Gehl R190, R220, R260 Operator's Manual

R190
R220
R260

Skid-Steer Loaders

Form No.

50950106

AP0313

English

Operator’s Manual

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
safety is involved!

Operators must have instructions
before running the machine.
Untrained operators can cause
injury or death.

CORRECT

WRONG

Never use loader
without ROPS/FOPS.
Never modify the
ROPS/FOPS
structure.

WRONG

Read Operator’s Manual
before using machine.

CORRECT

Always fasten seatbelt
snugly. Always keep feet on
the floor/pedals when
operating loader.

Never use the loader
to lift personnel.

WRONG

Do not use loader
around explosive dust
or gas, or where
exhaust can contact
flammable material.

R190, R220, R260 Skid-Steer Loader Operator’s Manual

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Controls and Safety Equipment . . . . . . . . . . . . . . . . . . . 19

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Loader Model Number

Loader Serial Number

Engine Serial Number

Gehl, Powerview, All-Tach and Power-A-Tach are registered trademarks of Manitou Americas, Inc.

Hydraloc and Hydraglide are trademarks of Manitou Americas, Inc.

CHAPTER 1

INTRODUCTION

This Operator’s Manual provides the owner/operator with information for operat­ing, maintaining and servicing models R190, R220 and R260 skid-steer loaders.
More important, this manual provides an operating plan for safe and proper use
of the machine. Major points of safe operation are detailed in the Safety chapter
of this manual.

Users should read and understand the contents of this manual completely and
become familiar with the machine before operating it. Contact your authorized
Gehl dealer if you have any questions concerning information in this manual,
require extra manuals, and for information concerning the availability of manuals
in other languages.

Throughout this manual information is provided set in italic type and introduced
by the word Note or Important. Read carefully and comply with those messages
– it will improve operating and maintenance efficiency, help avoid breakdowns
and damage, and extend the machine’s life.

A manual storage box in the operator’s compartment behind the seat holds the
Operator’s Manual and AEM Safety Manual (also available in Spanish). Please
return the manuals to this box and keep them with the unit at all times. If this
machine is resold, these manuals should be given to the new owner.

The attachments and equipment available for use with this machine have a wide
variety of applications. Read the manual provided with the attachment to learn
how to safely maintain and operate the equipment. Be sure the machine is suit­ably equipped for the type of work to be performed.

Do not use this machine for any applications or purposes other than those
described in this manual or those applicable for approved attachments. If the
machine is to be used with special attachments or equipment other than those
approved by Manitou Americas, consult your Gehl dealer. Any person using non­approved attachments or making unauthorized modifications is responsible for
the consequences.

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. Record these numbers
in the space provided on the Table of Contents page as a handy reference.

Please be aware that Manitou Americas strives to continuously improve its prod­ucts and reserves the right to make changes and improvements in the design and
construction of any part without incurring the obligation to install such changes
on any previously delivered unit.

If this machine was purchased “used,” or if the owner’s address has changed,
please provide your Gehl dealer or Gehl Service Department with the owner’s
name and current address, along with the machine model and serial number. This
will allow the registered owner information to be updated, so that the owner can
be notified directly in case of an important product issue, such as a safety update
program.

50950106/AP0313 1

Loader Identification

1. Attachment Bracket

2. Restraint Bar

3. Front Work Lights

4. Tilt Cylinders

5. Lift Arm

6. Tires

7. Lift Arm Support Device (in stowed position inside loader arm)

8. Auxiliary Couplers

1

2

5

4

3

3

6

7

8

1. Roll-Over/Falling Object Protective System (ROPS/FOPS)

2. Lift Cylinder

3. Engine Cover

4. Rear Work Lights

5. Tail Lights (Position Lights)

6. Rear Grille

7. Fuel Cap

2

6

3

5

1

5

7

4

4

2 50950106/AP0313

Control/Indicator Symbols

Power Off Power On Engine Start Battery Charge

Worklight w/Tail

Lights

Horn Read Operator’s

H-L

High – Low

Engine Air Filter

Engine Temperature Hydraulic System Hydraulic Oil

Worklight Safety Alert Hazard Flasher Fasten Seatbelt

Manual

N

Neutral

Engine Oil Engine Oil Filter Engine Oil Pressure Fuel Filter

Volume – Full Volume – Half Full Volume – Empty

F

Forward

Hydraulic Oil Filter Grease Lubrication

Temperature

R

Reverse

Electrical Power

Parking Brake

Point

Glow Indicator

Lamp

Fast Slow Ride Control Engine Malfunction

Bucket – Rollback Bucket – Dump

Lift Point Tie-Down Diesel Water

50950106/AP0313 3

Diesel Fuel Chaincase Oil Clockwise Rotation Counterclockwise

Shutdown

Lift Arm – Lower

Separator

Lift Arm – Raise Service Hours

Power-A-Tach®

Rotation

Bucket – Float

Air Circulating Fan

Control/Indicator Symbols, cont.

DPF Service Exhaust Gas

Temperature

DPF Regen

Acknowledgement

4 50950106/AP0313

CHAPTER 2

DANGER

WARNING

CAUTION

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. It is essential to
have competent and careful operators, who are not physically or mentally
impaired, and who are thoroughly trained in the safe operation of the machine
and the handling of loads. It is recommended that the operator be capable of
obtaining a valid motor vehicle operator’s license.

The use of skid-steer loaders is subject to certain hazards that cannot be elimi­nated by mechanical means, but only by exercising intelligence, care and
common sense. Such hazards include, hillside operation, overloading, instability
of the load, poor maintenance and using the equipment for a purpose for which it
is not intended or designed.

Manitou Americas ALWAYS considers the operator’s safety when designing its
machinery, and guards exposed moving parts for the operator’s protection. How­ever, some areas cannot be guarded or shielded in order to assure proper opera­tion. This Operator’s Manual and decals on the machine warn of additional haz­ards, and they should be read and observed closely.

Some photographs in this manual may show doors, guards or shields open or
removed for illustrative purposes only. Be sure that all doors, guards and shields
are in their proper operating positions before starting the engine to operate the
unit.

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.

“DANGER” indicates an imminently haz­ardous situation, which, if not avoided, will

result in death or serious injury.

“WARNING” indicates a potentially hazardous
situation, which, if not avoided, could result

in death or serious injury.

“CAUTION” indicates a potentially hazardous
situation, which, if not avoided may result in

minor or moderate injury. May also alert against unsafe practices.

50950106/AP0313 5

Mandatory Safety Shutdown Procedure

Before cleaning, adjusting, lubricating or servicing the unit, or leaving it
unattended:

1. Move the drive control handle(s) to the neutral position.

2. Lower the lift arm and attachment completely. If the lift arm must be left in the raised position, BE SURE to properly engage the lift arm support device (page 22).

3. Move the throttle to the low idle position, shut off the engine and remove the key.

4. Before exiting, move the lift/tilt control(s) to verify that the controls do not cause movement of the lift arm and hitch.

Safety Reminders

Before Starting

 Do not modify the ROPS/FOPS unless instructed to do so in installation

instructions. Modifications such as welding, drilling or cutting can weaken
the structure and reduce the protection it provides. A damaged ROPS/FOPS
cannot be repaired – it must be replaced.

 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, equip­ment damage and performance problems, use only attachments that are
approved for use on and within the operating capacity of the machine. Con­tact your dealer or Gehl Service Department for information on attachment
approval and compatibility with specific machine models. Manitou Americas
cannot be responsible if the machine is used with a non-approved attachment.

 Remove all trash and debris from the machine each day, especially in the

engine compartment, to minimize the risk of fire.

 Always face the loader and use the handholds and steps when getting on and

off the loader. Do not jump off the loader.

 Never use starting fluid (ether).
 Walk around the machine and warn all nearby personnel before starting the

machine.

 Always perform a daily inspection of the machine before using it. Look for

damage, loose or missing parts, leaks, etc.

During Operation

 Machine stability is affected by: load being carried, height of the load,

machine speed, abrupt control movements and driving over uneven terrain.

DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE
LOADER TO TIP, THROWING THE OPERATOR OUT OF THE

6 50950106/AP0313

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.

 When operating on inclines or ramps, always travel with the heavier end of

the loader toward the top of the incline for additional stability.

 Do not raise or drop a loaded bucket or fork suddenly. Abrupt movements

under load can cause serious instability.

 Never activate the float function with the bucket or attachment loaded or

raised, because this will cause the lift arm to lower rapidly.

 Do not drive too close to an excavation or ditch; be sure that the surrounding

ground has adequate strength to support the weight of the loader and the load.

 Never carry riders. Do not allow others to ride on the machine or attachments,

because they could fall or cause an accident.

 Always look to the rear before backing up the skid-steer loader.
 Operate the controls only from the operator’s seat.
 Always keep hands and feet inside the operator’s compartment while oper-

ating the machine.

 New operators must operate the loader in an open area away from bystanders.

Practice with the controls until the loader can be operated safely and
efficiently.

 Wear safety goggles and head protection while operating the machine. Oper-

ator must wear protective clothing when appropriate.

 Exhaust fumes can kill. Do not operate this machine in an enclosed area

unless there is adequate ventilation.

 When parking the machine and before leaving the seat, check the restraint bar

for proper operation. The restraint bar, when raised, deactivates the lift/tilt
control and auxiliary hydraulics, and applies the parking brake.

Maintenance

 Never attempt to by-pass the key switch to start the engine. Use only the

jump-starting procedure detailed in the Operation chapter of this manual.

 Never use your hands to search for hydraulic fluid leaks. Instead, use a piece

of paper or cardboard. Escaping fluid under pressure can be invisible and can
penetrate the skin and cause serious injury. If any fluid is injected into your
skin, see a doctor at once. Injected fluid must be surgically removed by a
doctor or gangrene may result.

 Always wear safety glasses with side shields when striking metal against

metal. In addition, it is recommended that a softer (chip-resistant) material be
used to cushion the blow. Failure to heed could lead to serious injury to the
eyes or other parts of the body.

 Do not smoke or have any spark-producing equipment in the area while

filling the fuel tank or while working on the fuel or hydraulic systems.

50950106/AP0313 7

Potential Hazards

A skid-steer loader operator must ALWAYS be conscious of the working environ­ment. Operator actions, the environmental conditions and the job being preformed
require the full attention of the operator so that safety precautions can be taken.

ALWAYS maintain a safe distance from electric power lines and avoid contact
with any electrically charged conductor or gas line. Accidental contact or rupture
can result in electrocution or an explosion. Contact the North American One-Call
Referral System at 8-1-1 in the U.S., or 1-888-258-0808 in the U.S and Canada,
for the local “Digger's Hotline” number or the proper local authorities for utility
line locations BEFORE starting to dig!

Exposure to crystalline silica (found in sand, soil and rocks) has been associated
with silicosis, a debilitating and often fatal lung disease. A Hazard Review
(Pub. No. 2002-129) by the U.S. National Institute for Occupational Safety and
Health (NIOSH) indicates a significant risk of chronic silicosis for workers
exposed to inhaled crystalline silica over a working lifetime. NIOSH recom­mends an exposure limit of 0.05 mg/m
10-hr. workday during a 40-hr. workweek. NIOSH also recommends substituting
less hazardous materials when feasible, using respiratory protection and regular
medical examinations for exposed workers.

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 electricity. Do not re-enter the machine but stay near the fuel filling point
during refueling to minimize the build-up of static electricity. Do not use cell
phones while fueling. Make sure the static line is connected from the machine to
the fuel truck before fueling begins.

Ultra-Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier
diesel formulations. Avoid death or serious injury from fire or explosion; consult
with your fuel or fuel system supplier to ensure the entire fuel delivery system is
in compliance with fueling standards for proper grounding and bonding practices.

3

as a time-weighted average for up to a

Safety Decals

The skid-steer loader has decals that provide safety information and precautions
around the loader. 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.

New Decal Application

Surfaces must be free of dirt, dust, grease and foreign material before applying
the decal. Remove the smaller portion of the decal backing paper and apply the
exposed adhesive to the clean surface, maintaining proper position and align­ment. Peel the rest of the backing paper and apply hand pressure to smooth out
the decal surface. Refer to the following pages for proper decal location. ANSI­style text decals begin on page 9; ISO-style no-text decals begin on page 13.

8 50950106/AP0313

ANSI-Style Safety Decals inside the ROPS/FOPS

242582 – Located behind operator’s left

shoulder

242260 – Located
on upper left
instrument panel

242397 – Located on lower left
instrument panel

242236 – Located
on upper right
instrument panel

242260

Main tain 3 -point contact

during entry and exit

Inspect w ork area ; avoid

all hazards

Look in dir ection of travel; Kee p

children and bystanders away

Start an d operate machine only

from the operato r's seat

Never carry riders;

Do not lift personnel in bucket

Operate only in well-ventilated

area

Keep away from electric powe r

lines, avoid contact

Do not wear loose cloth ing
while opera ting or servicin g
machine

Wear any needed Personal
Protective Equipment

AVOID INJURY OR DEATH

50950106/AP0313 9

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)

Before operating with attachment,
check engagement of loader
attachment bracket locking pin
to the attachment.

