Gehl R105 Mustang 1050R Skid-Steer Loader Service Manual 50950298 - PDF DOWNLOAD

Gehl R105 Mustang 1050R

Form No. 50950298 Revision A 05/17

Service Manual

SKID-STEER LOADERS

INTRODUCTION With correct maintenance and proper use, the Gehl R105 and Mustang 1050R skid-steer loaders will give years of dependable service. This service manual is intended to be a guide in the assembly and disassembly, installation and removal, adjustment and testing, troubleshooting and replacement of components that together make up the Gehl R105 and Mustang 1050R skid-steer loaders.

In many of the procedures found within, the installation steps are the exact opposite of the removal steps and vice versa, and therefore, the opposite procedure is not written. Instead, a note to reverse the procedure will be stated. This reduces redundancy and excessive pages in the manual. In cases though, where the assembly and disassembly or removal and installation procedures differ and additional steps or safety concerns are paramount, the entire reverse procedure will be written out to include the new information.

The Table of Contents and Index can be used to make the procedure you need to find an easier process.

Many schematics, photographs, and line art drawings are used to help perform the necessary repairs, tests, or adjustments that the skid-steer loader needs to keep it in good running condition.

If you have any additional questions, please contact your authorized Gehl or Mustang dealer or call the Manitou Americas Service Department for assistance.

GEHL R105 / MUSTANG 1050R

TABLE OF CONTENTS

TABLE OF CONTENTS Specifications

Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety

Page

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lift Arm Support Device Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lift Arm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ROPS – Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ROPS – Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Loader Raising Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Lubrication

Page

Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Grease Fitting Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cooling System Drain Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Mainframe

Page

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Mainframe (Chassis) - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Mainframe (Chassis) - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine Access Cover - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ROPS/FOPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Seat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ROPS/FOPS Rear Window Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Seat Slide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Restraint Bar Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 PRINTED IN USA

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TABLE OF CONTENTS

GEHL R105 / MUSTANG 1050R

Restraint Bar Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Lift Arm Components - Gehl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Lift Arm Components - Mustang. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 All-Tach® Hitch Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 All-Tach® Hitch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Lift Arm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Lift Arm Bushing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Lift Arm Stop Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Mainframe Components - DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Mainframe Components - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Floor Covers and Kickplate Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Fuel Sensor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Rear Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Wheel Drives

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Wheel Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Axle Housing Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Drive Chain Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Axle and Wheel Bearing Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Controls

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Control Locations - T-Bar and Hand/Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Wheel Drives, Foot Throttle and Lift Tilt Components - T-Bar - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Wheel Drives, Foot Throttle and Lift Tilt Components - Parts Listing - T-Bar - DPF Models. . . . . . . . . . . . . . . . 49 Wheel Drives, Foot Throttle and Lift Tilt Components - T-Bar - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . 50 Wheel Drives, Foot Throttle and Lift Tilt Components - Parts Listing - T-Bar - Non-DPF Models . . . . . . . . . . . 51 Wheel Drives, Auxiliary Hydraulics and Lift Tilt Components - Hand/Foot Models . . . . . . . . . . . . . . . . . . . . . . 52 Control Handle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Control Handle Position Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Pivot Tube Weldment Removal and Installation - T-Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Neutral Centering Device and Pump Arm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Neutral Centering Device Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Lift/Tilt Controls Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Lift/Tilt Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Auxiliary Hydraulics Cable Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Auxiliary Hydraulics Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Electric Foot Throttle Pedal Removal and Installation - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Handle Throttle, Hand Throttle Cable and Throttle Rod Removal and Installation - Non-DPF Models . . . . . . . . 64 Foot Throttle and Foot Throttle Cable Removal and Installation - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . 65 Hand Throttle Adjustment - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Hand Throttle Tension Adjustment - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Foot Throttle Adjustment - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 2

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GEHL R105 / MUSTANG 1050R Hydrostatic System

TABLE OF CONTENTS Page

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Hydrostatic Pump Assembly and Drive Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Hydrostatic Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Charge Pressure Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Drive Motor Hot-Oil Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Hydrostatic Pump Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Hydrostatic Pump Removal / Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Hydrostatic Pump Flexible Drive Coupling Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Drive Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Hydrostatic/Hydraulic Schematic - Gehl R105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Hydrostatic/Hydraulic Schematic - Mustang 1050R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Hydraulic System

Page

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Hydraulics - Self Level Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Hydraulics - Standard Auxiliary Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Hydraulics - Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Hydraulics - Chassis Components - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Hydraulics - Chassis Components - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Pressure Tests, Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Tilt Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Lift Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Self-Leveling Valve Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Solenoid Valve Test - Tilt, Lift, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Hydraulics - Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Tilt Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Lift Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Tilt Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Lift/Tilt Cylinder Disassembly / Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Gear Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Self-Leveling Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Self-Leveling Valve Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Safety Lock Valves - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Lift, Tilt and Brake Solenoid Valves - Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Main Control Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Control Valve Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Main Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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TABLE OF CONTENTS Electrical System

GEHL R105 / MUSTANG 1050R Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Description of Operation - Instrument Panel - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Description of Operation - Instrument Panel - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Electrical Chassis Components - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Electrical Chassis Components - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Electrical ROPS/FOPS Components - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Electrical ROPS/FOPS Components - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Power Distribution Module Test and Operation - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Relay Test and Operation - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Interlock Control Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Interlock Control Module Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Seats - Standard and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Restraint Bar Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Restraint Bar Switch Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Seat Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Electrical Lights Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Front and Rear Work Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Diesel Particulate Filter (DPF) Regeneration Procedures - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Dome Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Reset Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Reset Regeneration Inhibit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Stationary Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 DPF Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Forcing Stationary Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Chassis Electrical Schematic - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 ROPS/FOPS Electrical Schematic - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Electrical Schematic - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Engine

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Engine Components and Engine Controls - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Engine Components and Engine Controls - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Air Cleaner and Exhaust Components - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Air Cleaner and Exhaust Components - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Radiator/Cooler Components - DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Radiator/Cooler Components - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Air Cleaner Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Air Filter Element Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Fuel Filter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Water Separator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Changing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Changing the Water Separator Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Electric Fuel Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Priming the Diesel Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 4

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TABLE OF CONTENTS

Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Exhaust Assembly Removal and Installation - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Exhaust Tube Removal and Installation - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Fan Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Radiator/ Oil Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Fan Shroud and Support Brackets Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Fan Shroud Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Fan Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Fuel Tank Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Engine Diagnostic Chart (DPF Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Engine Diagnostic Trouble Codes (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Yanmar Engine Diagnostic Trouble Codes (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

INDEX

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TABLE OF CONTENTS

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GEHL R105 / MUSTANG 1050R

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

SPECIFICATIONS

SPECIFICATIONS Model Engine Make Engine Model (DPF Models) Engine Model (Non-DPF Models) Fuel Displacement Horsepower - Net (DPF Models) Horsepower - Net (Non-DPF Models) Peak Torque (DPF Models) Peak Torque (Non-DPF Models) Rated Operating Capacity Operating Weight Shipping Weight

R105 / 1050R Yanmar 3TNV88C-KMS 3TNV88-BKMS Diesel 100 CID (1,64 L) 35 hp (26 kW) @ 2800 rpm 35 hp (26 kW) @ 2600 rpm 80 lbf-ft. (109 N•m) @ 1820 rpm 80 lbf-ft. (109 N•m) @ 1200 rpm 1050 lbs. (476 kg) 4000 lbs. (1814 kg) 3515 lbs. (1594 kg)

Capacities Engine Oil Fuel Tank (DPF Models) Fuel Tank (Non-DPF Models) Chaincase (each) Hydraulic Reservoir Engine Coolant

Capacities 7.6 US qts. (7,2 L) 9.5 US gal. (36 L) 10.3 US gal. (39 L) 8.0 US qts. (7,6 L) 8.0 US gal. (30 L) 8.0 US qts. (7,6 L)

Electrical System Battery Starter Alternator (DPF Models) Alternator (Non-DPF Models)

Electrical 12-V DC, Group 34, 800 CCA, 110 Reserve 12-V DC (1,7 kW) 55 A 40 A

Hydraulic System Hydraulic System Pressures Standard Auxiliary Flow Rate Travel Speed (with standard tire)

Hydraulic System 2750 PSI (190 bar) 16.5 gal/min (62 L/min) 0 to 5.5 mph (0 to 9,0 km/h)

Tire Options 8.50 x 15 Heavy-Duty 8-Ply 27 x 8.50-15 Heavy-Duty 8-Ply 10.50 x 15 Heavy-Duty 8-Ply 27 x 10.50 Heavy-Duty 8-Ply 10 x 16.5 Heavy-duty 8-Ply 7 x 15 SS Narrow Buckets and Capacities

Tire Options Description Titan Titan Titan Titan Titan Titan

Width - Description 36 inches (914 mm) - Dirt/Construction 44 inches (1118 mm) - Dirt/Construction 48 inches (1219 mm) - Utility/Snow 15.75-19.68-24 inches (400-500-610 mm) Pallet

Capacity (Heaped) 5.3 cubic feet ; 0,15 cubic meters 7.4 cubic feet ; 0,21 cubic meters 9.8 cubic feet ; 0,28 cubic meters Not Applicable

*Operating capacity rated with a 8.50-15 tires, 10.3 cubic foot (0.3 m3) dirt/construction bucket in accordance with SAE J818, SAE J732 and ISO 14397-1.

PRINTED IN USA

50950298/AP0517

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SPECIFICATIONS

GEHL R105 / MUSTANG 1050R

R105 / 1050R1

Dimensional Specifications A B C D E F G J M O P Q R S V W X Y Z

Overall operation height - fully raised Height to hinge pin - fully raised Overall height - top of ROPS Overall length - bucket down Dump angle @ full height Dump height Dump reach - bucket (full height) Rollback at ground Rollback angle @ full height Seat-to-ground height Wheelbase - nominal Overall width - less bucket Overall bucket width Ground clearance to chassis (between wheels) Overall length (less bucket) Departure angle Clearance circle - front (with bucket) Clearance circle - front (less bucket) Clearance circle - rear

in.

142 107.5 70.3 118 82 25.25

32.5 34.5 48.5/57 55.3 6.25 88.5 72 42 54

mm 3607 2731 1786 2997 40º 2083 641 31º 101º 826 876 1232/1448 1404 159 2248 22º 1829 1067 1372

1 - w/10.5 cu.-ft. bkt. and 8.5 x 15 tires

2

50950298/AP0517

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

SAFETY Signal Words

DANGER “DANGER” indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

General Information The above safety alert symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! It stresses an attitude of “safety awareness” and can be found throughout this service manual and on decals on the machine.

Before operating or working on this machine, read and study the following safety information. In addition, be sure that everyone who operates or works on this equipment 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, but are not limited to, hillside operation, overloading, instability of the load, poor maintenance and using the equipment for a purpose for which it is not intended or designed.

Both Gehl and Mustang Company ALWAYS consider the operator’s safety when designing 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. The Operator’s Manual and the decals on the machine warn of additional hazards and should be read and observed closely.

These topics in the Safety chapter of the service manual include procedures, which, when followed, will allow safe performance of service procedures: Mandatory Safety Shutdown Procedure, Lift Arm Support Device, Roll-Over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS) Lock Mechanism, Loader Raising and Lowering Procedures, and Relieving Hydraulic Pressure.

PRINTED IN USA

WARNING “WARNING” indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

CAUTION “CAUTION” indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. May also alert against unsafe practices.

Additional Safety Reminders Read and understand the Service Manual and all decals before maintaining, adjusting or servicing this equipment.

Doors, Guards and Shields - Some photographs in this manual may show doors, guards and shields open or removed for illustrative purposes only. BE SURE all doors, guards and shields are in their proper operating positions before starting engine to operate unit.

Damaged or Worn-out Parts - For safe operation, replace damaged or worn-out parts with genuine Gehl/ Mustang service parts, before operating this equipment.

Attachments - Gehl and Mustang loaders are designed and intended to be used only with Gehl/Mustang Company attachments or approved referral attachments.

The Company cannot be responsible for operator safety if the loader is used with a non-approved attachment.

Battery Safety - To avoid injury from a spark or short circuit, disconnect the negative battery cable before servicing any part of the electrical system. Do not tip the battery more than 45º.

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SAFETY

GEHL R105 / MUSTANG 1050R

Loader Stability - A skid-steer loader’s stability is determined by its wheelbase and tread width. The following elements can affect stability: terrain, speed, load being carried or dumped, and sudden control movements. DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE LOADER TO TIP, POSSIBLY RESULTING IN DEATH OR SERIOUS INJURY. Therefore, ALWAYS have the operator restraint bar lowered and wear the seat belt. Operate the controls only from the operator’s seat. Operate the controls smoothly and gradually at an appropriate engine speed that matches the operating conditions.

DO NOT exceed the rated operating capacity of the machine. For additional stability when operating on inclines or ramps, ALWAYS travel with the heavier end of the loader toward the top of the incline.

ALWAYS look to the rear before backing up.

When parking machine, before leaving seat, check restraint bar for proper operation. The restraint bar, when raised, applies the parking brake and deactivates lift/tilt controls and auxiliary hydraulics.

Operator visibility is limited in certain areas; ROPS/ FOPS posts, attachments, the lift arm, items in the cab, etc., can obstruct the operator's view and could mask hazards or people in the area around the machine. It is very important the operator is aware of these masked visibility areas before operating the machine, especially on busy worksites.

To reduce the hazards posed by masked visibility areas: •

•

Use caution when raising or lowering attachments; masked visibility areas can change dramatically when attachments and/or the lift arm is moved.

Look around the machine before operating.

Objects near the machine and close to the ground can be difficult to see from the operator’s position.

•

Always look in the direction of travel, including reverse. A back-up alarm is not a substitute for looking behind you when operating the machine in reverse.

•

Keep bystanders out of, and away from, the work area.

•

Keep the lift arm as low as possible while traveling.

•

Additional equipment may be installed on the machine to serve as visual aids (e.g., mirrors, CCTV systems) that provide visibility to areas masked by the machine structure. Keep all machine components that affect visibility in a

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clean, properly adjusted state and in good working order.

Static electricity can produce dangerous sparks at the fuel-filling nozzle. Do not wear polyester, or polyesterblend 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.

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/m3 as a time-weighted average for up to a 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.

Keyswitch - NEVER attempt to bypass the keyswitch to start the engine. Use the jump-starting procedure detailed in the Service chapter of the Operator’s Manual.

Hydraulic Fluid Leaks - NEVER use hands to search for hydraulic fluid leaks. Instead, use paper or cardboard. Fluid under pressure can be invisible, penetrate the skin and cause a serious injury. If any fluid is injected into skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor or gangrene may result.

Wear Safety Glasses - ALWAYS wear safety glasses with side shields when operating the machine or 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 eyes or other parts of the body.

50950298/AP0517

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

SAFETY

ALWAYS wear safety glasses when searching for hydraulic leaks or when working near batteries.

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

Loaded Bucket/Fork - DO NOT raise or drop a loaded bucket or fork suddenly. Abrupt movements under load can cause serious loader instability.

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

NEVER push the lift control into the “float” position with the bucket or attachment loaded or raised, because this will cause the lift arm to lower rapidly.

Only after these precautions can you be sure it is safe to proceed. Failure to follow the above procedure could lead to death or serious injury.

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.

DO NOT smoke or have any sparkproducing equipment in the area while filling the fuel tank or while working on the fuel or hydraulic systems.

Exhaust Gases - Exhaust fumes can kill. DO NOT operate this machine in an enclosed area unless there is adequate ventilation.

Engine - NEVER use ether or starting fluid.

People - NEVER carry riders. DO NOT allow others to ride on the machine or attachment, because they could fall or cause an accident.

BE SURE all persons are away from the machine and warn others in the area before starting the engine.

ALWAYS face the machine and use handholds and steps when getting on and off. DO NOT jump off machine.

Wear appropriate ear protection for prolonged exposure to excessive noise.

ALWAYS perform a daily inspection of the machine before using it. Look for damage, loose or missing parts, leaks, etc.

Remove trash and debris from the machine and engine compartment each day to minimize risk of fire.

New operators MUST operate loader in an open area away from bystanders. Practice with controls until the loader can be operated safely and efficiently.

Mandatory Safety Shutdown Procedure BEFORE cleaning, adjusting, lubricating or servicing the unit or leaving it unattended: 1. Move 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.

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SAFETY

GEHL R105 / MUSTANG 1050R

Lift Arm Support Device

device to come down into contact with the lift cylinder.

WARNING BEFORE leaving operator’s compartment to work on the loader with the lift arm raised, ALWAYS engage the lift arm support device.

Turn the keyswitch to OFF, remove the key and take it with you.

Many service procedures require a raised lift arm to allow easier access to loader components. For operator and service personnel safety, a lift arm support device is standard on Gehl and Mustang skid-steer loaders. Used as a cylinder block, it helps prevent a raised lift arm from unexpectedly lowering.

BE SURE to engage the lift arm support device whenever the lift arm is raised. When the device is not being used, secure it to the anchor on the underside of the lift arm using the slide latch and retainer provided.

The lift arm support device is a safety device which must be kept in proper operating condition at all times.

Lock Pin

5. Return to the operator’s compartment and restart the engine.

6. Use the lift control to raise the lift arm until the lift arm support device drops over the end of the lift cylinder and around the lift cylinder rod. Slowly lower the lift arm until the free end of the support device contacts the top (rod end) of the lift cylinder.

The following procedures outline the correct way to engage and disengage the lift arm support device.

Lift Arm Support Device Engagement 1. Remove any attachment from the lift arm.

2. Lower the lift arm until contact with the loader frame.

3. Turn keyswitch to OFF position to stop engine.

4. Leave the operator’s compartment. Pull down on the lock pin button to release its locking mechanism. Pull out the lock pin holding the support device up against the lift arm. All the support

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7. Be sure the support device is secure against the cylinder end. Then, stop the loader engine, remove the key and leave the operator’s compartment.

50950298/AP0517

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

SAFETY

Lift Arm Support Device Disengagement

WARNING NEVER leave the operator’s compartment to disengage the lift arm support device with the engine running.

To return the lift arm support device to its storage position, proceed as follows: 1. Raise the lift arm completely.

ROPS – Raising For service, the ROPS can be unbolted and tilted back.

Gas-charged springs help tilt it back. A self-actuating lock mechanism engages to lock the ROPS in a rolledback position.

1. The lift arm should be lowered or locked in the raised position as per the “Lift Arm Support Device Engagement” procedure in this chapter.

2. Turn the keyswitch to the OFF position to stop the engine. Remove the key and take it with you.

3. Leave the operator’s compartment.

2. Turn the keyswitch to the OFF position to stop the engine, remove the key and take it with you.

WARNING

BEFORE testing the machine, ALWAYS clear people from the area.

DO NOT leave the operator’s compartment with the engine running. Before leaving the loader, shut off the engine according to the “Mandatory Safety Shutdown Procedure” described in this chapter.

3. Before leaving the operator’s compartment, check to be sure the lift arm is being held in the raised position by the solenoid valve (See NOTE).

4. Remove one capscrew, three washers and one nut and mounting isolator on each side of the ROPS forward stanchions

WARNING

NOTE: With the keyswitch OFF, and the solenoid valve functioning properly, the lift arm will not move when the lift control is moved forward. If the valve does not hold the lift arm, DO NOT leave the operator’s compartment. Instead, have someone store the support device for you. Then, contact your Gehl/Mustang dealer to determine the reason why the lift arm lowers while the keyswitch is in the OFF position.

4. To store the lift arm support device, remove it from the lift cylinder rod and return it to its storage location. Secure the support device under the lift arm with the lock pin.

Lock Pin

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5. Lift ROPS up and tilt it back until the self-actuating lock mechanism engages. The lock mechanism locks the ROPS in a rolled-back position.

2. Lower the ROPS until it contacts the chassis.

IMPORTANT Avoid damaging control handles by slowly lowering the ROPS. BE SURE the control handles clear the ROPS.

IMPORTANT BEFORE raising the ROPS, position the seat as far back as it will go. Avoid damaging control handles by slowly raising the ROPS. BE SURE the control handles clear the ROPS.

3. Be sure control handles clear the ROPS. 4. Reinstall the one capscrew, three washers and one nut and mounting isolator on each side of the ROPS forward stanchions.

ROPS – Lowering 1. With an assistant’s help, apply upward force on the ROPS while pulling the lock mechanism handle toward the front of the loader.

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Relieving Hydraulic Pressure

Loader Raising Procedure

The following procedure should be used to relieve pressure in the hydraulic system before performing service procedures on hydraulic system components.

The following procedure is used to raise the skid-steer loader so that all four tires are off the ground.

1. Completely lower the bucket or attachment.

2. Turn the keyswitch to the “OFF” position to shut off engine.

3. With the operator in the seat and the restraint bar lowered, turn the keyswitch to the “ON” position, but DO NOT start the engine.

WARNING BEFORE servicing the machine, exercise the “Mandatory Safety Shutdown Procedure” described in this chapter.

4. Move the lift, tilt and auxiliary hydraulics controls through several cycles.

WARNING T-Bar Controls

Lift and Tilt

Auxiliary Hydraulics

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 skid-steer loader.

1. To raise and block the skid-steer loader, obtain four jack stands (or blocks) of sufficient strength to support the loader. A reinforced pallet may also be used.

2. Using a jack or hoist capable of raising the fullyequipped loader, lift the loader until the tires are off the ground.

Hand/Foot Controls

3. Place the reinforced pallet, jack stands (or blocks) under the flat part of the loader chassis. Place them parallel with, but not touching, the tires.

Auxiliary Hydraulics

4. Slowly lower the loader so that its weight rests on the reinforced pallet, jack stands (or blocks).

5. When the procedure is finished, all four tires will be off the ground, and the wheels can be removed as necessary.

Lift and Tilt

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Loader Lowering Procedure When the service procedures are complete, the skidsteer loader can be taken down from the “raised” position. To lower the loader onto its tires: 1. Using a jack or hoist, raise the loader until its weight no longer rests on the reinforced pallet, jack stands (or blocks).

2. Carefully remove the reinforced pallet, jack stands (or blocks) under the loader.

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

NOTES

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LUBRICATION

General Information

Hydraulic Oil Reservoir

WARNING NEVER service this unit when any part of the machine is in motion. ALWAYS BE SURE to exercise the “Mandatory Safety Shutdown Procedure” (see Safety chapter) BEFORE servicing this equipment.

Routine lubrication is an important factor in preventing excessive part wear and premature failures. Loader and engine operation depend on using correct grade, highquality lubricating oils. This chapter and the chart below list locations, temperature ranges and types of recommended lubricants to be used when servicing this machine. In addition, refer to the engine manual for specific grades and ratings as specified by the engine manufacturer.

IMPORTANT

The oil reservoir for hydraulic and hydrostatic systems has a capacity of 8.0 U.S. gallons (30 liters). A dipstick built into the reservoir cap provides a visual oil level indicator for convenient maintenance of the hydraulic oil level.

Hydraulic Oil filter

Engine Oil Dipstick

Hydraulic Oil Fill and Dipstick

The hydraulic oil reservoir should be drained and filled after every 500 hours of operation or annually (whichever occurs first).

Whenever service is performed on hydraulic components (valves, cylinders, hoses, etc.), fuel tanks and lines, care must be taken to prevent discharging fluid onto the ground. Catch and dispose of fluid per local waste disposal regulations.

Hydraulic Oil Drain

Hydraulic System Reservoir Use Petro-Canada Premium HVI60, or equivalent that contains anti-rust, anti-foam, and anti-oxidation additives and conforms to ISO VG46.

Capacity: 8.0 Gallons (30 L)

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Chaincases

Grease Fittings

Crankcase Oil

Use hydraulic system oil or SAE grade 15W-40 motor oil.

Capacity (each side): 8.0 Quarts (7,6 L)

Use lithium-based grease

Below 32°F (0°C) use SAE Grade* 10 or 10W-30 Above 32°F (0°C) use SAE Grade* 15W-40 *Service Classification: API - CJ-4 SM Capacity (w/ filter change): 7.6 Quarts (7,2 L)

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Use Petro-Canada Premium HVI60 hydraulic oil (or ISO VG46 equivalent) that contains anti-rust, anti-foam and anti-oxidation additives. Hydraulic oil filter element should be replaced after every 500 hours of operation or annually (whichever occurs first). For details, refer to “Hydraulic Oil Filter Element Replacement” procedure in the Hydraulics System chapter.

Crankcase Oil The Yanmar three-cylinder diesel engine crankcase has a capacity of 7.6 U.S. quarts (7,2 liters). The chart below lists recommended oil viscosity for the Yanmar engine.

NOTE: An initial 50-hour hydraulic oil filter element replacement is recommended for new skid-steer loaders.

Hydraulic Oil Tank Drain Procedure Engine Oil Fill

1. Open the engine access cover and lock open the rear grille.

2. Because the tank is pressurized, slowly remove the hydraulic oil tank cap from the filler neck.

3. Underneath the left riser, remove the drain plug on the hydraulic oil tank. Place a suitable container under the drain plug hole to catch the hydraulic oil.

NOTE: Care must be taken to prevent discharging fluid onto the ground. Catch and dispose of fluid per the local waste disposal regulations.

Ambient Temperature

Viscosity

Below 32°F (0°C)

SAE 10 or 10W-30

Above 32°F (0°C)

SAE 15W-40

Service classification: API - CJ-4 SM

Engine oil should be changed and filter element replaced every 500 hours of service. Access to the engine oil filter and drain plug is from underneath the skid-steer, through the rear belly pan.

Rear Belly pan

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The engine oil filter is located on the left side of the engine.

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.

Engine Oil Filter Location

3. Reinstall the chaincase drain plug.

4. Remove the chaincase oil fill plug.

Chaincase Fill/Check Plug

Refer to engine operator’s manual (see NOTE) for details on changing oil, and to “Oil Filter Removal” and “Oil Filter Installation” procedures in Engine chapter of this manual.

NOTE: Refer to engine operator’s manual for additional information on oil change intervals, including the 50-hour initial oil change.

Chaincases Each chaincase requires 8.0 U.S. quarts (7,6 L) of motor oil. This quantity of oil should be maintained at all times. The oil in both chaincases should be drained and refilled every 1000 hours of operation or annually, whichever occurs first.

NOTE: An initial 50-hour chaincase oil change is

5. Add motor oil through the chaincase fill/check plug until oil begins to flow out of the fill/check plug.

6. Reinstall the fill/check plug.

Grease Fitting Locations Use lithium-based grease on all grease fittings.

recommended for new skid-steer loaders.

Grease every 10 hours of operation (or daily)

Change Chaincase Oil

1. Grease All-Tach® hitch attachment pivots.

1. Find a level position outdoors or in a workshop.

2. Remove drain plug on either chaincase and drain the oil into a suitable container.

Chaincase Drain Plug

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2. Grease tilt cylinder pivots.

3. Grease lift cylinder pivots.

Cooling System Drain Procedure Gehl R105 and Mustang 1050R kid-steer loaders use a hydraulic oil cooler/radiator design to help keep the hydraulic oil and engine coolant from overheating.

Many procedures in this Service Manual require partially or fully draining the radiator/cooler to perform the procedures.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine and allow it to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

Radiator Drain Procedure 1. Open the engine access cover and lock open the rear grille.

2. Remove the radiator cap.

3. A drain cock is located at the bottom rear of the radiator.

4. Place a catch pan with a capacity of at least 10-gallons (37,9 L) behind and underneath the chassis, below the drain cock or plug.

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5. Open the drain cock and drain the coolant into a suitable container.

2. On the cooler side, unscrew the bottom right cooler hose from the 90º fitting in the cooler port and plug/cap the hose and the 90º fitting.

