Gehl R105 (EU), Operator'S Manual

Page 1: ...R105 R105 EU R105 X SERIES SKID STEER LOADERS Operator s Manual Form No 50950260 AP1216 English...

Page 2: ...ed to BE ALERT Your personal safety is involved Operators must have instructions before running the machine Untrained operators can cause injury or death Read Operator s Manual before using machine CO...

Page 3: ...Table of Common Materials and Densities 105 Torque Specifications 107 Warranty 108 Index 109 R105 Skid Steer Loader Operator s Manual TABLE OF CONTENTS All Tach and Hydraloc are trademarks of Manitou...

Page 4: ...essure Equipment 2006 42 EC Machinery and 2000 14 EC Noise Emission as amended by 2005 88 EC 7 In accordance with EN ISO Standards EN ISO 3450 1996 ISO 6165 8 Category EARTH MOVING MACHINERY LOADERS C...

Page 5: ...ovided 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 appli...

Page 6: ...Front Work Lights 5 Handholds 6 Lift Arm 7 Auxiliary Hydraulic Couplers 8 Tilt Cylinders 9 Attachment Bracket 2 3 6 8 9 4 1 7 5 1 Engine Cover 2 Tail Lights 3 Rear Work Lights 4 Rear Door 5 Roll Over...

Page 7: ...h Low N Neutral F Forward R Reverse Parking Brake Engine Air Filter Engine Oil Engine Oil Filter Engine Oil Pressure Fuel Filter Engine Temperature Hydraulic System Hydraulic Oil Temperature Hydraulic...

Page 8: ...haust Gas Temperature DPF Regen Acknowledgement Service Interval Low Fuel Alarm Master Light Switch Position Lights Engine Speed Control DPF Regen Inhibited Self Leveling Unlock Lift Point Windshield...

Page 9: ...safety when designing its machinery and guards exposed moving parts for the operator s protection How ever some areas cannot be guarded or shielded in order to assure proper opera tion This Operator s...

Page 10: ...used only with Gehl attach ments and approved attachments To avoid possible personal injury equip ment damage and performance problems use only attachments that are approved for use on and within the...

Page 11: ...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 protect...

Page 12: ...ions 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 lin...

Page 13: ...vide 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...

Page 14: ...0950260 AP1216 Safety Decals inside the ROPS FOPS 242582 Located behind the operator s seat 137683 Located on ROPS left panel 137647 Located on operator s lower left side 137639 Located on ROPS left p...

Page 15: ...50950260 AP1216 11 Safety Decals on the outside of the Skid Loader 137655 Front of loader 50354117 and 50354121 Front of loader 184214 Under ROPS 137637 Lift arm support device loader left side...

Page 16: ...he Engine Compartment 50352528 HOT SURFACE Do not touch hot engine or hydraulic system parts ROTATING FAN Keep hands out or stop engine 50352529 137657 On right riser 50352528 On fuel tank 50352529 On...

Page 17: ...37847 Part of left 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...

Page 18: ...all 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...

Page 19: ...nd 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...

Page 20: ...otective 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...

Page 21: ...d 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 Restrai...

Page 22: ...or solenoid valves An interlock system is used on the loader for operator safety Together with solenoid valves switches and relays the interlock system Prevents the engine from starting unless the ope...

Page 23: ...dealer if necessary Seat Switch With the engine off and the restraint bar lowered unfasten the seatbelt Lift your weight up off the seat Try to start the engine If the engine starts turn off the engi...

Page 24: ...oaders 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 Rear Window Emergency Exit The ROPS r...

Page 25: ...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 loca tion Figure 4 on the...

Page 26: ...t arm Figure 5 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 left side of the ROPS FOPS headliner Push on th...

Page 27: ...is properly compressed To operate the lockable fuel cap 1 Shut off the engine and remove the key Insert the fuel cap key into the fuel cap lock 2 Turn the key 45 clockwise to unlock the fuel cap and t...

Page 28: ...starting procedure on page 42 On Non DPF Models a right hand con trolled throttle lever is provided on all models for adjusting the engine speed Move the control forward to increase the engine speed...