AVOID INJURY OR DEATH

139101 – Located on attachment bracket (power hitch loaders only)

10 50950106/AP0313

ANSI-Style Safety Decals on the outside of the Loader

184214 – Located under the ROPS/
FOPS

137637 – Located on the left side of the ROPS/FOPS and on the lift arm
support device

50352637 – Located on the ROPS/FOPS locking mechanism

Be sure lock
mechanism is securely
engaged before
working under
ROPS/FOPS.

Read instructions
for use in
Operat or's Ma nu al.

184214

50352637

Be sure lock mechanism is securely engaged
before working under ROPS/FOPS.
Read instructions for use in Operator's Manual.

50950106/AP0313 11

ANSI-Style Safety Decals in the Engine Compartment

ROTATING FAN

Keep hands out

or stop engine.

50352529

50352528

HOT SURFACE

Do not touch hot engine or

hydraulic system p arts.

137657 – Located on the right riser

50352529 – Located on fan shroud inside
engine compartment

50352528– Located on fan shroud
inside engine compartment

12 50950106/AP0313

ISO-Style (used Internationally)

242590

G

A

B

C

D

E

F

A – Forward tip hazard: Fasten seat belt. Carry load low. Do

not exceed Rated Operating Load.

B – Side tip hazard: Avoid steep slopes and high speed turns.

Travel up and down slopes with heavy end uphill.

C – Crush hazard: Keep out from under lift arm unless lift arm

is supported.

D – Crush hazard: Keep hands, feet and body inside cab when

operating.

Safety alert: Read Operator’s
Manual and all safety signs
before using machine. The
owner is responsible to ensure
all users are instructed on safe
use and maintenance.

242568 – Located behind
operator’s left shoulder

242246 – Located on right instrument panel

Safety alert: Always follow

“Mandatory Safety Shutdown
Procedure” in Operator’s
Manual.

1 – Lower equipment to ground.
2 – Reduce throttle, stop engine.
3 – Apply parking brake; remove

key.

4 – Check safety interlocks.

242590 –
Located on left
instrument
panel

Safety alert:
A – Check machine before

operating; Service per
Operator’s Manual. Contact
dealer (or manufacturer) for
information and service parts.

B – Maintain 3-point contact during

entry and exit.

C – Inspect work area. Avoid all

hazards. Look in direction of
travel. Keep children and
bystanders away.

D – Start and operate machine only

from seat.

E – Keep away from power lines;

avoid contact.

F – Wear any needed Personal

Protective Equipment. Do not
wear loose clothing while
operating or servicing machine.

E

242284 – Located on operator’s lower

right side

A

B

C

D

A

B

C

D

F

242408 – Located on operator’s lower

left side

A

B

C

D

Safety Decals inside the ROPS/FOPS

50950106/AP0313 13

ISO-Style (used Internationally)

137844

137844 – Located on front of loader and crossmember

132166 – Located
on rear window
emergency exit

137852 – Located on hitch (manual hitch loaders only)

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.

Crush hazard: Before operating with attachment, check engagement of hitch

locking pin to the attachment:

A – Incorrect attachment engagement C – Lock hitch lever
B – Correct attachment engagement D – Unlock hitch lever

AB

A

B

C

D

Before operating with attachment,
check engagement of loader
attachment bracket locking pin
to the attachment.

AVOID INJURY OR DEATH

139101 – Located on hitch (power hitch loaders only)

Crush hazard: Before operating with attachment, check engagement of hitch

locking pin to the attachment:

A – Incorrect attachment engagement
B – Correct attachment engagement

B

A

Safety Decals on the outside of the Loader

14 50950106/AP0313

ISO-Style (used Internationally)

50352631

50352566

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.

50352631 – Located on the left side of the
ROPS/FOPS and on the lift arm support
device

50352566 – Located on the ROPS/
FOPS locking mechanism

A

B

C

A

B

C

A – Crush hazard: Keep out from under lift

arm unless lift arm is supported.

B – Secure lift arm support device.
C – Read instructions for use in Operator’s

Manual.

A – Crush hazard: Be sure lock

mechanism is securely engaged
before working under ROPS/
FOPS.

B – Secure lift arm support device.
C – Read instructions for use in

Operator’s Manual.

Safety Decals on the outside of the Loader

50950106/AP0313 15

ISO-Style (used Internationally)

137845

50352527

STOP

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. Keep fire extinguisher nearby.

C – Run-over hazard: Jump-start per Operator’s Manual procedure.
D – Oil injection hazard: Do not use hands to find hydraulic leaks. Escaping oil under

pressure can be invisible and penetrate skin. Use a piece of cardboard to find leaks.

E – Burn hazard: Allow radiator to cool before removing cap. Loosen cap slowly to avoid

burns.

F – Suffocation hazard: Operate only in a well-ventilated area.

ABCD

EF

50352527 – Located on the fan shroud
inside engine compartment

A – Cutting Hazard, Fan: The fan rotates

at extreme speed.

B – Keep hands away from the fan.
C – Stop the engine before working

around the fan.

A

B

C

50352526

50352526 – Located on the fan
shroud inside engine compartment

A – Hot surface hazard: The engine and its

components generate temperatures
that can burn skin.

B – Hot surface: Do not touch hot engine or

hydraulic system parts.

B

A

Safety Decals in the Engine Compartment

16 50950106/AP0313

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. Engine plate: with, e.g., type designation, product and serial numbers

5. Component plate hydrostatic pump: with, e.g., product and serial numbers

6. Component plate drive motor: with, e.g., product and serial numbers

1

4

6

2

3

5

50950106/AP0313 17

Notes

18 50950106/AP0313

CHAPTER 3

WARNING

WARNING

WARNING

CONTROLS AND SAFETY EQUIPMENT

Become familiar with and know how to use all

safety devices and controls on the skid-steer
loader before operating it. 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 non­approved attachments.

Guards and Shields

Whenever possible and without affecting loader operation, guards and shields are
provided to protect against potentially hazardous areas. In many places, safety
decals are also provided to warn of potential hazards and/or to display special
operating procedures.

Read and thoroughly understand all safety

decals on the loader before operating it. Do
not operate the loader unless all factory-installed guards and
shields are properly secured in place.

Operator Restraint Bar

Lower the operator restraint bar after entering the operator’s compartment and
sitting in the seat. The restraint bar is securely anchored to the ROPS/FOPS. The
operator must be seated with the restraint bar in its lowered position to start or
operate the skid-steer loader. Refer to Safety Interlock System on page 20 for
more information.

Dual Joystick and Hand/Foot controlled loaders are equipped with a restraint bar
that provides fore-aft adjustment, allowing the operator to determine the most
comfortable position for the restraint bar. The right and left portions of the
restraint bar system can be adjusted independent of one another by pushing the
locking lever on the lower inside of either pad. The restraint pads can then be
adjusted to the desired position. The restraint pads lock in place when the locking
lever is released.

Never defeat the operator restraint bar or seat

switch electrically or mechanically. Always
wear the seatbelt.

50950106/AP0313 19

Operator’s Seat

Figure 1 Operator’s Seat

1. Restraint Bar

2. Seatbelt

3. Seat Position Adjustment Lever

4. Suspension Seat Weight Adjustment Knob (optional)

1

2

3

4

WARNING

WARNING

The seat is mounted on rails for rearward
and forward repositioning. A spring­loaded lever unlocks the seat position
adjustment mechanism.

Suspension seat (optional): A weight
adjustment knob is provided for indi­vidual operator adjustment.

Air Suspension Seat (optional): Adjust air
suspension seat by pushing in the knob on
the air seat to increase the amount of sus­pension. Pull knob out to release air and
decrease the suspension level.

Upper-Torso Restraint

Always wear the upper-torso restraint when
operating in High speed.

The seatbelt should always be fastened during operation.

Important: Inspect the seatbelt(s) for damage before use, and replace if dam­aged. Keep seatbelt(s) clean. Use only soap and water to wash seatbelt(s).
Cleaning solvents can cause damage to seatbelt(s).

Safety Interlock System

Hydraloc™

switches, relays or solenoid valves.

An interlock system is provided on the loader for operator safety. Together with
solenoid valves, switches and relays, the interlock system:

 Prevents the engine from starting unless the operator is sitting on the seat and

the operator restraint bar is lowered.

 Disables the lift arm, auxiliary hydraulics, attachment tilt and wheel drives

whenever the operator leaves the seat, turns the keyswitch to OFF or raises
the restraint bar.

20 50950106/AP0313

NEVER defeat the safety interlock system by
mechanically or electrically bypassing any

Note: The auxiliary hydraulic circuit can be detented in the “ON” position for

WARNING

Figure 2 Parking Brake Switch

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 opera­tion:

Restraint Bar

With the engine running, raise the restraint bar. Test each of the controls. There
should be no more than a slight movement of the lift arm, hitch and machine. If
there is any significant movement, troubleshoot and correct the problem immedi­ately. Contact your dealer if necessary.

Seat Switch

With the engine off and the restraint bar lowered, unfasten the seatbelt, and lift
your weight off the seat. Try to start the engine. If the engine starts, turn off the
engine, troubleshoot and correct the problem. Contact your dealer if necessary.

ROPS/FOPS

The ROPS/FOPS (Roll-Over/Falling Object Protective Structure) is designed to
provide protection for the operator from falling objects and in a tip over accident,
if the operator is secured inside the operator’s compartment by the seatbelt and
restraint bar.

Never operate the loader with the ROPS/FOPS
removed or locked back.

Parking Brake

This skid-steer loader is equipped with a
spring-applied, hydraulic-released parking
brake. The parking brake engages when
the operator lifts the restraint bar, exits the
seat or shuts off the engine. The brake can
also be applied manually by using the
switch located on the right instrument
panel. A red indicator in the switch lights
when the parking brake is applied.

Horn

On dual joystick and hand/foot loaders, pressing the right button on the left con­trol handle sounds the horn. On T-bar loaders, pressing the bottom button on the
left control handle sounds the horn.

50950106/AP0313 21

Rear Window Emergency Exit

WARNING

Figure 3 Lift Arm Support

Device Engaged

The ROPS/FOPS rear window has three functions: noise reduction, flying
objects barrier and emergency exit.

To use the emergency exit, pull on the yellow warning tag at the top of the
window and remove the seal. Push or kick out the window and then exit.

See your local automotive glass specialist to reinstall the window.

Lift Arm Support Device

The lift arm support device is used as a cylinder lock to prevent the raised lift arm
from lowering unexpectedly. Be sure to install the support device when the lift
arm is raised for service. When the support device is not being used, return it to
its storage position. The support device is a safety device, which must be kept in
proper operating condition at all times. The following steps ensure correct usage:

The safest method of engaging the lift arm

support device requires two people - one
person inside the loader and another person outside the loader to
engage the support device.

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

Engagement

To engage the lift arm support device:

1. Lower the lift arm fully.

2. Stop the engine.

3. Have an assistant remove the lift arm

support device from its storage loca­tion (Figure 4) on the left side of the
machine. Remove the lynch pin hold­ing the support device up against the
lift arm. Allow the support device to
come down into contact with the lift
cylinder (Figure 3).

4. Restart the engine.

5. Use the lift control to raise the lift arm

until the support device drops over the
end of the lift cylinder and around the
cylinder rod. Slowly lower the lift arm until the free-end of the support device
contacts the top end of the lift cylinder.

22 50950106/AP0313

6. Look to be sure the support device is secure against the cylinder end. Then,

WARNING

Figure 4 Lift Arm Support

Device Storage Location

stop the loader engine, remove the key and leave the operator’s compartment.

7. Stop the engine, and exit the machine.

Disengagement

The safest method of installing and removing

the lift arm support device requires two
people – one person inside the loader and another person outside
the loader to disengage the support device.

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

To return the lift arm support device to its storage position:

1. Start the engine;

2. Raise the lift arm fully;

3. Stop the engine;

4. Verify that the lift arm is being held in

the raised position by the safety inter­lock system.

5. To store the support device, have an

assistant raise it up until it contacts the
lift arm. Reinstall the lynch pin through
the welded steel post on the lift arm
(Figure 4).

ACCESSORY Plug

The 12-V accessory plug is located at the bottom of the right instrument panel.

Dome Light

The dome light is located on the right side of the ROPS/FOPS headliner. Push on
the dome light to switch it on.

50950106/AP0313 23

Work Lights

Figure 5 Heater/

Air Conditioner Controls

2

1

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).

1. Fan Speed Control: Controls the air flow.

2. Temperature Control: The potentiometer switch is a rotary dial for control of heat functions.

Heater and Air Conditioner (optional)

Loaders with the combination heater/air
conditioner have two control knobs on the
left instrument panel for controlling fan
speed and heater/air conditioner tempera­ture.