Anti-freeze Drain Cock

NOTE: Care must be taken to prevent discharging fluid onto the ground. Catch and dispose of fluid per the local waste disposal regulations.

6. Close the drain cock when finished draining.

7. Refill the radiator per the specifications found in the Specifications chapter.

Note: Plugging or capping the two hoses in steps 1 and 2 will help prevent hydraulic oil from spilling onto the floor of the chassis if removal of the radiator/cooler is required.

Hydraulic Oil Cooler Plug/Cap Procedure 1. On the oil cooler side, unscrew the 90º fitting from the top right cooler hose and plug/cap the hose and the 90º fitting.

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GEHL R105 / MUSTANG 1050R CHAPTER NOTES

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Introduction

sprockets. Oil is used inside these cases to ensure the chains always receive proper lubrication.

Gehl R105 and Mustang 1050R model skid-steer loaders have a welded steel chassis. Maintenance, service and repair may be performed through standard access panels.

The lift arm and the lift and tilt cylinders are mounted with pivot pins. Capscrews are used to secure the pivot pins. A Rollover Protective Structure/Falling Object Protective Structure (ROPS/FOPS) is standard for operator safety, and both the seat and restraint bar include interlock switches.

Two side chaincases provide mounting for the drive motors and for the front and rear axles. The side cases also serve as sealed housings for the drive chains and Mainframe (Chassis) - DPF Models

41

5

34 2

7

42

22

28

1 NOTE #1

21

42 29

17 20

42 42

35

42

37

30 16

3

36

2

15

20

27 2

40 11

1 6 43 31

39

32

4

14 9

23

42

20

20

25

26

42

24 42 12

8

40

19

38

13 10

9 18 33 18

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

TIE/CABLE CLAMP/HOSE NUT/FLLSUF LOCKNUT FUEL SENDER GASKET CAP ASSEMBLY-FILLER SENDER PLUG PLUG FILTER/VENT COVER/AXLE ACCESS COVER/CHAINCASE ACCESS COVER OIL PAN DOWN STOP VENT/REMOTE

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16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

NOTE: 1. USE WIRE TIE TO CONTROL POSITION OF CABLE. KEEP AWAY FROM GEAR PUMP.

PLATE/VALVE MOUNT KICK PLATE THWH TR LN FL SERR LN FL SERR CAP/FUEL FILLER STRAINER/FUEL CS FLAT HD COVER SHIM HOSE /FUEL FITTING/STRAIGHT CHASSIS PLATE/COVER FUEL TANK

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31 32 33 34 35 36 37 38 39 40 41 42 43

PLATE/FUEL SEPARATOR FITTING/90 PAN/BELLY FITTING/90 BOLT/CARRIAGE BOLT/CARRIAGE BOLT/CARRIAGE BOLT/CARRIAGE SCREW/CAP THWH TC USL HWHMS HWHTRS TAP/R SCREW/CAP

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Mainframe (Chassis) - Non-DPF Models 31 5 7 32

25

1 NOTE #1

32

20

18

27

32

20 29 13

32 17

3

28

16

2

30 11

1 6

33

4 23

24

15 9

21

32

32

22 32 12

8

30

14 10

9 19 26 19

1 2 3 4 5 6 7 8 9 10 11

18

TIE/CABLE CLAMP/HOSE NUT/FLLSUF LOCKNUT FUEL SENDER GASKET CAP ASSEMBLY-FILLER SENDER PLUG PLUG FILTER/ VENT COVER/AXLE ACCESS

NOTE: 1. USE WIRE TIE TO CONTROL POSITION OF CABLE. KEEP AWAY FROM GEAR PUMP.

12 13 14 15 16 17 18 19 20 21 22

COVER/CHAINCASE ACCESS FUEL TANK COVER OIL PAN DOWN STOP VENT/REMOTE PLATE/VALVE MOUNT KICK PLATE THWH TR NUT/FLRSUF CS FLAT HD COVER

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SHIM HOSE /FUEL CHASSIS PAN/BELLY BOLT/CARRIAGE BOLT/CARRIAGE BOLT/CARRIAGE THWH TC USL HWHMS HWHTRS TAP/R HN

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Engine Access Cover - Removal and Installation

Installation Procedure - Follow all warnings first, then reverse the removal steps.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

Removal Procedure 1. Open the engine access cover and lock open the rear grille.

2. Disconnect the gas spring from the engine access cover by removing the gas spring clip at the access cover end of the gas spring, and then pulling the gas spring off the ball stud on the access cover.

3. Holding up the engine cover, remove the hardware securing the access cover to the ROPS/FOPS assembly and remove the engine cover.

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Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS 33

23

24 39

35 16

46

7

46

23

13

40

43

9 NOTE 1

34 41

46 7

36

37

6

45

38

26

5

5

25

46

28 21

NOTE 1) APPLY LOCTITE 680 (703285) TO P/N 072490 WHEN INSTALLING LOCATE WINDOW SEAL SEAM AND RIP CORD TAG AT TOP CENTER AS SHOWN. APPLY BLACK RTV SEALANT TO SEAM. 19

18

29 22

8 48 17 30

43

31 47

1

11

42 11

3

14

4 2

12

27

15

20 10

44

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

20

SCREW/SHOULDER SCREW/SHOULDER SCREW/SHOULDER BUSHING/OILITE WASHER/FLAT MOUNTING/ISOLATOR NUT/SPEED HLN INST LN LG FL SERR LOCKNUT LOCKNUT LOCKNUT ISOLATOR/ROPS ROPS SUPPORT ROPS LATCH PLATE/UPRIGHT SUPPORT

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

32

BUSHING TAG/RIP CORD RING GAS SPRING/ROPS LN FL CTR ROPS/FOPS PHIL PAN S INSTRUMENT PANEL/LEFT PLATE/HEATER SEAL COVER/SEATPLATE SPRING/EXTENSION WASHER/FLAT PLATED STRIP/LOCKING REAR WINDOW/ROPS SEAL/WINDOW SPONGE RUBBER/SEAT PLT

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TOP WINDOW SHIELD/ASSEMBLY FOAM, REAR PANEL/ROPS FOAM, SIDE RH/ROPS FOAM, SIDE RH/ROPS FOAM, SIDE LH/ROPS FOAM, SIDE LH/ROPS FOAM, HEADLINER/ROPS HWHMS SCREW/CAP SCREW/CAP SCREW/CAP SCREW/CAP THMS FW FW

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ROPS/FOPS Removal and Installation

6. If equipped with a cab heater, remove the three clamps securing the heater hoses to the left side of the ROPS/FOPS.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

Removal Procedure 1. Remove the engine access cover per the procedure in this chapter.

2. Disconnect the negative (-) battery cable at the battery, or, if equipped, turn the electrical disconnect switch to OFF.

7. Remove one capscrew and flat washer securing each gas spring to the ROPS/FOPS.

3. Disconnect ROPS/FOPS harness connectors at the harness bulkhead, right of the fuel tank.

Harness Connectors

4. Raise the ROPS/FOPS per the procedure in the Safety chapter of this manual.

8. Disconnect the ROPS/FOPS lock mechanism from the welded hinge by removing the shoulder bolt and locknut. Remove the limiter assembly from the ROPS/FOPS.

5. With the ROPS/FOPS rolled back and locked, attach a suitable hoist of adequate capacity and a positive locking mechanism able to support the ROPS/FOPS or equivalent to the ROPS/FOPS.

WARNING The hoist MUST BE situated precisely above the ROPS/FOPS or else performing the following steps may cause the ROPS to swing as the bolts are removed. This could cause serious bodily injury and/or damage the loader.

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9. The hardware connecting the ROPS/FOPS to the chassis should already be removed per the engine access cover removal procedure in this chapter.

Seat Removal and Installation

10. Lift the ROPS/FOPS off the loader.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

Installation Procedure - Follow all warnings first, then reverse the removal steps.

Removal Procedure 1. Remove four nuts from the studs attaching the seat to the seat pan underneath the ROPS/FOPS.

2. Release the lock mechanism and lower the ROPS/ FOPS. 3. Disconnect seat switch from the wiring harness.

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4. Lift the seat from the seat pan.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

ROPS/FOPS Rear Window Removal and Installation

Seat Slide Replacement

WARNING

Replacement Procedure 1. Remove the seat per the procedure in this chapter.

BEFORE beginning this service procedure, perform the following SAFETY procedure:

2. Remove the four screws attaching the seat slides to the seat.

■ Shut off the engine.

2 of 4 Slide Screws Shown

(For detailed instructions, refer to the Safety chapter of this manual.)

Removal Procedure 1. Grab and pull emergency exit tag until the ripcord pulls free of rubber seal.

3. Replace with new slides using the existing screws.

2. With an assistant outside the ROPS/FOPS to catch the window, push window outward.

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GEHL R105 / MUSTANG 1050R

3. Slowly pull weatherstrip away from window frame.

Weatherstrip

5. Use L-hook tool between glass and weatherstrip and work it underneath the glass. Lift the glass lip up over the weatherstrip.

Installation Procedure 1. Recommended but not required: Mix a solution of 10% liquid dish soap and 90% water in a spray bottle.

6. Use the pigtail hook tool to “pull down” weatherstrip seal on the outside of the ROPS/FOPS to secure the window.

NOTE: To install the rear window, obtain two insert tools from your glass dealer.

Pigtail Hook

L-Hook

2. Apply soap solution to window, weatherstrip and metal frame surfaces.

3. Start at top of window frame and install weatherstrip with the ripcord lip facing inside the ROPS/ FOPS and the glass lip facing out.

4. From inside the ROPS/FOPS, spray soap solution between glass window and inside edge of rear window.

24

7. On the inside of the ROPS/FOPS, install the ripcord in the ripcord lip, starting at top of weatherstrip. Be sure to have emergency exit tag slipped over the ripcord before performing this step.

8. Using L-hook tool, secure the ripcord in the ripcord lip by “pulling down” the lip over the cord.

9. Test the window for security and mating of all seals.

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Restraint Bar Components

11 14 4 8 18 9 15 7

16 17

6 1 13 2 5

1 2 3 4 5 6 7 8 9

BOLT/SHOULDER BUSHING/OILITE NUT/SERRATED LOCK NUT/LOCK STUD/BALL GAS SPRING/SEAT BAR BAR/RESTRAINT SWITCH/PROXIMITY MAGNET/SWITCH ACTUATOR

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10 11 12 13 14 15 16 17 18

10

12

3

SCREW/PHILLIPS PAN COVER/PIVOT STOP/RESTRAINT BAR WASHER/SPECIAL CLIP/CHRISTMAS TREE WASHER/FLAT NUT/HEX MACHINE SCREW WASHER/LOCK STAR SCREW/MACHINE

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GEHL R105 / MUSTANG 1050R

Restraint Bar Removal and Installation Removal Procedure

3. Remove one shoulder bolt, washer and locknut securing each side of the restraint bar to the ROPS/ FOPS. Remove the restraint bar.

1. Pop four “Christmas tree” clips off each restraint bar hinge cover. Pull the cover over the shoulder bolt and down the arm of the restraint bar to the rubber arm rest.

Christmas Tree Clip

NOTE: For restraint bar switch removal, refer to the Electrical chapter.

Installation Procedure - Reverse the removal steps.

2. Unplug the restraint bar switch red wire from the ROPS/FOPS wire harness.

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Lift Arm Components - Gehl 18 6

1 15 1

5

3

8 13

8 17 19 7

17

10 21 11 20 8 2

4

17

12 3

2

15

16 9

19

14

1 2 3 4 5 6 7 8 9 10 11

BUSHING/OILITE BUSHING/OILITE NUT/LOCK PIN/KLIK LIFTARM PIN/LIFTARM SUPPORT/STEP NUT/CENTERLOCK PIN/PIVOT STOP/LIFTARM LEFT STOP/LIFTARM RIGHT

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12 13 14 15 16 17 18 19 20 21

ROD/WIPER STOP/RUBBER GUIDE/HOSE FITTING/GREASE SCREW/CAP BOLT/CARRIAGE SCREW/CAP SCREW/TAPPING NUT/JAM WASHER/LOCK

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Lift Arm Components - Mustang 18

6

1 15 1

5

3

8

8

13

17 10 19

11 17

7

21

20

4

17 2

8

12 3

2 15

16

9

NOTE: 1. TORQUE PN 651648 TO 160 IN-LBS MIN.

19

14

1 2 3 4 5 6 7 8 9 10 11

28

BUSHING/OILITE BUSHING/OILITE NUT/LOCK PIN/KLIK LIFTARM PIN/LIFTARM SUPPORT/STEP NUT/CENTERLOCK PIN/PIVOT STOP/LIFTARM LEFT STOP/LIFTARM RIGHT

12 13 14 15 16 17 18 19 20 21

ROD/WIPER STOP/RUBBER GUIDE/HOSE FITTING/GREASE SCREW/CAP BOLT/CARRIAGE SCREW/CAP SCREW/THREAD FORMING NUT/JAM WASHER/LOCK

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All-Tach® Hitch Components

SEE NOTE 1 18

8

5

7

10 SEE NOTE 1

3 9

14 13 2

4

17 SEE NOTE 1 12

11

15 1 SEE NOTE 2 6

16

NOTE: 1. APPLY LOCK TIGHT 242 TO ITEMS 10, 17, AND 18.

2. SPRING PIN TO EXTEND EQUAL DISTANCE ON EACH SIDE OF ADAPTOR ROD, BUT NOT BEYOND FACE PLATE OF WELDMENT.

1 2 3 4 5 6 7 8 9

PIN/SPRING NUT/HEX HANDLE/ATTACHMENT BRACKET LEFT HANDLE/ATTACHMENT BRACKET RIGHT SPRING/COMPRESSION PIN ADAPTOR/ROD ADAPTOR/PUSH ROD ASSEMBLY/ALL-TACH COMPLETE

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10 11 12 13 14 15 16 17 18

SCREW/SOCKET HEAD WASHER/SPECIAL WASHER/FLAT WASHER/FLAT WASHER/CUPPED SPRING GRIPS FITTING/GREASE SCREW/CAP SCREW/CAP

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All-Tach® Hitch Removal and Installation

Lift Arm Removal and Installation

Removal Procedure

Removal Procedure

1. Lower the lift arm and slightly extend the two tilt cylinders.

1. Lower the lift arm.

NOTE: Attach a suitable hoist of adequate capacity

3. Remove the hitch per the procedure in this chapter.

2. Remove the bucket or attachment from the loader.

and a positive locking mechanism able to support the hitch or equivalent before performing the next step.

2. Remove two capscrews and locknuts securing the lower tilt cylinder pivot pins. While supporting the tilt cylinders, drive the pins out of their mounts.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

■ Relieve hydraulic system pressure.

(For detailed instructions, refer to the Safety chapter of this manual.)

4. Attach a suitable hoist of adequate capacity and a positive locking mechanism able to support the lift arm or equivalent to the lift arm assembly.

5. Remove two locknuts and capscrews securing the lift cylinder pivot pins to the lift arm.

3. Remove two capscrews and locknuts securing the hitch to the lowest pivot pins on the lift arm, and drive the pins out of their mounts.

WARNING ALWAYS wear safety glasses with side shields when operating the machine or 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 eyes or other parts of the body.

Installation Procedure - Reverse the removal steps.

6. While supporting the lift cylinder, remove the lift cylinder pins from the lift arm. Left side lift cylinder: Remove the lift arm support device secured to the lift arm by the lift cylinder pin and lynch pin.

Keep lynch pin in a safe place.

7. Repeat steps 5 and 6 for other side of the lift arm.

NOTE: Always clean around hydraulic fittings before disconnecting any hydraulic line. When removing hydraulic lines, cap or plug the ends to prevent contaminating the hydraulic system.

NOTE: To help in the correct reassembly of the hydraulic hoses and tubes, mark them prior to 30

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disassembly with an oil-resistant chalk or marker or other suitable marking material.

8. Disconnect four upper and lower tilt cylinder hoses from the tilt cylinder.

11. Remove capscrews, line clips, hose guide and tee fittings from the tilt hoses secured underneath the lift arm and on its crossmember. Remove tilt hoses.

Upper Tilt Cylinder Hoses

Underneath the Crossmember

12. Disconnect two hydraulic tubes from their 90° fittings on two flat-faced quick couplers located on the left knee of the lift arm.

Lower Tilt Cylinder Hoses

9. Remove both tilt cylinders from the lift arm per the procedure in the Hydraulics System chapter.

10. Remove four self-tapping screws securing the support step to the hydraulic tubes cover plate and remove the plate.

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13. Remove three self-tapping screws securing the auxiliary bracket to the lift arm at the quick couplers.

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14. Remove both flat-faced couplers, 90° fittings and hardware from the lift arm.

15. Raise lift arm to gain access to the hydraulic hoses and the lift tube fittings.

18. Remove two capscrews and locknuts securing the lift arm pivot pins to the chassis. Drive the lift arm pivot pins out of the chassis.

16. Disconnect all hydraulic hoses attached to hydraulic tubes found underneath the lift arm.

19. Remove the lift arm assembly from the loader.

Installation Procedure - Reverse the removal steps.

17. Remove capscrews, line clips and locknuts securing all hydraulic tubes to the lift arm and remove the hydraulic tubes from the lift arm.

NOTE: After removing/replacing any components of the lift and tilt system, ALWAYS prime hydraulic system by operating the lift arm attachment (NO LOAD) slowly up and down for several cycles. Check system for hydraulic oil leaks following guidelines in the Safety chapter. Fill the hydraulic reservoir until fluid becomes visible in the hydraulic oil level sight gauge.

NOTE: Refer to the lift arm bushing installation procedure in replacement.

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if

bushings

require

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

MAINFRAME

Lift Arm Bushing Replacement

Lift Arm Stop Installation and Adjustment Installation/Adjustment Procedure

WARNING ALWAYS wear safety glasses with side shields when operating the machine or 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 eyes or other parts of the body.

NOTE: Lift arm stops should be shimmed as needed to ensure a gap of no more than 1/8" (3 mm) between the stops and the lift arm when the lift arm is fully lowered.

1. Lower lift arm and measure any gap between the stop and lift arm.

Replacement Procedure 1. Remove the lift arm from the loader per the procedure in this chapter.

2. Use a punch to drive out the four upper lift arm bushings, two on each side of the lift arm.

NOTE: Applying heat to the upper lift arm bushings will release the adhesive and simplify removal.

3. Clean inside the opening to provide a smooth surface for installation of the new bushings.

4. Apply Loctite® 680 or its equivalent to the new lift arm bushings and press or drive them into the lift arm.

5. If replacing the bushings in each lower lift arm, use a punch to drive them out of the lift arm. Use a long-nosed plier to carefully remove the rubber wiper rods at the lower attachment bracket pivot.

NOTE: It will be necessary to add one shim for every 1/8" (3 mm) gap.

2. Raise lift arm and engage the lift arm support device.

3. Remove one capscrew on the lift arm stop attached to the front of the chassis that needs adjustment.

6. Install new bushings by pressing them into place or using a rubber mallet to drive them into the lift arm.

4. Install shim(s) behind the rubber stop and secure with resecure the stop to the chassis. Use removable Loctite® 242 or equivalent retaining compound.

7. Reinstall the lift arm on the loader per the procedure in this chapter.

5. Start the engine and lower the lift arm. Verify gap and repeat procedure as needed.

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MAINFRAME

GEHL R105 / MUSTANG 1050R

Mainframe Components - DPF Models 41

5

34 2

7

42

22

28

1 NOTE #1

21

42 29

17 20

42 42

35

42

37

30 16

3

36

2

15

20

27 2

40 11

1 6 43 31

39

32

4

14 9

23

42

20

20

25

26

42

24 42 12

8

40

19

38

13 10

9 18 33 18

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

34

TIE/CABLE CLAMP/HOSE NUT/FLLSUF LN FUEL SENDER GASKET CAP ASSEMBLY-FILLER SENDER PLUG PLUG FILTER/VENT COVER/AXLE ACCESS COVER/CHAINCASE ACCESS COVER/OIL PAN DOWN STOP VENT/REMOTE PLATE/VALVE MOUNT KICK PLATE THWH TR LN FL SERR LN FL SERR CAP/FUEL FILLER STRAINER/FUEL

NOTE: 1. USE WIRE TIE TO CONTROL POSITION OF CABLE. KEEP AWAY FROM GEAR PUMP.

23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

CS FLAT HD COVER SHIM HOSE /FUEL FITTING/ST CHASSIS/WELDMENT PLATE/COVER FUEL TANK PLATE/FUEL SEPARATOR FITTING/90 PAN/BELLY FITTING/90 BOLT/CARRIAGE BOLT/CARRIAGE BOLT/CARRIAGE BOLT/CARRIAGE SCREW/CAP THWH TC USL HWHMS HWHTRS TAP/R SCREW/CAP

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GEHL R105 / MUSTANG 1050R

MAINFRAME

Mainframe Components - Non-DPF Models 31 5 7 32

25

1 NOTE #1

32

20

18

27

32

20 29 13

32 17

3

28

16

2

30 11

1 6

33

4 23

24

15 9

21

32

32

22 32 12

8

30

14 10

9 19 26 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

TIE/CABLE CLAMP/HOSE NUT/FLLSUF LN FUEL SENDER GASKET CAP ASSEMBLY-FILLER SENDER PLUG PLUG FILTER/ VENT COVER/AXLE ACCESS COVER/CHAINCASE ACCESS FUEL TANK COVER/OIL PAN DOWN STOP VENT/REMOTE PLATE/VALVE MOUNT

PRINTED IN USA

NOTE: 1. USE WIRE TIE TO CONTROL POSITION OF CABLE. KEEP AWAY FROM GEAR PUMP.

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

KICK PLATE THWH TR NUT/FLRSUF CS FLAT HD COVER SHIM HOSE /FUEL CHASSIS PAN, BELLY BOLT/CARRIAGE BOLT/CARRIAGE BOLT/CARRIAGE THWH TC USL HWHMS HWHTRS TAP/R HN

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MAINFRAME

GEHL R105 / MUSTANG 1050R

Floor Covers and Kickplate Removal and Installation

floor bracket per the procedure in the Controls chapter.

The floor covers and kickplate may be removed for access to handle assemblies, control linkages and connections to control rods, cables, tubes and hoses.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm, engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

3. Disconnect the foot throttle pedal electrical harness from the throttle pedal.

(For detailed instructions, refer to the Safety chapter of this manual.)

Removal Procedure - T-Bar 1. Remove four capscrews securing the upper floor plate to the kick plate and control mount. Pull the upper floor plate up and out around the foot throttle pedal and auxiliary pedal (if so equipped).

4. Remove the capscrews, two on the auxiliary pedal assembly, securing the lower plate to the chassis.

Pull the lower floor plate with the throttle pedal and auxiliary hydraulic pedals out the loader.

2. On the lower floor plate, disconnect the auxiliary hydraulics cable from the auxiliary pedal and the

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MAINFRAME

5. On the kickplate, loosen three screws on each boot cover, (six per control handle) and remove the boot cover.

Removal Procedure - Hand/Foot

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm, engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

6. Pull the boots up on the controls handles and remove the capscrews securing the kickplate to the chassis.

Kickplate

1. On the linkage cover, remove four capscrews securing the linkage cover to the kickplate. Two of the four capscrews are found at the front of the loader between and above the dirt clean-out openings and remove the linkage cover.

7. Pull the kickplate forward and up to remove it from the loader.

Installation Procedure - Reverse the removal steps.

PRINTED IN USA

2. At the floor plate, disconnect the control cables attached to the foot pedal pivots.

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GEHL R105 / MUSTANG 1050R

3. Remove four capscrews securing the foot pedal mount assembly to the center of the floor plate.

Pull the entire foot pedal assembly from the loader.

6. Pull the kickplate forward and up to remove it from the loader.

Fuel Sensor Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

4. At the kickplate, loosen the screws on each boot cover (six per control handle) and remove the boot covers.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Open the engine access cover and lock open the rear grille.

2. Locate the fuel level sensor right of the fuel tank cap.

3. Drain the fuel tank into a clean approved container.

Drain the fuel below the sensor mounting (½ full).

4. Disconnect the two wires from the sensor.

5. Remove the five screws securing the sensor, then remove the sensor and gasket from the tank.

5. Pull the boots up on the control handles and remove the capscrews securing the kickplate to the chassis.

Kickplate

Installation Procedure 1. Clean old gasket adhesive off the fuel tank.

2. Match the holes in the new gasket to the holes on the fuel tank.

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3. Install new gasket using Form-A-Gasket #7651211 (or equivalent) to seal sensor opening on fuel tank.

7. Attach the #25 (brown) wire to center stud with a nut, and the #0 (black) wire to ground stud with the fifth screw.

Rear Grille Removal and Installation The rear grille is bolted onto the chassis and can be removed to perform work on the cooling system, engine, engine fan and shrouds.

Removal Procedure 1. Open the engine access cover and lock open the rear grille.

2. Remove the hose from the top of the coolant recovery bottle secured to the rear grille.

4. Install the sensor in the fuel tank.

5. Install new gasket using Form-A-Gasket #7651211 (or equivalent) to the five screws.

3. Disconnect the tail lights wire harness and free the harness from the rear grille.

6. Install the five screws through the sensor into the fuel tank. DO NOT OVERTIGHTEN.

4. Attach a suitable hoist of adequate capacity and a positive locking mechanism able to support the rear grille or equivalent to the rear grille.

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MAINFRAME

GEHL R105 / MUSTANG 1050R

5. Remove the capscrew, washer and nut securing the top of the rear grille pin to the top hinge on the chassis.

Rear Grille Latch Removal and Installation Removal Procedure 1. Open the rear grille and lock open with the lock pin.

6. Remove the lock pin securing the bottom of the rear grille to the chassis.

2. Pull out the two carriage bolts, washers and bushing and remove the latch assembly.

Installation Procedure - Reverse the removal steps.

Installation Procedure - Reverse the removal steps.

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GEHL R105 / MUSTANG 1050R

WHEEL DRIVES

Introduction

motors. The drive motors are directly connected to chaincases. Each motor drives one set of wheels on each side of the loader through a chain and sprocket system.

This chapter covers removal, installation, assembly and adjustment procedures for wheel drive system components on Gehl R105 and Mustang 1050R model skid-steer loaders. Wheel drive components covered in this chapter are shown below.

Service procedures related to the hydrostatic pump and drive motors can be found in the Hydrostatic System chapter.

Gehl R105 and Mustang 1050R model skid-steer loaders are equipped with a hydrostatic pump assembly coupled to the diesel engine, providing hydrostatic power to the two fixed-displacement hydrostatic drive

Wheel Drive Components

ASSEMBLY INSTRUCTIONS STEP 1. TIGHTEN HEX NUT (653102) TO 100 FT LBS TO PRESS BEARINGS IN PLACE. USE RUBBER FACED HAMMER TO APPLY A SHARP BLOW TO OUTSIDE HUB OF AXLE. STEP 2. USE NUT RUNNER OR LIKE TOOL TO ROTATE AXLE 5-10 REVOLUTIONS TO HELP SEAT BEARINGS. STEP 3. BACK OFF NUT UNTIL WASHER (400-32535) IS FREE FROM PRESSURE. STEP 4. RE-TIGHTEN HEX NUT (653102) TO 30 FT LBS AND THEN BACK OFF TO NEAREST SLOT ALIGNMENT WITH COTTER PIN HOLE. IF NUT SLOT LINES UP WITH HOLE AT 30 FT LBS USE THAT SLOT. STEP 5. INSTALL COTTER PIN (651160).