Page 29: ...und conditions For hand foot loaders use your heel to push the left foot pedal up to horizontal to deactivate For T bar loaders pull the right control handle rearward to deactivate The float mode is a...

Page 30: ...to start the engine Release the key to RUN position after the engine starts Note The engine cannot be started unless the operator is sitting in the seat and the restraint bar is lowered 2 Information...

Page 31: ...e hydraulic system to cool and determine the cause of the high temperature During normal operation this indicator should be OFF 11 Parking Brake Switch Used to manually apply the parking brake Lights...

Page 32: ...d determine the cause for the pressure drop During normal operation this indicator should be OFF 6 Battery Lights if the charging voltage is too high or too low During normal opera tion this indicator...

Page 33: ...ne cannot be started unless the operator is sitting in the seat and the restraint bar is lowered 11 Parking Brake Switch Used to manually apply the parking brake The red indicator on the switch lights...

Page 34: ...ing the engine Operate the controls grad ually and smoothly Excessive speed and quick control movements without regard for conditions and circumstances are hazardous and could cause an accident Lift T...

Page 35: ...Be sure the controls are in neutral before starting the engine Operate the controls grad ually and smoothly Excessive speed and quick control movements without regard for conditions and circumstances...

Page 36: ...l iary hydraulic couplers Note When ignition power is interrupted auxiliary hydraulic function is reset to OFF Couplers are located on the left lift arm A port is pressure B port is return when the au...

Page 37: ...e latch pins To prevent unexpected release of the attach ment from the hitch be sure to secure the latch pins by rotating the levers all the way to the hitch Electrical Battery Disconnect Switch optio...

Page 38: ...eral screen navigation and other various functions depending upon screen and context P Increase Brightness Return Button Used for different functions depending upon screen and context Used to increase...

Page 39: ...the symbol is displayed on the screen Also initiates DPF regeneration if all appropriate conditions are met Used to return to previous screen Corresponds to the symbol on the display screen R Regen In...

Page 40: ...F Models on page 55 Note Strike through line through the symbol is dis played in red when DPF regeneration is inhibited Ambient engine compartment temperature Diesel Particulate Filter DPF regeneratio...

Page 41: ...s to display See page 39 E Engine coolant temperature amber warning region Indicates elevated coolant temperature F Engine coolant temperature red stop warning region Indicates serious coolant overhea...

Page 42: ...ion Procedures DPF Models on page 55 Secondary Screens All Secondary Screens Secondary screens are accessed by holding down the ok button N Figure 17 for 10 seconds while the Dual Gauge Display screen...

Page 43: ...s is displayed at the top left of the screen T Use buttons P and Q Figure 17 to scroll through the messages See Engine Diagnostic Chart DPF Models on page 73 for specific error code details DM2 Screen...

Page 44: ...wing Green Active Black Inactive Yellow Standby or Not Applicable Red Short Circuit Table 2 Status Maintenance and Error Code Screens Display Mode Description DIAGNOSTICS INPUTS Float Hydro Glide High...

Page 45: ...roduce 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 diss...

Page 46: ...p 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...

Page 47: ...t 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 re...

Page 48: ...oid 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 k...

Page 49: ...atch levers to a vertical position to fully retract the latch pins 2 Start the loader engine and be sure the lift arm is lowered and in contact with the loader frame 3 Align the loader squarely with t...

Page 50: ...rtment disconnect the auxil iary hydraulic hoses and rotate the latch levers completely vertical to fully retract the latch pins 5 Start the engine and be sure that the lift arm is fully lowered and i...

Page 51: ...e lift arm slightly raised and the bucket tilted forward until the edge contacts the ground Break the ground by driving for ward and gradually lowering the lift arm With the bucket filled tilt the buc...

Page 52: ...bucket extends half way over the edge of the embank ment Tilt the bucket forward and raise the lift arm to dump the material After the material is dumped back away from the embankment while tilting t...

Page 53: ...on WBV Hand Arm Vibration HAV This section will cover primarily WBV issues because evaluations have shown that operation of mobile compact construction equipment on jobsites typically results in HAV l...