1. Fan Speed Control: Controls the air flow.

2. Temperature Control: The potenti-
ometer switch is a rotary dial for con­trol of heat and air conditioning
functions.

24 50950106/AP0313

Engine Speed Control

Figure 6 Engine Speed Control

Figure 7 Foot Throttle

(Joystick and T-Bar controls)

WARNING

WARNING

WARNING

An engine speed control (Figure 6) is pro­vided 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. See the engine diagnostic chart for
the DTC’s on page 81 or the cold starting
procedure on page 48.

With dual joystick and T-bar controls, a
foot pedal (Figure 7) is provided as a sec­ondary throttle, which can be used to
override the engine speed control. If the
foot throttle is released, the engine will
return to the speed set by the engine speed
control.

Two-Speed Drive (Travel Mode Only) (optional)

Dual joystick and hand/foot loaders use the left button on the left control handle
for shifting between High (H) and Low (L). T-Bar loaders use the top button on
the left control handle. Shifting to High allows the machine to exceed 7.5 mph
(12,0 km/h), up to a maximum speed of 12.5 mph (20 km/h). When the loader is
in High (H) an H icon on the Indicator and Warning Light Display (page 27) will
illuminate. Press the button once to activate, and again to deactivate.

Note: Speed varies slightly with tire size.

at full speed is not recommended and damage may result.

Standard equipment on dual joystick and hand/foot loaders, use the right button
on the right control handle for shifting between normal mode and ride control
mode. Optional equipment on T-bar loaders, use the top button on the right con­trol handle. The ride control system provides a smoother ride over uneven sur­faces. Press the button once to activate the system, and again to deactivate. The
ride control system is automatically deactivated when the machine is shut off.

inches with a heavy load.

50950106/AP0313 25

When two-speed drive is activated, down
shifting to single-speed drive while traveling

Hydraglide™ Ride Control System

When ride control is activated, the lift arm
may drop slightly without a load, or several

Float Control

Figure 8 All-Tach® Hitch

WARNING

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. For dual joystick and hand/foot loaders, press and hold the
button for three seconds or longer to detent, and press again to deactivate. For T­bar loaders, pull the right control handle rearward to deactivate. The float mode
is automatically deactivated when the machine is shut off.

Attachment Mounting

The skid-steer loader is equipped with either the standard manual
All-Tach
attachments (Figure 8).

All-Tach

A manual latch lever engages the latch
pins. While standing outside the machine,
rotate the lever all the way to the left to
engage the latch pins. Rotate the lever (as
viewed from the front) all the way to the
right to disengage the latch pins. (Refer to
page 51 for more information.)

latch pins by rotating the lever all the way to the hitch.

®

hitch or optional Power-A-Tach® hitch for mounting a bucket or other

®

Hitch

To prevent unexpected release of the attach­ment from the hitch, be sure to secure the

Power-A-Tach® System

A three-position momentary rocker switch is used to operate the Power-A-Tach
System hitch. The Power-A-Tach System is equipped with a warming circuit.
The warming circuit reduces the amount of time required to operate the hydraulic
cylinder. It is recommended to use this circuit when the temperature is below
32°F (0°C), see the Cold-Starting Procedure on page 48. Continuous use of the
warming circuit is recommended when the temperature is below 0° F (-18° C).
The hitch will not operate if the parking brake switch is activated or if the
restraint bar is in its vertical (open) position. (Refer to page 51 for more informa­tion.)

To retract the hitch pins:

Press up and hold the switch until the pins are fully retracted on the Power-A­Tach switch in the right instrument panel. The switch will return to neutral
(middle position) when released.

26 50950106/AP0313

To extend the hitch pins:

WARNING

Figure 9 Indicator and Warning Lamp Display

7

8

9

10

11

1

2

3

4

5

6

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-

ment from the hitch, be sure the latch pins are
secure by verifying that the pin flags have moved fully to the out­side of the hitch.

Activating The Warming Circuit

Press down the Power-A-Tach switch in the right instrument panel. The switch
will detent “on”, illuminating the lamp and notifying the operator that the
warming circuit is on.

To deactivate the warming circuit, push the switch to the neutral (middle) posi­tion. Also, when retracting the pins, the warming circuit will deactivate and stay
off until activated again.

Note: It is safe to operate the loader with the warming circuit on or off, it won't
affect the performance of the loader.

Indicator and Warning Lamp Display

The instrument panels and the indicator and warning lamp display (Figure 9)
contain the switches and indicator lamps. Symbols on the indicator lamps are vis­ible only when the indicator lamps are on.

50950106/AP0313 27

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. During normal operation this indicator should be OFF.

3. Hydraulic Oil Temperature – Lights if the hydraulic oil is too hot, warning the operator to reduce the hydraulic load and determine the cause of the high temperature. During normal operation this indicator should be OFF.

4. Engine Oil Pressure Warning – Lights if the engine oil pressure is too low, warning the operator to immediately stop the engine and determine the cause for the low pressure. During normal operation this indicator should be OFF.

5. Engine Coolant Temperature – Lights if the engine coolant is too hot, warn-
ing the operator to stop the engine and determine and correct the cause of the
high temperature. During normal operation this indicator should be OFF.

6. High-Speed – Lights when two-speed (optional) is engaged.

7. Hydraglide™ Ride Control System – Lights when the ride control system is activated.

8. Float Indicator – Lights when the lift arm “float” function is activated.

9. Pre-heat Indicator – Lights when the (automatic) pre-heat is active. During normal operation this indicator should be OFF.

10. Fasten Seatbelt – A momentary visual (and audible) indicator to remind the operator to fasten the seatbelt(s).

11. Engine Malfunction Shutdown Indicator – Lights when the engine elec-
tronic control unit (E-ECU) has detected a failure warranting an automatic
shutdown. Review the electronic display for error code details. See Engine
Diagnostics chart on page 81.

28 50950106/AP0313

Information Center Electronic Display

Figure 10 Information Center Electronic Display

WARNING

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, bat­tery and environmental parameters. The diagnostic trouble codes (DTC) for this
system are shown in the Engine Diagnostic Chart (page 81).

During normal operation, the buttons have no specific functions, the display is
used exclusively to provide diagnostic codes and show icons associated with the
DPF modes. When pressing any button once, a dynamic pop-up menu appears.
The menu contains function icons aligned above the associated button. The user
selects the required function from the displayed menu. After a few seconds, the
menu will be hidden.

If the LCD is broken, care must be taken with

any leaking fluid. If LCD fluid gets onto your
skin, wipe with a cloth and wash the area with mild soap and
water. If LCD fluid gets into your eyes, thoroughly rinse your eyes
with clean water for several minutes and seek medical assistance.
If the LCD fluid is swallowed, rinse your mouth thoroughly with
clean water, then drink a substantial volume of water and induce
vomiting. Then seek medical assistance.

50950106/AP0313 29

Display Modes - Information Center Electronic Dis­play

The information center is used to dis­play live parameters and diagnostic
trouble codes available on the J1939
bus. By pressing the center button the
user can scroll through the available
parameters on the vehicle's network. A
complete list of supported parameters
can be found in the Supported Parame­ters section.

At any time in any display mode, the
user can select the tool icon (left
button) to access the setting menu and
change the current display mode. See
Settings Menu section.

Single Screen

This mode is used to monitor one
parameter at a time. The screen also
displays the associated parameter icon,
the description, the units and a bar
graph.

Bar Graph Limits Adjust

The Single Screen mode has a special
function for bar graph limits minimum
and maximum adjustment. This can be
done by selecting the related param­eter and then pressing the limits button
(right button). The unit should now
display the bar graph limits adjust
mode. Use +/- for adjustment and
select Exit when finished.

Dual Screen

The Dual Screen mode is used to mon­itor two parameters at a time. The
screen also displays the associated
parameter icon and units. To change to
dual screen mode press the left
“wrench” button. This will bring up an
option screen with the top line “dis­play mode” will be highlighted. Press
the center “arrow” button to change

the screen display to dual, multi or
DTC screen. Press the left “wrench”
button to return to the main display.

Multi-Screen

The Multi-Screen mode is used to
monitor a list of four parameters
selected by the user. Every item is
listed with its associated icon and
units.

DTC Screen

The DTC Screen mode is used to dis­play Data Trouble Codes according to
SAE J1939-73. The main screen dis­plays all vehicle active faults (DM1)
and occurs faults (DM2). A bright bulb
means that the current fault is active
while a dark bulb means that the cur­rent fault has occurred. The header
contains the total active/inactive faults,
the associated SPN and FMI and the
numbers of occurrences as well.

DTC Detailed Information

For a given DTC, the user may select
the ? function from the menu. A
detailed screen of the selected DTC
including the SPN description
(Header), the FMI Description
(Header), the fault status (Status), the
SPN Number (SPN), the FMI Number
(FMI), the total number of occurrences
(OCC) and the related node source
address (SRC) will then appear.

Display Mode

This setting is used to select the cur­rent display mode: Single, Dual, Multi
or DTC.

30 50950106/AP0313

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 dis­crete sensor input. In this mode, the
local information is also broadcast on
the J1939 network to other nodes. In
Network mode, the device reads the
fuel signal from the associated PGN
on the J1939 network.

Contrast /Backlight

Contrast and backlight commands
according to the user's preferences.

Supported Parameters

The following three pages list the sup­ported parameters of the information
center electronic display.

50950106/AP0313 31

Information Center Electronic Display (cont.)

32 50950106/AP0313

Information Center Electronic Display (cont.)

50950106/AP0313 33

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. The operator
should take action to reduce load on the engine and allow the
engine to cool.

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. See the ash cleaning mode description on page 60
for more details.

Elevated EGT (Exhaust Gas Temperature)

The EGT icon is used to notify the operator of high exhaust
temperatures during an active reset/stationary regeneration.

Parking Brake

The parking brake icon is used to remind the operator that the
parking brake switch must be engaged prior to a stationary
regeneration.

DPF Regeneration Acknowledgement

The DPF regeneration acknowledgement icon is
used to notify the operator that the E-ECU has
received the stationary regeneration request. It is
used to prompt the operator to start a stationary
regeneration request or to allow a reset regeneration.

34 50950106/AP0313

Instrument Panels

1

2

3

5

4

6

Figure 11 Left Panel

A

B

C

D

8

7

Figure 12 Lower Left Panel

9

Left Panel

1. Indicator and Warning Lamp Display –

See page 27.

2. Rotating Beacon/Strobe Switch (optional)

– Controls the warning lamp (strobe or bea­con).

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. Switch
does not turn lights on or off.

5. Turn Signal Switch (optional) – Used to

turn on turn indicator lights. Directional
indicator lights are the same lights as the
flashers. The flashers will override the turn
signals.

6. High-Flow Auxiliary Switch (optional) –

Controls the direction of hydraulic oil flow.
Push the right side of the rocker switch for
forward flow, or the left side for reverse
flow. To disengage, push and release either
side of the switch, or raise the restraint bar.
Turning off the machine and restarting the
engine will also reset the high-flow to neu­tral.

7. Light Switch – Master control of the lights.

Push the right side of the rocker switch to activate front and rear lights, or to
the left side for deactivation of the front and rear lights. It also provides
power to a machine equipped with flashers.

8. Light Switch – Controls all the lights on the

loader. Push the rocker switch to the middle
detent for front work lights and rear position
lights. Push the rocker switch fully to the
right for front work lights and rear work
lights operation.

9. Self-Leveling Cancel (optional) – Press the

top of the switch to deactivate self-leveling.
Press the bottom of the switch to restore the
self-leveling function.

50950106/AP0313 35

Right Panel

1

2

3

4

Figure 13 Right Panel

8

5

7

6

1. Information Center Electronic Dis­play – See page 29.

2. Parking Brake Switch – Used to manu­ally apply the parking brake. Lights
when the parking brake is applied.

3. Front Wiper/Washer (optional)

4. Rear Wiper/Washer (optional)

5. DPF (Diesel Particulate Filter) Regen-
eration Switch – The DPF switch oper­ates in this manner:

Regen Auto: The neutral center AUTO posi­tion of the switch allows the E-ECU to per­form low-level DPF regeneration as
required, without operator input.

Regen Request (Allow): The left side of the
switch is a momentary switch used for
starting a stationary regeneration.

Regen Request (Allow) Lamp: The lamp
prompts the operator to implement a sta­tionary regeneration. It is used for notifying
the operator that the regen request (allow)
switch is being activated.

Regen (Cancel): The right side of the toggle
switch is used for delaying or cancelling a
reset or stationary regeneration.

Regen (Cancel) Lamp: The lamp is used for
notifying the operator that the reset/sta­tionary regeneration is in a “standby” mode.

6. Keyswitch – In a clockwise rotation, the positions are:

• OFF Position – With the key verti­cal, power from the battery is discon­nected from the controls and
instrument panel electrical circuits. This is the only position from which
the key can be inserted or removed.

• ON (or RUN) Position – With the key turned one position clockwise
from vertical, power from the battery is supplied to all control and instru­ment panel circuits.

• START Position – With the key turned fully clockwise, the electric
starter engages, to start the engine. Release the key to RUN position after
the engine starts.