4

SEE ASSEMBLY INSTRUCTIONS 19 7

APPLY LOCTITE 242 TORQUE TO 18 35 FT LBS 12

13

11

14

1

2 8

16 10

9 TORQUE TO 120 FT LBS 17 15 5 14 3 6

1 2 3 4 5 6

BOLT/HUB CONE/BEARING CUP/BEARING ASSY/ROLLER CHAIN 80K 52 PITCHES ASSY/ROLLER CHAIN 80K 64 PITCHES SEAL/OIL

PRINTED IN USA

7 8 9 10 11 12 13 14 15 16 17 18 19

PLATE/MOTOR MOUNT ASSEMBLY/AXLE AND LUG BOLT NUT/LUG NUT/HEX FLANGED TOP LOCK O-RING RING/SNAP INTERNAL SPROCKET/MOTOR SPROCKET/AXLE WASHER/SPECIAL WASHER/BACKING PIN/COTTER SCREW/CAP NUT/HEX SLOTTED

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WHEEL DRIVES

GEHL R105 / MUSTANG 1050R drive motor in the slots on the motor mounting plate to adjust chain tension.

Drive Chain Adjustment Skid-steer loader drive chain tension should be checked every 1000 hours of operation.

Adjustment Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

■ Raise and securely block the loader so all four tires are off the ground.

6. After the proper chain tension is obtained, retighten the locknuts on the drive motor.

(For detailed instructions, refer to the Safety chapter of this manual.)

NOTE: The drive chain must have a minimum of 1/2"

1. Remove the wheels and tires on the side of the loader to be serviced.

2. Remove screws on the chaincase access cover (between tires) to access the drive chain.

(13 mm) deflection; overtightening causes premature drive chain and sprocket wear.

7. Scrape off the old oil-resistant RTV and reapply new RTV. Reinstall the access cover.

8. Remove the fill plug on the chaincase access cover.

9. Refill the chaincase oil until the oil is up to the fill plug.

Chaincase Access Cover Screws

10. Reinstall the wheels and tires. Axle nut torque is: 100 ft.-lbs. (136 N•m) to press the bearings into place. Loosen the nut, then retighten to 30 ft.-lbs.

(41 N•m).

11. Repeat the adjustment procedure for the other side.

Fill Plug

3. Drain the oil from the chaincase. See the procedure in the Lubrication chapter.

4. Correct chain deflection is ½" @ 20 lbs. force (13 mm @ 89 N) - halfway between the sprockets.

5. To adjust chain tension, loosen the locknuts on the drive motor on one side of the loader. Slide the

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50950298/AP0517

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

WHEEL DRIVES

Axle Housing Assembly Removal and Installation

6. Inside the loader, remove the screws on the axle access cover on each axle to be serviced.

Removal Procedure

7. Remove a large cotter pin on a slotted axle nut on the axle hub.

Axle Nut

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise and securely block the loader so all four tires are off the ground.

Cotter Pin

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the lug nuts (120 ft-lbs.) (163 N•m), on the wheels and tires on the side of loader being serviced.

2. Drain the oil from the chaincase. See the procedure in the Lubrication chapter.

3. Remove the floor cover(s) per the procedure in the Mainframe chapter for access to the front axle access covers. Rear axle access covers are behind the drive motors on the chaincase housing.

8. With a wrench, remove the slotted axle nut and the special washer beneath it.

9. Use a slide hammer mounted the axle hub. A slight impact is needed to remove the axle from the inner bearing.

10. Attach a suitable hoist of adequate capacity and a positive locking mechanism able to support the axle assembly or equivalent to the axle assembly.

11. Remove the outer axle bearing and, if needed, the seal.

NOTE: Note the orientation of the bearing and the seal at remove for the correct reassembly procedure.

Installation Procedure 1. Install a new seal (if old was replaced) and an outer bearing on the axle.

4. Remove the screws on the chaincase access cover (between tires) to access the drive chain.

5. Remove the drive chains per the procedure in this chapter.

PRINTED IN USA

NOTE: Pack the tapered bearings with grease before assembling.

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43

WHEEL DRIVES

GEHL R105 / MUSTANG 1050R 10. Install the cotter pin.

2. Reinstall the inner bearing on the axle.

11. Install and adjust the drive chains per the procedure in this chapter.

12. Fill the chaincase with oil until it is up to the oil fill/level check plug.

13. Reinstall the chaincase access cover using oilresistant RTV sealant (or equivalent) between the cover and the chaincase.

14. Reinstall the wheels and tires. Wheel nut torque is: (120 ft-lbs.) (163 N•m).

Drive Chain Removal and Installation 3. Attach a suitable hoist of adequate capacity and a positive locking mechanism able to support the axle assembly or equivalent to the axle assembly and insert it into the axle sprocket in the axle housing weldment.

4. Slip the washer onto the axle hub. Tighten the slotted locknut on the axle hub to 100 ft.-lbs. (136 N•m) to press the bearings into place. Loosen the nut, then retighten to 30 ft.-lbs. (41 N•m).

5. Rotate the axle for 10 revolutions to help seat the bearings.

6. Strike the outside end of the axle with lead shot or a soft hammer to ensure the bearings are seated.

7. Recheck the slotted locknut on the axle hub is tightened to 100 ft.-lbs. (136 N•m).

8. Back off the slotted locknut until the nut is free from pressure.

9. Retighten the slotted locknut to 30 ft.-lbs. (41 N•m) then increase to alignment slot with the cotter pin hole. If the nut lines up with the cotter pin hole at 30 ft.-lbs. (41 N•m), then use that slot.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

■ Raise and securely block the loader so all four tires are off the ground.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the wheels and tires on the side of the loader being serviced.

2. Drain the oil from the chaincase. See the procedure in the Lubrication chapter.

3. Remove the screws on the chaincase access cover to gain access to the drive chain.

4. Split the drive chain by removing the connector pin and connector link. On the connector link, remove the sidebar, then pull the link out from the back of

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WHEEL DRIVES

the chain. It may be necessary to rotate the drive chain for access to the connector link.

1. Wrap the chain around sprocket of the axle.

2. Wrap the chain around the drive motor sprocket.

3. Connect the drive chain with the connector link and sidebar.

Sidebar and Connector Link

4. Adjust the drive chain to the proper tension per the procedure in this chapter.

5. Install the chaincase access covers using oil-resistant RTV sealant (or equivalent) between the covers and chaincase. Refill the chaincase oil until the oil is up to the fill plug.

6. Reinstall the oil fill/level check plug.

7. Reinstall the wheels and tires. Wheel nut torque is: (120 ft-lbs.) (163 N•m).

Axle and Wheel Bearing Disassembly and Assembly Disassembly Procedure 1. Remove the axle housing assembly per the procedure in this chapter.

2. Remove the outer bearing cone from the axle shaft.

3. Remove the axle shaft from the chassis per the procedure in this chapter.

4. Remove the inner bearing cone from the axle shaft.

5. Remove the axle seal and outer bearing cup from the axle housing assembly.

6. Turn housing assembly over and remove the inner bearing cup from the axle housing assembly.

Assembly Procedure

Connector Link

NOTE: Pack the tapered bearing cones with synthetic grease before assembling.

5. Remove the drive chain from the chaincase.

Installation Procedure - Follow the Removal Procedure warnings first, then:

NOTE: When installing the left and right side drive chains, install the inside chain first.

PRINTED IN USA

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WHEEL DRIVES

GEHL R105 / MUSTANG 1050R

1. Install the bearing cup in the axle housing with a force of 6000 lbf. (26,7 kN) using a bearing press.

4. Place the axle shaft on a flat surface with the shaft in a vertical position. Press the bearing cone onto the axle shaft with a suitable driver or a press at a force of 6000 lbf. (26,7 kN). Note the orientation of the first bearing cone.

Bearing Cone

Bearing Cups

2. Install the double-lip axle seal in the axle housing.

Use suitable drivers or a press to countersink all components until they bottom out.

Axle Seal

3. Turn the axle housing over and press an additional bearing cup into the other side of the axle housing with a force of 6000 lbf. (26,7 kN) using a bearing press.

Bearing Cup

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GEHL R105 / MUSTANG 1050R

CONTROLS

Introduction

Hand/Foot Controls

This chapter covers the removal, installation, assembly, and adjustment procedures for standard and optional controls on Gehl R105 and Mustang 1050R model skidsteer loaders.

Equipment Identification Because there are a variety of options available for Gehl R105 and Mustang 1050R models, it is necessary to properly identify the controls before beginning the service procedures. Illustrations and photographs are provided with procedures to aid in servicing this equipment.

On loaders with “Hand/Foot Controls”, the left and right drive control handles operate independently of each other. With both control handles pushed forward together, the loader moves forward, but push either one farther forward than the other and the loader turns.

Separate foot pedals control the lift and tilt functions of the lift arm and bucket. Engine speed is controlled with a hand throttle on the right instrument panel. The auxiliary hydraulics are actuated by the right control handle.

T-Bar Controls On skid-steer loaders with “T-Bar Controls,” the left TBar operates the drive wheels and pumps for both sides of the skid-steer loader. The right T-Bar controls the lift and tilt functions of the lift arm and bucket. Engine speed is controlled by the hand and/or foot throttles.

Standard-flow auxiliary hydraulics is controlled by a foot pedal.

Control Locations - T-Bar and Hand/Foot

T-Bar controls

Hand/Foot controls

3

6

6 3 4

4 1

5

5 2 1

1 - Drive Control 2 - Lift/Tilt Control

PRINTED IN USA

3 - Horn Button Switch 4 - Auxiliary Hydraulics

50950298/AP0517

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5 - Foot Throttle 6 - Hand Throttle Handle

47

CONTROLS

GEHL R105 / MUSTANG 1050R

Wheel Drives, Foot Throttle and Lift Tilt Components - T-Bar - DPF Models

41

43

59 28 55

25

31

61 7

55

1

41

28

59

8

43

59

40

40 8

59 24

22 14

55

10

48 13

1

58 27

46

12 63

4

17

12 55

34

57

14 1

3

61 11

33

39

3

41 67

63

65 56

11

4

2

62 61 30 37

51

47

18 NOTE 1

46 16 11

29

11 53

23

13

47

2

13

56

13

2

60

61

18

13 13

38

56 58

14

32

6

52

49

2

26

56

56

20 2

19

9 8

15

45

54

5

56

8 59

66

8

44

49

14 59

21 42

15 35

50 64 35

64

ADJUST BOLT UNTIL FOOT PEDAL PIVOT WELDMENT CONTACTS BOLT HEAD WHEN AUXILIARY SPOOL IS IN FULL FLOW POSITION

36

NOTE: 1. USE THESE ITEMS TO PLUG UN-USED HOLES IN KICKPLATE TO HELP REDUCE OPERATOR SOUND LEVELS.

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GEHL R105 / MUSTANG 1050R

CONTROLS

Wheel Drives, Foot Throttle and Lift Tilt Components - Parts Listing - T-Bar - DPF Models

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

BEARING/FLANGE MOUNT/FM BEARING/FLANGE MOUNT/FL BOOT COVER/RH BOOT COVER/LH BUSHING/SUPER OILITE BUSHING/OILITE BUSHING/OILITE BALL JOINT BALL/JOINT ASSY FW NUT/FLLSUF LN LN LN CS FL LOCK HFS NUT/FLRSUF HFS DRIVE CONTROL PIVOT WELD DRIVE CONTROL HLN INST T-BAR STOP CENTERING DEVICE LT HANDLE ASSY-GRIP RT HANDLE ASSY-GRIP CONTROL BRKT ASSY HYDRAULIC CNTRL SUPPORT ROD/CONTROL LIFT BRACKET/STIFFENER CONTROL MOUNT/WELDMENT BRACKET WELD/CONTRL MNT CABLE CLEVIS/SHORT CABLE MOUNT/WELDMENT

PRINTED IN USA

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67

LN FL SERR LN FL SERR NUT/FLRCL HN CENTERLOK PIN/CLEVIS PIN/CLEVIS PIN/CLIP/RUE AUXILIARY PEDAL YOKE CONTROL ROD SCREW F/WHIZLOCK SPACER BOOT/T-BAR BUSHING FOOT THROTTLE/ELECTRIC CONTROL MOUNT PLATE/FLOOR FOAM/FOOT PLATE/T-BAR HWHTFS HTB CS CS CS CS HN CS CB CB SCREW/HHM USL HWHTRS TAP/R FW 5/16 CS HN

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CONTROLS

GEHL R105 / MUSTANG 1050R

Wheel Drives, Foot Throttle and Lift Tilt Components - T-Bar - Non-DPF Models

59 35

67

59

1

7

B

32

A 28

48

50

64

48 D

32

64

8

50

64

47

47 64

8 C

25

59

10

56

14

13

1

53

31

C

1 4

17

12

48

69

2

73

11 4 48

34

B

44

46 42

D

18 NOTE 1

53 16

41

26

13

23

55

2

13

11

33

11

57

61

13

2

66

67

18

13 13

38

15

63

E

6

8

19

54 65 48

30

61

61

22 2

20

8

51

52 5

72

61

8 64

9

14

58 64

24 6

2

21

42

E 46

45

61 14

29

3

61 71

67

37

55

39

46

68

59

A

40

62

14

3

67 11

12 69

27

63

49 36 70

60

ADJUST BOLT UNTIL FOOT PEDAL PIVOT WELDMENT CONTACTS BOLT HEAD WHEN AUXILIARY SPOOL IS IN FULL FLOW POSITION

43

NOTE: 1. USE THESE ITEMS TO PLUG UN-USED HOLES IN KICKPLATE TO HELP REDUCE OPERATOR SOUND LEVELS.

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CONTROLS

Wheel Drives, Foot Throttle and Lift Tilt Components - Parts Listing - T-Bar - Non-DPF Models

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

BEARING/FLANGE MOUNT/FM BEARING/FLANGE MOUNT/FL BOOT COVER/RH BOOT COVER/LH BUSHING/SUPER OILITE BUSHING/OILITE BUSHING/OILITE FLANGED BALL JOINT BALL/JOINT ASSY FW NUT/FLLSUF LN LN LN LN HFS NUT/FLRSUF HFS CABLE THROTTLE PEDAL WELDMENT DRIVE CONTROL PIVOT WELD DRIVE CONTROL BRACKET/CABLE MOUNT HLN INST T-BAR STOP CENTERING DEVICE LT HANDLE ASSY-GRIP RT HANDLE ASSY-GRIP SCREW/SHOULDER CONTROL BRKT ASSY HYDRAULIC CNTRL SUPPORT ROD/CONTROL LIFT BRACKET/STIFFENER CONTROL MOUNT BRACKET WELD/CONTRL MNT CONTROL MOUNT PLATE/FLOOR

PRINTED IN USA

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73

CABLE CLEVIS/SHORT CABLE MOUNT FOAM/FOOT PLATE/T-BAR YOKE/CLEVIS LN FL SERR NUT/FLRCL HN CENTERLOK PIN/CLEVIS PIN/CLEVIS PIN/CLIP/RUE AUXILIARY PEDAL YOKE CONTROL ROD SCREW F/WHIZLOCK SPACER SPRING BOOT/T-BAR BUSHING HWHTFS HTB CS CS CS CS CS HN CP CS CB CB SCREW/HHM USL HWHTRS TAP/R FW CS HN

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Wheel Drives, Auxiliary Hydraulics and Lift Tilt Components - Hand/Foot Models

26

38

F 33

6 42

41

34

27

14

26

7

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31 47

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A 31

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7

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44 G

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22 4

11 1

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46 12

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49

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39 12 50 28

50

ADJUST BOLT UNTIL FOOT PEDAL PIVOT WELDMENT CONTACTS BOLT HEAD WHEN TILT SPOOL IS IN FULL ROLL BACK POSITION ADJUST BOLT UNTIL FOOT PEDAL PIVOT WELDMENT CONTACTS BOLT HEAD WHEN LIFT SPOOL IS IN FULL FLOAT POSITION

1 BOLT/SHOULDER 2 COVER/BOOT RIGHT 3 COVER/BOOT LEFT 4 BUSHING/OILITE 5 END/ROD 6 NUT/SERRATED LOCK 7 NUT/LOCK 8 NUT/LOCK 9 NUT/LOCK 10 NUT/LOCK 11 SCREW/WHIZLOCK 12 PEDAL/FOOT 13 SPACER/PIVOT

52

14 15 16 17 18 19 20 21 22 23 24 25 26

39

19

45 E

4

30

35

17

BEARING/FLANGED HANDLE/LOWER ABSORBER/SHOCK PLATE/FLOOR HANDLE LEFT PIVOT/PEDAL PIVOT/PEDAL GRIP HANDLE/CONTROL BRACKET/STIFFENER MOUNT/CONTROL CABLE CLEVIS/SHORT

27 28 29 30 31 32 33 34 35 36 37 38 39

MOUNT/CABLE MOUNT/CABLE COVER/LINKAGE FOAM/FOOT PLATE CLEVIS NUT/LOCK PIN/CLEVIS PIN/CLIP RUE WASHER/FLAT WASHER/SPECIAL BOOT/T-BAR GRIP BOLT/HEX TAP

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SCREW/SET SCREW/CAP SCREW/CAP SCREW/CAP SCREW/CAP SCREW/CAP BOLT/CARRIAGE SCREW/CAP BOLT/CARRIAGE SCREW/MACHINE SCREW/THREAD

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CONTROLS

Control Handle Removal and Installation Capscrew

WARNING

Center Control Rod

BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

Jam Nut

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

Left T-Bar Control Handle

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

Removal Procedure - T-Bar Models 1. Remove the kickplate per the procedure in the Mainframe chapter.

3. Disconnect the electrical connector in the left control handle from the wiring harness (if so equipped).

Horn Button Wiring in Control Handle

2. Right T-Bar: Remove the locknut and t-bar stop on the studded rod end attached to the tilt control rod at the control handle. Pull the rod end out of the control handle and remove the control handle. Left T-Bar: Remove the locknuts and capscrews securing the control handle to the drive control weldment and chassis.

T-Bar Stop Rod End

4. Remove the left control handle.

Capscrew

Capscrew

Note the wire terminal connections in the electrical connector for reassembling the control handle if replacing the handle’s electrical cable.

Tilt Rod

Lift Rod

IMPORTANT

Right T-Bar Control Handle

Installation Procedure: Follow all warnings first, then reverse the removal steps (see NOTE below).

NOTE: When the control handle is installed, and if the control rod(s) are adjusted correctly, the control handle shafts have a 10° forward tilt. If changes are needed, refer to the “Control Handle Position Adjustment” procedure in this chapter.

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Removal Procedure - Hand/Foot Models 1. Remove the floor cover and kickplate per the procedure in the Mainframe chapter.

2. Right Handle: Remove the locknut and studded rod end and the shock absorber attached at the far left end of the control handle. Remove the large capscrew and locknut securing the control handle to the pivot weldment. Disconnect the auxiliary hydraulics control cable inside and below the hand grip and pull cable out from the bottom. Remove the control handle.

Right Handle

3. Left Handle: Remove all items attached to the left control handle and remove the control handle.

Right Handle

Right Handle

Left Handle

Installation Procedure: Follow all warnings first, then reverse the removal steps (see NOTE below).

NOTE: When the control handle is installed, and if the control rod(s) are adjusted correctly, the control handle shafts have a 10° forward tilt. If changes are needed, refer to the “Control Handle Position Adjustment” procedure in this chapter.

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CONTROLS

Control Handle Position Adjustment

NOTE: If control handle does not return to

Control handles are adjusted two ways for proper operation: a vertically straight appearance and the handle orientation.

Adjustment Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

NEUTRAL position after adjustment, refer to the “Neutral Centering Device” adjustment procedure in this chapter.

3. T-Bar Models; Right control handle: Remove the locknut and t-bar stop on the studded rod end attached to the tilt control rod at the control handle.

Pull the rod end out of the handle. Remove the locknut on the studded rod end attached to the lift control rod and the bottom of the t-bar pivot.

Loosen the jam nuts on the lift and tilt controls rods and adjust rod ends to obtain a 10° forward tilt to the control handle. After adjustment is made, retighten the jam nuts against the rod ends and reconnect the control rods to the handle and pivot with their hardware. BE SURE the adjustment allows for full activation of the control valve in both directions of handle operation.

■ Tilt back ROPS/FOPS until lock engages.

Control Handle Orientation

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the floor cover and kickplate per the procedure in the Mainframe chapter.

2. T-Bar Models; Left control handle: Install two 3/ 8” (9.5 mm) alignment rods, one through the pivot weldment and control weldment, and the other through the control weldment and the t-bar pivot.

Loosen the jam nuts on the center control rod and adjust the rod between the rod ends. Retighten the jam nuts. Next, loosen the jam nuts on the turnbuckles and adjust the turnbuckles on the hydrostatic pump arm rods to obtain a 10° forward tilt to the left handle. Retighten the turnbuckle jam nuts.

Remove the temporary alignment rods. BE SURE the adjustment allows for full activation of the hydrostatic pump arm in both directions of operation.

4. Hand/Foot Models; Left and Right Control Handles: Loosen the jam nuts and adjust two turnbuckles on the hydrostatic pump arm rods to obtain a 10° forward tilt to the control handles. Retighten the turnbuckle jam nuts. BE SURE the adjustment

Left Handle Alignment Rod Holes

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allows for full activation of hydrostatic pump arms in both directions of handle operation.

Turnbuckles

Pivot Tube Weldment Removal and Installation - T-Bar

3. Remove the locknuts on the rod ends attaching the hydrostatic pump arms and central control arm to the pivot weldment.

4. Remove the locknut and washer securing the neutral centering device to the pivot weldment.

Pivot tube exploded views are good references for the pivot tube’s removal and installation procedures. Refer to these views for locations of components in the assemblies.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

5. Remove hardware on the pivot weldment securing the weldment on the left and right sides.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the floor cover and kickplate per the procedure in the Mainframe chapter.

2. Remove the control handles per the procedure in this chapter.

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CONTROLS 1. Disconnect the hydrostatic pump arm control rods from the pump arms.

6. Remove the pivot weldment from the loader.

NOTE: It’s recommended that good notes be taken to aid in reassembly. If necessary, mark the holes on the levers.

Installation Procedure: Follow all warnings first, then reverse the removal steps.

2. Remove the horizontal locknuts and capscrews securing the upper bracket to the lower bracket.

Loosen the center locknut until the upper bracket lifts free.

Center Locknut

1. Attach all the control rods and centering devices to the appropriate levers on the pivot tube assembly.

Neutral Centering Device and Pump Arm Removal and Installation The neutral centering device and pump arm weldment are designed to be interchangeable on the front and rear hydrostatic pumps.

Remove Procedure

WARNING

3. Remove capscrews securing the lower neutral centering device bracket to the hydrostatic pump.

BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

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4. Remove capscrews securing the pump arm retainer and pump arm weldment to the hydrostatic pump shaft.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Rotate the neutral centering device, checking the centering torsion spring backlash.

2. Adjust torsion spring backlash by loosening three locknuts on the horizontal bolts.

Pump Arm Retainer

Pump Arm

5. Repeat steps 1-4 for the other neutral centering device.

Installation Procedure*: Follow all warnings first, then reverse the removal steps. * After installation, perform the “Neutral Centering Device Adjustment” procedure in this chapter, BUT, if the control rods’ length were not altered and the rod end slips right in, then no adjustment should be necessary.

3. Rock the upper bracket side-to-side to remove clearance between the torsion spring “legs”, neutral adjusting plate and the pump arm pin.

Neutral Centering Device Adjustment Gehl R105 and Mustang 1050R skid-steer loaders come equipped with two neutral centering devices on the hydrostatic pump assembly. These devices allow the control handles and control arms to automatically return to NEUTRAL when the operator releases the control handles.

Adjustment Procedure

Torsion Spring “Legs”

WARNING

4. Retighten the three locknuts on the horizontal bolts.

BEFORE beginning this service procedure, perform the following SAFETY procedures:

5. Start the loader. Release the parking brake, lower the restraint bar down and depress the seat switch.

■ Remove attachment from lift arm.

■ Raise and block loader so the tires are off the ground.

6. Run the loader at half throttle and check for a NEUTRAL setting of the hydrostatic pump arms.

When the pump arms are in NEUTRAL, the tires MUST remain stationary.

■ Raise lift arm; engage lift arm support device.

7. To remove any noticeable tire creep, loosen the locknuts on bolts at the top of the centering device,

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

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CONTROLS

NOT the center bolt. Twist the upper bracket until any tire creep is eliminated. Retighten the locknuts.

Lift/Tilt Controls Removal and Installation

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

8. To test the operation of the control handle(s), move the control handle(s) forward and backward and allow the neutral centering devices to return the control handles to a NEUTRAL position.

(For detailed instructions, refer to the Safety chapter of this manual.)

Removal Procedure - Right T-Bar Control Handle 1. Remove the locknut securing the studded rod end of the lift and tilt control rods to the control handle and pivot. Release the rod ends from the handle assembly.

Right T-Bar Control Handle

Tilt Rod

Lift Rod

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CONTROLS

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2. Disconnect the lift and tilt control rods from the control valve spools by remove clip pins and clevis pins.

Installation Procedure: Follow all warnings first, then reverse the removal steps.

valve. Loosen the jam nuts on the control cables and remove the lift and tilt cables from the loader.

Installation Procedure: Follow all warnings first, then reverse the removal steps.

Lift/Tilt Control Adjustment

Remove Procedure - Hand/Foot Controls 1. Remove the floor cover and kickplate per the procedure in the Mainframe chapter.

2. Remove the clip pins and clevis pins on the short clevis at the foot controls pivot. Loosen the jam nuts on the control cables and slide the cable up and out.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

Adjustment Procedure - T-Bar Controls

3. Disconnect the lift and tilt control cables from the control valve spools. Remove the clip pins and clevis pins from the short clevis at the control

The lift and tilt control rod lengths can be adjusted to obtain proper position of the T-Bar. Refer to “Control Handle Position Adjustment” procedure in this chapter.

The “Self-leveling Valve Adjustment” procedure in the Hydraulic System chapter is also related to the correct operation of the lift and tilt controls. Refer to this procedure as needed.

Adjustment Procedure - Hand/Foot Controls 1. Remove the floor cover and kickplate per the procedure in the Mainframe chapter.

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CONTROLS

2. With the lift and tilt spools in NEUTRAL position, adjust the lift and tilt control cables at the control valve so that both cables at the foot pedals are even and parallel to the kickplate. Tighten the hardware.

2. Remove the clevis and clip pin securing the auxiliary hydraulics cable to the main control valve spool.

3. Reinstall the kickplate.

4. Check for full range of spool travel for both the lift and tilt cables.

5. Move the lift spool into detent (FLOAT) position.

6. On the lift pedal: Adjust the length of the lift control cable. Loosen the jam nut on the cable until the pedal is level and parallel to the floor plate.

7. Retighten the jam nut.

8. On the tilt pedal: Adjust the length of the tilt control cable. Loosen the jam nut on the cable until the tilt pedal matches the position of the lift pedal.

9. Retighten the jam nut.

3. Loosen the jam nut on the auxiliary cable at the welded bracket in front of the control valve. Pull the cable out of the welded bracket.

Auxiliary Hydraulics Cable Removal and Installation T-Bar models use a control cable between the auxiliary pedal and the control valve to actuate the auxiliary hydraulics. In Hand/Foot models, the actuation of the auxiliary hydraulics is in the right control handle.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

4. At the other end of the cable, remove the ball joint off the ball stud on the auxiliary cable rod end at the auxiliary bellcrank. Loosen the jam nut on the cable at the welded tab.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the floor cover and kickplate per the procedure in the Mainframe chapter.

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5. Remove the cable. If replacing the auxiliary hydraulics control cable, remove the rod ends, washers and jam nuts from the old cable.

