Gehl R190 R220 R260 Manitou Mustang 1900R 2200R 2600R Service Manual Skid Steer Loader manuals in PDF

Factory Service Manual For Gehl, Manitou, Mustang Skid Steer Loader. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.

Format: PDF
Language: English
Pages: 328
Issued: august 2020
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes

Model

Gehl Skid Steer Loader
R190
R220
R260
Manitou/Mustang Skid Steer Loader
1900R
2200R
2600R

Contents

-SPECIFICATIONS
Specifications
-SAFETY
General Information
Signal Words
Additional Safety Reminders
Mandatory Safety Shutdown Procedure
Lift Arm Support Device
Lift Arm Support Device Engagement
Lift Arm Support Device Disengagement
ROPS/FOPS – Raising
ROPS/FOPS-Lowering
Relieving Hydraulic Pressure – T-Bar Controls – Lift/Tilt/Auxiliary
Relieving Hydraulic Pressure – Dual Joystick, Dual Hand and Hand/Foot Controls – Lift/Tilt Auxiliary
Loader Raising Procedure
Loader Lowering Procedure
-LUBRICATION
General Information
Hydraulic Oil Reservoir
Crankcase Oil
Chaincases
Grease Fitting Locations
Cooling System Drain Procedure
-MAINFRAME
Introduction
Mainframe (Chassis) Components
Grille and Engine Cover Components
Engine Access Cover – Removal and Installation
Roll-Over and Falling Object Protective Structure Components – ROPS FOPS
ROPS/FOPS Removal and Installation
Seat Removal and Installation
Seat Slide Replacement
Side Console Removal and Installation
Non-HVAC Assembly – ROPS/FOPS
HVAC Assembly – ROPS/FOPS
Heater-Only Assembly – ROPS TOPS
Air Duct Louver Replacement
ROPS/FOPS Rear Window Removal and Installation
Restraint Bar Components
Restraint Bar Removal and Installation
All-Tach Hitch Components – R190/1900R Models
Actuator Group Components – All-Tach Hitch – R190/1900R Models
All-Tach Hitch Components – R220/R260/2200R/2600R Models
Actuator Group Components – All-Tach Hitch – R220/R260/2200R/2600R Models
Power-A-Tach Components
All-Tach and Power-A-Tach Hitch Removal and Installation
Lift Arm Components
Lift Arm Removal and Installation
Lift Arm Bushing Replacement
Lift Arm Stop Installation and Adjustment
Control Console Removal and Installation
Clean-Out Cover Floor Plate and Kickplate Cover Removal and Installation
Crossmember Removal and Installation
Hydraulic Oil Reservoir Removal and Installation
Fuel Sensor Removal and Installation
Rear Grille Removal and Installation
Rear Grille Latch Removal and Installation
-WHEEL DRIVES
Introduction
Wheel Drive Components
Drive Chain Adjustment
Axle Housing Assembly Removal and Installation
Axle Assembly Components
Drive Chain Removal and Installation
Axle and Wheel Bearing Disassembly and Assembly
-CONTROLS
Introduction
Control Locations – Dual Joystick Dual Hand and Hand/Foot Controls
Control Locations – T-Bar Controls
Wheel Drive – Lift/Tilt Components
Control Handle Assembly (Both Control Handles) Removal and Installation
Control Handle Removal and Installation – Electrical Auxiliary Grip – Dual Joystick Dual Hand and Hand/Foot Controls
Control Handle Removal and Installation – T-Bar Controls
T-Bar Control Handle Assembly
Dual Joystick, Dual Hand and Hand/Foot Control Handle Assembly
Pivot Tube Removal and Installation Disassembly and Assembly – T-Bar Controls
Control Handle Position Adjustment – T-Bar Controls
Control Handle Tracking Adjustment
Neutral Centering Test and Adjustment
Lift/Tilt Control Removal and Installation
Lift/Tilt Control Adjustment – T-Bar Controls
Electrical Foot Throttle Components – Dual Joystick and T-Bar Controls
Electrical Foot Throttle Removal and Installation – T-Bar Dual Hand and Dual Joystick Controls
-HYDROSTATIC SYSTEM
Introduction
Hydrostatic Components R260/2200R’2600R H/F, DH & DJS Controls
Charge Pressure Test and Adjustment
Hydrostatic Pump Relief Valves
Hydrostatic Pump Removal and Installation
Hydrostatic Pump Drive Coupling Removal and Installation
Drive Motor Removal and Installation
Troubleshooting Guide
Hydrostatic/Hydraulic Schematic
-HYDRAULIC SYSTEM
Introduction
Troubleshooting Guide
Hydraulics
Pressure Check, Test and Adjustment
Tilt Cylinder Test
Tilt Circuit Spool Leakage Test
Self-Leveling Valve Test
Lift Cylinder Test
Lift Circuit Spool Leakage Test