36 50950106/AP0313

Note: The engine cannot be started unless the operator is sitting in the seat and

Figure 14 Dual Joystick Controls

1. Lift/Tilt Control

2. Drive Control

1

2

WARNING

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; press the bottom of the switch to extend
(engage) the hitch pins and activate the warming circuit. Set the switch to the
neutral position (middle) to turn off the warming circuit (see page 26).

8. Engine Speed Control – Controls the engine speed. Move the control clock-

wise to increase and counter-clockwise to decrease the engine speed.

Joystick Controls

The loader may be equipped
with dual joystick controls,
(Figure 14). The left joystick
controls the drive, and the right
joystick controls the lift/tilt.

Drive Controls

Forward, reverse, speed and
turning maneuvers are accom­plished by movement of the left
joystick. To go forward, push
the drive control forward; for
reverse, pull the control rear­ward. To turn right, push the
control right; to turn left, push
the control left. To go forward
and left, move the control for­ward and left. To go forward
and right, move the control forward and right. To move back and left, move the
control back and to the right. To move back and right, move the control back
and to the left.

trols gradually and smoothly. Excessive speed and quick control
movements without regard for conditions and circumstances are
hazardous and could cause an accident.

Moving the joystick farther from neutral increases the speed steadily to the max­imum travel speed. Tractive effort decreases as speed increases. For maximum
tractive effort, move the joystick only slightly away from the neutral position.
The engine may stall if the control is moved too far forward when loading the
bucket.

50950106/AP0313 37

Be sure the joystick controls are in neutral
before starting the engine. Operate the con-

Lift/Tilt Control

WARNING

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 for­ward and downward, move the control to the right; to tilt the attachment up
and back, move the control to the left.

Note: The speed of the lift/tilt motion is directly proportional to the amount of
joystick movement and engine speed.

To place the lift arm into the “float” position, push and hold the left button on the
right joystick. This mode allows the lowered lift arm to follow the ground con­tour while traveling over changing ground conditions. An indicator lamp in the
indicator and warning lamp display will blink when float is activated.

Never push the float control button with the
attachment raised, because this will cause the

lift arm to lower very rapidly.

Releasing the float button will cancel the float mode if the button was pressed
less than five seconds. If the float mode button is pressed longer than five sec­onds, the float feature will remain on and the float indicator lamp will remain lit
until the button is pressed again or the machine is turned off.

38 50950106/AP0313

Hand/Foot Controls

Figure 15 Hand/Foot Controls

1. Left Drive Control Handle

2. Right Drive Control Handle

3. Lift Control Pedal

4. Tilt Control Pedal

1

2

3

4

1

2

4

3

WARNING

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 accom­plished by movement of the con­trol handles. To go forward,
push both handles forward; for
reverse, pull both handles rear­ward. For turning, move one
handle farther forward or rear­ward than the other handle. Turn
direction is determined by which
handle is moved farther forward.
To turn left, move the right
handle farther forward than the
left handle; to turn right, move
the left handle farther forward than the right handle. For sharp turns, move the
handles in opposite directions.

Be sure the controls are in neutral before

starting the engine. Operate the controls
gradually and smoothly. Excessive speed and quick control move­ments without regard for conditions and circumstances are haz­ardous and could cause an accident.

Moving the handles farther from neutral increases the speed steadily to the max­imum travel speed. Tractive effort decreases as speed increases. For maximum
tractive effort, move the handles only slightly away from the neutral positions.
The engine will stall if the handles are moved too far forward when loading the
bucket.

50950106/AP0313 39

Lift/Tilt Controls

WARNING

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; to lower the lift arm, push down on the front of the left pedal with
the toes of your left foot. To tilt the attachment forward and down, push down
on the front of the right pedal with the toes of your right foot; to tilt the attach-
ment up and back, push down on the back of the right pedal with your right
heel.

Note: The speed of the lift/tilt motion is directly proportional to the amount of
pedal movement and engine speed.

To place the lift arm into the “float” position, push and hold the left button on the
right-hand control. This mode allows the lowered lift arm to follow the ground
contour while traveling over changing ground conditions. An indicator lamp in
the indicator and warning lamp display will blink when float is activated.

Never push the float control button with the
attachment raised, because this will cause the

lift arm to lower very rapidly.

Releasing the float button will cancel the float mode if the button was pressed
less than five seconds. If the float mode button is pressed longer than five sec­onds, the float feature will remain on and the float indicator lamp will remain lit
until the button is pressed again or the machine is turned off.

40 50950106/AP0313

T-Bar Controls

Figure 16 T-Bar Controls

1. Lift/Tilt Control

2. Drive Control

1

2

WARNING

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 accom­plished by movement of the left
T-bar. To go forward, push the
control forward; for reverse, pull
the control rearward. To turn
right, turn the control clockwise;
to turn left, turn the control coun­terclockwise. For gradual turns,
move the T-bar slightly forward
or rearward. For sharp turns, turn
the control clockwise or counter­clockwise.

Moving the T-bar farther from neutral increase the speed steadily to the max­imum travel speed. Tractive effort decreases as speed increases. To get maximum
tractive effort, move the T-bar only slightly away from the neutral position. The
engine will stall if the control is moved too far forward when loading the bucket.

gradually and smoothly. Excessive speed and quick control move­ments without regard for conditions and circumstances are haz­ardous and could cause an accident.

50950106/AP0313 41

Be sure the controls are in neutral before

starting the engine. Operate the controls

Lift/Tilt Control

WARNING

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; to tilt the attachment up and
back, twist the control counterclockwise.

Note: The speed of the lift/tilt motion is directly proportional to the amount of T­bar movement and engine speed.

To place the lift arm into the “float” position, push the right control handle fully
forward to detent. This mode allows the lowered lift arm to follow the ground
contour while traveling over changing ground conditions. An indicator lamp in
the indicator and warning lamp display will blink when float is activated.

Never push the right control handle fully for-

ward to detent the float control with the
attachment raised, because this will cause the lift arm to lower
very rapidly.

42 50950106/AP0313

Auxiliary Hydraulic System

Figure 17 Joystick Electric

Auxiliary Control

Figure 18 High-Flow Auxiliary

Switch

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 flat­face couplers. The couplers are located on top or inside of the lift arm on the left
side.

Loaders Equipped with Electric Auxiliary:
The black rocker switch located on the
right-hand control controls the direction
and amount of flow. The farther the switch
is moved from center, the higher the flow to
the auxiliary circuit. The direction of flow
is reversed when the rocker switch is
moved in the opposite direction from the
center. Pushing the switch to the right (or
up on T-bar controls) will pressurize the
standard auxiliary male coupler. For con­tinuous operation, move the switch in
either direction and push the trigger button,
located on the front of the grip for five sec­onds, and release. To cancel continuous
operation, push the button or move the black switch in either direction.

High-Flow Auxiliary Hydraulic Control (Optional)

In addition to a standard-flow auxiliary
hydraulic system, loaders may be
equipped with a reversible high-flow aux­iliary hydraulic system. The couplers are
located on top or inside of the right lift
arm. The high-flow auxiliary hydraulic
system is used for operating certain
hydraulic attachments (e.g., cold planer,
snowblower) that require higher flows.

The high-flow auxiliary switch controls
the direction of hydraulic oil flow. The
switch is located on the upper left side
instrument panel. Push the right side of
the rocker switch for forward flow, or the left side for reverse flow. Pushing the
switch to the right will pressurize the high-flow male coupler. To disengage, push
and release either side of the switch. Turning off the machine, raising the restraint
bar, or restarting the engine will also reset the high-flow to neutral. A lamp on

50950106/AP0313 43

either side of the switch will illuminate when the high-flow auxiliary hydraulic

Figure 19 DPF Switch

WARNING

WARNING

system is engaged.

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. To begin a DPF regeneration procedure
go to page 59.

All DPF regenerative functions are controlled by
the E-ECU (Engine-Electronic Control Unit) and
the DPF switch.

The DPF switch operates in this manner.

1. Regen Auto: The neutral center AUTO posi-

tion of the switch allows the E-ECU to perform low-level DPF regeneration
as required, without operator input.

2. Regen Request (Allow): The left side of the switch is a momentary switch

used for starting a stationary regeneration.

3. Regen Request (Allow) Lamp: The lamp prompts the operator to implement a

stationary regeneration. It is used for notifying the operator that the regen
request (allow) switch is being activated.

4. Regen (Cancel): The right side of the toggle switch is used for delaying or

cancelling a reset or stationary regeneration.

5. Regen (Cancel) Lamp: The lamp is used for notifying the operator that the

reset/stationary regeneration is in a “standby” mode.

Note: During regeneration, there may be a change in sound due to the intake
throttle and the EGR (Exhaust Gas Recirculation) valve opening changes, but
normal regeneration should otherwise be transparent to the operator. The
exhaust may also smell different from non-DPF equipped diesel engines.

There is a possibility of carbon monoxide

poisoning if the regeneration occurs in
enclosed spaces. Be sure to allow for an outside air source
or park the loader outside during a regeneration.

During regeneration there will be high

exhaust gas temperatures, even at low
load. Be sure to stay clear of the DPF during a regeneration.

44 50950106/AP0313

Electrical Battery Disconnect Switch

Figure 20 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.

50950106/AP0313 45

Notes

46 50950106/AP0313

CHAPTER 4

WARNING

OPERATION

Before starting the engine and operating the

loader, review and comply with all safety rec­ommendations in the Safety chapter of this manual. Know how to
stop the loader before starting it. Also, be sure to fasten and prop­erly adjust the seatbelt(s) and lower the operator restraint bar.

Before Starting the Engine

Before starting the engine and running the loader, refer to the Controls and Safety
Equipment chapter and become familiar with the various operating controls, indi-

cators and safety devices on the loader.

Fuel

Use only ultra-low sulfur diesel fuel to maintain proper engine performance. Use
of diesel fuel with more than 15 ppm of sulfur can potentially damage the engine.
BioDiesel mixtures of up to a 5% (B5) are acceptable. Ultra-Low Sulfur Diesel
(ULSD) fuel lubricity must have a maximum scar diameter of 0.45 mm, as mea­sured by ASTM D6079 or ISO 12156-1, or a minimum of 3100 grams, as mea­sured by ASTM D6078. Contact your fuel supplier for details.

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 electricity. Do not re-enter the machine but stay near the fuel filling point
during refueling to minimize the build-up of static electricity. Do not use cell
phones while fueling. Make sure the static line is connected from the machine to
the fuel truck before fueling begins.

Ultra-Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier
diesel formulations. Avoid death or serious injury from fire or explosion; consult
with your fuel or fuel system supplier to ensure the entire fuel delivery system is
in compliance with fueling standards for proper grounding and bonding practices.

Starting the Engine

The following procedure is recommended for starting the engine:

1. Carefully step up onto the back of the bucket or attachment and grasp the

handholds to enter the operator’s compartment.

2. Close the door, fasten the seatbelt(s) and lower the restraint bar.

3. Verify the following:

 the lift/tilt, drive and auxiliary hydraulic controls are in their neutral

positions,

 the parking brake switch is ON.

Note: When the key is turned to the RUN position, an indicator lamp will light on
the instrument panel and a buzzer will sound momentarily to remind users to
fasten the seatbelt.

50950106/AP0313 47

4. Turn the key to the START position.

WARNING

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.
Allow the starter to cool for 20 seconds and repeat step 4.

After the engine starts, allow a five minute low idle warm-up period before oper­ating the controls.

Important: Avoid extended engine idling after the engine reaches normal oper­ating temperature to prevent frequent DPF regenerations. If the indicator
warning lamps do not go off, stop the engine and investigate the cause.

Cold-Starting

If the temperature is below 32°F (0°C), the following is recommended to make
starting the engine easier:

 Replace the engine oil with API-CJ-4/SAE 5W-30 oil as recommended

by the viscosity chart;

 Make sure the battery is fully charged;
 Install a block heater on the engine.

Let the engine run for a minimum of five minutes to warm the engine and
hydraulic fluid before operating the loader. A block heater is recommended for
starting in temperatures of 14°F (-10°C) or lower. See your dealer for heater
options.

Cold-Starting Procedure

Do not use starting fluid (ether) with pre-heat
systems. An explosion can result, which can

cause engine damage, injury or death.

1. Turn the key to the RUN position. If the preheat lamp symbol on the indicator and warning lamp display comes on, wait for this symbol to go out.

2. Immediately turn the key to the START position.

3. If engine does not start, return key to OFF position and repeat steps 1 and 2.

4. If equipped with the optional Power-A-Tach System, activate the warming circuit.

Important: During cold start conditions, 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 loader
should be turned off for one minute or longer. To protect the starter, the E-ECU
system turns off the starter circuit if it is energized for 30 seconds or longer. The
starter will remain de-energized for 30 seconds more before the loader can be
restarted.

Upon a successful start, let the engine run for a minimum of five minutes to
warm the engine and hydraulic fluid before operating the loader.

48 50950106/AP0313

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.