Page 54: ...ating steering braking etc in a smooth manner Adjust machine speed appropriately Adjust the controls mirrors and seat suspension for comfortable operation Travel across the smoothest parts of the work...

Page 55: ...trailer See Transporting Towing the Loader on page 54 For short distance highway travel attach an SMV Slow Moving Vehicle emblem purchased locally to the back of the loader For highway operation inst...

Page 56: ...of the ROPS FOPS Four point lift only Note The loader may 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 excessi...

Page 57: ...mission 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 a...

Page 58: ...optional brake release package page 48 facilitates loader retrieval in such situ ations When transporting a loader 1 Block the front and rear of the hauling vehicle s tires 2 If the loader has an att...

Page 59: ...Occurs automatically but can be inhibited by the operator Increases exhaust gas temperatures Reset regeneration occurs approximately every 100 hours of operation See Reset Regeneration on page 56 Note...

Page 60: ...re 9 displays on the screen Reset Regeneration Inhibit DPF regeneration inhibit prevents reset regeneration from occurring Permanently inhibiting regeneration is not recommended as this will eventuall...

Page 61: ...dismissed for as long as the request remains active Important Perform stationary regeneration as soon as possible when the stationary regeneration request screen displays Postponing stationary regener...

Page 62: ...rogress percentage disappears when stationary regeneration completes Note Stationary regeneration takes approximately 25 30 minutes It is not necessary to stay in the machine during stationary regener...

Page 63: ...screen displays Back Up Alarm A back up alarm system is optionally available which serves to warn people working in the area around the machine of the machine s rearward movement The back up alarm is...

Page 64: ...60 50950260 AP1216 Notes...

Page 65: ...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...

Page 66: ...OPS removed or locked back Be sure the lock is securely engaged when the ROPS FOPS is tilted back Properly sup port the ROPS FOPS when unlatching the lock mechanism and low ering the ROPS FOPS Be sure...

Page 67: ...re complete the skid steer loader can be taken down from the raised position To lower the loader onto its tires 1 Using a jack or hoist raise the front of the loader until its weight no longer rests o...

Page 68: ...an RTV or gasket sealant around the gasket when restoring the fuel sender Drive Chains The drive chains do not require routine adjustment Refer to the Service Manual for the initial setup procedure Re...

Page 69: ...prevent contamination Replace any missing or damaged fittings To minimize dirt build up avoid excessive greasing Hydraulic System Use Petro Canada HVI60 Mobil DTE 15M or equivalent which contain anti...

Page 70: ...66 50950260 AP1216 Figure 5 Grease Every 10 Hours or daily 1 Lift arm pivots 2 2 Lift cylinder pivots 4 3 Tilt cylinder pivots 2 4 Attachment Bracket pivots 2 2 4 3 1...

Page 71: ...Lift Arm Pins page 65 Check Oil Level in Chaincases page 80 Change Engine Oil and Filter page 71 Change Hydraulic Oil Filter page 78 Change Hydraulic Oil page 78 Change Chaincase Oil page 80 Check and...

Page 72: ...he reset button on the indicator Start the engine and adjust the throttle to full speed If the indicator does not turn red do not replace the element s The outer element should be replaced only when t...

Page 73: ...ter element if any damage is noted The outer element must be replaced if it is oil or soot laden Inner Element Note Replace the inner element only if it is dirty or if the outer element has been repla...

Page 74: ...For new units the initial oil change should be after the first 50 hours Open the rear door and engine access cover Pull out the dipstick and check the oil level Markings on the dipstick repre sent FUL...

Page 75: ...Check the oil level Add oil if it is not at the top mark on the dipstick For a replacement element refer to the Replacement Parts topic page 63 Changing Fuel Filter The engine has a fuel filter locat...

Page 76: ...ock on the water separator to the open position Start the engine and check for leaks Servicing Water Separator Non DPF Models Periodically check for water in water separator by checking level of float...

Page 77: ...eize coating on the plug 7 Reinstall and tighten the plug Alternator Fan Belt Refer to the separate engine manual for setting proper belt tension If the belt is worn cracked or otherwise deteriorated...