Solenoid Valve Test – Lift Arm Pilot Supply, Joystick Drive Supply Power-A-Tach, Brake Two-Speed
Safety Locks and Ride Control
Hydraulic Oil Filter Element Replacement
Lift Cylinder Components
Tilt Cylinder Components
Tilt Cylinder Removal and Installation
Lift Cylinder Removal and Installation
Lift/Tilt Cylinder Disassembly / Assembly
Auxiliary Pump Removal and Installation
Self-Leveling Valve (Optional) Removal and Installation
Self-Leveling Valve Adjustment
Brake/Two-Speed Lift Arm Pilot Supply and Safety Lock Solenoid Valves – Removal and Installation
Joystick Drive Supply, Power-A-Tach and Hydraglide Ride Control Solenoid Valves – Removal and Installation
Lift/Tilt, Joystick Drive Supply, Brake Two-Speed All-Tach, Fan and Hydraglide Ride Control Solenoid Valves – Disassembly and Assembly
Main Control Valve Components – Standard
Main Control Valve Components – High-Flow
Control Valve Removal and Installation
Control Valve Disassembly and Assembly
Control Valve Solenoid Removal and Installation
Inlet Relief Valve Port Relief Valve and High-Flow Relief Valve Removal and Installation
Hydraulic Oil Reservoir Removal and Installation
Hydraglide Ride Control Accumulator Removal and Installation
-ELECTRICAL SYSTEM
Introduction
Description of Operation – Right and Left Instrument Panels
Troubleshooting Guide
Electrical Chassis Components
Electrical Chassis Components – Hydraglide Ride Control/Two Speed Components
Electrical ROPS/FOPS Components
Power Distribution Module Test and Operation
Interlock Control Module Test
Interlock Control Module Truth Table – PN 137753 – Earlier Models
Interlock Control Module Truth Table – PN 50305144 – Later Models
Two-Speed Ride Control and Float Module Test
Two-Speed Ride Control and Float Module Truth Table
High-Flow Controller Module Test
Standard Auxiliary Flow Controller Module Test
Standard Auxiliary Flow Module Truth Table
Control Handle Actuation Buttons – Two-Speed and Ride Control and Float Module
Electrically-Controlled Standard Auxiliary Hydraulic Flow System Test and Operation
Engine Throttle Test and Operation
Seat Switch Removal and Installation
Electrical Lights Components
Restraint Bar Components
Restraint Bar Switch Removal and Installation
Master Disconnect Switch – Remote Battery Terminal Removal and Installation
Front and Rear Work Light Bulb Replacement
Dome Light Bulb Replacement
Information Center Electronic Display Removal and Installation
Information Center Electronic Display – The Display Modes
DPF (Diesel Particulate Filter) Regeneration
Stationary Regeneration Safety
Other Stationary Regeneration Topics
Stationary Regeneration Procedure
Stationary Regeneration Abort Procedure
DPF Regen Flowcharts Introduction
DPF Regen Flowcharts
Electrical Heater Schematic
Electrical HVAC Schematic
Electrical 14-Pin Auxiliary Schematic
Electrical Engine Schematic (DPF Models)
Electrical Engine Schematic (Non-DPF Models)
Electrical Chassis Schematic (DPF Models)
Electrical Chassis Schematic (Non-DPF Models)
Electrical ROPS/FOPS Schematic
-ENGINE
Introduction
Troubleshooting Guide
Engine Components – R190/1900R
Parts Listing for R190/1900R Engine Illustration On Previous Page
Engine Components – R220/R260/2200R/2600R
Parts Listing for R220/R260/2200R/2600R Engine Illustration On Previous Page
Ah Cleaner and Exhaust Components – R190/1900R
Ah Cleaner and Exhaust Components – R220/R20/2200R/2600R
Radiator/Cooler Components – R190/1900R
Radiator/Cooler Components – R220/R260/2200R/2600R
Oil Filter Element Removal and Installation
Ah Cleaner Assembly Removal and Installation
Ah Filter Element Removal and Installation
Battery and Battery Tray Removal and Installation
Starter Removal and Installation
Exhaust Pipe Removal and Installation
Alternator Belt Adjustment
Radiator/Cooler Removal and Installation
Fan Shroud and Mounting Plates Removal and Installation
Fan Adjustment
Fan Removal and Installation
Engine Removal and Installation
Engine Diagnostic Fault Codes
Yanmar 4TNV98C-CT/NMS/T4 Engine Diagnostic Fault Codes (DPF Models)
Yanmar 4TNV98ZNMS2R / T-ZXNMSRIT4 Engine Diagnostic Fault Codes (Non-DPF Models)
INDEX

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