 At an ambient temperature of 14° F (-10° C) or below, a healthy battery

is essential as glow cycles and cranking cycles can induce a substantial
load on the battery during start. An engine block heater is recommended
at this temperature to reduce starter load and improve the engine warm­up period prior to loader operation. Attempting to start the loader
without a block heater will result in multiple glow/crank cycles or pos­sible extended cranking time approaching 20 seconds.

 At an ambient temperature of 5° F (-15° C) or below, a healthy battery is

imperative. A recommended battery charger/maintainer applied before
or during a start cycle will help maintain 12 V to the starter circuit
during a potential long crank cycle of 20 seconds or more. A required
block heater will reduce starter load, reduce crank time and improve the
overall engine warm-up time during extreme cold starts.

Speed Limit Protection During A Cold Start

 Depending upon coolant temperature, 14° F (-10° C) or below, the max-

imum engine speed allowable is 1500 rpm. This 1500 rpm limit remains
in effect for approximately 10 seconds or less. If a throttle command
above 1500 rpm is requested during this 10 second time frame, the oper­ator must return the throttle to a command less than 1500 rpm before
returning to a desired throttle position above 1500 rpm.

Stopping the Loader

The following procedure is the recommended sequence for stopping the loader:

1. Check that the drive control handle(s) is (are) in neutral position.

2. Lower the lift arm and rest the attachment on the ground.

3. Turn throttle knob back to the low idle position (and release the throttle pedal for joystick and T-bar control machines). Allow the engine to idle for five minutes if the engine was operated under full load.

4. Turn the keyswitch to the OFF position and remove the key.

5. Move the lift/tilt control to verify that the safety interlock system is prevent­ing movement.

6. Raise the restraint bar, unfasten the seatbelt(s) and grasp the handholds while climbing out of the operator’s compartment.

Note: The skid-steer loader is equipped with a spring-applied automatic parking
brake. The parking brake is applied when the operator lifts the restraint bar,
leaves the operator’s seat or shuts off the engine, or actuates the parking brake
switch.

50950106/AP0313 49

Parking the Loader

WARNING

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.

The ONLY safe method for jump-starting a

discharged battery is for TWO PEOPLE to
perform the following procedure. The second person removes the
jumper cables so that the operator does not have to leave the
operator’s compartment with the engine running. NEVER make
jumper cable connections directly to the starter solenoid of either
engine. DO NOT start the engine from any position other than on
the operator’s seat and then ONLY after being sure ALL controls
are in “neutral.”

Closely follow the procedure, in order, to avoid personal injury. In
addition, to protect your eyes wear safety glasses and avoid
leaning over the batteries while jump-starting.

DO NOT jump-start the battery if it is frozen, because it may rupture or explode.

Note: BE SURE the jumper battery is a 12-volt D.C. battery.

1. Turn the keyswitches of both vehicles to OFF, be sure the vehicles are in

“neutral” and NOT touching each other.

2. Connect the positive (+) jumper cable to the positive (+) battery terminal on

the disabled loader first. DO NOT allow the positive clamps to touch any
metal other than the positive (+) battery terminals.

3. Connect the other end of the positive jumper cable to the jumper vehicle’s

battery positive (+) terminal.

4. Connect the negative (-) jumper cable to the jumper vehicle’s battery negative

(-) terminal.

5. Make the final negative (-) jumper cable connection to the disabled loader’s

engine block or loader frame (ground), such as the rear grille latch post –
NOT to the disabled battery’s negative post. If connected to the engine, keep
the jumper clamp away from the battery, fuel lines and moving parts.

6. Start the loader. If it does not start at once, start the jumper vehicle engine to

avoid excessive drain on the booster battery.

7. After the disabled loader is started and running smoothly, have the second

person remove the jumper cables (negative [-] jumper cable first) from the
jumper vehicle’s battery and then from the disabled loader while being sure
NOT to short the two cables together.

Allow sufficient time for the skid-steer loader alternator to build-up a charge in
the battery before attempting to operate the loader or shut the engine off.

50 50950106/AP0313

Changing Attachments

WARNING

Figure 21 Manual Hitch

1. Latch Lever

2. Latch Pins

1

2

2

To prevent unexpected release of the attach-

ment from the hitch, be sure to properly
secure the hitch latch pins by rotating the latch lever fully (manual
All-Tach
the outside of the hitch. (Power-A-Tach
be fully engaged 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.

On a manual hitch (Figure 21), one latch lever engages the latch pins to secure
the attachment.

Connecting Attachments

1. Manual hitch: Rotate the latch lever

2. Start the loader engine and be sure the

3. Align the loader squarely with the

4. Tilt the hitch forward until the top edge of the hitch is below the flange on the

5. Slowly drive the loader forward and, at the same time, tilt the hitch back to

6. Stop forward travel when the flange is engaged, but continue to tilt the hitch

7. Manual hitch: Exercise the MANDATORY SAFETY SHUTDOWN PRO-

Note: It is safe to operate the loader with the warming circuit on or off, it won't
affect the performance of the loader.

Important: To check that the attachment is properly installed tilt the attachment
forward slightly, apply downward pressure to the attachment prior to operating.

®

hitch), or by verifying that the pin flags moved fully to

®

hitch.) Locking pins must

to the right as viewed from the front to
fully retract the latch pins.

Power hitch: Activate the switch to
unlock the hitch and fully retract the
latch pins. (See page 26 for a detailed
description of this procedure.)

lift arm is lowered and in contact with
the loader frame.

back of the attachment.

back side of the attachment and centered between the vertical plates.

engage the flange on the back side of the attachment.

back to lift the attachment off the ground.

CEDURE (page 6). Leave the operator’s compartment and rotate the latch
lever to the left when viewed from the front to fully engage the latch pins.

Power hitch: Press the Power-A-Tach switch in the right instrument panel to
extend the hitch pins and to lock the hitch and fully engage the latch pins.
After the pins are fully engaged, set the switch back to neutral (middle) to
turn off the warming circuit. If the temperature is below 0° F (-18° C) it is
recommended to leave the warming circuit on.

50950106/AP0313 51

Connecting Auxiliary Hydraulic Couplings

WARNING

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.

Standard-Flow Auxiliary Hydraulics

Couplers are located on the left lift arm. When the auxiliary control switch is
activated in either direction, the inside and outside couplers can be “pressure,” or
“return” depending on which direction the switch is activated. The smaller center
coupler is for the case drain.

High-Flow Auxiliary Hydraulics (optional)

Couplers are located on the right lift arm. When the auxiliary control switch is
activated in either direction, the inside and outside couplers can be “pressure,” or
“return” depending on which direction the switch is activated. The smaller center
coupler is for the case drain.

Only connect high-flow attachment couplers
to the high-flow auxiliary couplers.

Removing Attachments

1. Tilt the hitch back until the attachment is off the ground.

2. Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 6).

3. With the engine off, leave the operator’s compartment and disconnect the auxiliary hydraulic hoses.

4. Manual hitch: Rotate the latch lever to the right when viewed from the front to fully retract the latch pins.

Power hitch: Start the engine, press the top edge of Power-A-Tach switch on
the right instrument panel to retract the hitch pins to unlock the hitch and fully
retract the latch pins. Release the switch.

5. Start the engine (if it is not already on) and be sure that the lift arm is fully lowered and in contact with the loader frame.

6. Tilt the hitch forward and slowly back the loader away until the attachment is free from the loader.

Self-Leveling (optional)

The self-leveling feature is intended to automatically keep the attachment level
while the lift arm is being raised. Self-leveling operates only when the lift arm is
raised; when the lift arm is lowered, self-leveling is not activated.

52 50950106/AP0313

Self-Leveling Cancel (optional)

WARNING

Figure 22 Digging

WARNING

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

power lines and avoid contact with any elec­trically charged conductor or gas line. Accidental contact or rup­ture can result in electrocution or an explosion. Contact the “Call
Before You Dig” referral system at 8-1-1 in the U.S., or 888-258­0808 in the U.S. and Canada or proper local authorities for utility
line locations before starting to dig.

Driving over Rough Terrain

When traveling over rough terrain, activate the ride control system and drive
slowly with the bucket lowered.

Driving on an Incline

When traveling on an incline, travel with the heavy end pointing uphill.

Digging with a Bucket

Approach the digging site with the lift
arm slightly raised and the bucket tilted
forward until the edge contacts the
ground. Dig into the ground by driving
forward and gradually lowering the lift
arm (Figure 22).

When the bucket is filled, tilt the bucket
back and back the loader away from the
material. Rest the lift arm against the
loader frame before proceeding to the
dumping area.

Always carry the loaded bucket with the lift

arm resting on the loader frame. For addi­tional stability when operating on inclines, always travel with the
heavier end of the loader toward the top of the incline.

50950106/AP0313 53

Loading a Bucket

Figure 23 Loading

WARNING

Figure 24 Dumping into a Truck

(or Hopper)

WARNING

Approach the pile with the lift arm fully
lowered and the bucket tilted slightly for­ward 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).

Dumping the Load onto a Pile

Carry a loaded bucket as low as possible
until the pile is reached. Gradually stop forward motion and raise the lift arm
high enough so that the bucket clears the top of the pile. Then, slowly move the
loader ahead to position the bucket to dump the material on top of the pile. Dump
the material and then back the loader away while tilting the bucket back and low­ering the lift arm.

Never use the “float” control with the bucket
or attachment raised, because this will cause

the lift arm to lower rapidly. For more information, see page 26.

Dumping the Load into a Truck (or Hopper)

Carry the loaded bucket low and approach
the vehicle (or hopper.) Stop as close to
the side of the truck (or hopper) as pos­sible while allowing for clearance to raise
the lift arm and loaded bucket. Next, raise
the lift arm until the bucket clears the top
of the truck (or hopper) and move the
loader ahead to position the bucket over
the inside of the truck (or hopper.) Dump
the material and then back away while
tilting the bucket back and lowering the
lift arm (Figure 24).

Dumping the Load over an Embankment

Do not drive too close to an excavation or

ditch. Be sure the surrounding ground has
adequate strength to support the weight of the loader and the
load.

Carry the loaded bucket as low as possible while traveling to the dumping area.
Stop the loader where the bucket extends half-way over the edge of the embank­ment. Tilt the bucket forward and raise the lift arm to dump the material. Dump
the material, and then back away from the embankment while tilting the bucket
back and lowering the lift arm.

54 50950106/AP0313

Scraping with a Bucket

Figure 25 Scraping

Figure 26 Leveling the Ground

WARNING

For scraping, the loader should be oper­ated 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
bucket in this position, material can flow
over the cutting edge and collect inside
the bucket (Figure 25).

Leveling the Ground

Drive the loader to the far edge of the area
to be leveled. Tilt the bucket forward to
position the bucket cutting edge at a 30 to
45 degree angle to the surface being
leveled. Then place the lift arm into
“float” position and drive the loader rear­ward, dragging the dirt and, at the same
time, leveling it (Figure 26).

Note: For information on how the “float” detent is activated, see page 26.

Check that the work area is clear of people
and obstacles. Always look in the direction of

travel.

Highway Travel

If it becomes necessary to move the loader a long distance, use a properly rated
trailer. (See Transporting the Loader on page 57.) For short distance highway
travel, attach an SMV (Slow-Moving Vehicle) emblem (purchased locally) to the
back of the loader. For highway operation, install the optional amber strobe light.
Check state and local laws and regulations.

50950106/AP0313 55

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. Add stabilizer to the fuel per the fuel supplier’s recommendations. If the fuel

has a mixture of BioDiesel, empty the fuel tank before storing.

5. Turn the electrical battery disconnect switch to its OFF position and remove

the battery, charge it fully and store in a cool, dry location.

6. Protect against extreme weather conditions such as moisture, sunlight and

temperature.

Removing Loader from Storage

1. Check the tire air pressure and inflate the tires if they are low.

2. Connect the battery and check that the electrical battery disconnect switch is

turned to its ON position.

3. Check all fluid levels (engine oil, transmission/hydraulic oil, engine coolant

and any attached implements). (Review and follow the engine manufacturers
recommendations from the Engine Operator’s Manual.)

4. Start the engine. Observe all gauges. If all gauges are functioning properly

and reading normal, move the machine outside.

5. Once outside, park the machine and let the engine idle for at least five min-

utes.

6. Shut the engine off and walk around machine. Make a visual inspection look-

ing for evidence of leaks.

56 50950106/AP0313

Transporting the Loader

WARNING

Figure 27 Front Tie-Downs /

Retrieval Points

Figure 28 Rear Tie-Downs /

Retrieval Points

Park the truck or trailer on a level surface. Be

sure the vehicle and its ramps have the
weight capacity to support the loader. Make sure the vehicle sur­face and its ramps are clear of debris and slippery material that
may reduce traction. Move the loader on and off the vehicle ramp
slowly and carefully. Failure to follow these instructions could
result in an overturn accident.