6. Hand/Foot Control Models Only: Remove the shoulder screw and washer attaching auxiliary control cable the right control handle. Loosen the jam nut on the auxiliary cable, and remove the cable from the control handle.

Auxiliary Hydraulics Cable Adjustment The auxiliary hydraulics cable should be adjusted so that the hydraulic control valve is engaged when the auxiliary foot pedal is depressed for T-Bar Models, or, the right control handle cable is locked in ON position for Hand/Foot models. Refer to the exploded views for identifying the parts and components.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

Installation Procedure: Follow all warnings first, then reverse the removal steps.* * For cable adjustment, refer to the “Auxiliary Hydraulics Cable Adjustment” procedure in this chapter.

(For detailed instructions, refer to the Safety chapter of this manual.)

Adjustment Procedure - T-Bar Controls 1. Remove the floor cover and kickplate per the procedure in the Mainframe chapter.

2. With the auxiliary hydraulics spool in NEUTRAL position, loosen jam nuts on the auxiliary cable at the pivot foot pedal and adjust so that the foot pedal is horizontal (level).

3. Disconnect the ball joint on the cable from the auxiliary pedal assembly by removing the hex nut.

4. Twist the ball joint in to tighten or out to loosen the auxiliary hydraulics cable (most adjustments will require a tightening of the cable.)

5. Retighten the jam nut snug against the ball joint to set the adjustment.

6. Reinstall the ball joint and hex nut and secure it to the auxiliary hydraulics pedal assembly.

7. Check for full range of spool travel. Retighten the jam nuts on the auxiliary cable.

8. Check operation of auxiliary hydraulics cable by using an appropriate attachment.

Adjustment Procedure - Hand/Foot Controls 1. Remove the floor cover and kickplate per the procedure in the Mainframe chapter.

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2. On the control valve, place the auxiliary hydraulics spool in NEUTRAL position.

Electric Foot Throttle Pedal Removal and Installation - DPF Models

3. At the right control handle, loosen the jam nuts securing the auxiliary cable to the control handle weldment.

Removal Procedure - T-Bar Controls

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the floor cover and kickplate per the procedure in the Mainframe chapter.

4. Right the hand grip of the right control handle to its most vertical position and check that the auxiliary spool end at the control valve engages fully.

2. At the foot throttle pedal, unplug the electrical harness that powers the pedal.

5. Check for full-range spool travel in the auxiliary hydraulics spool on the control valve by using an appropriate attachment.

3. Remove capscrews and locknuts securing the electric foot pedal to the plate.

Installation Procedure: Follow all warnings first, then reverse the removal steps.

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Handle Throttle, Hand Throttle Cable and Throttle Rod Removal and Installation Non-DPF Models

5. At the engine mount weldment, remove the clevis pin and cotter pin on the yoke attaching the other end of the throttle cable to the hand throttle pivot.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

Hand Throttle Cable

■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the floor cover and kickplate per the procedure in the Mainframe chapter.

2. Remove the clevis pin and cotter pin securing the hand throttle cable yoke to the throttle handle grip.

6. Loosen the jam nut securing the hand throttle cable to the tab welded to the engine mount weldment.

7. Remove the cable. If replacing the cable, remove the yokes, washers and jam nuts from the old cable.

8. Disconnect the ball joint on the ball stud securing the throttle control rod to the support bracket on the rear lower left side of the engine.

Fuel Injector Arm

Jam Nut

3. Remove the carriage bolt, locknut, friction washer and spring washers securing the hand throttle lever to the chassis. Note the orientation of the two spring washers for reassembly later. Remove the hand throttle grip.

4. Loosen the jam nut on the throttle cable below the control handle and lift the cable our of the slot in the mainframe.

64

Throttle Support Bracket

9. Remove the shoulder bolt and locknut securing the throttle rod support bracket to the fuel injector arm on the engine. Pull the throttle rod out the back of the loader.

Installation Procedure* - follow all warnings first, the reverse the removal steps. * Perform the “Hand Throttle Adjustment” procedure found in this chapter after the installation is complete.

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CONTROLS

Foot Throttle and Foot Throttle Cable Removal and Installation - Non-DPF Models

4. Remove the screw and locknut securing the foot pedal throttle to the auxiliary control mount weldment and remove the pedal.

Removal Procedure - T-Bar Controls

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the floor cover and kickplate per the procedure in the Mainframe chapter.

5. Loosen the jam nut on the foot throttle cable securing the cable to the throttle tab. Slide the cable out of the tab.

6. At the engine cable mount weldment, disconnect the clevis pin and clip pin securing the yoke of the foot throttle cable to the foot throttle pivot.

2. Remove the clevis pin and clip pin on the throttle cable yoke connected to the foot pedal assembly.

Throttle Tab

Foot Throttle Cable

3. Remove the shoulder screw securing the extension spring to the throttle pedal.

7. Loosen the jam nut securing the foot throttle cable to the cable mount bracket and pull the cable out of the bracket.

8. Remove the cable. If replacing the cable, remove the yokes, washers and jam nuts from the old cable.

Installation Procedure* - follow all warnings first, the reverse the removal steps. * Perform the “Foot Throttle Adjustment” procedure found in this chapter after the installation is complete.

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Hand Throttle Adjustment - Non-DPF Models

3. Push and pull the hand throttle to check for correct operation. Repeat the adjustment steps as needed.

The handle throttle is adjusted at the factory to provide a full range of engine speed adjustment, from IDLE to FULL throttle. If the hand throttle is replaced, it may be necessary to make the following adjustment.

4. Tighten the jam nut against the yoke or ball joint to secure the adjustment.

Adjustment Procedure The hand throttle can be adjusted at four different locations: (1) at the yoke attached to the throttle grip, (2) at the yoke on the throttle pivot, (3) at the ball joint end of the throttle rod, and (4) the clevis attached to the engine.

Hand Throttle Tension Adjustment - NonDPF Models Hand throttle tension should be tight enough to maintain the desired engine RPM, but loose enough to allow easy operation. The hand throttle tension can be INCREASED or DECREASED. Adjustment Procedure

WARNING

WARNING

BEFORE beginning this service procedure, perform the following SAFETY procedures:

BEFORE beginning this service procedure, perform the following SAFETY procedures:

■ Remove attachment from lift arm.

■ Shut off the engine.

■ Raise lift arm; engage lift arm support device.

(For detailed instructions, refer to the Safety chapter of this manual.)

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

IMPORTANT DO NOT attempt to adjust the hand throttle lever at the two fuel injection pump adjustment screws.

NOTE: The spring washers and the friction washer must be installed properly to provide tension against the hand throttle.

1. To INCREASE TENSION, tighten the capscrew and locknut that attaches the hand throttle to the mainframe.

2. To DECREASE TENSION, loosen the capscrew and locknut that attaches the hand throttle to the mainframe.

1. Test the movement of the hand throttle to determine if the cable needs to be shortened or lengthened. When the hand throttle and the fuel injection pump are at the low idle position simultaneously, proper adjustment is achieved. BE SURE that the hand throttle lever does not interfere with the yoke attached to it.

2. If the cable needs adjustment, choose a location and: (1) loosen the jam nut on the yoke, clevis or ball joint, (2) remove the clevis pin and cotter pin on the yoke or the ball joint on the ball stud, (3) twist the yoke or ball joint to shorten or lengthen the throttle cable as needed, (4) reattach the yoke or ball joint.

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Foot Throttle Adjustment - Non-DPF Models Loaders with T-bar controls include a foot throttle to control the engine RPM, to match increased power requirements. The foot throttle is coupled to the hand throttle through a throttle rod pivot assembly. The foot throttle is at proper adjustment when pushing the hand throttle FULLY FORWARD causes the foot pedal to be pressed flush against the floor plate.

Adjustment Procedure - T-Bar Controls

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the floor cover and kickplate per the procedure in the Mainframe chapter.

2. With the hand throttle pulled back to the IDLE position, disconnect the clevis pin attaching the yoke on the foot pedal assembly.

3. Push down on the foot pedal until it is flush with the top of the auxiliary control mount weldment.

4. Loosen the jam nut on the yoke of the foot pedal assembly. Adjust the foot throttle cable after moving the hand throttle lever to its HIGH IDLE position. Retighten the jam nut on the yoke.

5. Start the engine and test the foot pedal throttle for full range of engine speed. Repeat the adjustment steps as needed.

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CHAPTER NOTES

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HYDROSTATIC SYSTEM

Introduction

of the loader through a chain-and-sprocket system. The pumps and motors are controlled individually, allowing complete flexibility in forward, reverse, gradual, pivot and spin turns.

This chapter covers troubleshooting, testing, removal, installation, and adjustment procedures for the tandem pump system on Gehl R105 and Mustang 1050R model skid-steer loaders.

For detailed information on pump and motor internal repairs, consult the Gehl-Mustang Service Department or the component manufacturer’s service manual.

Related hydraulic components are covered in the Hydraulic System chapter of this manual.

A hydrostatic pump assembly coupled to the engine provides power to two fixed-displacement hydrostatic drive motors. The motors drive the wheels on each side Hydrostatic Pump Assembly and Drive Motors

31 25 10 15

4 13

14 8

7

21 27

A 23

16

3

6

9 12

18 19

26 TORQUE TO 120 FT LBS APPLY LOCTITE 242

11

30

5 28

1 A 2 14

22

24

29 17

13

B

2 20

B 22 5

11

12

1 FITTING/STRAIGHT 2 FITTING/TEE 3 FITTING/90° 4 FITTING/STRAIGHT 5 FITTING/STRAIGHT 6 FITTING/STRAIGHT 7 FITTING/STRAIGHT 8 VALVE/RELIEF 9 SUPPORT/PUMP 10 PUMP/TANDEM 11 HOSE 12 HOSE 13 HOSE

PRINTED IN USA

14 HOSE 15 HOSE 16 HOSE 17 TUBE/MOTOR BRAKE 18 TUBE/BRAKE VALVE 19 TUBE ASSEMBLY/MOTOR PORT 20 TUBE/MOTOR END PORT 21 TUBE/MOTOR SIDE PORT 22 MOTOR/DRIVE 23 FITTING/STRAIGHT 24 FITTING/TEE 25 SCREW/CAP FLANGED 26 SCREW/CAP FLANGED

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Hydrostatic Controls

4 14

1.36 INITIAL SET DIMENSION

2

21

11

22 24 18

21

20

7

3

9

6

17 15

12

3

20

16 8

13 5

14 14

4

23 19

23 1

18 20 10 12

15 21

20 22 24 21

1 2 3 4 5 6 7 8

70

BRACKET/NEUTRAL CENTERING PLATE/NEUTRAL ADJUST HUB/NEUTRAL SPRING MOUNT NUT/SERRATED LOCK NUT/LOCK SCREW/CAP NUT/SPIRALOCK ARM/PUMP

22

9 ROD/CONTROL RIGHT 17 SPRING/TORSION 10 ROD/CONTROL LEFT 18 ROD END/FEMALE 11 ASSY/CENTERING BRACKET 19 SCREW/CAP 12 TURNBUCKLE 20 NUT/HEX 13 RETAINER/PUMP ARM 21 BOLT/CARRIAGE 14 NUT/LOCK FLANGE CENTERLOCK 22 SCREW/CAP 15 NUT/HEX 23 SCREW/CAP 16 SCREW/CAP WHIZLOCK 24 WASHER/FLAT

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HYDROSTATIC SYSTEM

Charge Pressure Test and Adjustment Gehl R105 and Mustang 1050R model skid-steer loaders have, as standard equipment, a charge pressure test port as part of the hydrostatic pump system. Before performing the following test, run the skid-steer loader to be sure the hydraulic oil is at normal operating temperature.

NOTE: This test requires a minimum of a 500 psi (34.5 bar) pressure gauge.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

■ Raise and block the loader so that all four tires are off the ground.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

Test Procedure 1. Using an Allen wrench, remove the plug and install the pressure gauge on the brake valve charge pressure port.

2. Start the engine ensuring that the brake switch on the instrument panel shows the parking brakes locked.

3. Check pressure reading on the gauge under three different conditions: (1) with the steering controls in NEUTRAL, (2) both pumps stroked forward and backward, and (3) when stroking each pump individually. The gauge should read as follows: 130150 psi (9-10 bar). Minimum pressure should be: 100 psi (7 bar).

4. A slight drop in pressure is normal when a load is put on the hydrostatic pump. If the pressure reading on the gauge is either lower or higher than specified, refer to the manufacturer’s service manual for the hydrostatic pump, and the charge pressure adjustment procedure that follows.

Adjustment Procedure Add or remove shims on the charge pressure relief valve (next section) to adjust the charge pressure. Add shims to increase the charge pressure; remove shims to decrease the charge pressure.

Charge Pressure Test Port

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Hydrostatic Pump Relief Valves

Hydrostatic Pump Removal / Installation

Each hydrostatic pump is equipped with two highpressure relief valves, for a total of four hydrostatic pump relief valves in the hydrostatic drive system. The two front relief valves on the hydrostatic pump assembly control the front hydrostatic pump, which drives the left side of the skid loader. The two rear relief valves on the hydrostatic pump assembly control the rear hydrostatic pump, which drives the right side of the skid-steer loader. Refer to the manufacturer’s manual for service procedures.

Relief Valves Location

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this service manual.)

Removal Procedure 1. Remove the pressure cap from the hydraulic reservoir to relieve any pressure.

2. Drain the oil from the hydraulic reservoir per the procedure in the Lubrication chapter.

IMPORTANT Drive Motor Hot-Oil Shuttle Valve The hot-oil shuttle valve is a spring-loaded spool valve located in the end cover of each drive motor. The purpose of the shuttle is to allow a small portion of the closed-loop circuit oil back to the hydraulic reservoir for cooling and filtering (this is referred to as “case drain” oil).

Mark the hoses, tubes and fittings for reassembly, and cap or plug them after they are disconnected to prevent contaminants from entering the hydraulic system.

3. Disconnect the hydrostatic pump are control rods from the neutral centering devices.

Cooling oil must be taken from the low-pressure side of the closed-loop circuit. This is necessary to prevent loss of drive power. Because the drive motor are reversible, neither of the ports are continuously high or low pressure, depending on the direction of travel.

The spool valve senses pressure differentials and moves to block the high-pressure port and open the lowpressure side to the hydraulic reservoir. When the loader is in NEUTRAL, the spool is in a center position.

There is another shuttle relief valve in the case drain line to control the amount of oil flow and to maintain pressure in the drive motor circuit. It is necessary to remove the drive motors to service this shuttle. Refer to the manufacturer’s manual for service procedures.

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4. Disconnect three hydraulic pressure hoses at the gear pump.

8. Remove two screws (35 ft-lbs) (48 N•m) connecting the pump support to the pump flange.

5. Support the gear pump. Remove two screws and washers securing the gear pump to the hydrostatic pump. Pull the gear pump forward and up, out of the chassis.

9. Remove the two screws (80 ft-lbs.) (112 N•m) securing the hydrostatic pump to the flywheel housing cover. Lift the pump slightly to remove the screws.

6. Label and disconnect all the hydraulic hoses connected to the hydrostatic pump.

7. Position a suitable hoist of adequate capacity and a positive locking mechanism able to support the hydrostatic pump. Attach lifting straps around the pump and raise the hoist to remove slack from the strap/hook. The hoist should now support the weight of the pump.

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10. Shift the hydrostatic pump forward to disengage the splined shaft drive of the pump and pull the pump out of the flywheel.

11. Lift and maneuver the hydrostatic pump out of the skid-steer loader.

Installation Procedure* - Follow all warnings first, then reverse the removal steps. * Coat pump shaft splines (male and female) with molybdenumdisulfide (“moly”) grease.

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Hydrostatic Pump Flexible Drive Coupling Removal and Installation Removal Procedure

3. Remove three carriage bolts (80 ft-lbs.) (112 N•m) and locknuts securing the top of the engine mount weldment to the engine cross-angle brace.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm, engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the hydrostatic pump per the procedure in this chapter.

4. Remove the remaining capscrews securing the flywheel housing cover to the engine and remove the cover.

2. Remove two screws (50 ft-lbs.) (70 N•m) and washers securing the pump support to the flywheel housing cover.

5. Remove the eight capscrews (18 ft-lbs.) (24 N•m) attaching the flexible coupling plate to the engine.

Installation Procedure - Follow all warnings first, then reverse the removal steps.* 74

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HYDROSTATIC SYSTEM

* Regrease the tooth spline of the flexible drive coupling plate before reinstalling the hydrostatic pump.

Drive Motor Removal and Installation

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

■ Raise and securely block the loader so all four tires are off the ground.

(For detailed instructions, refer to the Safety chapter of this manual.)

Removal Procedure 1. Underneath the skid-steer loader, remove the screws securing the front belly pan and then remove the belly pan from the chassis.

2. Remove drive chains per the procedure in the Wheel Drives chapter.

3. If necessary, drain oil from hydraulic reservoir per the procedure in the Hydraulic System chapter.

NOTE: If the hydraulic hoses and tubes are plugged after removal to prevent oil leakage, it should not be necessary to drain the hydraulic reservoir. Hydraulic hoses and tubes should be plugged to prevent contaminants from entering the hydraulic system.

4. BEFORE disconnecting hydraulic hoses and tubes from the drive motor, mark each hose/tube and the port where it attaches to the drive motor (so that

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hoses/tubes can be correctly re-attached during installation).

5. Disconnect all hydraulic hoses and tubes on each drive motor.

6. Remove screws (120 ft-lbs.) (168 N•m) (Loctite 242) and seal washers attaching the drive motor to the chaincase. Lower the drive motor and o-ring seal through the belly pan with a suitable hoist of adequate capacity and a positive locking mechanism to support the drive motor.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

NOTE: Install o-ring seal on the drive motor. Scrape off old gasket material and apply new sealant to mating surface of the drive motor before reassembly to the chassis. Perform the drive chain adjustment procedure in the Wheel Drives chapter after reinstallation of the drive chains.

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Troubleshooting Guide The troubleshooting guide lists potential hydrostatic system problems, as well as possible causes and remedies.

If you cannot locate a particular hydrostatic system problem in this chart, consult the troubleshooting chart in the Hydraulic System chapter.

Problem No response from the hydrostatic drive or the lift/tilt systems

When a problem occurs, don’t overlook simple causes.

A malfunction could be caused by something as simple as low fluid level in the hydraulic reservoir. After a mechanical failure has been corrected, be sure to locate the cause of the problem.

Possible Cause

Remedy

Hydraulic oil viscosity too high

Allow longer warm-up or replace oil with the proper viscosity oil.

Hydraulic oil supply too low

Check for low oil level in reservoir. Add oil as needed.

Hydrostatic pump drive disconnected Drive coupling failure.

Check for broken or worn pump drive coupling and replace, as needed.

Parking brake engaged.

Disengage parking brake.

Hydraulic oil supply too low

Check for low oil level in reservoir. Add oil if necessary.

Control rod linkage disconnected

Check linkage connection at control levers and neutral centering mechanisms. Reconnect linkage.

Low or no charge pressure

See hydrostatic pump manual.

Hydrostatic pump relief valves malfunctioning

Inspect and clean the relief valves.

Replace them as needed.

Drive wheels do not turn in proper direction for T-Bar movement

High pressure hydraulic hoses between hydrostatic pump and drive motors connected incorrectly

Reconnect hoses to proper ports on the drive motors. Refer to schematic and figures in the Hydrostatic System chapter.

Lift/tilt controls fail to respond

Hydraulic oil viscosity too high

Allow longer warm-up or replace with the proper viscosity oil.

Hydraulic oil level low

Check oil level in reservoir. If oil is low, check for an external leak. Repair and add oil.

Solenoid valve(s) malfunctioning

Check electrical connections to lift/tilt solenoids and repair.

Restraint bar or seat switch malfunction

Check switches.

Traction drive will not operate in either direction

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Problem Neutral difficult to maintain

Sluggish acceleration

Hydrostatic drive overheating

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GEHL R105 / MUSTANG 1050R

Possible Cause

Remedy

Rod ends loose on centering mechanism or servo rod

Check and tighten or replace components.

Neutral centering mechanism(s) out of adjustment

Adjust neutral centering mechanism(s).

See Controls chapter for procedure.

Clamping bolt loose

Tighten clamp bolt.

Hydrostatic pump out of adjustment

See hydrostatic pump manual.

Air in the hydraulic system

Cycle the lift and tilt cylinders to maximum stroke and maintain pressure for a short time to clear air from system.

Check hydraulic oil reservoir; fill as needed.

Hydraulic oil supply too low

Check hydraulic oil reservoir. Add oil, if necessary.

Low hydrostatic system charge pressure

See hydrostatic pump manual.

Drive motor(s) or hydrostatic pump(s) have internal damage or leakage

Refer to component manufacturer’s service manual.

Engine not responding under load

Troubleshoot engine.

Automatic parking brake partially engaged

Contact your dealer.

Drive system overloaded continuously

Improve efficiency of operation.

Lift, tilt or auxiliary system overloaded continuously

Improve efficiency of operation.

Drive motor(s) or hydrostatic pump(s) have internal damage or leakage

Refer to component manufacturer’s service manual.

Oil cooler plugged with debris

Clean oil cooler fins.

Loader being operated in a high temperature area with no air circulation

Reduce duty cycle and improve air circulation.

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Problem Hydrostatic (drive) system noisy

Right side doesn’t drive in either direction. Left side operates normally

Right side doesn’t drive in one direction

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HYDROSTATIC SYSTEM

Possible Cause

Remedy

Hydraulic oil viscosity too high

Allow longer warm-up or replace oil with the proper viscosity oil.

Drive motor(s) or hydrostatic pump(s) have internal damage or leakage

Refer to component manufacturer’s service manual.

Air in hydraulic system.

Cycle lift and tilt cylinders to maximum stroke and maintain pressure for a short time to clear air from system.

Check oil level in reservoir; fill as needed.

Excessive internal leakage in right drive motor

Repair or replace as needed. Refer to motor manufacturer’s service manual.

Excessive leakage in engine-end hydrostatic pump

Refer to the pump manufacturer’s manual for service procedures. Repair or replace rear pump as needed.

Servo controller malfunctioning

Refer to the pump manufacturer’s manual for service procedures. Repair or replace rear pump as needed.

Relief valves on engine-end hydrostatic pump malfunctioning

Switch valves with those on front hydrostatic pump. See “Hydrostatic Pump Relief Valves” information in this chapter; problem should switch to the left side. Replace defective relief valve.

Control rod linkage to engine-end hydrostatic servo is disconnected

Reattach control rod linkage.

Key missing on rear pump arm control shaft.

Replace the key. Torque screw on the arm to 30 fit-lbs. (40 N•m).

Relief valve on engine-end hydrostatic pump malfunctioning

Switch one relief valve with the other relief valve on rear pump; problem should switch to reverse direction.

Clean or replace the faulty valve as needed.

Engine-end hydrostatic pump malfunctioning

Refer to pump manufacturer’s manual for service procedures. Repair or replace rear pump as needed.

Servo controller malfunctioning

Refer to pump manufacturer’s manual for service procedures. Repair or replace rear pump as needed.

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Problem

Possible Cause

Remedy

Left side doesn’t drive in either direction. Right side operates normally

Excessive internal leakage in left drive motor

Repair or replace as needed. Refer to motor manufacturer’s service manual.

Excessive leakage in gear-end hydrostatic pump

Refer to pump manufacturer’s manual for service procedures. Repair or replace the front pump as needed.

Relief valves on gear-end hydrostatic pump malfunctioning

Switch valves with those on rear hydrostatic pump. See “Hydrostatic Pump Relief Valves” information in this chapter; problem should switch to the right side. Replace defective relief valve as needed.

Servo controller malfunctioning

Refer to the pump manufacturer’s manual for service procedures. Repair or replace rear pump as needed.

Control rod linkage to gear-end hydrostatic servo disconnected

Reattach control rod linkage.

Key missing on front pump arm control shaft.

Replace the key. Torque screw on the arm to 30 fit-lbs. (40 N•m).

Relief valve on gear-end hydrostatic pump malfunctioning

Switch relief valve with other relief valve on front pump; problem should switch to the reverse direction. Clean or replace the faulty valve as needed.

Gear-end hydrostatic pump malfunctioning

Refer to pump manufacturer’s manual for service procedures. Repair or replace front pump as needed.

Servo controller malfunctioning

Refer to pump manufacturer’s manual for service procedures. Repair or replace front pump as needed.

Left side doesn’t drive in one direction

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D

C

LIFT

B

TILT

OPTIONAL SELF-LEVEL

EATON SELF-LEVEL VALVE WITH RELIEF UNLOAD SPOOL

A

LIFT

TILT

STANDARD FLOW NON SELF-LEVEL

B1 A1

B2 A2

P

A1

B1

A2

B2

A3

B3

LIFT

TILT

AUX

X

X

2828 PSI

3480 PSI

3480 PSI

T

36/3840

4240

GEHL R105 / MUSTANG 1050R HYDROSTATIC SYSTEM

Hydrostatic/Hydraulic Schematic - Gehl R105

81

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C

LIFT

B

TILT

OPTIONAL SELF-LEVEL

D

EATON SELF-LEVEL VALVE WITH RELIEF UNLOAD SPOOL

A

LIFT

TILT

STANDARD FLOW NON SELF-LEVEL

B1 A1

B2 A2

B3

P

A1

B1

A2

B2

A3

LIFT

TILT

AUX

X

X

2828 PSI

3480 PSI

3480 PSI

T

HYDROSTATIC SYSTEM GEHL R105 / MUSTANG 1050R

Hydrostatic/Hydraulic Schematic - Mustang 1050R

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GEHL R105 / MUSTANG 1050R

HYDRAULIC SYSTEM

Introduction

Information on recommended hydraulic fluids, capacities and filter change intervals is in the Lubrication chapter. For detailed information on gear pump or control valve internal repair, consult the GehlMustang Service Department and/or the hydraulic component manufacturer’s service manual. Hydraulic components related to the drive system are covered in the Hydrostatic System chapter.

This chapter covers troubleshooting, testing, removal, installation and adjustment procedures for hydraulic system components on Gehl R105 and Mustang 1050R model skid-steer loaders. Primary hydraulic system components in this chapter are shown below and on following pages.

Power for the lift arm functions and auxiliary hydraulics is provided by a gear pump attached to the front of the tandem pumps.

Models include a standard-flow auxiliary hydraulics system with two hydraulic couplers on the left lift arm for attachment hookup.

When a problem occurs, don’t overlook simple causes.

A malfunction could be caused by something as simple as low fluid level in the hydraulic reservoir. After a mechanical failure has been corrected, be sure to locate the cause of the problem.