Page 78: ...74 50950260 AP1216 Engine Diagnostic Chart DPF Models...

Page 79: ...50950260 AP1216 75 Engine Diagnostic Chart DPF Models cont...

Page 80: ...76 50950260 AP1216 Engine Diagnostic Chart DPF Models cont...

Page 81: ...50950260 AP1216 77 Engine Diagnostic Chart DPF Models end...

Page 82: ...rubber gasket of the new filter element 3 Install and tighten the filter element 3 4 of a turn past the point where the gasket contacts the filter head 4 For a replacement element refer to the Replac...

Page 83: ...ooler by blowing through the fins with high pres sure water or air Note The radiator can be tipped out for cleaning by loosening and rotating the over center links on each side This will also help in...

Page 84: ...the check plug from each chaincase housing If the oil can be reached with the tip of your finger the oil level is adequate 3 If the level is low add fluid through the check plug until the oil level re...

Page 85: ...rained personnel should service and mount tires To avoid possible death or serious injury follow the safety precautions below 1 Be sure the rim is clean and free of rust 2 Lubricate the tire beads and...

Page 86: ...ept 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...

Page 87: ...ing soda in 1 gallon 4 L of water b 1 pint 0 5 L of household ammonia in 1 gallon 4 L of water Whenever the battery is removed be sure to disconnect the nega tive battery terminal connection first Fus...

Page 88: ...s Non DPF Models The are no fuse panels located in the engine compartment or in the ROPS FOPS at the operator s right elbow area However three relays can be found behind a panel in the FOPS FOPS at th...

Page 89: ...ttery terminals cables loose corroded Clean battery terminals and cables and tighten Main wiring harness connectors at rear of ROPS FOPS not properly plugged in Check main harness connectors Reconnect...

Page 90: ...erminal connections Check wiring connections Alternator malfunction Repair replace alternator Hour meter malfunction Replace information center electronic display Work road lights inoperative Single l...

Page 91: ...e turns over but will not start Engine cranking speed too slow Check battery and charge replace as necessary tighten battery terminals In cold temperatures pre warm the engine Fuel tank empty Fill tan...

Page 92: ...With engine off remove restriction Fan shroud improperly positioned With engine off reposition shroud contact dealer Improper oil grade or oil excessively dirty Change engine oil Exhaust restricted A...

Page 93: ...ne off reposition shroud contact dealer Improper oil grade or oil excessively dirty Change engine oil Exhaust restricted Allow exhaust to cool remove restriction Air filter restricted Replace filter s...

Page 94: ...ust spaces Cool operating temperatures Blue smoke Blue smoke indicates engine oil combustion which could be caused by Worn valve guides or seals Wear in cylinders piston rings ring grooves etc Cylinde...

Page 95: ...rod linkage disconnected Check linkage connection at control levers and neutral centering mechanisms Reconnect linkage Low or no charge pressure Contact your dealer Hydrostatic pump s relief valves ar...

Page 96: ...ded continuously Improve efficiency of operation Drive motor s or hydrostatic pump s have internal damage or leakage Contact your dealer Oil cooler fins plugged with debris Clean oil cooler fins Loade...

Page 97: ...dealer Relief valves on rear hydrostatic pump malfunctioning Contact your dealer Control rod linkage to rear hydrostatic pump disconnected Attach control rod linkage Right side doesn t drive in forwa...

Page 98: ...ler Restraint bar switch malfunctioning Check electrical connections to restraint bar switch and repair connections as needed If switch is still not functioning properly contact your dealer Hydraulic...

Page 99: ...No down pressure on the bucket Control valve in float position Take control out of float position Tilt cylinders are malfunctioning Contact your dealer Relief valve in control valve not functioning pr...

Page 100: ...aler Oil leaking past lift spool in control valve Contact your dealer Self leveling valve malfunctioning Contact your dealer Leaking hydraulic hoses tubes or fittings between control valve and cylinde...

Page 101: ...at intervals Perform the maintenance at 1000 hours Maintenance Interval Chart Service Procedure Maximum Interval 10 Hours or Daily 250 Hours 500 Hours or Yearly Check Engine Air Cleaner Restriction In...

