera- ture, open the engine cover. Looking at its plastic coolant recovery tank, check that the coolant tank fluid is half way up on the recovery tank,...
  • Page 94 Draining/Flushing the Cooling System 1. Drain, flush and refill once every year or at 1,000 operating hours. 2. Lower the lift arm and stop the engine. Allow the machine to cool. 3. Raise the engine cover and open the rear grille (page 70). 4.

  • Page 95: Checking Tire Pressure

    Tires Inflating or servicing tires can be dangerous. WARNING When possible, trained personnel should ser- vice and mount tires. To avoid possible death or serious injury, follow the safety precautions below. To keep tire wear even, rotate the tires from front to rear and rear to front. It is important to keep the same size tire on each side of the loader to prevent excessive wear on tires, chains, or other damage.
  • Page 96 Heater/Air Conditioner Filters The optional heater and heater/air conditioner include two filters: fresh air intake and recirculation air. Refer to the Replacement Parts topic (page 68) for filter part numbers. Filters should be replaced as needed. Fresh Air Intake Filter: Located directly behind the cover on the HVAC (heating, ventilating and air conditioning) housing mounted on the upper rear corner of the cab.
  • Page 97 Electrical System Fuse Panels The fuse panels (Figure 50) are located in the engine compartment on the chassis left riser, as well as behind a swell latch panel at the operator’s left foot area. Figure 50 Fuse Panels in the Engine Compartment Figure 51 Fuse Panels in the Operator’s Compartment REAR WORK...
  • Page 98 Battery Before servicing the batteries or electrical WARNING system, be sure the electrical battery discon- nect switch is in the OFF position or disconnect the negative (ground) battery cable. The battery on the loader is a 12-volt, group 24, wet-cell battery. To access the battery, open the engine access cover and lock open the rear grille.

  • Page 99: Troubleshooting

    CHAPTER 6 TROUBLESHOOTING Electrical System Problem Possible Cause Remedy Battery disconnect switch is Turn battery disconnect in OFF position. switch to ON. Main wiring harness Check main harness connectors at rear of ROPS/ connectors. FOPS not properly plugged in. Entire electrical Faulty keyswitch.
  • Page 100 Electrical System Problem Possible Cause Remedy Single light not working; light Check and replace light bulb bulb burned out, faulty as needed. Check wiring wiring. connection to light. No lights; light fuse blown. Check circuit and locate Work lights not trouble before replacing fuse.
  • Page 101 Engine Problem Possible Cause Remedy Engine cranking speed too Battery requires recharging slow. or replacing, or, in cold temperatures, pre-warm the engine. Auxiliary valve engaged. Return control valves to neutral. Fuel tank empty. Refill fuel tank. Engine turns over but will not start. Water in fuel filter.

  • Page 102: Hydrostatic Drive System

    Hydrostatic Drive System Problem Possible Cause Remedy Hydraulic oil viscosity too Allow longer warm-up or heavy. replace oil with proper No response from viscosity oil. either hydrostatic drive or the lift/tilt Hydraulic oil too low. Check for low oil level in systems.
  • Page 103 Hydraulic System Problem Possible Cause Remedy Hydraulic oil viscosity too Allow longer warm-up or heavy. replace oil with proper viscosity oil. Air in hydraulic system. Cycle lift and tilt cylinders to maximum stroke and Hydrostatic (drive) maintain pressure for short system is noisy.
  • Page 104 Hydraulic System Problem Possible Cause Remedy Restraint bar raised. Lower restraint bar. Hydraulic oil viscosity too Allow longer warm-up or heavy. replace with proper viscosity oil. Hydraulic oil level low. Check oil level in reservoir. If Lift/Tilt controls fail oil is low, check for external to respond.
  • Page 105 Hydraulic System Problem Possible Cause Remedy Float or Hydraglide activated. Turn off float and Hydraglide. No down pressure on Tilt cylinders malfunctioning. Contact your dealer. the bucket. Malfunctioning relief valve in Contact your dealer. main control valve. Oil leaking past tilt cylinder Contact your dealer.
  • Page 106 Hydraulic System Problem Possible Cause Remedy Restraint bar raised. Lower the restraint bar. Pilot solenoids Check electrical connections malfunctioning. to pilot solenoids, repair connections as needed. If still not functioning properly, contact your dealer. Control handle Contact your dealer. Auxiliary hydraulics malfunctioning.

  • Page 107: Maintenance

    CHAPTER 7 MAINTENANCE This Maintenance Interval chart was developed to match the Service chapter of this manual. Detailed information on each service procedure is in the Service chapter. A Maintenance Log follows this chart for recording maintenance performed. Recording 10-hour (or daily) service intervals is impractical and is not recommended. Important: Under severe operating conditions, more frequent service than the recommended intervals may be required.

  • Page 108: Maintenance Log

    Maintenance Log Date Hours Service Procedure 50950106/AP0313...
  • Page 109 Maintenance Log Date Hours Service Procedure 50950106/AP0313...
  • Page 110 Maintenance Log Date Hours Service Procedure 50950106/AP0313...

  • Page 111: Specifications

    CHAPTER 8 SPECIFICATIONS Loader Specifications Specification R190 Operating Weight (approx) 6880 lbs. (3121 kg) Shipping Weight (approx) 6250 lbs. (2835 kg) 1900 lbs. (862 kg) Rated Operating Load 2110 lbs. (957 kg) Rated Operating Load w/ optional 315 lb counterweight...