Hydraulics - Self Level Valve Components

11 11

4

7

3 6 8

8

5 2 1 10

9

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ELBOW/SWIVEL FITTING/90 FITTING/ST TEE RUN TEE RUN VALVE SELF LEVEL TUBE/SELF LEVEL BOTTOM LN TUBE/LIFT TUBE/CONTROL VALVE/LIFT CB

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Hydraulics - Standard Auxiliary Components

4 11 1 3

2

5 9

3 10

7

6

8

1 2 3 4 5 6 7 8 9 10 11

84

FITTING/90 CAP PLATE/TOP SIZE CLAMP/TUBE TWIN CLAMP/TUBE TWIN FITTING/TEE TUBE/LIFT LH TUBE/CONTROL VALVE/LIFT TUBE/LIFT RIGHT CS CS

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Hydraulics - Lift Arm Components 27 12 24

42

3

18 12

39

HIGH FLOW OPTION SHOWN

34

7

18 17

3

13

25 24

42

13

2

41

25

28

21

39

14 23

29

13

4

17

15

13

44

7

39

8

3 34

7

20

1

4

2

41

10

43

34

35

16

39

23

3

11

29 7

4

6

16

5 31

37

37 38

30 26

9

22

33

35 5

43

6

22

26

40 41

9 40

32 36

29

7 41

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

31

BRACKET/COUPLER RETAINER FITTING/STRAIGHT FITTING/90 SCREW/CAP LOCKING FITTING/TEE FITTING/90 NUT/LOCK FITTING/90 FITTING/45 COUPLER/HYDRAULIC COUPLER/HYDRAULIC TIE/CABLE CYLINDER/LIFT HYDRAULIC LINE/OUTER HYDRAULIC LINE/INNER

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29

32 7

36

16 HOSE/HYDRAULIC 17 ASSY/HOSE AND TUBE 18 ASSY/HYDRAULIC HOSE 19 HYDRAULIC LINE/LIFT CYLINDER 20 ASSY/HYDRAULIC LINE 21 ASSY/HYDRAULIC LINE 22 ASSY/HYDRAULIC HOSE 23 CLAMP/HOSE 24 PIN/PIVOT LIFT 25 HOSE 26 CYLINDER/TILT 27 HOSE/PRESSURE 28 HOSE/PRESSURE 29 PIN/PIVOT

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30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

PIN/PIVOT TILT CYLINDER SCREW/CAP SEAL RING/SNAP CLIP/HYDRAULIC LINE CLIP/HYDRAULIC LINE WASHER/SPECIAL WASHER/SPECIAL WASHER/SPECIAL FITTING/STRAIGHT FITTING/90 SCREWCAP SCREW/CAP SCREW/TAPPING SCREW/CAP

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Hydraulics - Chassis Components - DPF Models 12

18 9

21 48

41 4

7

24 46 13

47 26

11

36 36

21 10

32

34 40 RETURN TO TANK THROUGH COOLER

47

23 31

37

38 39

36

2 36

37

24 38

36

45

37

23 4

26

1 20 45

AUXILIARY CIRCUIT

27 14

33

TO TANK

43

22 46

15

6

13

35

36

6

42

3 28

17

6

TILT CIRCUIT LIFT CIRCUIT

29

4

TO GEAR PUMP

11

44 7

30

25 5 19

16

1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17

86

ELBOW 90 CLAMP/HOSE ELBOW/SWIVEL FITTING/90 Elbow/90 FITTING/ST FITTING/ST FITTING/90 FITING/TEE CLAMP/HOSE BHSCS CAP PLATE/TOP TWIN CLAMP/TUBE HFS UNION/HYDRAULIC

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

7

OIL TEMP SWITCH FITTING/90 FITTING/TEE RUN FILTER ASSY FITTING/ST NUT/SPIRALOCK STRAP VALVE PACKAGE VALVE/SOLENOID TUBE/TANK-BRAKE FITTING/TEE RUN TUBE/VALVE TO LIFT/LEFT VALVE/CONTROL FITTING/TEE TUBE/VALVE TO LIFT/RIGHT TUBE/MAIN CONTROL/LIFT

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34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

TUBE/TILT UPPER TUBE/TANK RETURN NUT/FLRSUF CLIP/HYD LINE TUBE/AUXILIARY/UPPER TUBE/AUXILIARY/LOWER TUBE/TILT LOWER TUBE/OIL FILTER PLUG CS CB CB CB CB PLUG

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HYDRAULIC SYSTEM

Hydraulics - Chassis Components - Non-DPF Models 10 7

4

7

22 45

24

44

9

19

39

34 8 30

45

21 2

29

35

34 35

22

36

34

37

35

21

43 34

4

24

1 43

18

12

41

31

TO TANK 20 44

13

6

11

33

40

25 6

3

27

26

15

6 4

23

9

42

7

28

5 17

7 14

16 32 46 38 36 11 34

AUXILIARY CIRCUIT

34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

ELBOW 90 CLAMP/HOSE ELBOW/SWIVEL FITTING/90 Elbow/90 FITTING/ST FITTING/ST FITTING/TEE RUN CLAMP/HOSE BHSCS CAP PLATE/TOP TWIN CLAMP/TUBE HFS UNION/HYDRAULIC OIL TEMP SWITCH FITTING/90 FITTING/TEE FILTER ASSEMBLY FITTING/ST NUT/SPIRALOCK STRAP VALVE PACKAGE VALVE/SOLENOID TUBE/TANK-BRAKE FITTING/TEE RUN TUBE/VALVE TO LIFT VALVE/CONTROL FITTING/TEE TUBE/VALVE TO LIFT TUBE/LIFT TUBE/TILT UPPER TUBE/TANK RETURN NUT/FLRSUF CLIP/HYD. LINE TUBE/AUXILIARY TUBE/AUXILIARY TUBE/TILT LOWER TUBE/OIL FILTER PLUG CS CB CB CB CB PLUG

RETURN TO TANK THROUGH COOLER

TILT CIRCUIT LIFT CIRCUIT TO GEAR PUMP

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Pressure Tests, Control Valve The control valve on the skid-steer loader controls lift and tilt functions of the lift arm and standard auxiliary hydraulics. It is located on the right side of the chassis.

The relief valve in the control valve can be tested at the lift arm couplers.

Test Procedure

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

■ Tilt back ROPS/FOPS until lock engages.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

(For detailed instructions, refer to the Safety chapter in this manual.) a. Standard auxiliary relief valve can be found at the front of the control valve.

Relief Valve Location

■ Shut off the engine.

■ Relieve hydraulic system pressure.

(For detailed instructions, refer to the Safety chapter of this manual.)

NOTE: To prevent contamination, ALWAYS clean the area around hydraulic fittings before disconnecting any hydraulic plug, hose or tube.

1. What you’ll need: an assistant and a minimum 5000 psi (345 bar) pressure gauge.

2. Perform the pressure tests at the auxiliary hydraulic couplers located on the left lift arm.

b. Loosen the small lock nut threaded on the valve.

Auxiliary Couplers

3. Install the pressure gauge in the end of the male coupler and activate the auxiliary hydraulic circuit to pressurize the line.

4. For this test, engine should be at HIGH IDLE. 5. Have assistant observe the pressure reading on the gauge. The pressure reading on the loader should be at least 2750 psi (190 bar).

6. If the pressure reading is NOT at the specified pressure, adjust pressure as follows: 88

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b. With an Allen wrench, turn the adjuster screw IN to increase pressure or OUT to decrease pressure.

Adjuster Screw

Tilt Cylinder Test If the bucket (or attachment) drifts down with the tilt control in the NEUTRAL position, first check the tilt cylinders for external leakage. If external leakage is evident, a new seal kit should be installed in the leaking cylinder(s). If no external leakage is evident, check the tilt cylinders for internal leakage according to the following procedure.

NOTE: When checking for drifting, the ignition key MUST BE in the OFF position, operator in the seat, and the restraint bar lowered. The maximum allowable tilt cylinder circuit drifting with a loaded bucket is 0.88" (22 mm) of cylinder extension in 15 minutes.

Test Procedure

c. Repeat steps 4 and 5. d. After the pressure is within the correct PSI range, tighten the locknut on the control valve adjuster screw to secure the adjustment.

7. If, after the adjustment, there is NO CHANGE in the pressure reading, this indicates either a defective hydraulic gear pump or relief valve cartridge (on the control valve). To determine which is the cause, first replace the relief valve cartridge. If the pressure reading still does not change, the hydraulic gear pump should be repaired or replaced.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

■ Relieve hydraulic system pressure.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Load the bucket and allow it to rest on the ground.

NOTE: To prevent contamination, ALWAYS clean the area around hydraulic fittings before disconnecting any hydraulic hose or tube.

2. Checking the right tilt cylinder: Remove the lower hydraulic hose from the right tilt cylinder and cap or plug the hose and cylinder port. Caps or plugs MUST BE able to withstand full hydraulic pressure.

Right Tilt Cylinder

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3. Crack open (slightly loosen) the upper hydraulic hose on the right tilt cylinder.

WARNING

8. Checking the left tilt cylinder: Remove the lower hydraulic hoses on the left tilt cylinder and cap or plug the cylinder ports. Caps or plugs MUST BE able to withstand full hydraulic pressure.

Left Tilt Cylinder

BEFORE raising a loaded bucket, BE SURE no personnel are near the loader. Serious personal injury can result if bucket drops suddenly or its contents spill out.

4. Climb back into the operator’s seat, lower the restraint bar, and start the engine.

5. Raise the lift arm enough for the bucket (or attachment) to clear the ground.

6. Shut off the engine, turn the ignition key to the ON position (engine OFF) and operate the tilt control in both directions.

7. If the bucket drifts, the blocked tilt cylinder has leaking piston seals. If it DOES NOT drift, lower the lift arm and reconnect/retighten the hydraulic hose(s) to the cylinder.

9. Connect the two hoses, just removed, together with a straight fitting.

10. Crack open (slightly loosen) the inside upper hydraulic hose on the left tilt cylinder.

11. Repeat steps 4 - 7 for the left tilt cylinder.

12. After both tilt cylinders have been tested, be sure the hydraulic hoses are reconnected or retightened.

NOTE: If both tilt cylinders have good seals, and the bucket still drifts, the fault could be in either the control valve or the self-leveling valve. Continue the test procedure with step 13, below. Also, refer to the Troubleshooting Guide in this chapter.

13. To determine if either the control valve or self-leveling valve is faulty and causing the bucket to drift, perform the “Self-Leveling Valve Test” procedure in this chapter.

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Self-Leveling Valve Test

Lift Cylinder Test

Test Procedure

If the lift arm drifts with the lift control in NEUTRAL position, and the ignition key OFF, first check the lift cylinders for external leakage. If external leakage is evident, a new seal kit should be installed in the leaking cylinder(s). If no external leakage is evident, check the lift cylinders for internal leakage according to the following procedure.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

(For detailed instructions, refer to the Safety chapter in this manual.)

1. Open the engine access cover and lock open the rear grille.

2. Loosen the jam nut on the self-leveling valve adjuster screw.

Self-Leveling Valve Adjuster Screw

NOTE: When checking lift arm for drifting, BE SURE the ignition key is in the OFF position. The maximum allowable lift cylinder drifting is 0.75" (19 mm) of cylinder retraction in 15 minutes.

Test Procedure 1. Remove the bucket or attachment from the attachment bracket.

2. Raise the lift arm to maximum height. Then release the lift cylinder lift arm support device and slowly lower the lift arm to engage the device.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

■ Relieve hydraulic system pressure.

(For detailed instructions, refer to the Safety chapter in this manual.)

NOTE: For step 3, BE SURE to count and record the number of turns, so the adjuster screw can be returned to its original setting after the test.

3. Remove the clamp securing the hydraulic tubes to the lift cylinder on the side being tested.

3. With an Allen wrench, turn the adjuster screw in (clockwise) until it bottoms out. The self-leveling valve is now disabled and will not affect the tilt operations.

4. Perform steps 4 - 7 of the “Tilt Cylinder Test” procedure. If the bucket no longer drifts, the self-leveling valve is defective. If the bucket continues to drift, the control valve is defective and in need of repair or replacement.

5. Refer to the “Self-Leveling Valve Adjustment” procedure in this chapter for correct adjustment of the self-leveling valve.

Hose to remove on base end

NOTE: To prevent contamination, ALWAYS clean around hydraulic fittings before disconnecting any hydraulic lines.

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4. Disconnect the hydraulic tube from the rod end port of the lift cylinder to be tested.

Solenoid Valve Test - Tilt, Lift, Brake During normal operations, the solenoid valves should prevent operation of the lift arm and drive functions if any of the safety interlock system switches are open, for example: » Operator not sitting on the seat. » Restraint bar not lowered.

Test Procedure 1. Climb into the operator’s seat, lower the restraint bar and start the engine.

2. Using the lift control, raise the lift arm off the ground enough so that the attachment can be tilted.

5. Install a plug on hydraulic tube. Attach a hose to rod end port of the cylinder and run the other end of the hose into a suitable container. Lower the ROPS. 6. Climb back into the operator’s seat, lower the restraint bar and start the engine.

3. Raise the restraint bar, use the lift and tilt controls (one at a time) to see if either function will operate. » If the lift arm can be raised or lowered, the lift solenoid is malfunctioning.

7. Hold the lift control in the RAISE position. If the seals in the cylinder are defective and leaking, oil will flow out of the rod-end port.

8. Lower the lift arm support device back against the lift cylinder. Shut off the engine and move the lift control in both directions to relieve hydraulic pressure.

Lift Solenoid

9. Reconnect the hydraulic tube to the cylinder, then reattach the clamp around the hydraulic tubes and cylinder.

NOTE: If neither lift cylinder shows signs of external or internal leakage, and the lift arm still drifts, the problem could be due to leaking hydraulic hose fittings between the control valve and the lift cylinders. Check all hydraulic hose fittings thoroughly. The fault could also be in either the control valve or the self-leveling valve. Continue the test procedure with step 11. Also refer to the Troubleshooting Guide in this chapter.

» If the attachment can be tilted, the tilt solenoid is malfunctioning.

10. The other cylinder can be checked the same way.

11. To determine if either the control valve or the selfleveling valve is faulty, perform the “Self-Leveling Valve Test” procedure in this chapter.

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4. Lower the restraint bar. BE SURE the parking brake on the instrument panel is in the OFF position.

Hydraulic Oil Filter Element Replacement

5. Raise the restraint bar. Use the drive controls (one at a time) to see if the tires will move.

Gehl R105 and Mustang 1050R model skid-steer loaders have one hydraulic oil filter. The hydraulic oil filter element should be replaced after every 250 hours of operation or annually (whichever occurs first).

» If the skid loader moves forward or backward, the brake solenoid is malfunctioning.

NOTE: There is an initial 50-hour element replacement schedule for new skid-steer loaders with original filters.

Brake Solenoid

Hydraulic Oil Filter Location

6. If any solenoid in the above tests appears to be malfunctioning, test that solenoid coil as follows:

Replacement Procedure

WARNING

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedure: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

(For detailed instructions, refer to the Safety chapter of this manual.) » Have an assistant sit in the operator’s seat, lower the restraint bar and turn the keyswitch to ON. DO NOT start the engine.

BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine.

(For detailed instructions, refer to the Safety chapter in this manual.)

1. Open the engine access cover and lock open the rear grille.

2. Using a filter wrench, turn the filter element counterclockwise to remove it from the filter head.

» Using a thin strip of steel (such as a pocket ruler), check the suspected solenoid by moving the steel strip close to the solenoid coil. » If the steel strip is magnetically attracted to the solenoid coil, the coil works and the solenoid cartridge may be causing the malfunction.

7. For service procedures, refer to “Solenoid Valve Removal and Installation/Disassembly and Reassembly” procedure in this chapter.

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3. Install the filter element. Before installation, apply a light coat of oil to the gasket, and then install it on the filter head.

4. Hand-tighten element until the gasket contacts the filter head. Turn element another 3/4 turn to seat the gasket.

5. Refer to the Lubrication chapter in this manual for the hydraulic fluid requirements and specifications.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

6. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

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Hydraulics - Auxiliary

8

11 4

7

2

TO LOWER MOUNTING BOLT OF FUEL TANK

10

10

TO TANK

12

5

3

6 14

13 SEE NOTE 14

1

9

NOTE: 1. APPLY LOCTITE 242 2. TORQUE TO 30 FT/LBS

1 2 3 4 5 6 7

FITTING/ST O-RING FITTING/90 CLAMP/HOSE FITTING/90 PUMP/GEAR DBL HOSE/SUCTION

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8 HYDRAULIC HOSE/TUBE 9 HOSE/MP 10 CLAMP/T-BOLT 11 LN FL SERR 12 FITTING/45 13 CS 14 LW

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Tilt Cylinder Removal and Installation Removal Procedure NOTE: Refer to the “Lift Arm Removal and Installation” procedure in the Mainframe chapter for instructions on removing the complete lift arm group, including the tilt cylinders.

5. While supporting the weight of the tilt cylinder, remove the capscrew and locknut securing the lower tilt cylinder pivot pin. Then drive the pivot pin out to release the lower end of the tilt cylinder.

1. Remove the bucket or attachment.

2. With the engine running, lower the lift arm until it is in contact (or near contact) with the lift arm stops (on front of chassis).

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

■ Relieve hydraulic system pressure.

(For detailed instructions, refer to the Safety chapter in this manual.)

3. Position a suitable hoist of adequate capacity and a positive locking mechanism able to support the attachment bracket (hitch).

4. Disconnect the upper and lower tilt cylinder hoses from the cylinder ports. BE SURE to install plugs in the hoses and cap the fittings to prevent fluid loss and contamination of the hydraulic system.

6. Remove the snap ring on the cylinder pin of the tilt cylinder being removed.

7. Loosen the capscrew on the upper tilt cylinder pin by two or three counterclockwise turns. Strike the bolt head to drive the pin into the lift arm to break 96

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the pin free of the taper. Remove the capscrew and washer. Remove the upper tilt cylinder pin while supporting the tilt cylinder and remove the tilt cylinder.

tor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

4. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

8. Using a punch, remove the upper tilt cylinder pins and remove the cylinders.

Installation Procedure 1. Install the upper end of the tilt cylinder in position on the lift arm and insert the pivot pin. Use Loctite® 242 or equivalent on the capscrew before reinstalling and torque to 80 ft.-lbs. (108 N•m).

Secure the pivot pin with its snap ring.

2. Position the lower end of the tilt cylinder and insert the pivot pin through the cylinder and attachment mount. Secure the pivot pin with a capscrew and locknut.

NOTE: The grease fitting on the base and rod end of the tilt cylinder should face inward as installed.

3. Remove plugs/caps and attach the upper and lower tilt cylinder hoses to the cylinder.

NOTE: After removing/replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary.

Refer to the Lubrication chapter in this manual for the hydraulic fluid requirements and specifications.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a docPRINTED IN USA

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Lift Cylinder Components

1 2 3 4 5 6 7 8 9 10 11

WELDMENT/BARREL NUT/HEX WASHER/SPECIAL PISTON KIT/SEAL GLAND CAP/HEAD GLAND SCREW/SET WELDMENT/ROD BUSHING/OILITE ZERK/GREASE

1 2 3 4 5 6 7 8 9 10 11 12

WELDMENT/BARREL NUT/HEX WASHER/SPECIAL PISTON KIT/SEAL GLAND CAP/HEAD GLAND SCREW/SET WELDMENT/ROD BUSHING ZERK/GREASE BUSHING

Tilt Cylinder Components

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Lift Cylinder Removal and Installation Removal Procedure

plugs/caps in the hoses/tubes to prevent fluid loss and contamination of the hydraulic system.

1. Remove the bucket or attachment.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

■ Relieve hydraulic system pressure.

(For detailed instructions, refer to the Safety chapter in this manual.)

2. Attach a suitable hoist of adequate capacity and a positive locking mechanism able to support the hitch and raise the lift arm to a position where access to the tubes and hoses on the lift cylinder is maximized.

5. Remove the capscrew and locknut securing the front lift cylinder pivot pin. Then drive the pivot pin out to release the rod end of the lift cylinder.

3. Remove the clamp that secures the hydraulic tubes to the lift cylinder.

6. Open the engine access cover and lock open the rear grille.

NOTE: To aid in correct reassembly of the hydraulic hoses/tubes, mark the hoses/tubes to be removed BEFORE disassembly in step 3.

4. Disconnect the hydraulic hoses from their hydraulic tubes on the lift cylinder. BE SURE to install

7. While supporting the weight of the lift cylinder, remove the capscrew and locknut securing the rear lift cylinder pivot pin. Drive the pivot pin out the hole on the outside of the chassis. Remove the lift cylinder from the chassis.

8. Remove fittings and any o-rings from the cylinder.

Installation Procedure 1. Attach a suitable hoist of adequate capacity and a positive locking mechanism able to support the hitch and raise the lift arm to a position where access to the tubes and hoses on the lift cylinder is maximized.

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2. Install the lift cylinder on the chassis so the rod end is facing forward and the hydraulic tube ports on the cylinder are facing up.

Lift/Tilt Cylinder Disassembly / Assembly

3. Insert the rear and front pivot pins through the lift cylinder pivots and secure them with capscrews and locknuts.

Remove the cylinder from the skid-steer loader. See “Lift Cylinder Removal” or “Tilt Cylinder Removal” in this chapter.

4. Remove the plugs/caps and connect the hydraulic hoses to their hydraulic tubes on the lift cylinder according to the markings made at removal. If no markings were made or new parts were installed, refer to the Hydraulic System chapter exploded views.

1. Purge the oil from the cylinder by facing the ports downward and pumping the cylinder rod back and forth several times.

Disassembly Procedure

2. Use an Allen wrench to loosen the set screw on the cylinder collar.

5. Secure the lift tubes/hoses to the cylinder with the hose clamp.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter in this manual for the hydraulic fluid requirements and specifications.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

3. Clamp a suitable shaft in a vise and slide the cylinder onto the shaft to prevent the cylinder tube from turning.

4. Use a chain clamp or pipe wrench to remove the collar from the cylinder tube.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

6. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

7. Remove the hoist.

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5. Remove the rod assembly and inspect both the cylinder rod and the tube for dents or nicks that may cause damage to the o-rings and seals.

8. Slide the head gland, seals, and o-rings off the cylinder rod and inspect them for wear.

9. Change the seals as needed.

6. Loosen and remove the locknut that secures the head gland, seal kit and piston on the cylinder rod.

NOTE: Soaking the seals in warm water prior to installation will make them pliable and easier to install.

However, BE SURE to dry them and coat with hydraulic oil for proper installation.

Assembly Procedure 1. Slide the collar onto the cylinder rod (threaded end of the collar should face the threaded end of the cylinder rod).

2. Slide the head gland, larger diameter first, onto the cylinder rod.

3. Install the piston on the cylinder rod.

4. Secure the head gland and piston on the cylinder rod with a locknut. The locknut should be torqued to 350 ft.-lbs. (474 N•m).

7. Remove the piston assembly.

5. Install the cylinder rod into the tube.

Piston

6. Slide the collar down to the cylinder tube, thread it onto the tube and tighten with a chain clamp wrench. Tighten the set screw on the collar and torque to 79 ft-lbs. (107 N•m).

7. Install the cylinder on loader. See the “Lift Cylinder Installation” or the “Tilt Cylinder Installation” procedures in this chapter.

Head Gland

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Gear Pump Removal and Installation Removal Procedure

3. Disconnect two hydraulic pressure hoses at the gear pump.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Relieve hydraulic system pressure.

■ Tilt back ROPS/FOPS until lock engages.

Note: Mark the hoses, tubes and fittings for

(For detailed instructions, refer to the Safety chapter in this manual.)

reassembly, and cap or plug them after they are disconnected to prevent contaminants from entering the hydraulic system.

1. Drain the oil from the hydraulic reservoir per the procedure in the Lubrication chapter.

4. Position a suitable hoist of adequate capacity and a positive locking mechanism able to support the gear pump. Remove two capscrews securing the gear pump to the hydrostatic pump.

2. Loosen the hose clamp on the suction line and pull the hose off the beaded insert. Plug hose and cap the insert.

5. Pull the gear pump forward and out of the hydrostatic pump. BE CAREFUL not to lose the o-ring.

Installation Procedure 1. Install the o-ring on the mating surface of the gear pump.

2. Attach the gear pump to the hydrostatic pump (BE SURE the gear pump shaft engages the splined coupler). Install two capscrews with Loctite® 242 applied to secure the gear pump to the hydrostatic pump.

3. Remove the caps/plugs and connect the hydraulic hoses to the gear pump.

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4. Install a new hydraulic oil filter.

5. Reinstall the hydraulic reservoir drain plug.

6. Replace the hydraulic oil drained out of the reservoir in step 1.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of the hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for the hydraulic fluid requirements and specifications.

Self-Leveling Valve Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

■ Relieve hydraulic system pressure.

(For detailed instructions, refer to the Safety chapter in this manual.)

NOTE: Cap or plug the hydraulic hoses and fittings after disconnecting them to prevent fluid loss and contamination of the hydraulic system.

NOTE: In order to remove the hydraulic tubes from their fittings on the self-leveling valve, it may be necessary to loosen the hydraulic tube at the other end to give it some free-play.

1. Open the engine access cover and lock open the rear grille.

2. Disconnect the rear grille electrical harness and move the harness out of the way.

3. Disconnect all the hydraulic tubes from their hydraulic fittings on the self-leveling valve.

7. ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

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4. Loosen the bulkhead nut immediately beneath the self-leveling valve.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

5. Remove the two capscrews securing the self-leveling valve to the chassis.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

Self-Leveling Valve Adjustment Adjustment Procedure 6. Pull the self-leveling valve off the carriage bolts and remove the self-leveling valve.

7. If replacing, remove the fittings from the valve ports.

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of the hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for the hydraulic fluid requirements and specifications.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

1. Raise and lower the lift arm several times to ensure there is no air in the hydraulic system.

2. Lower the lift arm completely then fully retract the tilt cylinders (roll back).

3. Raise the lift arm to its maximum height; then lower it to the ground.

4. Measure how far the tilt cylinder rod extends from the tilt cylinder. The distance should be between 81/4 and 8-1/2” (210-216 mm). If measurement is outside this range, the self-leveling valve should be adjusted according to steps 5 - 9 of this procedure.

ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system.

WARNING BEFORE continuing this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

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■ Surfaces inside the engine compartment may be extremely hot, particularly the engine muffler and exhaust pipes. Serious injury may occur from touching components which have become hot while the engine was running.

extension. Turn the screw OUT (counterclockwise) to lengthen the cylinder extension.

(For detailed instructions, refer to the Safety chapter in this manual.)

WARNING Surfaces inside the engine compartment may be extremely hot, particularly the engine muffler and exhaust pipes. Serious injury may occur from touching components that have become hot while the engine was running.

5. Open the engine access cover and lock open the rear grille.

6. Loosen the jam nut on the self-leveling valve adjuster screw.

8. To check for proper operation, lower the ROPS/ FOPS, climb into the operator’s seat, lower the restraint bar and start the engine.

9. Repeat steps 2 through 4 above to check for proper operation of the self-leveling valve. If further adjustment is needed, perform the safety procedures again and repeat steps 7 through 9.

10. After adjustment is complete, tighten the adjuster screw locknut while holding the adjuster screw with the Allen wrench.

7. Insert an Allen wrench into the adjuster screw on the self-leveling valve and adjust the valve. Turn the screw IN (clockwise) to shorten the cylinder

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Safety Lock Valves - Removal/Installation Gehl R105 and Mustang 1050R model skid-steer loaders have separate electric solenoid safety interlock valves for the lift, tilt and drive functions of the hydraulic system. The lift safety interlock valve is located behind the ROPS/FOPS on the right side. The tilt safety interlock valve is located on the right side of the chassis, near the self-leveling valve. The brake solenoid valve is located on top the left inside chaincase.

Lift Lock Valve

Lift, Tilt and Brake Solenoid Valve Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

Brake Lock Valve

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Relieve hydraulic system pressure.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter in this manual.)

2. Remove the solenoid from the skid-steer loader.

1. Disconnect the electrical connector on the solenoid coil. Disconnect the hydraulic tubes/hoses from their fittings on the solenoid body. Remove all hardware securing the solenoid to the chassis.

NOTE: Cap or plug ALL hydraulic hoses, tubes, fittings, and control valve ports immediately after they are disconnected to prevent fluid loss and contamination of the hydraulic system.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

Tilt Lock Valve

106

NOTE: After removing and/or replacing any component in the hydraulic system, ALWAYS check the level of hydraulic fluid in the reservoir. Add fluid if necessary. Refer to the Lubrication chapter for hydraulic fluid requirements and specifications.