Page 102: ...98 50950260 AP1216 Maintenance Log Date Hours Service Procedure...

Page 103: ...50950260 AP1216 99 Maintenance Log Date Hours Service Procedure...

Page 104: ...100 50950260 AP1216 Maintenance Log Date Hours Service Procedure...

Page 105: ...dels 35 hp 26 kW 2800 rpm Power net Non DPF Models 35 hp 26 kW 2600 rpm Peak Torque DPF Models 80 ft lbs 109 N m 1820 rpm Peak Torque Non DPF Models 80 ft lbs 109 N m 1200 rpm Hydraulic System theoret...

Page 106: ...Dual Front and Rear Work Lights Removable Belly Plate and Access Cover Dual Element Air Cleaner with Visual Indicator Vandalism Lock Provisions Top and Rear Windows Spark Arrestor Muffler Headliner a...

Page 107: ...F Dump Height 84 5 2146 G Dump Reach Bucket Full Height 22 8 579 J Rollback at Ground 29o M Rollback Angle at Full Height 99o O Seat to Ground Height 32 6 828 P Wheel Base Nominal 34 5 876 Q Overall W...

Page 108: ...0 27 m3 254 lbs 115 kg 1061 lbs 481 kg 61 5 in 13 0 ft3 1562 mm 0 37 m3 383 lbs 174 kg 975 lbs 422 kg Utility Buckets 55 5 in 13 5 ft3 1410 mm 0 38 m3 313 lbs 142 kg 1061 lbs 481 kg 61 5 in 15 2 ft3 1...

Page 109: ...oal 53 63 848 1008 Concrete 115 1840 Cinders 50 800 Coal anthracite 94 1504 Coke 30 480 Earth dry loam 70 90 1121 1442 Earth wet loam 80 100 1281 1602 Granite 93 111 1488 1776 Gravel dry 100 1602 Grav...

Page 110: ...del loader using Dirt Construction Bucket the bucket capacity is 10 5 ft3 and the loader rating is 1050 lbs Multiply the density of snow 50 lbs ft3 by the capacity of the bucket 10 5 ft3 to achieve th...

Page 111: ...50 56 9 9 9 10 17 19 75 86 13 14 12 14 25 25 9 10 18 20 3 8 16 3 8 24 7 16 14 7 16 20 20 23 32 36 15 17 24 27 30 35 50 55 23 25 35 40 45 50 70 80 35 35 55 60 1 2 13 1 2 20 9 16 12 9 16 18 50 55 70 80...

Page 112: ...EATER RIGHTS UNDER YOUR STATE LAW GEHL WARRANTY DOES NOT INCLUDE 1 Transportation to selling dealer s business location or at the option of the Original Retail Purchaser the cost of a service call 2 U...

Page 113: ...48 C Capacities and Ratings 104 Chaincases 80 Checking and Adding Oil 80 Draining Oil 80 Changing Attachments 45 Cold Starting Procedure 42 Cold Starting 42 Control Indicator Symbols 3 4 Controls 37 C...

Page 114: ...ment 15 ISO Style used Internationally Safety Decals on the outside of the Skid Steer Loader 14 J Jump Starting the Engine 44 L Lift Arm Support Device 21 Lifting the Loader 52 Loader Lifting 52 Lower...

Page 115: ...02 Standard Features 102 Standard Features 102 Starting the Engine 41 Before Starting the Engine 41 Stopping the Loader 43 Storing the Loader 52 Switches Seat and Restraint Bar 80 T Table of Common Ma...

Page 116: ...112 50950260 AP1216 NOTES...

Page 117: ...raised Load unload and turn on flat level surface WRONG Never carry riders Keep bystanders away from work area WRONG Never modify equipment Use only attachments approved for the loader WRONG Never lea...

Page 118: ...is machine contact your dealer or the Gehl Company Service Department before starting or continuing operation Manitou Americas Inc One Gehl Way P O Box 179 West Bend WI 53095 0179 U S A www gehl com C...