Observe all local regulations governing the loading and transporting of equip­ment (Reference: U.S. Federal Motor Carrier Safety Regulations, Section 392).
Ensure that the hauling vehicle meets all safety requirements before loading the
skid-steer loader.

1. Block the front and rear of the hauling

vehicle’s tires.

2. If the loader has an attachment, lift it

slightly off the ground.

3. Back the loader slowly and carefully

up the ramp onto the vehicle.

4. Lower the loader attachment to the

vehicle deck, turn off the engine and
remove the key.

5. Fasten the loader to the hauling vehi-

cle at the points indicated by the tie­down decals (Figure 27 and
Figure 28).

6. Measure the clearance height of the

loader and hauling vehicle. Post the
clearance height in the cab of the
vehicle.

50950106/AP0313 57

Lifting the Loader

WARNING

The loader can be lifted using a single-point or four-point lift kit, which are avail­able from your Gehl dealer.

• Before lifting, check the lift kit for proper installation.

• Never allow riders in the operator’s compartment while the
loader is lifted.

• Keep everyone a safe distance away from the loader while it is
lifted.

• Loader may only be lifted with an empty bucket or empty pallet
forks, or with no attachment. Never lift the loader with attach­ments other than those stated.

Lift equipment used and its installation is the responsibility of the party con­ducting the lift. All rigging MUST comply with applicable regulations and
guidelines.

1. Using suitable lift equipment, hook into the lift eyes. Adjust the length of the

slings or chains to lift the loader level.

Note: The loader my be slightly off level (10 degrees max.) when lifted.

2. Center the hoist over the ROPS/FOPS. To prevent shock loading of the equip-

ment and excessive swinging, slowly lift the loader off the ground. Perform
all movements slowly and gradually. As needed, use a tag line to help posi­tion the loader and keep it from swinging.

58 50950106/AP0313

DPF (Diesel Particulate Filter) Regeneration

Figure 29 DPF Switch

WARNING

WARNING

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.

All DPF regenerative functions are controlled by
the E-ECU (Engine-Electronic Control Unit) and
the DPF switch.

The DPF switch operates in this manner.

1. Regen Auto: The neutral center AUTO posi­tion of the switch allows the E-ECU to per­form low-level DPF regeneration as required, without operator input.

2. Regen Request (Allow): The left side of the switch is a momentary switch used for starting a stationary regeneration.

3. Regen Request (Allow) Lamp: The lamp prompts the operator to implement a stationary regeneration. It is used for notifying the operator that the regen request (allow) switch is being activated.

4. Regen (Cancel): The right side of the toggle switch is used for delaying or cancelling a reset or stationary regeneration.

5. Regen (Cancel) Lamp: The lamp is used for notifying the operator that the reset/stationary regeneration is in a “standby” mode.

Note: During regeneration, there may be a change in sound due to the intake
throttle and the EGR (Exhaust Gas Recirculation) valve opening changes, but
normal regeneration should otherwise be transparent to the operator. The
exhaust may also smell different from non-DPF equipped diesel engines.

enclosed spaces. Be sure to allow for an outside air source
or park the loader outside during a regeneration.

load. Be sure to stay clear of the DPF during a regeneration.

Before executing a regeneration procedure, it is recommended that operators
become familiar with some terms and definitions related to a DPF (Diesel Partic­ulate Filter) regeneration.

50950106/AP0313 59

There is a possibility of carbon monoxide
poisoning if the regeneration occurs in

During regeneration there will be high
exhaust gas temperatures, even at low

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

EGT: Exhaust Gas Temperature

Passive regeneration and assist regeneration: These automatic DPF regen

modes occur without any operator input and without affecting machine opera­tion.

Reset regeneration: This DPF regen mode intentionally increases exhaust gas
temps to remove PM. Review all precautions regarding high exhaust temps. The
operator can continue to operate all skid-steer loader functions. Reset regenera­tion is initiated by the E-ECU, but the operator has the option to delay this func­tion. A reset-regeneration is a 100 hour recurring event unless other factors, such
as engine load and effective PM levels determine otherwise.

Note: The operator can improve the effectiveness of the reset regen by oper­ating the skid-steer loader at a middle to high throttle position during the reset
regen.

Stationary Regeneration: This DPF regen mode includes engine speed control
for a more effective and complete DPF regen. When the DPF regen-required
lamp illuminates, the operator should move the skid-steer loader to a safe place
without flammable material nearby before operating the stationary regen. For
operation and other details, refer to the flow chart and stationary regen operating
procedures.

Backup Mode: In the backup mode, the engine has reduced revolutions per
minute (RPM) and power. A number of DTC’s are to be expected. Refer to the
DTC listing (page 81) for a complete summary and troubleshooting techniques.
To cancel the backup mode, the service tool (Smart Assist) is required. Contact
your dealer for full details.

Ash Cleaning Mode: The ash cleaning mode details are under development.
Contact your dealer for information.

60 50950106/AP0313

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. See the ash cleaning mode description on page 60
for more details.

Elevated EGT (Exhaust Gas Temperature)

The EGT icon is used to notify the operator of high exhaust
temperatures during an active reset/stationary regeneration.

Parking Brake

The parking brake icon is used to remind the operator that the
parking brake switch must be engaged prior to a stationary
regeneration.

DPF Regeneration Acknowledgement

The DPF regeneration acknowledgement icon is
used to notify the operator that the E-ECU has
received the stationary regeneration request. It is
also used to prompt the operator to start a stationary
regeneration request or to allow a reset regeneration.

50950106/AP0313 61

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.

 Do not touch the exhaust pipes during stationary regen to avoid injury.

Be sure there are no people close to the exhaust pipes.

 After stationary regeneration starts, white smoke may be discharged

from the exhaust pipe. This is not a fault, but steam discharged when the
exhaust temperature is low. As the exhaust temperature increases, the
white smoke should disappear.

 Stationary regen may not operate while the engine is cold. Start it after

the engine has warmed to normal operating temperature, 140° F (60° C)
or above.

 The exhaust gas has a different odor from that of a conventional diesel

engine. This is not a fault. The different odor is generated because the
exhaust gas is purified by the catalyst integrated in the DPF.

Other Stationary Regeneration Topics

Besides the safety concerns listed above, the operator must also be aware of these
additional stationary regen topics:

 Extended duration of engine idling will rapidly increase soot levels

in the DPF, requiring more frequent regen operations.

 It is not a good practice to keep the DPF switch depressed in the

CANCEL position for extended periods of time, as this could reduce the
standby-time allowed prior to some of the regen modes.

 It is advised to not perform any additional machine functions during the

stationary regen.

 The operator does not have to be in the operator’s seat during the sta-

tionary or reset regen modes.

 Inadvertent pressing of the DPF regen switch does not harm the DPF

system, since the DPF will not execute a regen request until all the
requirements in the operating procedures are met.

 The stationary regen procedure consumes approximately 1 gal. (3,8 L)

of diesel fuel.

62 50950106/AP0313

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. Ensure the engine’s coolant temperature is above 140° F (60° C).

3. Engage the parking brake.

4. When the DPF regen request switch is pressed:

 Operator Initiated: Press and hold for 10 seconds, release, then hold for

an additional three seconds and the stationary regen starts. The engine
speed will gradually increase to a high idle speed.

 E-ECU Initiated: Press and hold for three seconds and the stationary

regen starts. The engine speed will gradually increase to a high idle
speed.

5. The stationary regen procedure takes approximately 25 to 30 minutes to per­form.

6. When the above time has passed, the engine speed gradually decreases to the low idle speed and the DPF regen acknowledgement lamp and the EGT lamp turn off. Stationary regen is completed.

Note: When stationary regen starts, the DPF regen-required lamp turns off, the
DPF acknowledge lamp briefly appears and the EGT lamp illuminates.

Stationary Regeneration Abort Procedure

To abort a stationary regen, perform any one of the following steps.

1. Set the DPF switch to its inhibit/cancel state.

2. Command the accelerator to a position above its lowest position.

3. Turn the manual parking brake switch to its OFF position.

4. Turn the keyswitch to the OFF position.

Note: Depending upon the PM levels and which switch was used to abort the sta­tionary regen, the E-ECU will either go back to normal operation or stationary
regen standby mode.

Note: Interrupting a reset or stationary regen will require a full reset or sta­tionary regen process in the future. The E-ECU does not command partial reset
or stationary regens.

50950106/AP0313 63

DPF Regen Flowcharts

If a SStationary Regen Mode is requested by Machine Operator:

How many hours since last Staonary Regen?

< 50 Hours

> 50 Hours

E– ECU returns to

Normal Operaon

Staonary Regen is not allowed.

Staonary Regen is allowed.

Staonary Regen

See Staonary Regen Procedure for complete details.

DPF SWITCH

Press and hold Staonary Regen Request

switch for 10 seconds, release, then hold

for an addional three seconds.

These icons will appear on

the Electronic display during

the Staonary Regen mode.

E– ECU returns to

Normal Operaon

64 50950106/AP0313

DPF Regen Flowcharts, cont.

Reset Regen is now acve

How can the operator cancel Reset Regen?

DPF SWITCH

Keeping the DPF Switch in the

center AUTO posion, the E-ECU

will complete the Reset Regen in

about 25-30 minutes.

See Reset Regen Descripon for complete details.

Cancelling a Reset Regen transfers the E-ECU

to a Reset Standby mode for three hours.

Press the CANCEL side of the DPF switch.

DPF SWITCH

During the three hour Reset Standby

mode, seng the DPF switch back

to the center AUTO posion allows

the Reset Regen mode to become

available and then acve as

necessary depending upon PM.

DPF SWITCH

Keeping the DPF

switch in the CANCEL

posion for three hours or

if there is excessive

soot levels in the DPF,

the E-ECU automacally

prompts the E-ECU to

request a Staonary Regen.

If a Reset Regen Mode is iniated by the ENGINE— ECU:

DPF SWITCH

E– ECU returns to

Normal Operaon

E– ECU returns to

Normal Operaon

Exhaust Gas Temp icon appears on the electronic display.

See next page.

50950106/AP0313 65

DPF Regen Flowcharts, cont.

What happens if a Staonary

Regen Procedure is not performed

within 10 hours?

DPF SWITCH

Keeping the DPF switch in the CANCEL

posion for more than 10 hours

OR

Keeping the DPF switch in the center

AUTO posion for more than 10 hours

automacally transfers the E-ECU to

Backup mode.

If a Stationary Regen Mode is requested by the

ENGINE— ECU

DPF SWITCH

When these icons are acve, the E-ECU is requesng a Staonary Regen.

DPF SWITCH

DPF REGEN ACKNOWLEDGE

(Electronic Display)

See Staonary Regen Procedure

for complete details.

DPF SWITCH

Press and hold Staonary Regen

Request switch for three seconds.

These icons will appear on

the Electronic display during

the Staonary Regen mode.

E– ECU returns to

Normal Operaon

A Staonary Regen Procedure is

required within 10 hours.

Staonary Regen

Backup Mode (Limp Mode)

66 50950106/AP0313

CHAPTER 5

WARNING

Figure 30 Rail removed from

window frame.

SERVICE

Before servicing the machine, unless
expressly instructed to the contrary, exercise

the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 6).

After service has been performed, be sure to restore all guards,
shields and covers to their original positions before resuming
operation.

This

Service

chapter details procedures for performing routine maintenance checks,
adjustments and replacements. Most procedures are referred to in the
and

Maintenance

(page 103) for service intervals. Refer to the separate engine manual for engine­related adjustments, lubrication and service procedures.

Note: All service procedures, except those described under the Dealer Services
topic are owner-operator responsibilities.

Important: Always dispose of waste lubricating oils and hydraulic fluids
according to local regulations or take to a recycling center for disposal. Do not
pour onto the ground or down the drain.

chapters of this manual. Refer to the

Maintenance Interval Chart

Dealer Services

The following areas of component service, replacement and adjustments require
special tools and knowledge for proper servicing and should be performed only
by your authorized Gehl skid-steer loader dealer: hydrostatic drive components,
hydraulic system pumps, valves, hydraulic cylinders, electrical components
(other than battery, fuses or relays).

Troubleshooting

Sliding Side Window Removal Procedure

The sliding side windows inside the
ROPS/FOPS can be removed for
cleaning. To begin, open the cab door and
slide one of the side windows to the rear.
Using a non-marring tool, separate the
front plastic rail underneath the sliding
window from the window frame. Pull the
plastic rail forward until it releases from
the window frame. Then slide the side
window to the front and separate the rear
plastic rail from the window frame in the
same manner, pulling the rail rearward to
release it from the window frame. The
sliding side window may now be removed
from the ROPS/FOPS. To reinstall the
window, reverse the removal steps.

50950106/AP0313 67

Replacement Parts

Part Description Gehl Part No.