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Lift, Tilt and Brake Solenoid Valves - Disassembly and Assembly

3. Unscrew cartridge from the valve body.

Lift, tilt and brake solenoid valves can be removed from the loader for parts replacement, but it may not be necessary. If it is necessary, refer to the procedure in this chapter.

Disassembly Procedure 1. Remove the nut that secures the coil to the cartridge.

4. Install seal kit (or other new parts). Assemble solenoid valve in reverse order of disassembly.

O-Ring

O-Ring

O-Ring

2. Remove the coil from the cartridge.

Backup Rings

IMPORTANT DO NOT torque coil retaining nut more than 45 in.-lbs. (5.1 N•m).

5. If removed from the loader, install the lift, tilt or brake solenoid on the hydraulic system. Refer to the applicable procedure in this chapter.

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Main Control Valve Components

2

9 SEE NOTE 2

5 1

4 11

1-1/16 - 12 UNF

7 3

NOTES: 1. 192658 IS AN O-RING KIT. 2. 192685 COIL IS AVAILABLE AS SINGLE PART, OR, AS A COMPONENT OF KIT 240285.

11 6

1 2 3 4 5 6

108

10

KIT/CHECK VALVE KIT/SPOOL RETURN ACTION VALVE/RELIEF MAIN KIT/DETENT KIT/SPOOL RETURN ACTION PLUG

7 8 9 10 11

VALVE/RELIEF ADJUSTABLE KIT/O-RING COIL REATAINER/SEAL KIT/PLUG

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Control Valve Removal and Installation The main hydraulic control valve is located on the right side of the chassis, in front of the engine. This procedure highlights steps for removing the hydraulic hoses/tubes that connect to the control valve in order to remove the control valve. The removal of the lift, tilt and auxiliary connections at the control valve are highlighted in their respective procedures in the Controls chapter of this manual. The control valve ports are numbered for reference.

2. Remove control rods and/or cables that control the lift, tilt and auxiliary hydraulics of the skid-steer loader. Refer to their removal procedures in the Controls chapter of this manual.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

3. Disconnect the electrical connector at the rear of the control valve.

■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine.

■ Relieve hydraulic system pressure.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. If necessary (see following NOTE), drain oil from hydraulic reservoir. For this procedure refer to “Hydraulic Reservoir” in the Lubrication chapter.

NOTE: If hydraulic hoses and tubes are plugged to prevent oil leakage, it should not be necessary to drain hydraulic reservoir. BE SURE to plug/cap ALL hydraulic hose and tube fittings to prevent contamination of the hydraulic system.

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NOTE: To aid in re-assembly of hydraulic hoses and tubes, mark hoses and tubes to be removed before disassembly.

disconnected to prevent fluid loss and contamination of the hydraulic system.

Installation Procedure 1. Secure the control valve to the chassis with four capscrews and locknuts. If straight or 90° fittings are not in the valve, install them at this time.

2. Port A1: Connect the hydraulic tube to the 90° fitting on the control valve.

3. Port A2: Connect the hydraulic tube to the 90° fitting on the control valve.

4. Port A3: Connect the hydraulic tube to the straight fitting on the control valve.

5. Port B1: Connect the hydraulic tube to the 90° fitting on the control valve.

6. Port B2: Connect the hydraulic tube to the 90° fitting on the control valve.

7. Port B3: Connect the hydraulic tube to the straight fitting on the control valve.

8. Re-connect the auxiliary hydraulics spool lock electrical connector at the front of the control valve.

9. Re-connect the electrical connector at the rear of the control valve.

4. Port B3: Disconnect the hydraulic tube from the straight fitting on the control valve.

5. Port B2: Disconnect the hydraulic tube from the 90° fitting on the control valve.

6. Port B1: Disconnect the hydraulic tube from the 90° fitting on the control valve.

7. Port A3: Disconnect the hydraulic tube from the straight fitting on the control valve.

10. Connect control rods and/or cables that control the lift, tilt and auxiliary hydraulics of the skid-steer loader. Refer to their installation procedures in the Controls chapter of this service manual.

11. Install hydraulic reservoir drain plug and refill with correct type of hydraulic oil. Refer to the Lubrication chapter for hydraulic oil requirements and specifications.

12. ALWAYS check for hydraulic fluid leaks after reassembling any component of the hydraulic system.

8. Port A2: Disconnect the hydraulic tube from the 90° fitting on the control valve.

9. Port A1: Disconnect the hydraulic tube from the 90° fitting on the control valve.

10. Remove four screws and locknuts securing the control valve to its mounting bracket.

11. Lift out the control valve. Removal may require loosening the opposite ends of some of the disconnected hydraulic tubes.

NOTE: Cap or plug ALL hydraulic hoses, tubes, fittings and control valve ports immediately after being 110

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically

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HYDRAULIC SYSTEM

removed by a doctor familiar with this type of injury or gangrene may result.

1. With a wrench, loosen and remove the relief valve from the main control valve.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

Main Relief Valve Removal and Installation

2. Check condition of o-rings and clean off debris.

A main relief valve is integrated within the control valve. It activates when oil pressure inside the control valve reaches an unacceptable level, to relieve that pressure and prevent damage to valve and the hydraulic system.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Shut off the engine.

■ Relieve hydraulic system pressure.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

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Troubleshooting Guide Problem Lift/tilt controls fail to respond

Lift arm does not raise; bucket tilt works properly

Possible Cause

Remedy

Hydraulic oil viscosity too heavy

Allow longer warm-up or replace with proper viscosity oil.

Solenoid valve(s) malfunctioning

Check electrical connections to solenoid and repair connections as needed. Perform “Solenoid Valve Test.” Replace solenoid as needed.

Hydraulic oil level low

Check oil level in reservoir. If oil is low, check for an external leak.

Repair and add oil.

Hydraulic oil flow to the gear pump blocked

Inspect suction hose. Clean or replace as needed.

System relief valve malfunctioning

Adjust or replace relief valve as needed.

Drive disconnected

Check for broken or worn pump drive coupling. Replace as needed.

Sheared spline or broken shaft in hydrostatic pump assembly

Check splined shaft of pump closest to engine. Replace shaft if broken or if splines are sheared.

Sheared spline or broken shaft in gear pump

Remove gear pump from hydrostatic pump and inspect the splined shaft and coupler. Replace components as needed.

Restraint bar switch or seat switch not closing

Check switches and wiring. Replace as needed.

Lift spool in control valve not actuated or leaking

Check hose or tube connection to valve. Check pressure and flow.

Lift solenoid malfunctioning

Check electrical connections to solenoid. Repair or replace as needed.

This troubleshooting guide lists potential hydraulic system problems, as well as possible causes and remedies, for Gehl R105 and Mustang 1050R skid-steer loaders.

If you cannot locate a particular hydraulic system problem in this chart, consult the Hydrostatic System chapter troubleshooting chart.

When a problem occurs, don’t overlook simple causes.

A malfunction could be caused by something as simple as low fluid level in the hydraulic reservoir. After a mechanical failure has been corrected, be sure to locate the cause of the problem.

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Troubleshooting Guide Problem Hydraulic cylinder action slow for lift/tilt function

Jerky lift arm and bucket action

Auxiliary hydraulics function slowly

PRINTED IN USA

Possible Cause

Remedy

Low engine speed

Operate engine at higher speeds.

Hydraulic oil viscosity too heavy

Allow longer warm-up or replace existing oil with proper viscosity oil.

Hydraulic oil leaking past cylinder piston seals

Replace cylinder seals and o-rings as needed.

Hydraulic oil level low

Check oil level in reservoir. If oil is low, check for an external leak.

Repair and add oil.

Control linkage is restricted

Check for control linkage restriction and adjust.

Worn gear pump

Remove gear pump from hydrostatic pump and inspect. Replace components as needed.

Solenoid valve(s) malfunctioning

Check electrical connections to solenoid. Repair or replace as needed.

Relief valve in control valve malfunctioning (squealing noise evident while operating)

Check pressures in relief valve.

Repair or replace as needed.

Restraint bar switch or seat switch malfunction

Check electrical connections to the switch. Replace switch as needed.

Air in hydraulic system

Cycle lift and tilt cylinders to maximum stroke and maintain pressure for short time to clear air from system.

Oil in hydraulic reservoir low

Check and add oil to reservoir as needed.

Low engine speed

Operate engine at higher engine speeds.

Hydraulic oil level low

Add oil to reservoir.

Hydraulic oil viscosity is heavy

Allow long warm-up period.

Auxiliary spool in control valve leaking or not fully activated

Repair any leak found; readjust the auxiliary spool for full travel.

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Troubleshooting Guide Problem Lift arm doesn’t maintain raised position with lift control in NEUTRAL

Lift arm will not lower or raise

Bucket drifts downward with tilt control in NEUTRAL

No downward pressure on bucket

114

Possible Cause

Remedy

Oil leaking past lift cylinder seals (internal or external)

Check cylinder tube bore condition.

Replace seals or cylinder tube as needed.

Oil leaking past lift spool in control valve

Check valve body for scores or cracks. Replace control valve as needed.

Self-leveling valve malfunctioning

Repair or replace as needed.

Leaking hydraulic hoses, tubes or fittings between control valve and cylinders

Inspect hoses and tubes; tighten fittings as needed. Replace hoses or tubes as needed.

Lift cylinder lift arm support device engaged

Raise lift arm and disengage the lift arm support device.

Solenoid valve malfunctioning

Check electrical connections to solenoid. Repair or replace as needed.

Restraint bar not lowered

Lower restraint bar.

Restraint bar switch or seat switch malfunction

Check electrical connections to the switch. Replace switches as needed.

Blown fuse or relay

Replace fuse or relay.

Oil leaking past tilt cylinder seals (external or internal)

Check cylinder tube bore condition.

Replace seals, o-rings or cylinder as needed.

Self-leveling valve malfunctioning

Repair or replace as needed.

Leaking hydraulic hoses, tubes; or fittings between control valve and cylinders

Inspect hoses and tubes, tighten fittings as needed. Replace hoses or tubes as needed.

Control valve in “float” position

Take control out of “float” position.

Tilt cylinders malfunctioning

Check condition of cylinder tube bore. Replace seals, o-rings and/or cylinder tube as needed.

Main relief valve malfunctioning (squealing noise evident while operating)

Check pressures in relief valve.

Repair or replace as needed.

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HYDRAULIC SYSTEM

Troubleshooting Guide Problem Lift arm will not raise a heavy load or any load

Possible Cause

Remedy

Lift solenoid malfunctioning

Check electrical connections to solenoid. Repair or replace as needed.

Lift spool in control valve not actuated or leaking

Check valve body for scores or cracks. Replace control valve as needed.

Main relief valve malfunctioning (squealing noise evident while operating)

Check pressures in relief valve.

Repair or replace as needed.

Bucket does not level on the lift cycle

Self-leveling valve misadjusted or malfunctioning

Repair or replace self-leveling valve as needed.

Bucket will not tilt; lift arm works properly

Tilt solenoid valve malfunctioning

Check electrical connections to tilt solenoid and repair connections as needed. Replace solenoid as needed.

Tilt spool in control valve not actuated or leaking

Check hose or tube connection to valve. Check pressure and flow.

Control linkage misadjusted

Check linkage; readjust for full spool travel.

Low engine speed

Operate engine at higher speeds.

Hydraulic oil level low

Add oil to reservoir.

Hydraulic oil viscosity too heavy

Allow for longer warm-up period.

Control valve relief pressure low

Check pressure at control valve.

Readjust if necessary.

Restraint bar raised

Lower restraint bar

Restraint bar switch or seat switch malfunctioning

Replace malfunctioning switch

Blown fuse or relay

Replace fuse or relay.

Faulty electrical connections

Check electrical connections for security, broken or damaged wires.

Replace as needed.

Solenoid valve malfunctioning

Check electrical connections to solenoid. Repair or replace as needed.

Auxiliary hydraulics functions slowly

Auxiliary hydraulics do not function

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CHAPTER NOTES

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Introduction Description of Operation - Instrument Panel - DPF Models

1

2

The instrument panel for Gehl R105 and Mustang 1050R DPF model skid-steer loaders includes a parking brake switch, engine preheat switch, light switch, 12VDC power outlet and keyswitch.

The instrument panel contains the following switches and indicators. Symbols on the panel represent various functions and conditions, and are visible only when indicator lamps are on.

1. Keyswitch – In a clockwise rotation, these 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.

3

8

4

9

5

10

6 7

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.

NOTE: The engine cannot be started unless the 11

12

operator is sitting in the seat and the restraint bar is lowered. To verify that the seat and restraint bar switches are working properly, after the keyswitch is turned to ON, raise the restraint bar or lift body off the seat. Either action should prevent the engine from cranking with the keyswitch turned to START. 2. Information Center Electronic Display.

3. Fuel Level Gauge – Displays the amount of fuel in the tank.

13

14

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

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

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6. Battery – Lights if the charging voltage is too high or too low. During normal operation, this indicator should be OFF. 7. Preheat Indicator Lamp – Lights when the (automatic) preheat is active. During normal operation this indicator should be OFF. 8. Engine Malfunction Lamp – Indicates the engine ECU has detected a malfunction of the engine.

9. Engine Coolant Temperature – Lights if the engine coolant becomes too hot, warning the operator to stop the engine. Allow the engine to cool, determine the cause for the high temperature and correct the problem before restarting the engine. During normal operation, this indicator should be OFF. 10. Hydraulic Oil Temperature – Lights if the hydraulic oil becomes too hot, warning the operator to stop engine. Allow the 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 when the parking brake is applied.

12. Engine Speed Control – Controls the engine speed.

Move the control clockwise to increase and counter-clockwise to decrease the engine speed.

13. Light Switch – Controls all the lights on the loader.

Symbols denote the four positions of the light switch. In a clockwise direction these are: OFF Front Work Lights with Tail Lights ON both Front and Rear Work Lights For the lights to function, the keyswitch must be in the RUN position.

14. Accessory Outlet – 12-volt DC power outlet.

NOTES

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ELECTRICAL SYSTEM Description of Operation - Instrument Panel - Non-DPF Models The instrument panel for Gehl R105 and Mustang 1050R Non-DPF model skid-steer loaders includes a parking brake switch, engine preheat switch, light switch, 12-VDC power outlet and keyswitch.

10

1

2

The instrument panel contains the following switches and indicators. Symbols on the panel represent various functions and conditions, and are visible only when indicator lamps are on.

1. Hourmeter – Displays the total operating hours on the loader.

2. Fuel Level Gauge – Displays the amount of fuel in the tank.

3

3. Engine Coolant Temperature Gauge – Indicates the engine coolant temperature.

NOTE: Items 4 through 9 are indicator lamps which display the following: 4 8

5 6

9

7

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

5. Engine Oil Pressure – Lights if the engine oil pressure drops too low, warning the operator to immediately stop the engine and 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 operation, this indicator should be OFF.

11

7. Preheat Indicator Lamp – Lights when the preheat switch is pressed. During normal operation, this indicator should be OFF. 8. Engine Coolant Temperature – Lights if the engine coolant becomes too hot, warning the operator to stop the engine. Allow the engine to cool, determine the cause for the high temperature and correct the problem before restarting the engine. During normal operation, this indicator should be OFF.

12

13

14

9. Hydraulic Oil Temperature – Lights if the hydraulic oil becomes too hot, warning the operator to stop engine. Allow the hydraulic system to cool and determine the cause of the high temperature.

During normal operation, this indicator should be OFF. 10. Keyswitch – In a clockwise rotation, these positions are:

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

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 electrical circuits.

START Position – With the key turned fully clockwise, the electric starter energizes, start the engine.

Release the key to the 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. To verify that the seat and restraint bar switches are working properly, after the keyswitch is turned to ON, raise the restraint bar or lift body off the seat. Either action should prevent the engine from cranking with the keyswitch turned to START. 11. Parking Brake Switch – Used to manually apply the parking brake. The red indicator on the switch lights when the parking brake is applied.

12. Light Switch – Controls all the lights on the loader.

Symbols denote the four positions of the light switch. In a clockwise direction these are: OFF Tail Lights ON Front Work Lights with Tail Lights ON both Front and Rear Work Lights For the lights to function, the keyswitch must be in the RUN position.

13. Circuit Breakers – Four circuit breakers on the instrument panel protect the loader’s electrical circuits.

IMPORTANT: Do not attempt to defeat the circuit protection by jumping across a circuit breaker or by using a higher amperage circuit breaker.

14. Accessory Outlet – 12-volt DC power outlet.

NOTES

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ELECTRICAL SYSTEM

Troubleshooting Guide Problem

Possible Cause

Seat belt buzzer indicator not sounding Plugged or obstructed buzzer when keyswitch turned to “ON” indicator lamps work properly.

Faulty buzzer

Electrical system does not function

Engine temperature gauge does not work - Non-DPF Models Only.

Hour meter inoperative - Non-DPF Models Only

Control pad and information center display do not activate with ignition keyswitch in the ON/RUN position

PRINTED IN USA

Replace parking brake module.

Reconnect wires to buzzer.

Battery disconnect switch is in OFF position.

Battery terminals or cables loose or corroded.

Turn battery disconnect switch to the ON position.

Clean battery terminals and cables and retighten.

Test battery. Recharge/replace as necessary.

Correct over-current problem and replace main fuse.

Check harness connectors. Reconnect/ repair as needed.

Repair/replace ignition switch.

Battery malfunction.

ROPS/FOPS wiring harness not properly plugged into chassis harness.

Ignition switch malfunction.

Fuel gauge does not work.

Clean out buzzer.

Buzzer is disconnected

Blown main fuse.

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

Remedy

Circuit breaker tripped

Consult wiring diagram, check circuit and locate trouble before resetting breaker.

Battery terminals or cables loose or corroded

Clean battery terminals and cables and tighten them.

ROPS/FOPS power fuse blown

Consult wiring diagram, check circuit and locate trouble before replacing fuse.

Faulty fuel gauge sender

Replace fuel gauge sender.

Loose wiring/terminal connections

Verify wiring connections.

Faulty fuel gauge

Replace fuel gauge.

Faulty sender

Replace temperature sender.

Loose wiring/terminal connections

Verify wiring connections.

Faulty temperature gauge

Replace temperature gauge.

Loose wiring/terminal connections.

Alternator malfunction.

Check wiring/connections.

Repair/replace alternator.

Replace information center electronic Hour meter malfunction. display.

Blown fuse.

Check circuit and replace fuse.

Clean battery terminals and cables and Battery terminals/cables loose/corroded. tighten.

ROPS/FOPS wiring harness not Check harness connectors. Reconnect/ properly plugged into chassis harness. repair as needed.

Relay malfunction.

Replace relay.

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Troubleshooting Guide Problem

Possible Cause

Remedy

Poor electrical connections in start circuit.

Starter does not engage when ignition keyswitch turned to the START position

Battery will not recharge.

Check connections and repair as necessary.

Clean battery terminals and cables and Battery terminals/cables loose/corroded. tighten.

Starter relay malfunction.

Test relay; replace if necessary.

Test battery. Recharge/replace if Battery discharged/malfunctioning. necessary.

Starter solenoid malfunction.

Repair/replace as necessary.

Starter or pinion malfunctioning.

Check wiring for poor connections, Ignition wiring, seat switch, restraint bar broken leads; repair wiring or switch, etc. loose or disconnected. connection.

Restraint bar raised.

Lower restraint bar.

Engine fault code(s).

Resolve engine fault.

Battery terminals or cables loose or corroded

Clean battery terminals and cables and tighten them. Replace cables as needed.

Battery or alternator defective

Test battery and alternator. Replace as needed.

Work/road lights inoperative

Single light not working— light bulb burned out, faulty wiring.

No lights—blown fuse.

Light switch malfunction, poor ground or other wiring connection.

Check and replace light bulb as needed, check wiring connections.

Check circuit and replace fuse.

Check ground/wire connections, replace light switch.

Lift/Tilt and/or Drive Solenoids do not work.

Wiring to solenoids disconnected or faulty

Refer to wiring diagram, locate trouble and repair as needed.

Faulty seat or restraint bar switch

Replace seat or restrain bar switches as needed.

Faulty solenoid valve coil

Replace solenoid valve coil.

Faulty hydraulic solenoid relay in the fuse box

Test relay, replace as needed.

Battery terminals or cables loose or corroded.

Battery not recharging

Battery malfunction.

Alternator malfunction.

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Clean battery terminals and cables and tighten securely. Replace cables if necessary.

Replace battery.

Check alternator function. Repair/ replace as necessary.

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ELECTRICAL SYSTEM

Electrical Chassis Components - DPF Models

21

14 ECU PROVIDED WITH ENGINE

18 4

ECU MOUNTING

25

6

RELAY PROVIDED WITH ENGINE 23

4

3

12

4

10 8

3 24 1 5 20

3

9 13 MOUNT TO FUEL TANK 15 17

ROPS CONNECTIONS

16

2

ENGINE CONNECTORS TO ALTERNATOR ENGINE OIL PRESSURE 19

HYD TEMP

TO STARTER HORN CONNECTORS

7 28 GROUND BOSS 26 TO ENGINE

TO FOOT THROTTLE

1 2 3 4 5 6 7 8 9 10

STOP/BATTERY TIE/CABLE HLN INST HLN INST LN CS FL LOCK CS FL LOCK SOLENOID LN FL SERR CLAMP/BATTERY

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11 12 13 14 15 16 17 18 19 20

HARNESSS/CHASSIS MOUNT/ELECTRICAL/ASSY MOUNT/FUSE BOX MOUNT/ECU CABLE/BATTERY/POS CABLE/ALTERNATOR CABLE/BATTERY/NEG ISOLATOR/NEOPRENE LEAD WIRE/STARTER CB

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CS FW CB CB CB CS CS STRAP GRND

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Electrical Chassis Components - Non-DPF Models

13

TO CIRCUIT BREAKER #11 RED TO LINE #10 & #10A RED TO LOAD

3

20

30

TO FUEL SENDER

28 22

15 11 24

27

TO FLASHER OPTION TO REAR TAIL/ WORK LIGHTS

13

17

8 NOTE 3

1

12

29 21

13

16

6

31

18

3

TO HORN (OPTION) TO AUTO GLOW MODULE TO GLOW SOLENOID A&B PORT TO GLOW SOLENOID POST ROPS MAIN POWER 14 28

TO TILT SOLENOID

25

7 4 TO ENGINE WATER TEMP TO GLOW PLUGS

TO ALTERNATOR NOTE 2 TO STARTER

19 3

HARNESS GROUND

23 TO ROPS MAIN CONNECTOR

TO PRESSURE PUMP TO FUEL SHUTOFF

TO LOCKOUT LIFT SOL.

26 33

3

10

3 32

3

CHASSIS GROUND

9

14

2 HARNESS GROUND

TO AUX. SOL. LOCK

5

3 NOTE 4 FOR ENGINE GROUND

TO ENGINE OIL

14 3

TO HORN SWITCH TO HYD. TEMP (OPTION) SWITCH TO BRAKE SOLENOID

AUXILIARY POWER

TO BACKUP ALARM (OPTION) NOTE 1

NOTES: 1. COIL AND TIE BACKUP ALARM WIRES IN SAFE LOCATION WHEN NOT IN USE. 2. WIRE TIE ALTERNATOR WIRES TO THE STARTER. WIRES CANNOT CONTACT EXHAUST MANIFOLD OR MUFFLER. 3. APPLY HI-TACK GASKET ADHESIVE.

1 2 3 4 5 6 7 8 9 10 11

124

STOP/BATTERY CABLE/BATTERY TIE/CABLE HLN INST NUT/FLLSUF HLN INST LN FUEL SENDER GASKET CABLE/BATTERY CS FL LOCK NUT/HEX

12 13 14 15 16 17 18 19 20 21 22

SENDER NUT/SPIRALOCK CLAMP/HOSE AUTO GLOW CONTROL SOLENOID RELAY MOUNTING BRKT ASSY COVER/ELECTRICAL NUT/FLRSUF RELAY MOUNT COVER ASSY RELAY/40 AMP/SEALED CLAMP/BATTERY

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CABLE CIRCUIT BREAKER 35AMP BATTERY 12 V HARNESS/CHASSIS CB CB CB HHTFS HJN LW EXT T CS

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ELECTRICAL SYSTEM

Electrical ROPS/FOPS Components - DPF Models 17

35 18

33

6 8

7

25 34

10

30

20

18

35

31

13

14

15

9 11

28

12

23

22 26 19

1 2

2

16

HEADLIGHT 36

21

27

32

37 29

DOME LIGHT

34 3

34

HEADLIGHT

24

MOUNT TO ROPS RESTRAINT BAR MOUNT TO CHASSIS TOWER

SEAT

1 TIE/CABLE 2 CLAMP/HOSE 3 HLN INST 4 CS FL LOCK 5 NUT/SPEED 6 HOUSING/DISPLAY 7 BULB/LAMP 8 GASKET. DISPLAY HOUSING 9 CLAMP/HOSE 10 GAUGE-FUEL LEVEL 11 CONNECTOR,12V POWER PORT 12 COVER,12V POWER PORT 13 LIGHT SWITCH

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14 15 16 17 18 19 20 21 22 23 24 25 26

KNOB/CONTROL SKIRTED LN FL SERR LN FL SERR SWITCH/IGNITION PHIL PAN MOUNT/WIRE SWITCH/BRAKE MOMENTARY MODULE/CONTROL INTERLOCK KNOB/CLAMPING PANEL/INSTRUMENT/ASSY HARNESS/ROPS DISPLAY/PROGRAMMED COVER/ELECTRICAL

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MOUNT/COVER/WLDMNT DECAL/INSTRUMENT PANEL COVER/ELECTRICAL HARNESS THROTTLE/HAND BHSCS BHSCS LW HN SCREW THM SLTD BHSCS HWHTRS

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Electrical ROPS/FOPS Components - Non-DPF Models

24

8

39 14 1

13

2

35 36

11

10

9

21 4

26

35 27

36

19 37

37

5

18

5

17

40 20 38

22

3

34

7 3

28

36

29 6

30

15 16

31

25

3 23

36

32

12 33

29

TO DOME LIGHT OPTION

TO HEADLIGHTS

TO ROPS MAIN POWER TO SEAT BAR SWITCH

TO MAIN CHASSIS CONNECTOR

TO SEAT SWITCH

1 TIE/CABLE 2 CLAMP/HOSE 3 HLN INST 4 CS FL LOCK 5 NUT/SPEED 6 NUT/FLLSUF 7 HLN INST 8 GAUGE/HOURMETER 9 HOUSING/DISPLAY 10 BULB/LAMP 11 GASKET. DISPLAY HOUSING 12 CLAMP/HOSE 13 GAUGE-TEMP (WATER) 14 GAUGE-FUEL LEVEL

126

15 16 17 18 19 20 21 22 23 24 25 26 27 28

CONNECTOR COVER,12V POWER PORT BREAKER/CIRCUIT 15 AMP BREAKER/CIRCUIT 25 AMP LIGHT SWITCH KNOB/CONTROL SKIRTED NUT/FLRSUF STANDOFF RELAY/40 AMP/SEALED SWITCH/IGNITION CIRCUIT BREAKER 8 AMPS MOUNT/WIRE SWITCH/BRAKE MOMENTARY MODULE/CONTROL INTERLOCK

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KNOB/CLAMPING COVER/ELECTRICAL PANEL/INSTRUMENT/ASSEMBLY DECAL/INSTRUMENT PANEL WIRE HARNESS/ROPS MOUNT/COVER ASSY LW HN THMS BHSCS HWHTRS HSP LW

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ELECTRICAL SYSTEM

Power Distribution Module Test and Operation - DPF Models

NOTES

The electrical circuitry of Gehl R105 and Mustang 1050R DPF model skid-steer loaders are protected from overloading and short circuits by a combination of fuses and relays that are contained in the power distribution modules located in the engine and operator’s compartments. The Power Distribution Modules (PDM’s) in the engine compartment are positioned on the right side of the machine besides the fuel tank.