  • Page 112: Loader Specifications

    Loader Specifications Specification R220 Operating Weight (approx) 7980 lbs. (3620 kg) Shipping Weight (approx) 7250 lbs. (3289 kg) 2200 lbs. (998 kg) Rated Operating Load 2370 lbs. (1075 kg) Rated Operating Load w/ optional 315 lb counterweight Engine Make Yanmar (Turbocharged) Model 4TNV98CT-NMS Displacement...
  • Page 113 Loader Specifications Specification R260 Operating Weight (approx) 8200 lbs. (3719 kg) Shipping Weight (approx) 7500 lbs. (3402 kg) 2600 lbs. (1179 kg) Rated Operating Load 2780 lbs. (1261 kg) Rated Operating Load w/ optional 315 lb counterweight Engine Make Yanmar (Turbocharged) Model 4TNV98CT-NMS Displacement...

  • Page 114: Standard Features

    Couplers   Sliding Side Windows Impact-Resistant Front Door  Window Rear-View Mirror  Engine Air Pre-Cleaner (R190 Only)  Front Door with Wiper  Single and Four-Point Lift  Operator’s Compartment Heater/  Power-A-Tach ®...
  • Page 115 Dimensional Specifications 15.1 ft (0.43 m ) Bucket R190 w/10 x 16.5 Tires inches A Overall Operation Height – Fully Raised 4013 B Height to Hinge Pin – Fully Raised 120.5 3061 C Overall Height – Top of ROPS 2032 D Overall Length –...
  • Page 116 Dimensional Specifications 16.1 ft (0.46 m ) Bucket R220 w/12 x 16.5 Tires inches A Overall Operation Height – Fully Raised 4089 B Height to Hinge Pin – Fully Raised 3124 C Overall Height – Top of ROPS 2057 D Overall Length – Bucket Down 136.5 3467 E Dump Angle at Full Height...
  • Page 117 Dimensional Specifications 16.1 ft (0.46 m ) Bucket R260 w/12 x 16.5 Tires inches A Overall Operation Height – Fully Raised 4089 B Height to Hinge Pin – Fully Raised 3124 C Overall Height – Top of ROPS 2057 D Overall Length – Bucket Down 3632 E Dump Angle at Full Height 40°...

  • Page 118: Capacities And Ratings

    Capacities and Ratings R190, R220, R260 Note: Use the Common Materials and Densities table (page 116) for selecting the appropriate bucket. Dirt/Construction Buckets Description R190 R220 R260 Weight Rating Rating Rating 415 lbs. 1835 lbs. 66 in./15.1 ft. (1676 mm/0.43 m...
  • Page 119 Utility (Light Material) Buckets Description R190 R220 R260 Weight Rating Rating Rating 476 lbs. 1740 lbs. 66 in./19.0 ft. (1676 mm/0.43 m (216 kg) (789 kg) Utility 502 lbs. 1705 lbs. 1930 lbs. 2245 lbs. 70 in./20.3 ft. (1778 mm/0.46 m...

  • Page 120: Common Materials And Densities

    Common Materials and Densities Density Material lbs./cu. ft. kg/m Ashes 35-50 560-800 Brick-common 1792 Cement 1760 Charcoal Clay, wet-dry 80-100 1280-1600 Coal 53-63 848-1008 Concrete 1840 Cinders Coal-anthracite 1504 Coke Earth-dry loam 70-90 1121-1442 Earth-wet loam 80-100 1281-1602 Granite 93-111 1488-1776 Gravel-dry 1602...
  • Page 121 Bucket Selection To use the table, find the material to be loaded and its maximum density. Then multiply the volumetric rating of the attachment by the material density to deter- mine if the attachment can safely be used. See page 114 for a listing of attach- ments and their ratings.
  • Page 122 Notes 50950106/AP0313...

  • Page 123: Torque Specifications

    CHAPTER 9 TORQUE SPECIFICATIONS Use these torque values when tightening hardware (excluding locknuts, and self- tapping, thread-forming, and sheet metal screws) unless otherwise specified. 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...

  • Page 124: Warranty

    GEHL COMPANY WARRANTY GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months from the Warranty Start Date.

  • Page 125: Index

    INDEX Accessory Plug ....23 Capacities and Ratings ..114 Activating The Warming Circuit . . . 27 Chaincases ....75 Checking and Adding Oil .
  • Page 126 Engine Air Cleaner ... . . 77 Engine Compartment Dealer Services ....67 Access ..... . 70 Digging with a Bucket .
  • Page 127 Hydraulic System ... . . 87 Maintenance Interval Chart..103 Changing Oil ... . . 88 Maintenance Log .
  • Page 128 New Decal Application..8 No-Text Decals ... 13 T-Bar Controls ....41 Text Decals .
  • Page 129 WRONG WRONG Never exceed rated Always carry attachment operating load. as low as possible. Do not travel or turn with the lift arm raised. Load, unload and turn on flat level surface. WRONG WRONG Never carry riders. Never modify equipment. Keep bystanders away Use only attachments from work area.

  • Page 130: 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 © 2013 MANITOU AMERICAS, INC.

This manual is also suitable for:

R220R260

Table of Contents