Air Cleaner Element, Primary (outer) - R190

Air Cleaner Element, Secondary (inner) - R190

Air Cleaner Element, Primary (outer) - R220/
R260

Air Cleaner Element, Secondary (inner) - R220/
R260

Hydraulic Oil Filter Element - All Models

Engine Oil Filter Element - All Models

Fuel Filter Element - All Models

Fuel Separator Element - All Models

Fresh Air Intake Filter (heater option)

Recirculation Air Filter (heater option)

Belt, Alternator/Fan - R190

Belt, Alternator/Fan - R220/R260

Belt, AC Compressor - All Models

Note: Part numbers may change. Your Gehl dealer will always have the latest
part numbers.

184146

184195

50352454

50352455

074830

195568

50352551

50352550

195660

242832 (2 per)

50350094

241477

242274

Important: To ensure continued warranty coverage, use only genuine Gehl
replacement filters.

68 50950106/AP0313

Loader Raising Procedure

WARNING

Figure 31 Loader Properly Blocked

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

raised position without additional blocking
and supports. Serious personal injury could result from improp­erly raising or blocking the loader.

1. To block the loader, obtain enough suitable blocks (solid wood, hard plastic

or metal) so all of the tires are raised off the ground.

2. Using a jack or hoist capable of lifting the fully-equipped weight of the loader

(with all attached options), lift the rear of the loader until the rear tires are off
the ground.

3. Stack wooden, hard plastic or metal blocks under the flat part of the loader

chassis. They should run parallel with, but not touch, the rear tires.

4. Slowly lower the loader until its weight rests on the blocks. If the tires still

touch the ground, raise the loader again, add more blocks and lower again.

5. Repeat steps 2 through 4 for the front end. When the procedure is finished, all

four tires are off the ground, so they could be removed.

50950106/AP0313 69

Loader Lowering Procedure

Figure 32 Rear Grille Latch Location

Figure 33 Engine Compartment

Access Door and Cover

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.

2. Carefully remove the blocking under the front of the loader.

3. Slowly lower the loader until the front tires are resting on the ground.

4. Repeat steps 1 through 3 for the rear of the loader. When the procedure is finished, all four tires will be on the ground and the blocks removed from under the loader.

Engine Compartment Access

To open the engine compart­ment, lift the engine cover. Then
pull the rear grille latch up
(Figure 32) and carefully swing
open the rear grille. There is
another rear grille latch near the
top hinge pin of the grille to
secure the grille in an open posi­tion.

70 50950106/AP0313

Tilting Back the ROPS/FOPS

Figure 34 ROPS/FOPS

Lock Mechanism – Engaged

Figure 35 ROPS/FOPS

Lock Mechanism – Disengaged

WARNING

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. Tilt it back slowly,
moving the control handles out of the way.
Two gas-charged springs help tilt it back.
A self-actuating lock mechanism will
engage to lock when the ROPS/FOPS is in
a rolled-back position. To lower the ROPS/
FOPS, return the lock mechanism to the
unlocked position (flipper up). Lower the
ROPS/FOPS slowly onto the chassis.
Reinstall the anchor bolts, washers and
locknuts. Refer to the Torque Specifica­tions chart (page 119) for torque informa­tion.

mechanism is securely engaged when the ROPS/FOPS is tilted
back. Be sure to reinstall the anchor bolts, washers and locknuts
before resuming operation. Additionally, DO NOT raise or lower
the lift arm with the ROPS/FOPS rolled back.

50950106/AP0313 71

Never operate the loader with the ROPS/FOPS
removed or tilted back. Be sure the lock

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:

• around the lift cylinders

• at the front of the loader

• on the hitch, especially around tilt cylinder

• around the hydraulic oil reservoir breather

• in the engine compartment

• in the operator’s compartment

Important: Build-up of foreign materials in these areas can interfere with the
operation of the loader, cause component damage or become a fire hazard.

72 50950106/AP0313

Lubrication

Listed below are the temperature ranges and types of lubricants for this machine.
Refer to the separate engine manual for more information regarding engine lubri­cants, quantities and grades required.

Note: Refer to the specific service sections for detailed information on periodic
checking and replenishing of lubricants.

Refer to Figure 36 for grease fitting locations. Wipe dirt from the fittings before
greasing them to prevent contamination. Replace any missing or damaged
fittings. To minimize dirt build-up, avoid excessive greasing.

Important: Always dispose of waste lubricating oils and hydraulic fluids
according to local regulations or take to a recycling center for disposal. Do not
pour onto the ground or down the drain.

System Lubricant

Use Petro Canada HVI60, Mobil DTE 15M or equivalent, which
contain anti-rust, anti-foam and anti-oxidation additives, and

Hydraulic

System Oil

Chaincase Oil

Grease Fittings Use lithium-based grease.

conforms to ISO VG46.

Entire System Capacity, R190: 11 U.S. gallons (41,6 L)
Entire System Capacity, R220: 12 U.S. gallons (45,4 L)
Entire System Capacity, R260: 12 U.S. gallons (45,4 L)
Bare Reservoir Capacity: 8.0 U.S. gal. (30,3) L

Use SAE grade 10W-30 motor oil.

R190 Capacity (each side): 9.5 U.S. quarts (9,0 L)
R220 Capacity (each side): 10 U.S. quarts (9,5 L)
R260 Capacity (each side): 11 U.S. quarts (10,4 L)

Important: Refer to the Engine Operator’s Manual for specific
engine oil recommendations.
Service Classification: API-CJ-4 SM

R190 Capacity: 9.5 U.S. quarts (9,0 L)
R220/R260 Capacity: 11.0 U.S. quarts (10,4 L)

Engine Oil

50950106/AP0313 73

Lubrication Procedure

50/250

250

10

50/500

500

250

Figure 36 Service Locations (see Maintenance Chart on page 103.)

Check Engine Oil Level (page 80)

Check Hydraulic Oil Level (page 87)

Grease Hitch, Hitch-related Cylinder Pivots
and Latch Pins (page 73)

Grease Lift Arm Pins (page 73)

Check Oil Level in Chaincases (page 75)

Change Engine Oil and Filter (page 80)

Change Hydraulic Oil Filter (page 87)

Change Hydraulic Oil (page 88)

Change Chaincase Oil (page 75)

Check and Drain Water Separator (page 81)

Replace Filter in Water Separator (page 81)

10 Hours
(or Daily)50Hours

250

Hours

500 Hours
(or Yearly)




















 Perform the initial procedure at 50 hours, then at the indicated intervals.

74 50950106/AP0313

Chaincases

Figure 37 Fill and Check Plug

Figure 38 Drain Plug

(R190 Shown)

There is a chaincase on each side of the loader. Refer to the Maintenance Interval
Chart (page 103) for change intervals. Refer to the Lubrication chart (page 74)

for the type of lubricant.

Checking and Adding Oil

1. Park the loader on a level surface and raise the lift arm, refer to the Lift Arm
Support Device Engagement Procedure (page 22). Shut off the engine and

remove the key.

2. On each chaincase cover, between the axles, is a fill and check plug (Figure 37). Remove this plug. The oil level should be at the plug level or no more than 1/4 in. (6 mm) below the plug.

3. If the oil level is low, add oil through the check and fill plug until the oil level reaches the check plug hole. Reinstall the plug.

Draining Oil

1. Park the loader on a level surface, or on a sloping surface with the loader facing downhill and the tires blocked.

2. At the front of the loader, remove the chaincase drain plug (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.

50950106/AP0313 75

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. Rotate each tire by hand. The proper amount of chain defection should be 1/8
inch to 1 inch (3 to 25 mm) forward and rearward tire movement. If the chain
defection is more than 1 inch (25 mm) or less than 1/8 inch (3 mm) in either
direction, the chains should be adjusted.

Adjusting Chain Tension

1. Raise the loader following the Loader Raising Procedure (page 69).

2. Remove the tire from the axle to be adjusted.

3. Loosen (but DO NOT remove) the bolts holding the axle to the chaincase.

4. Front Chain Tension – To tighten the front chain, move the front axle assembly toward the front of the loader. To loosen the chain, move the front axle assembly toward the rear of the loader.

Rear Chain Tension – To tighten the rear chain, move the rear axle assembly
rearward. To loosen the chain, move the rear axle assembly toward the front
of the loader.

5. After proper tension is achieved, retighten the bolts.

Important: Be careful not to over-tighten the drive chains. Over-tightening will
cause premature drive chain and axle sprocket wear.

6. Reinstall the tire.

7. Repeat steps 2 through 6 for any other axle requiring adjustment.

8. Lower the loader following the Loader Lowering Procedure (page 70).

76 50950106/AP0313

Engine Air Cleaner

1

27 2 6

325

2

4

2

2

3

2

5

1

2

3

2

4

Figure 39 Dual-Element Air Cleaner

1. Element Housing (includes filters)

2. Hose Clamp

3. Elbow Hose

4. Reducer/Adapter

5. Restriction Indicator

6. Sound Diffuser

7. Air Intake Tube

R190

R220/R260

Important: Failure to follow proper filter servicing instructions could result in
catastrophic engine damage.

The air cleaner assembly consists of an outer (primary) filter element and an
inner (secondary) filter element. There is an electrical air filter restriction indi­cator for monitoring the condition of the elements. If the air filter becomes
restricted, this indicator will trigger a lamp light in the indicator and warning
lamp display to warn the operator that the air cleaner requires service. For
replacement elements, refer to the Replacement Parts chart (page 68).

The outer element should be replaced only when the restriction indicator lamp
lights. The inner element should be replaced every third time the outer element is
replaced, unless the outer element is damaged or the inner element is visibly
dirty.

Along with a daily check of the restriction indicator, check that the air cleaner
intake hose and clamps, and the mounting bracket hardware are properly secured.

Access

1. Open the engine cover and then the rear grille (page 70).

2. Unlatch the three clamps on the air cleaner cover and remove the cover. Clean out any dirt built up in the cover assembly.

50950106/AP0313 77

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. Use a trouble light inside the outer element to inspect for bad spots, pinholes
or ruptures. Replace the outer element if any damage is noted. The outer ele­ment must be replaced if it is oil- or soot-laden.

Note: Cleaning the outer element is not recommended.

Inner Element

Note: Replace the inner element only if it is visibly dirty or if the outer element
has been replaced three times.

1. Before removing the inner element from the housing, 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.

2. Remove the inner element.

Reinstallation

1. Check the inside of the housing for any damage that may interfere with the elements.

2. Be sure that the element sealing surfaces are clean.

3. Insert the element(s), making sure that they are seated properly.

4. Secure the cover to the housing with the three clamps.

5. Check the hose connections and make sure they are all fitted and tightened properly.

Note: Periodically inspect intake system tubes, rubber elbows and connections.
Inspect for cracks, loose fits and loose clamps. Tighten or replace as needed.
Intake system must be air tight.

Note: Refer to the Maintenance Interval chart (page 103) for change intervals.
Refer to the Replacement Parts chart (page 68) for filter part numbers.

78 50950106/AP0313

Engine Service

2

1

3

4

5

6

7

8

9

10

11, 12

13

14

2

1

3

4

5

6

7

8

9

10

12

13

14

11

Figure 40 Engine Service Components

1. Muffler

2. Air Cleaner

3. Coolant Bottle

4. Engine Radiator

5. Hydraulic Cooler

6. Hydraulic Filter

7. Remote Engine Oil Filter

8. Water Separator

9. Fuel Filter

10. Remote Engine Oil Drain

11. Engine Oil Fill Cap

12. Engine Oil Dipstick

13. Starter

14. Alternator

R220/R260 Models

R190 Models

50950106/AP0313 79

Refer to the Maintenance Interval chart (page 103) for change intervals. Refer to

WARNING

Figure 41 Remote Engine Oil Filter

Figure 42 Remote Engine

Oil Drain Cap

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. Refer to the Torque Speci-
fications Chart (page 119) for torque information.

Allow hot engine and hydraulic system com­ponents to cool before servicing.

Checking Engine Oil Level

Open engine cover (page 70), pull out the dipstick and check the oil level. Mark­ings on the dipstick represent FULL and LOW (add oil) levels.

Changing Engine Oil and Filter

Note: For new units, the initial oil change should be after the first 50 hours.

Important: Always dispose of waste

lubricating oil according to local
regulations or take to a recycling
center for disposal; do not pour
onto the ground or down the drain.

The remote engine oil filter is
located behind the engine, above the
battery. Raise the engine cover and
lock open the rear grille to access
the oil filter (Figure 41).

Access for draining the engine oil is
located behind the left rear tire
(Figure 42).

To add new oil, open the engine
access cover. Remove the oil fill
cap and add the recommended type
and quantity of oil. Refer to the
Lubrication chart, page 73. Visually
inspect the remote oil drain hose for
damage or leaks.

Important: It is recommended that
the engine oil change occur after
every five engine DPF (diesel par­ticulate filter) regenerations, if five
stationary regenerations occur
during the duration of the 250 hour
oil change interval. See page 44 for more information on the engine regeneration
process.

80 50950106/AP0313

Changing Fuel Filter

Figure 43 Location of Water

Separator

Figure 44 Data Port for

the Engine

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. Lubricate the seal on the new filter element
with fuel before installing. Return the fuel line petcock on the water separator to
the open position. Start the engine and check for leaks. See page 79 for location
on the engine.