These modules contain fuses and power relays that protect those circuits which utilize live power from the battery. The power relays function to provide keyswitched power to the circuits located in the forward PDM’s in the operator’s compartment. The outer surface of the cover of each PDM bears a decal that identifies the fuses and relays contained in that module.

Engine Area Power Distribution Modules

The PDM located in the operator’s compartment is located behind the steel access cover on the right side of the cab at the operator’s elbow and contains circuitspecific fuses and relays for basic machine functions.

ROPS/FOPS Power Distribution Module

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Power Distribution Module Fuse Test The following procedure can be used to test the fuses found inside the engine and ROPOS/FOPS PDM’s.

4. Engine Modules: The PDM’s in the engine compartment contain fuses that protect the main power relays, engine operation circuits and rear lights.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

Power Relay

1. The ROPS/FOPS PDM contains fuses for the instrument panel functions, headlights and safety interlock functions. A decal on the metal access cover identifies the fuses.

2. ROPS/FOPS Module: Fuses can be checked by removing them and inspecting the internal metal link. If the link is separated, replace the fuse.

ROPS/FOPS Power Distribution Module

Power Relay Power Relays

5. Fuses can be checked by removing them and inspecting the internal metal link. If the link is separated, replace the fuse. Fuses may also be tested using a volt/ohm multimeter and checking for continuity between both fuse prongs.

6. Larger 60 amp fuses: Check for continuity between test points with the circuits turned “OFF”.

3. Fuses may also be tested using a volt/ohm multimeter and checking for continuity between both fuse prongs.

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Power Distribution Module Relay Test There are two power relays inside the engine compartment PDM’s that supply power to the fuses for individual circuits. The cover identifies the relays.

Relays #86

There are several other relays in the ROPS/FOPS and engine compartment PDM’s that supply power for other circuits. The covers have a decal or is information is etched into the cover to identify the relays.

Machine Test: The relays can be tested in the machine as follows:

#87

#87a

#30

#85

1. With an operator in the seat and the restraint bar lowered, turning the keyswitch to the “ON” position should produce an audible “click” from each relay closing.

2. While the keyswitch is in the “ON” position, test each relay individually, pull one relay out of the panel at a time, listening for the audible “click” of the relay opening.

4-prong relay space

3. Plug the relay back into the panel and listen for the audible “click” of the relay re-closing, if the circuit is activated.

4. Replace any relay for which there is no discernible “clicking” sound heard at keyed power or opening (removing) of the relay.

• The solenoid lock relay and start safety relay will actuate only with the keyswitch in the “ON” position, the restraint bar down and an assistant in the seat.

5. Replace any relay that does not have continuity between powered terminals #85 and #86.

Bench Test: The relays can also be tested on a work bench as follows:

1. A relay may be tested by removing it and taking it to a work bench. Apply a ground to terminal #85 and a 12 V source to terminal #86. The relay should actuate. There should be continuity between terminal #30 and terminal #87.

2. Replace any relay that does not have continuity between powered terminals.

Power Relays

#86 #30

#87 #85

PRINTED IN USA

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ELECTRICAL SYSTEM

GEHL R105 / MUSTANG 1050R

Solenoid Test - Both DPF and Non-DPF Models The following procedure can be used to test the engine starter and glow solenoids. They are located in the engine compartment on a panel on the right chassis riser. The bottom solenoid is used for the engine starter and the top solenoid is used for the engine glow circuit.

• With keyswitch in “OFF” position, there should be 12 VDC only on the top left large copper stud of each solenoid.

3. The top solenoid, the engine glow circuit will engage for a time, dependent on what the ambient temperature is. For DPF model loaders, the engine’s ECU provides the control current for the solenoid: • With keyswitch in “OFF” position, there should be 12 VDC only on top left large copper stud of the solenoid.

• Unplug the control current connector and install a test lamp between #85 and #86 in the connector.

Have a second operator turn the keyswitch to “ON” position, the test lamp should light if ambient temperature is low enough.

4. For the engine starter solenoid: • With keyswitch in “OFF” position, there should be 12 VDC only on top left large copper stud of the solenoid.

• The external starter solenoid will engine when the keyswitch output calls for START.

#86

• Unplug the control current connector and install a test lamp between #85 and #86 in the connector. Have an second operator turn the keyswitch to crank and the test lamp should light.

#85

Live Power

Load

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine.

■ Raise engine cover, lock open the rear grille.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove two protective electrical covers from the solenoids.

2. Using a volt/ohm multimeter or test lamp, confirm the following condition with the wiring connected.

130

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GEHL R105 / MUSTANG 1050R

ELECTRICAL SYSTEM

Relay Test and Operation - Non-DPF Models Gehl R105 and Mustang 1050R Non-DPF model skidsteer loaders utilize relays in the electrical system to maximize the efficiency of engine, hydraulic, power and electrical operations. Following in this section are test and operation procedures.

Relay Test The following procedure can be used to the test relays located behind a metal cover in the cab at the operator’s right elbow.

Non-DPF Relays

1. There should be 12-VDC on terminal #87 (#2 red wire from battery supply) at all times. Pushing horn button on left control handle should provide 12-VDC to terminal #86 and produce an audible “click” from relay. There should be 12-VDC on terminal #30 while horn button is pressed.

2. Relay coil test: Using a volt/ohm multimeter with all wires disconnected, measure the resistance across terminals #85 and #86. There should be 75 ohms ± 5 ohms. There should be no continuity between terminals #30 and #87.

87

87a 85

86

30

PRINTED IN USA

Relay Terminals

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ELECTRICAL SYSTEM

GEHL R105 / MUSTANG 1050R

Interlock Control Module Test The following procedure can be used to test the interlock control module located inside the ROPS/ FOPS, behind the right metal access panel, near the operator’s right elbow.

2. Put an operator in the seat with the restraint bar down.

3. Most module troubleshooting can be done by observing green diagnostic LED indicators.

•

Disconnect 12-pin and 6-pin connectors and inspect terminals. Be sure no pins are bent on module and no sockets are damaged on harness.

Replace damaged components and reconnect harness to control module.

4. Refer to truth table to analyze functionality of module. The module controls operation of components listed in OUTPUTS section of truth table.

The ON or OFF state of various outputs is determined by ON or OFF state of various input conditions listed in INPUTS section of truth table. The keyswitch must be in “ON” position.

• Example 1 (initial keyswitch “ON”): At initial keyswitch ON, input LED “12-VDC In” should light and internal seat belt alarm should sound for five seconds.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure:

5. The truth table section “Diagnostic LED States” specifies active (ON) state of each input and output.

■ Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

• Example: Active (ON) state of engine oil pressure switch input (connector #1, pin #8) is a low or grounded input. Active state of seat switch input (connector #1, pin #3) is a high or 12VDC input.

1. Remove two knobs securing the right metal access panel to the right ROPS/FOPS panel.

Interlock Control Module Illustration GREEN LED DIAGNOSTIC INDICATORS (15)

OUTPUT PIN DESCRIPTIONS:

+12VDC BRAKE SOL NOT USED START RELAY HYD RELAY SEAT BELT LT PARK BRAKE LT CRANK SIGNAL RESTRAINT BAR SW DOOR SW SEAT SW PARK BRAKE SW HYD TEMP SW NOT USED IGN VOLT SENSE

1. BLUE - PARK BRAKE SOLENOID, (5 AMP MAX CONTINUOUS) 2. YELLOW - HYD RELAY, (3 AMP MAX CONTINUOUS) 3. BROWN - SEAT BELT LIGHT, (2 AMP MAX CONTINUOUS) 4. GREEN - PARK BRAKE LIGHT, (2 AMP MAX CONTINUOUS) 5. NOT USED 6. PINK - START RELAY, (3 AMP MAX CONTINUOUS) MATING CONNECTOR: DEUTSCH PNB DT06-06S

ALARM BUZZER OUTPUT CONNECTOR 6 PIN DEUTSCH DT15-06

132

INPUT PIN DESCRIPTIONS: 1. RED - KEYED POWER 2. BLACK - GROUND 3. WHITE - SEAT SWITCH 4. GREEN - RESTRAINT BAR SWITCH 5. PURPLE - PARK BRAKE SWITCH 6. GRAY - HYD TEMP SWITCH 7. ORANGE - ENG TEMP SWITCH 8. GRAY - IGN VOLT SENSE 9. WHITE - DOOR SWITCH 10. RED - CRANK SIGNAL 11. NOT USED 12. NOT USED MATING CONNECTOR: DEUTSCH PNB DT06-12S

INPUT CONNECTOR 12 PIN DEUTSCH DT15-12PA

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GEHL R105 / MUSTANG 1050R

ELECTRICAL SYSTEM

Interlock Control Module Truth Table

PRINTED IN USA

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ELECTRICAL SYSTEM

GEHL R105 / MUSTANG 1050R

Seats - Standard and Suspension

2

Standard Seat

1 2 3 4 5

NUT/HEX WHIZLOCK SEAT BRACKET/SEAT BELT SCREW/CAP WASHER/FLAT

3

5

4 1

5

1

1

4

1

2

Suspension Seat

1 1

1 1

134

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GEHL R105 / MUSTANG 1050R

ELECTRICAL SYSTEM

Restraint Bar Components

11 14 4 8 18 9 15 7

16 17

6 1 13 2 5

1 2 3 4 5 6 7 8 9

BOLT/SHOULDER BUSHING/OILITE NUT/SERRATED LOCK NUT/LOCK STUD/BALL GAS SPRING/SEAT BAR BAR/RESTRAINT SWITCH/PROXIMITY MAGNET/SWITCH ACTUATOR

PRINTED IN USA

10 11 12 13 14 15 16 17 18

10

12

3

SCREW/PHILLIPS PAN COVER/PIVOT STOP/RESTRAINT BAR WASHER/SPECIAL CLIP/CHRISTMAS TREE WASHER/FLAT NUT/HEX MACHINE SCREW WASHER/LOCK STAR SCREW/MACHINE

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ELECTRICAL SYSTEM

GEHL R105 / MUSTANG 1050R

Seat Switch Removal and Installation Removal Procedure

Restraint Bar Switch Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove seat per the procedure found in the Mainframe chapter. Turn the seat over.

2. Remove the two Phillips-head screws and nuts securing the seat switch to the seat. Press the three tabs to separate the dome from the base. Press the two tabs to remove the switch from the base.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Remove the restraint bar assembly per the procedure in the Mainframe chapter.

2. Remove the two machine screws, washers and hex nuts that secure the restraint bar switches to the restraint bar and restrain bar mount.

Seat Switch

Restraint Bar Actuator Switches

3. Remove the switches from the bracket assembly.

WARNING DO NOT attempt to operate the loader without the seat switch installed.

Installation Procedure - Follow all warnings first, then reverse the removal steps*. * Install seat on loader per the procedure in the Mainframe chapter.

WARNING DO NOT attempt to operate loader without the restraint bar switch installed.

Installation Procedure - Follow all warnings first, then reverse the removal steps*. * Adjust position of restraint bar switch and actuator switch so they are aligned with each other when restraint bar is down against the rubber stops. * Install the restraint bar according to the procedure in the Mainframe chapter.

136

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GEHL R105 / MUSTANG 1050R

ELECTRICAL SYSTEM

Electrical Lights Components

7

7 8

9

4 5

9

8

5 2 6

1 2 3 4 5 6

TIE/WIRE CLAMP/INSULATED HOSE NUT/LOCK CLIP/SINGLE CLIP/DOUBLE HARNESS/REAR LIGHT

PRINTED IN USA

3

2 3

3

2

2 3

4

7 GROMMET 8 LIGHT/RED 9 LIGHT/WORK 10 LOCK/SECONDARY 11 HOUSING/CONNECTOR FEMALE 12 HEADLIGHT

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ELECTRICAL SYSTEM

GEHL R105 / MUSTANG 1050R

Front and Rear Work Light Bulb Replacement Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine.

■ Raise engine cover; lock open the rear grille.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Front Work Light Only: Loosen the work light mount screw and turn the light down. Detach the electrical connector.

3. Front Work Light Only: Twist the lamp base counterclockwise and remove bulb. If needed, replace bulb with the same wattage rate H3 bulb as GE862.

2. Rear Work Lamps/Lights: Release the bulb retaining clip and remove the bulb.

Clip

IMPORTANT Halogen bulbs SHOULD NOT be touched with bare fingers; they can fail prematurely. Wear clean gloves or use a clean rag if you must handle the halogen bulbs.

4. Replace the used bulb with a new 55 W H3 bulb (if a white work light), or a new 35 W H3 bulb (for red warning light).

Installation Procedure - Follow all warnings first, then reverse the removal steps.

138

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ELECTRICAL SYSTEM

Diesel Particulate Filter (DPF) Regeneration Procedures - DPF Models

Dome Light Bulb Replacement Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Climb into the cab and find dome light assembly on the left front stanchion of the cab.

2. Find the notches and pop the dome light lens cover out of the recessed base with a flat-tipped screwdriver.

The Diesel Particulate Filter (DPF) treats exhaust emissions in compliance with Tier 4 / Stage 3B emission standards. The DPF filter relies on high exhaust temperatures. Periodic DPF maintenance (regeneration) is required, dependent upon machine operation load / temperature.

Note: Machines operated primarily at high loads and operating temperatures require less frequent DPF maintenance. Extended periods of engine idling rapidly increases DPF soot levels, requiring more frequent regeneration operations.

There are three modes of DPF regeneration: • Passive / Assist Regeneration: Occurs automatically without operator input. Passive/assist regeneration does not affect machine operation.

• Reset Regeneration: Occurs automatically, but can be inhibited by the operator. Increases exhaust gas temperatures. Reset regeneration occurs approximately every 100 hours of operation.

Note: Reset regeneration effectiveness is improved if the machine is operated at mid- to high-throttle settings when reset regeneration mode is in progress.

• Stationary Regeneration: Requires operator action to initiate and takes approximately 25-30 minutes to complete.

3. Replace the used bulb with a new GE168 bulb.

Important: The machine cannot be operated and must be parked in a well-ventilated area away from flammable materials when stationary regeneration is in progress.

There is a possibility of carbon monoxide poisoning if stationary regeneration occurs in an enclosed space. Always perform stationary regeneration in a well-ventilated area.

WARNING

During regeneration, there will be high exhaust gas temperatures, even at low load. Stay clear of the DPF during regeneration.

WARNING

PRINTED IN USA

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139

ELECTRICAL SYSTEM

GEHL R105 / MUSTANG 1050R

Reset Regeneration

Stationary Regeneration

Important: Reset regeneration can be prevented from occurring.

Reset regeneration occurs automatically (unless inhibited) approximately every 100 hours of operation.

Stationary regeneration may be periodically required to reduce DPF soot build-up. The frequency of stationary regeneration is dependent upon machine operation and engine load.

Note: Reset regeneration effectiveness is improved if the machine is operated at mid- to high-throttle settings while regeneration is in progress.

The machine cannot be used during stationary regeneration and cannot be moved without interrupting the stationary regeneration process.

When reset regeneration occurs, the DPF in-progress (elevated temperature) symbol (K) displays on the screen.

When stationary regeneration needs to be performed, the regeneration request screen displays on the information center electronic display.

K

C

n/min

1234.5 Reset Regeneration Inhibit DPF regeneration inhibit prevents reset regeneration from occurring.

Permanently inhibiting regeneration is not recommended, as this will eventually cause significant reduction in engine power and will force premature DPF soot filter replacement.

CAUTION

To temporarily inhibit reset regeneration, hold down button (U) until the strikethrough in the Reset Regeneration symbol (W) turns to red.

U

W

Note: The stationary regeneration request screen can be temporarily dismissed by pressing the reset regeneration inhibit button (U) for three seconds. Until the previous screen displays. The stationary regeneration request screen will return 1 minute after being 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 regeneration for extended periods will cause significant reduction in engine power and will force premature DPF filter core replacement.

To proceed with stationary regeneration: 1. Park the machine in a safe, well-ventilated location away from flammable materials.

2. The following conditions need to be met before stationary regeneration continues: A. Press the button on the control keypad or lift the operator restraint bar to apply the parking brake. A checkmark is displayed next to the parking brake symbol (A).

ok

Note: DPF in-progress (elevated temperature) symbol (K) will not be displayed when reset regeneration is inhibited.

140

B. When engine coolant has reached operating temperature (above 140° F / 60° C, a checkmark is displayed next to the coolant temperature symbol (B).

50950298/AP0517

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GEHL R105 / MUSTANG 1050R

ELECTRICAL SYSTEM

C. Place throttle controls to the lowest speed setting. A checkmark is displayed next to the engine RPM symbol when the engine is running at low idle.

Forcing Stationary Regeneration

A

Stationary regeneration can be performed at any time after 50 operating hours following the previous stationary regeneration.

B

To perform stationary regeneration on-demand:

C

Press button (Y) associated with the DPF regeneration symbol (X), until the regeneration screen displays.

n/min

X

ok

Z

Y

3. When all three checkmarks (A, B & C) are displayed on the Stationary Regeneration screen, press and hold the button (Z) until the Stationary Regeneration In-Progress screen displays.

ok

DPF Maintenance DPF soot filter replacement is required when the DPF (Diesel Particulate Filter) Service Screen displays.

22 %

Note: Stationary regeneration can be interrupted at any time by releasing the parking brake, advancing the throttle, or stopping the engine. Stationary regeneration must start again from the beginning if it is interrupted.

Note: Contact your dealer when the DPF Service screen displays.

Stationary regeneration completion percentage is displayed as during the stationary regeneration progresses. Progress percentage disappears when stationary regeneration completes.

Note: Stationary regeneration takes approximately 2530 minutes.

It is not necessary to stay in the machine during stationary regeneration. Keep the machine under observation while regeneration is in progress in case of malfunction.

Keep bystanders away from the machine while regeneration is in progress.

CAUTION

PRINTED IN USA

50950298/AP0517

141

142

21 GRN-18

A

00BE BLK-06

166 BLU-18 167 ORG-16 167A ORG-16 00AK BLK-16 PLUG PLUG

80C YEL-16 49C GRN-16

80B YEL-16 49B GRN-16

80A YEL-14 00AY BLK-14

42B GRN-16 146 PNK-16 49 GRN-16 00AC BLK-14

36B BLU-16 00AD BLK-16

40 GRY-16

10A RED-12 10B RED-12 00AA BLK-10

1

1 2 3 4 5 6

1 2

1 2

1 2

A B C D

1 2

1

A B C

72

CHASSIS GROUND

EGR RELAY

BACKUP ALARM SWITCH

BACKUP ALARM SWITCH

REAR ACC

REAR DOOR

34

BRAKE SOLENOID

HYD TEMP SWITCH

26B

CAB POWER

35

33

32

31

30

29

56

50950298/AP0517

35C BLU-18 00AF BLK-18

35D BLU-18 00AG BLK-18

1 2

1 2

AUX LOCK SOL

TILT LOCK SOL

LIFT LOCK SOL

PRINTED IN USA

1 2

FOOT THROTTLE

47

60

120 RESISTOR

TAIL LIGHTS

EGR RELAY

ECU POWER

63 02A RED-08 64 81A RED-08 PLUG 65 PLUG 66 PLUG 67 PLUG 68 PLUG 69 PLUG 70 19 02C RED-14 20 12 RED-14 21 02D RED-14 22 94 RED-14 23 02E RED-16 24 167 ORG-16 13 13A RED-16

242B RED-16 14B PUR-16

267 RED-18 268 WHT-18 109 BLK-18

1 2 3

FUEL SENDER

46

25 BRN-16 00AI BLK-16

78 GRY-16 00AH BLK-16

1 2

45

IGNITION PWR

GLOW RELAY

44

FEED PUMP

1 2

81 RED-10

14A PUR-18

1

42

GLOW PLUG

ENGINE OIL

43 PRESSURE SWITCH

1

6 ORG-16 8 YEL-16

1 2

HORN BUTTON

41

6 ORG-16 00AJ BLK-16

1 2

HORN

40

39

38

35B BLU-18 00AE BLK-18

1 2

37

141 PNK-14

1

FLASHER

36

CHASSIS CONNECTOR

25B

82 WHT-10

1

RELAY TO START SOL

A 12 RED-14 B 9318L BLK C 9318H RED D 9318SHLD E 05 RED-16 F 25 BRN-16 G 215A PNK-16 H 242 RED-16 J 16 PNK-18 K 14 PUR-16 L 31 ORG-18 M 04 BLU-18 34 YEL-16 N PLUG O P 40 GRY-16 Q 71 BLK-18 R 69 WHT-18 S 70 RED-18 29 YEL-16 T 36 BLU-14 U V 42 GRN-16 W 141 PNK-14 X 20 BRN-18

82A WHT-08

1

POWER TO START RELAY

55

B

54

START RELAY SOL

92 PUR-18

81 RED-10

RELAY TO GLOW PLUGS

53

1

97 PNK-18

B

81A RED-08

00AL BLK-18

00BD BLK-12

A

1

POWER TO GLOW RELAY 1

52

GLOW RELAY SOL

51

73

ECU GROUND

00AL BLK-18 00AE BLK-18 00AG BLK-18 00AM BLK-16 00AN BLK-16 00AU BLK-16

239A DBL-16 239B DBL-16

238A YEL-16 238B YEL-16

00AK BLK-16 00AC BLK-16 00AF BLK-18 00AJ BLK-16 00AI BLK-16

00AA BLK-10 00BE BLK-06

35B BLU-18 35C BLU-18 35D BLU-18

36B BLU-16 36 BLU-14 36A BLU-16

34 YEL-16

14 PUR-16 14B PUR-16

05 RED-16 05B RED-16 05C RED-16

10A RED-12 10B RED-12 10 RED-8

242 RED-16 242B RED-16

80C YEL-16 80B YEL-16 80A YEL-14 49C GRN-16 49B GRN-16 49 GRN-16

94 RED-14

00BD BLK-12

SPL 6

SPL 5

SPL 4

SPL 3

SPL 2

05A RED-16

242A RED-16

80 YEL-14 98 BRN-16

94A RED-14 94B RED-14 94C RED-14

00AV BLK-14 00AW BLK-14 00AX BLK-14

SPL 17 00AB BLK-14 00BC BLK-12

176A BLK-20 176C BLK-20 176B BLK-20

00BA BLK-12

00BC BLK-12 00BB BLK-12 00BA BLK-12

35A BLU-14

00BB BLK-12 00AQ BLK-20 00AP BLK-16 00AR BLK-16 00AS BLK-16 SPL 16

SPL 20 239 DBL-16

SPL 21 238 YEL-16

SPL 15

SPL 10

SPL 9

34A YEL-18 34B YEL-16

14C PUR-16 SPL 7 14A PUR-18

SPL 14

SPL 8

SPL 1

SPL 18

SPL 19

00AY BLK-14 00AD BLK-16 00AH BLK-16 00AZ BLK-16

176 BLK-20

1 2

PLUG 1 PLUG 2 PLUG 3 238 YEL-16 4 5 239 DBL-16 PLUG 6 228 RED-20 7 235 RED/WHT-20 8 PLUG 9 PLUG 10 227 PNK-20 11 223 DGN-20 12 PLUG 13 PLUG 14 PLUG 15 241C RED-16 16 241B DGN-16 17 241A BLK-16 18 225 YEL-16 19 226 DBL-16 20 PLUG 21 PLUG 22 PLUG 23 PLUG 24 232 BLK-20 25 231 DGN-20 26 PLUG 27 102 ORG-20 28 224 BLK-20 29 PLUG 30 PLUG 31 PLUG 32 236C YEL-16 33 PLUG 34 PLUG 35 PLUG 36 37 240 DBL-20 38 9320 SHLD 39 9320 BLK PLUG 40 PLUG 41 PLUG 42 PLUG 43 PLUG 44 PLUG 45

94A RED-14 1 00AV BLK-14 2 94B RED-14 3 00AW BLK-14 4 94C RED-14 5 00AX BLK-14 6 PLUG 7 PLUG 8 PLUG 9 PLUG 10 PLUG 11 PLUG 12 PLUG 13 PLUG 14 14C PUR-16 15 PLUG 16 PLUG 17 PLUG 18 PLUG 19 222 DGN-20 20 196 BLK-20 21 PLUG 22 219 RED-20 23 174 RED-20 24 PLUG 25 PLUG 26 PLUG 27 92 PUR-18 28 PLUG 29 PLUG 30 PLUG 31 PLUG 32 263 WHT-20 33 PLUG 34 20 BRN-18 35 PLUG 36 PLUG 37 PLUG 38 159 WHT-20 39 PLUG 40 PLUG 41 PLUG 42 70 RED-18 43 267 RED-18 44 173 RED-20 45 PLUG 46 PLUG 47 PLUG 48 31 ORG-18 49 04 BLU-18 50 PLUG 51 220 BLK-20 52 9318L BLK 53 168 PUR-20 54 109 BLK-18 55 172 YEL-20 56 PLUG 57 268 WHT-18 58 PLUG 59 PLUG 60 61 71 BLK-18 69 WHT-18 62 175 DBL-20 63 PLUG 64 9318 SHLD 65 34A YEL-18 66 PLUG 67 166 BLU-18 68 PLUG 69 70 97 PNK-18 PLUG 71 PLUG 72 73 21 GRN-18 74 178 BLK-20 9318H RED 75 197 GRY-20 76 176 BLK-20 77 PLUG 78 179 PNK-20 79 170 BRN-20 80 171 RED/WHT-20 81 PLUG 82 PLUG 83 PLUG 84 165 YEL-20 85 247 GRY-20 86 PLUG 87 05A RED-16 88 PLUG 89 PLUG 90 PLUG 91 92 16 PNK-18 PLUG 93 PLUG 94

00AB BLK-14 1

170 BRN-20 176B BLK-20

71

48

ECU

ECU CASE GROUND

65

DPF TEMP (MID)

66

DPF TEMP (INLET)

1 2 67 3 4 DPF PRESSURE SENSOR 5 6

171 RED/WHT-20 1 176C BLK-20 2

PLUG 176A BLK-20 174 RED-20 223 DGN-20 175 DBL-20 PLUG

ELECTRICAL SYSTEM GEHL R105 / MUSTANG 1050R

Chassis Electrical Schematic - DPF Models (schematic overlaps onto following page)

50

FUSE/RELAY BOX 2

49

FUSE/RELAY BOX 1

60

ROPS POWER RELAY

ROPS POWER

HYD LOCK RELAY

60

REGEN INTERLOCK

HORN

REAR AUX

HYD LOCK

FUEL PUMP

START RELAY

CHASSIS POWER RELAY

60

TAIL LIGHTS

REAR LIGHTS

TAIL LIGHTS

EGR RELAY

ECU POWER

CHASSIS POWER

REAR LIGHTS

60

IGNITION PWR

GLOW RELAY

47

50950298/AP0517

02A RED-08 81A RED-08 PLUG PLUG PLUG PLUG PLUG PLUG 02C RED-14 12 RED-14 02D RED-14 94 RED-14 02E RED-16 167 ORG-16 13A RED-16 146A PNK-16 13B RED-16 42A GRN-16 PLUG PLUG 215A PNK-16 146 PNK-16 PLUG PLUG 42 GRN-16 42B GRN-16 146A PNK-16 00AM BLK-16 PLUG PLUG 42A GRN-16 00AN BLK-16 01A RED-08 01C RED-08 PLUG PLUG 01C RED-08 13 RED-08 00AU BLK-16 05B RED-16