Checking the Water Separator

The water separator is located between
the fuel tank and the main fuel filter and is
used to remove finely dispersed water in
diesel fuel. Check on a daily basis and
drain if necessary. Water can be drained
from the separator by opening the valve
located at the bottom of the separator
bowl.

Important: Water in the fuel system can
cause severe engine damage. Drain water
from the water separator anytime water is
present.

To change the water separator filter, turn
the plastic petcock located on top of the water separator a 1/4 turn to stop fuel
flow. Unscrew the separator bowl from the housing and pull down on the existing
filter to release it from the housing. Replace with a new filter and reinstall the
bowl. Return the petcock on the water separator to the open position. Start the
engine and check for leaks.

Engine Diagnostic Chart

When detecting faults, the information
center electronic display (page 29) uses a
diagnostic trouble code (DTC) screen to
alert the operator to the occurrence of the
fault conditions.

The data port for accessing the diagnostic
trouble codes can be found behind a swell
latch panel at the operator’s left foot.

The following pages list descriptions,
diagnostic trouble codes and fault codes
for the engine.

50950106/AP0313 81

Engine Diagnostic Chart

82 50950106/AP0313

Engine Diagnostic Chart (cont.)

50950106/AP0313 83

Engine Diagnostic Chart (cont.)

84 50950106/AP0313

Engine Diagnostic Chart (cont.)

50950106/AP0313 85

Engine Diagnostic Chart (cont.)

86 50950106/AP0313

Hydraulic System

WARNING

Figure 45 Sight Gauge and Fill

Tub e

Figure 46 Hydraulic Oil

Filter Location

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
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. Check the fluid level with
the lift arm lowered and attachment
bracket on the ground (Figure 45).

Add hydraulic oil as required in the
hydraulic oil fill tube. Refer to the Lubri-
cation chart (page 73). Replace the fill
cap.

Changing Hydraulic Oil Filter

The hydraulic filter element is located to
the right of the radiator/cooler, against the
side of the chassis. To change hydraulic
filter element:

1. Park the loader on a level surface. Shut off the engine and remove the key.

2. Open the reservoir drain plug, located on the inside bottom of the right riser (Figure 47).

3. Drain the hydraulic oil out to a level below the point where the filter attaches to the reservoir.

Note: Unbolt the water separator from the chassis for greater access to the
hydraulic filter, if needed.

50950106/AP0313 87

4. Replace the reservoir drain plug.

Figure 47 Hydraulic Oil

Drain Plug

5. Clean any dirt/debris off the surface of the filter housing.

6. Spin off the old hydraulic filter ele­ment and spin on the new filter ele­ment.

7. Lubricate the seal on the new filter element with hydraulic oil before installing.

8. Refill the hydraulic oil reservoir with
oil (if needed). Refer to the Lubrica-
tion chart (page 73).

Changing Hydraulic Oil

The hydraulic oil must be replaced if it becomes contaminated, after major
repairs and after 500 hours or one year of use.

1. Install a catch pan of sufficient capacity under the oil reservoir. See page 73.

2. Open the reservoir drain plug (Figure 47), and allow the oil to drain.

3. Reinstall the drain plug.

4. Change the oil filter.

5. Refill the reservoir. Refer to the Lubrication chart (page 73).

6. Start the engine and operate the hydraulic controls.

7. Stop the engine and check for leaks at the filter and reservoir drain plug.

8. Check the fluid level and add fluid, if needed.

Bucket Cutting Edge

The bucket cutting edge should be replaced when it is worn to within 1 in.
(25 mm) of the bucket body.

Alternator Belt

Refer to the separate engine manual for setting proper belt tension. If the belt is
worn, cracked or otherwise deteriorated, replace the belt following the procedure
in the engine manual.

Wheel Nuts

Wheel nut torque must be checked before initial operation and every two hours
thereafter until the wheel mounting hardware torque remains at 180 ft.-lbs.
(244 N·m). When wheels are removed and reinstalled this procedure must be
repeated.

88 50950106/AP0313

Cooling System

Figure 48 Coolant Recovery

Tank

WARNING

Important: Check the cooling system daily to prevent overheating, loss of perfor­mance and engine damage. Drain, flush and refill coolant every year or 1,000
hours.

Checking Coolant Level

1. With the engine at operating tempera­ture, 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,
between full and low markings on the
coolant tank (Figure 48).

2. Allow the coolant to cool. Do not remove the fill tube cap when the coolant is hot. Serious burns may occur.

3. Add premixed coolant, 50% water and 50% ethylene glycol, to the tank if the coolant level is low.

Cleaning the Cooling System

Allow sufficient time for the oil radiator to
cool before working on or near it. Parts get

extremely hot during operation and can burn you.

The radiator assembly is mounted between the engine and the hinged rear grille.
When operating correctly, air is blown through the openings between the fins by
the engine fan. During operation dust and debris can build up on the engine side
of the radiator and restrict air flow through the fins. To remove this restriction,
use compressed air and direct the flow through the fins from the rear of the radi­ator toward the engine.

1. Lower the lift arm and stop the engine. Allow the machine to cool.

2. Raise the engine cover and open the rear grille (page 70).

3. As necessary, clean the radiator and air cooler by blowing compressed air through the fins from the rear, toward the engine.

50950106/AP0313 89

Draining/Flushing the Cooling System

Figure 49 Radiator Drain Cock

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. Remove the radiator cap on the coolant tank.

5. Open the drain cock on the radiator (Figure 49) and drain the coolant into a suitable container.

Note: Coolant must be drained from the
radiator and the engine.

6. Close the drain cock.

Note: Protect the cooling system by
adding premixed 50% water and 50%
ethylene glycol to the system.

7. Fill the radiator fully and the coolant tank to half full.

8. Reinstall the radiator cap and run the engine until it is at operating tempera­ture.

9. Stop the engine and let it cool. Check the coolant level. Add more fluid, if necessary.

90 50950106/AP0313

Tires

WARNING

Inflating or servicing tires can be dangerous.

When possible, trained personnel should ser­vice 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. If different sizes are used, tires
will be turning at different speeds, causing excessive wear.

Note: The tread bars of all tires should point the same direction.

 BE SURE the rim is clean and free of rust.
 Lubricate the tire beads and rim flanges with a soap solution. Do NOT use oil

or grease.

 Use a clip-on tire chuck with remote hose and gauge, allowing you to stand

clear while inflating the tire.

 NEVER inflate beyond 35 psi (240 kPa) to seat the beads. If the beads have

not seated by the time the pressure reaches 35 psi (240 kPa), deflate the
assembly, reposition the tire on the rim, lubricate both parts and re-inflate.
Inflation pressure beyond 35 psi (240 kPa) with unseated beads may break the
bead or rim with explosive force sufficient to cause death or serious injury.

 After seating the beads, adjust the inflation pressure to the recommended

operating pressure.

 Do NOT weld, braze or otherwise attempt to repair and use a damaged rim.

Checking Tire Pressure

Correct tire pressure should be maintained to enhance operating stability and
extend tire life. Refer to the chart below for proper inflation pressures.

Inflation Pressure

Tire Size

psi kPa

10 x 16.5 8-ply HD Flotation 60 415

10 x 16.5 10-ply Severe-Duty 65 450

12 x 16.5 10-ply HD Flotation 65 450

12 x 16.5 12-ply Severe-Duty 65 450

33 x 15.5 x 16.5 Extra-Wide Flotation 60 415

14 x 17.5 12-ply HD Flotation 65 450

14 x 17.5 14-ply HD Flotation 65 450

14 x 17.5 14-ply Severe-Duty 65 450

50950106/AP0313 91

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. Remove the threaded knobs on both sides of the cover to
access the filter.

Recirculation Air Filters: Located behind the covers in the headliner
directly above the rear window. The access, remove the screws on either side
of the covers.

Important: Keeping the cab clean will reduce need for service and help ensure
proper air conditioner and heater operation. Failure to do so can cause evapo­rator and heater core plugging, fan noise, vibration and failure.

92 50950106/AP0313

Electrical System

Figure 50 Fuse Panels

in the Engine Compartment

Figure 51 Fuse Panels in the

Operator’s Compartment

A/C

HEAT

20A

BACK-UP

ALARM

5A

REAR WORK

LIGHTS

15A

SAFETY

START

FLASHER

10A

KEY POWER

15A

REGEN

INTERLOCK

REAR WIPER

WASHER

15A

POWER

ALL-TACH

10A

SOL. LOCK

PILOT

SOL LOCK

PILOT

15A

ACCESSORY
(CHASSIS)

20A

ACCESSORY

(CAB)

30A

FUEL PUMP

5A

RIDE/2 SP

10A

OPEN

FRONT WORK

LIGHTS

15A

SEAT

COMPRESSOR

20A

INTERLOCK

10A

FRT WIPER

WASHER

15A

OPEN

HORN

10A

AUX. HYD

CONTROL

10A

GAUGE
POWER

10A

LIGHTS

20A

OPEN

SELF-LEVEL

5A

RADIO

10A

HORN

DOME/

STROBE

10A

OPEN

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.

50950106/AP0313 93

Battery

WARNING

WARNING

Before servicing the batteries or electrical

system, be sure the electrical battery discon­nect 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.

The battery top must be kept clean. Clean it with an alkaline solution (ammonia
or baking soda and water). After foaming has stopped, flush the battery top with
clean water. If the terminals and cable connection clamps are corroded or have a
build-up, disconnect the cables and clean the terminals and clamps with the same
alkaline solution. Apply protective spray to prevent corrosion.

Explosive gas is produced when a battery is

in use or being charged. Keep flames and
sparks away from the battery area. ALWAYS charge the battery in
a well-ventilated area.

Never lay a metal object on top of a battery, because a short circuit
can result.

Battery acid is harmful on contact with skin or fabrics. If acid spills,
follow these first-aid tips:

1. Immediately remove any clothing on which acid spills.

2. If acid contacts the skin, rinse the affected area with running water for 10 to

15 minutes.

3. If acid contacts the eyes, flood the eyes with running water for 10 to 15 min-

utes. See a doctor at once. Never use any medication or eye drops unless pre­scribed by the doctor.

4. To neutralize acid spilled on the floor, use one of the following mixtures:

a. 1 pound (0.5 kg) of baking soda in 1 gallon (4 L) of water, or
b. 1 pint (0.5 L) of household ammonia in 1 gallon (4 L) of water

Whenever a battery is removed, be sure to disconnect the negative
(-) battery terminal connection first.

94 50950106/AP0313

CHAPTER 6

TROUBLESHOOTING

Electrical System

Problem Possible Cause Remedy

Entire electrical
system does not
function.

No instrument panel
lamps with keyswitch
turned to “ON.”

Starter will not
engage when key is
turned to START.

Battery disconnect switch is
in OFF position.

Main wiring harness
connectors at rear of ROPS/
FOPS not properly plugged in.

Faulty keyswitch. Replace keyswitch.

15 amp fuse blown (key
switch).

Battery terminals or cables
loose or corroded.

Battery is faulty. Test battery, replace as

Fuse has blown. Replace fuse.

Main wiring harness
connectors at rear of ROPS/
FOPS not properly plugged in.

Battery terminals or cables
are loose or corroded.

Battery terminal or cables
loose or corroded.

Battery discharged or
defective.

Seat or restraint bar switch
malfunctioning or not
actuated.

Ignition wiring, seat switch,
restraint bar switch, etc.
loose or disconnected.

Start safety relay malfunction
located in fuse panel.

Starter solenoid not
functioning.

Starter relay malfunctioning. Verify relay is working

Starter or pinion faulty. Remove starter; repair/

Engine fault code: (E-ECU
will not allow crank if certain
faults are present).

Turn battery disconnect
switch to ON.

Check main harness
connectors.

Replace keyswitch.

Clean battery terminals and
cables and retighten them.

needed.

Check main harness
connectors.

Clean battery terminals and
cables and retighten them.

Clean terminal, cables and
retighten

Recharge or replace battery.

Contact your dealer.

Check wiring for poor
connections, broken leads;
repair wiring or connection.

Verify proper operation.

Contact your dealer.

properly, replace.

replace as needed.

Contact your dealer.

50950106/AP0313 95

Electrical System

Problem Possible Cause Remedy

Work lights not
functioning properly.

Single light not working; light

bulb burned out, faulty

wiring.

No lights; light fuse blown. Check circuit and locate

Faulty light switch(es) or

poor ground.

Check and replace light bulb
as needed. Check wiring
connection to light.

trouble before replacing fuse.

Check ground wire
connections. Replace light
switch.

Lift/Tilt and/or drive
solenoids do not
work.

Wiring to solenoids

disconnected or faulty.

Restraint bar or seat switch

malfunction.

Faulty solenoid valve coil. Contact your dealer.

Solenoid relay

malfunctioning.

Faulty fuse. Verify relay is working

Troubleshoot circuit, repair.

Contact your dealer.

Verify relay is working
properly, replace.

properly if not, replace.

96 50950106/AP0313