02B RED-08 82A WHT-08 PLUG PLUG PLUG PLUG PLUG PLUG 13C RED-16 78 GRY-16 13D RED-14 35 BLU-14 13E RED-14 80 YEL-14 13F RED-16 8 YEL-16 PLUG PLUG PLUG PLUG PLUG 36A BLU-16 247 GRY-20 PLUG 29 YEL-16 35A BLU-14 PLUG 00AQ BLK-20 PLUG 00AP BLK-16 35 BLU-14 00AR BLK-16 01B RED-08 01D RED-08 PLUG PLUG 01D RED-08 10 RED-8 00AS BLK-16 05C RED-16

63 64 65 66 67 68 69 70 19 20 21 22 23 24 13 14 15 16 17 18 7 8 9 10 11 12 1 2 3 4 5 6 71 72 77 78 76 73 74 75

63 64 65 66 67 68 69 70 19 20 21 22 23 24 13 14 15 16 17 18 7 8 9 10 11 12 1 2 3 4 5 6 71 72 77 78 76 73 74 75

-

242B RED-16 14B PUR-16

1 2

BATTERY

70

1

1

+

BATTERY POWER

02 RED-06

PRINTED IN USA 01 RED-06

120 RESISTOR

59

BATTERY POWER

01A RED-08 01B RED-08 01 RED-06

02A RED-08 02C RED-14 02D RED-14 02E RED-16 02B RED-08 02 RED-06

13A RED-16 13B RED-16 13 RED-08 13C RED-16 13D RED-14 13E RED-14 13F RED-16

00AL BLK-18 00AE BLK-18 00AG BLK-18 00AM BLK-16 00AN BLK-16 00AU BLK-16

239A DBL-16 239B DBL-16

S B

SPL 13

SPL 12

SPL 11

00BB BLK-12 00AQ BLK-20 00AP BLK-16 00AR BLK-16 00AS BLK-16 SPL 16

SPL 20 239 DBL-16

1

82 WHT-10 RELAY TO STARTER

60

98 BRN-16 34B YEL-16 1 2

2

1

57

ALTERNATOR

IG

L

B+

ALTERNATOR

173 RED-20 165 YEL-20 159 WHT-20 178 BLK-20 179 PNK-20 196 BLK-20 102 ORG-20 224 BLK-20

1 2 3 4 5 6 7 8

167A ORG-16 1 168 PUR-20 2 3 197 GRY-20 00AZ BLK-16 4 219 RED-20 5 222 DGN-20 6 220 BLK-20 7 225 YEL-16 8 226 DBL-16 9 264 YEL 20 10 263 WHT-20 11 PLUG 12

228 RED-20 1 231 DGN-20 2 232 BLK-20 3 235 RED/WHT-20 4 240 DBL-20 5 237 BLK-20 6 7 9320 BLK 8 9320 RED 9320 SHLD 9 172 YEL-20 10 227 PNK-20 11 230 BLK-20 12

PLUG 1 PLUG 2 236A YEL-16 3 241A BLK-16 4 236B YEL-16 5 241B DGN-16 6 236C YEL-16 7 241C RED-16 8 238A YEL-16 9 238B YEL-16 10 239A DBL-16 11 239B DBL-16 12

232 BLK-20 25 231 DGN-20 26 PLUG 27 102 ORG-20 28 224 BLK-20 29 PLUG 30 PLUG 31 PLUG 32 236C YEL-16 33 PLUG 34 PLUG 35 PLUG 36 37 240 DBL-20 38 9320 SHLD 39 9320 BLK PLUG 40 PLUG 41 PLUG 42 PLUG 43 PLUG 44 PLUG 45 PLUG 46 236B YEL-16 47 236A YEL-16 48 PLUG 49 242A RED-16 50 230 BLK-20 51 237 BLK-20 52 PLUG 53 54 9320 RED PLUG 55 PLUG 56 PLUG 57 PLUG 58 264 YEL-20 59 PLUG 60

61

INTERMEDIATE CONNECTION E

62

INTERMEDIATE CONNECTION F

63

INTERMEDIATE CONNECTION G

64

INTERMEDIATE CONNECTION H

GEHL R105 / MUSTANG 1050R ELECTRICAL SYSTEM

Chassis Electrical Schematic - DPF Models

143

144

50950298/AP0517

2

3

1

PRINTED IN USA

FUSE/RELAY BOX

27

VIEW FROM SWITCH SIDE

1

6

ROPS HARNESS

5

4

VIEW FROM GAUGE SIDE

1

FUEL GAUGE

3

6

30 PUR-16 89A RED-16 PLUG PLUG PLUG PLUG 37 GRN-16 89B RED-16

71 BLK-18 69 WHT-18 70 RED-18 PLUG PLUG PLUG

1 2 3 4 5 6 7 8

A B C D E F

9

PARK BRAKE 12V ACC DOME LIGHT INTERLCOK

LCD DISPLAY CONTROLS HEADLIGHTS ROPS ACC

B

A

12 VOLT ACC

16

15

LIGHTS

HAND THROTTLE

14

PARK BRAKE

13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

A B

1 2 3 4 5 6

15 BRN-16 242H RED-16

1 2

SEAT BELT LAMP

242F RED-16 34 YEL-16

1 2

12

BATTERY LAMP

10A RED-18 10B RED-14 10C RED-16 10D RED-14 276 RED-18 11 RED-14 143D BRN-16 63 RED-14 10E RED-16 10F RED-14 10G RED-16 10H RED-16 89 RED-16 56 RED-14 84 RED-16 54 RED-14 PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG

00P BLK-14 56 RED-14

141 PNK-14 215 PNK-16 11A RED-14 42 GRN-16 PLUG 11B RED-16

242E RED-18 04 BLU-18

1 2

11

GLOW PLUG LAMP

242D RED-18 40A GRY-18

1 2

10

HYD TEMP LAMP

COOLANT LAMP

ENIGNE OIL LAMP

242C RED-18 31 ORG-18

242B RED-16 14 PUR-16

1 2

ENGINE MALF. LAMP

1 2

242A RED-18 16 PNK-18

1 2

5

ROPS AUX

7

00I BLK-14 63 RED-14

A B

FUEL GAUGE LAMP

17

143C BRN-16 00G BLK-16

00E BLK-16 25 BRN-16 11C RED-16

12A RED-16 12B RED-16 05 RED-16 20C BRN-16

A B C D

1 2 3

EVC073-BRN EVC073-WHT EVC073-BLU EVC073-BLK EVC073-GRY

1 2 3 4 5

1 2

4

3

2

IGNITION SWITCH

2

LCD DISPLAY

00I BLK-14 00J BLK-16 00K BLK-16 00L BLK-16

10A RED-18 10B RED-14 10C RED-16 10D RED-14 10E RED-16 10F RED-14 10G RED-16 10H RED-16

54 RED-14

11C RED-16 11A RED-14 11B RED-16 11 RED-14

SPL 15

SPL 5

SPL 10

SPL 16

20A BRN-16 20B BRN-16

SPL 14

SPL 13

SPL 4

SPL 12

SPL 6

SPL 7

SPL 19

SPL 18

SPL 3

SPL 1

SPL 9

SPL 11

SPL 8

SPL 17

SPL 2

89A RED-16 89B RED-16 89 RED-16

40A GRY-18

00D BLK-14 00E BLK-16 00G BLK-16 00P BLK-14

EVC073-BLU 00D BLK-14

242A RED-18 242B RED-16 242C RED-18 242D RED-18 242E RED-18 242F RED-16 242H RED-16

CBL3 9318SHLD CBL2 9318SHLD

CBL2 9318H RED CBL3 9318H RED CBL3 9318L BLK CBL2 9318L BLK

EVC073-BLK CBL3 9318H RED CBL3 9318L BLK EVC073-GRY

12A RED-16 12B RED-16

143C BRN-16 143 BRN-16

EVC073-WHT 276 RED-18

00H BLK-12 00 BLK-10 00M BLK-20 00N BLK-16

10 RED-08

54D RED-16 54A RED-16 54B RED-14 54C RED-16 54E RED-16

20 BRN-16

40 GRY-16 40B GRY-16

00H BLK-12

00C BLK-16 00A BLK-16 00B BLK-16 00T BLK-16

10A RED-12 10B RED-12 10 RED-08

242 RED-16 242G RED-20

CBL1 9318SHLD

CBL1 9318L BLK

CBL1 9318H RED

160A RED-18 161A BLK-18

12 RED-14

143A BRN-16 143B BRN-16

160A RED-18 161A BLK-18

242G RED-20 CBL2 9318H RED CBL2 9318L BLK 00M BLK-20 PLUG PLUG

36 BLU-14 29 YEL-16 15 BRN-16 37 GRN-16 PLUG 33 PNK-16

54D RED-16 00N BLK-16 100 WHT-14 17 GRN-16 30 PUR-16 40B GRY-16 PLUG 54E RED-16 52 WHT-16 273 GRY-16 PLUG PLUG

12 RED-14 CBL1 9318L BLK CBL1 9318H RED 9318SHLD 05 RED-16 25 BRN-16 215A PNK-16 242 RED-16 16 PNK-18 14 PUR-16 31 ORG-18 04 BLU-18 34 YEL-16 PLUG 40 GRY-16 71 BLK-18 69 WHT-18 70 RED-18 29 YEL-16 36 BLU-14 42 GRN-16 141 PNK-14 20 BRN-16

10A RED-12 10B RED-12 00 BLK-10

17 GRN-16 54C RED-16

100 WHT-14 54B RED-14

54A RED-16 52 WHT-16 00T BLK-16 PLUG

84 RED-16 00B BLK-16

143B BRN-16 00A BLK-16

143A BRN-16 00C BLK-16

1 2

1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12

A B C D E F G H J K L M N O P Q R S T U V W X

A B C

1 2

A B

1 2 3 4

1 2

1 2

1 2

18

80 TERMINATING RESISTOR

YDT

28

24B

INTERLOCK OUTPUTS

24A

INTERLOCK INPUTS

25A

CHASSIS CONNECTOR

CAB POWER

26A

RESTRAINT BAR SWITCH

23

SEAT SWITCH

22

DOOR SENSOR

21

DOME LIGHT

20

LH HEAD LIGHT

19

RH HEAD LIGHT

ELECTRICAL SYSTEM GEHL R105 / MUSTANG 1050R

ROPS/FOPS Electrical Schematic - DPF Models (schematic overlaps onto following page)

PRINTED IN USA

2

3

1

50950298/AP0517

SAFE START RELAY

CRANK SIGNAL RELAY

HEADLIGHTS

FUSE/RELAY BOX

27

VIEW FROM SWITCH SIDE

1

6

ROPS HARNESS

5

4

VIEW FROM GAUGE SIDE

3

6

30 PUR-16 89A RED-16 PLUG PLUG PLUG PLUG 37 GRN-16 89B RED-16

71 BLK-18 69 WHT-18 70 RED-18 PLUG PLUG PLUG

1 2 3 4 5 6 7 8

A B C D E F

9

PARK BRAKE 12V ACC DOME LIGHT INTERLCOK

LCD DISPLAY CONTROLS HEADLIGHTS ROPS ACC

B

A

12 VOLT ACC

16

15

LIGHTS

HAND THROTTLE

14

PARK BRAKE

13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

A B

1 2 3 4 5 6

15 BRN-16 242H RED-16

1 2

SEAT BELT LAMP

242F RED-16 34 YEL-16

1 2

12

BATTERY LAMP

10A RED-18 10B RED-14 10C RED-16 10D RED-14 276 RED-18 11 RED-14 143D BRN-16 63 RED-14 10E RED-16 10F RED-14 10G RED-16 10H RED-16 89 RED-16 56 RED-14 84 RED-16 54 RED-14 PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG 215A PNK-16 143 BRN-16 PLUG PLUG 143D BRN-16 215 PNK-16 00J BLK-16 00K BLK-16 00L BLK-16 20A BRN-16 273 GRY-16 20B BRN-16 20C BRN-16 33 PNK-16

00P BLK-14 56 RED-14

141 PNK-14 215 PNK-16 11A RED-14 42 GRN-16 PLUG 11B RED-16

242E RED-18 04 BLU-18

1 2

11

GLOW PLUG LAMP

242D RED-18 40A GRY-18

1 2

10

HYD TEMP LAMP

COOLANT LAMP

ENIGNE OIL LAMP

242C RED-18 31 ORG-18

242B RED-16 14 PUR-16

1 2

1 2

242A RED-18 16 PNK-18

1 2

5

7

00I BLK-14 63 RED-14

A B

ROPS AUX

17

FUEL GAUGE LAMP

25 BRN-16 11C RED-16

143C BRN-16 00G BLK-16

2 3

1 2

4

FUEL GAUGE

ENGINE MALF. LAMP

3

EVC073-GRY

00I BLK-14 00J BLK-16 00K BLK-16 00L BLK-16

10A RED-18 10B RED-14 10C RED-16 10D RED-14 10E RED-16 10F RED-14 10G RED-16 10H RED-16

54 RED-14

11C RED-16 11A RED-14 11B RED-16 11 RED-14

SPL 15

SPL 5

SPL 10

SPL 16

20A BRN-16 20B BRN-16

SPL 14

SPL 13

SPL 4

SPL 12

SPL 6

SPL 9

SPL 11

SPL 8

SPL 17

SPL 19 SPL 7

89A RED-16 89B RED-16 89 RED-16

40A GRY-18

00D BLK-14 00E BLK-16 00G BLK-16 00P BLK-14

EVC073-BLU 00D BLK-14

242A RED-18 242B RED-16 242C RED-18 242D RED-18 242E RED-18 242F RED-16 242H RED-16

CBL3 9318SHLD CBL2 9318SHLD

CBL2 9318H RED CBL3 9318H RED CBL3 9318L BLK CBL2 9318L BLK

00H BLK-12 00 BLK-10 00M BLK-20 00N BLK-16

10 RED-08

54D RED-16 54A RED-16 54B RED-14 54C RED-16 54E RED-16

20 BRN-16

40 GRY-16 40B GRY-16

00H BLK-12

00C BLK-16 00A BLK-16 00B BLK-16 00T BLK-16

10A RED-12 10B RED-12 10 RED-08

242 RED-16 242G RED-20

CBL1 9318SHLD

CBL1 9318L BLK

CBL1 9318H RED

160A RED-18 161A BLK-18

242G RED-20 CBL2 9318H RED CBL2 9318L BLK 00M BLK-20 PLUG PLUG

36 BLU-14 29 YEL-16 15 BRN-16 37 GRN-16 PLUG 33 PNK-16

54D RED-16 00N BLK-16 100 WHT-14 17 GRN-16 30 PUR-16 40B GRY-16 PLUG 54E RED-16 52 WHT-16 273 GRY-16 PLUG PLUG

12 RED-14 CBL1 9318L BLK CBL1 9318H RED 9318SHLD 05 RED-16 25 BRN-16 215A PNK-16 242 RED-16 16 PNK-18 14 PUR-16 31 ORG-18 04 BLU-18 34 YEL-16 PLUG 40 GRY-16 71 BLK-18 69 WHT-18 70 RED-18 29 YEL-16 36 BLU-14 42 GRN-16 141 PNK-14 20 BRN-16

10A RED-12 10B RED-12 00 BLK-10

17 GRN-16 54C RED-16

100 WHT-14 54B RED-14

54A RED-16 52 WHT-16 00T BLK-16 PLUG

1 2

1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12

A B C D E F G H J K L M N O P Q R S T U V W X

A B C

1 2

A B

1 2 3 4

21

80 TERMINATING RESISTOR

YDT

28

24B

INTERLOCK OUTPUTS

24A

INTERLOCK INPUTS

25A

CHASSIS CONNECTOR

CAB POWER

26A

RESTRAINT BAR SWITCH

23

SEAT SWITCH

22

DOOR SENSOR

GEHL R105 / MUSTANG 1050R ELECTRICAL SYSTEM

ROPS/FOPS Electrical Schematic - DPF Models

145

ELECTRICAL SYSTEM

GEHL R105 / MUSTANG 1050R

Electrical Schematic - Non-DPF Models (schematic overlaps onto following page)

ENGINE COOLANT TEMPERATURE

FUEL GAUGE

HOURMETER

SWITCH/BRAKE MOMENTARY E

37 DGN-16

00 BLK-16 43 ORG-16

34 YEL-16

GRD

00 BLK-16

POS

I

43 ORG-16

GRD

25 BRN-16

43 ORG-16

53 RED-16 53 RED-16 04 DBL-16 34 YEL-16 14 PUR-16 53 RED-16 15 BRN-16

31 ORG-16 40 GRY-16

53 RED-16

53 RED-16

S

00 BLK-16

I

00 BLK-16

GRD

53 RED-16

S

12V

00 BLK-16

PLUG

00 BLK-16

2 3

PLUG

HEAD LIGHT

12V REAR LIGHT

53 RED-16

PLUG

53 RED-16

WARNING

22 DGN-16

4 5

1

PLUG

6

30 PUR-16

F

EAD & TAIL LIGHT

7

8

53 RED-16

HEAD LIGHT 00 BLK-16

43 ORG-16 56 RED-16

05 RED-16

14 PUR-16

IGNITION SWITCH

ROPS AUX POWER CONNECTION BAT

B

IGN

C

40 GRY-16 31 ORG-16

02 RED-16 02 RED-16

OFF

ST

D

BAT

A

20 BRN-16

20 BRN-16

85+

-86

30

87

00 BLK-16

ON 273 GRY-16

02 RED-12 43 ORG-16 42 DGN-16 48 WHT-16

ST

ENGINE HARNESS 50315676

SAFETY START RELAY

CIRCUIT BREAKER 15A

02 RED-10

00 BLK-16

CRANK SIGNAL RELAY

33 PNK-16

85+

-86

30

87

00 BLK-16

07 RED-10 53 RED-16

21 DGN-16

CIRCUIT BREAKER 8A

07 RED-16

20 BRN-16

84 RED-12

4-PIN DEUTSCH CONN DT04-4P DOOR SENSOR

654321

36 DBL-16 35 DBL-16 15 BRN-16 37 DGN-16 PLUG 33 PNK-16

INTERLOCK MODULE

53 RED-16

1 2 3 4

DEUTSCH DT06-6S

84 RED-12 00 BLK-16

OUTPUT

CIRCUIT BREAKER 15A

INPUT

53 RED-16 00 BLK-16 10 WHT-16 17 DGN-16 30 PUR-16 67 PNK-16 PLUG 54 RED-16 52 WHT-16 273 GRY-16 PLUG PLUG

80 YEL-16

DEUTSCH DT06-12S

56 RED-16

CIRCUIT BREAKER 15A

12 11 10 9 8 7 6 5 4 3 2 1

CIRCUIT BREAKER 25A

52 WHT-16 00 BLK-16 PLUG 53 RED-16

ROPS HARNESS 50315543

10 WHT-16 53 RED-16

53 RED-16

17 DGN-16

25 BRN-16 35 DBL-16 36 DBL-16 04 DBL-16

05 RED-16

-86

85+

48 WHT-16 42 DGN-16 43 ORG-16 80 YEL-16

00 BLK-16

34 YEL-16 02 RED-10

31 ORG-16

07 RED-10 30

87

22 DGN-16 17 DGN-16

CAB POWER RELAY

40 GRY-16 14 PUR-16 21 DGN-16

02 RED-10 00 BLK-10

DEUTSCH CONNECTOR

MET POW

146

50950298/AP0517

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

ELECTRICAL SYSTEM Electrical Schematic - Non-DPF Models

BACKUP ALARM KIT (OPTION) 49 DGN-16 80 YEL-16

00 BLK-16

BACKUP ALARM SWITCH (OPTION)

80 YEL-16 08 ORG-16

49 DGN-16

HORN BUTTON

80 YEL-16

GE

HOURMETER

BACKUP ALARM SWITCH (OPTION)

FLASHER POWER 48 WHT-16

HYDRAULIC TEMP SWITCH

HYD VALVE LOCKOUTS

00 BLK-14 43 ORG-16

AUX

F

HEAD LIGHT

TILT

LIFT

40 GRY-16

REAR LIGHTS

35 DBL-16

ACCESSORY POWER

HORN KIT (OPTION)

35 DBL-16

TAIL LIGHT

00 BLK-14 42 DGN-16

00 BLK-16

BRAKE SOLENOID

35 DBL-16

00 BLK-16 43 ORG-16

34 YEL-16

00 BLK-16

43 ORG-16

00 BLK-16

53 RED-16

08 ORG-16

GRD

00 BLK-14

POS

I

53 RED-16

ENGINE PRESSURE PUMP

00 BLK-16

53 RED-16

FUEL CUTOFF SOLENOID

01 RED-12 34 YEL-16 98 TAN-16

1 21 DGN-16 R L

00 BLK-10

25 BRN-16 00 BLK-10

04 DBL-16

53 RED-16

00 BLK-16 82 WHT-12

00 BLK-16

4

GLOW CONTROL MODULE

2 3

6

ALTERNATOR

ENGINE HARNESS 50315676

5

00 BLK-16

44 PNK-16

BAT

ENGINE WATER TEMP SWITCH

31 ORG-16

00 BLK-16

654321

DEUTSCH DT06-6S

OUTPUT

FUEL SENDER

36 DBL-16 35 DBL-16 15 BRN-16 37 DGN-16 PLUG 33 PNK-16

14 PUR-16

A

30

B

87

SS

01 RED-12

03 DBL-12

GLOW PLUGS GROUND CABLE

00 BLK-16

25 BRN-16

34 YEL-16

22 DGN-16 17 DGN-16

85+

30

87

01 RED-12

17 DGN-16

35 DBL-16 82 WHT-12

02 RED-16

48 WHT-16 42 DGN-16 43 ORG-16 80 YEL-16

31 ORG-16

-86

SEAT BAR (AUXILIARY) RELAY

35 DBL-16 36 DBL-16 04 DBL-16

ENGINE OIL PRESSURE SWITCH

44 PNK-16

00 BLK-16

53 RED-16

ENGINE WATER TEMP SENDER

01 RED-10 02 RED-10

GLOW SOLENOID

LOCK ULE

22 DGN-16

FUEL SENDER HARNESS

35A CIRCUIT BREAKER

00 BLK-16 -86

STARTER

85+ 21 DGN-16

STARTER RELAY

BATTERY BATTERY CABLE

82 WHT-12 30

87 02 RED-12

40 GRY-16 14 PUR-16 21 DGN-16

02 RED-10 00 BLK-10

TSCH CONNECTOR METRI PACK POWER CONNECTOR

PRINTED IN USA

50950298/AP0517

147

ELECTRICAL SYSTEM

GEHL R105 / MUSTANG 1050R

CHAPTER NOTES

148

50950298/AP0517

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

ENGINE

Introduction

Troubleshooting Guide

This chapter covers troubleshooting, removal, installation, and adjustment procedures for engine components on Gehl R105 and Mustang 1050R model skid-steer loaders. The primary engine system components are shown on following pages.

They are equipped with a Yanmar model 3TNV88CKMS (DPF Models) or a 3TNV88-BKMS (Non-DPF) naturally-aspirated diesel engine. Both are threecylinder engines with 100 cubic inch (1,64 L) displacement and a 18.5.1 compression ratio. The direct injection four-stroke engines have a firing order of 1, 3, 2.

A “full-flow” oil filter is used in the lubrication system.

As with any engine, clean oil, fuel and air are critical to satisfactory performance and long engine life. If properly maintained, this engine can be expected to provide thousands of hours of trouble-free operation.

When ordering engine parts, always check the Gehl or Mustang Parts Manual to see if a special part has been fitted to the engine. If Gehl or Mustang parts are required, they can be ordered from Gehl Company.

The following troubleshooting guide lists potential engine problems, as well as possible causes and remedies, for Gehl R105 and Mustang 1050R model skid-steer loaders.

When a problem occurs, don’t overlook simple causes.

A malfunction could be caused by something as simple as an empty fuel tank. After a mechanical failure has been corrected, be sure to locate the cause of the problem. For further troubleshooting information, refer to the engine manufacturer’s manual.

IMPORTANT DO NOT attempt to service or repair major components, such as the fuel injector pump, unless authorized to do so by your Gehl or Mustang dealer. Any unauthorized repair will void the warranty.

Troubleshooting Guide

Problem Starter will not engage when keyswitch is turned to “START”

Possible Cause

Remedy

Seat or restraint bar switch malfunctioning or not activate

Replace switches as needed.

Battery terminals or cables are loose or corroded

Clean battery terminals and cables and tighten them.

Battery discharged or defective

Recharge or replace battery.

Starter solenoid in chassis malfunctioning

Troubleshoot circuit per wiring diagram to locate trouble. Replace starter solenoid.

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

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

Starter or pinion faulty Remove starter; repair or replace as needed.

PRINTED IN USA

50950298/AP0517

149

ENGINE

GEHL R105 / MUSTANG 1050R

Troubleshooting Guide Problem

Engine does not turn over

150

Possible Cause

Remedy

Blown fuse.

Check circuit and replace fuse.

Dead battery.

Charge or replace battery.

Battery disconnect switch in open position or malfunctioning.

Place battery disconnect switch into closed position— Repair or replace if necessary.

Starter malfunction.

Repair/replace starter.

Operator not in operator’s seat.

Operator’s seat must be occupied for the engine to start.

Malfunctioning seat/restraint bar/door switch/wiring.

Replace seat/restraint bar/door switch.

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

Cab door open (if equipped).

Close cab door.

Engine electronics logic error.

Resolve error

Engine fault code(s) displayed.

Identify problem and correct.

Relay malfunction.

Replace relay.

Solenoid malfunction.

Troubleshoot circuit per wiring diagram. Replace solenoid as necessary.

50950298/AP0517

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

ENGINE

Troubleshooting Guide Problem

Possible Cause

Engine cranking speed too slow.

Engine turns over but will not start

PRINTED IN USA

Remedy Check battery and charge/replace as necessary—tighten battery terminals.

In cold temperatures, pre-warm the engine.

Fuel tank empty.

Fill tank and vent fuel system if necessary.

Fuel filter plugged or restricted.

Change fuel filter.

Fuel paraffin separation in winter.

Use winter grade diesel fuel.

Fuel line leak.

Tighten all threaded connections and clamps; replace fuel line as necessary.

Fuel shut-off solenoid not energizing.

Check electrical connections/voltage to shut-off solenoid.

Fuel filter restricted/fuel hose restriction.

Replace filter/check for pinched fuel hose.

Fuel pump malfunction.

Repair/replace fuel pump.

Water in fuel filter.

Purge water from filter.

Fuel valve on water separator in the OFF position.

Turn the valve to the ON position.

Engine fault code(s) displayed.

Identify problem and correct.

Engine too cold/ambient temperature too low.

Pre-heating module malfunction; check connection and voltage and charge/ replace as necessary. Install block heater.

50950298/AP0517

151

ENGINE

GEHL R105 / MUSTANG 1050R

Troubleshooting Guide Problem

Engine overheating

152

Possible Cause

Remedy

Crankcase oil level incorrect.

Adjust oil level.

Cooling air circulation restricted.

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.

Allow exhaust to cool; remove restriction.

Air filter restricted.

Replace filter(s).

Low coolant level.

Top off coolant.

Loose fan belt.

Tighten fan belt.

Dirty/restricted radiator.

Clean radiator.

Thermostat malfunction.

Replace thermostat.

Engine overloaded.

Reduce operating load.

Loose V-belt.

Properly tension V-belt.

Blocked coolant hose.

Find and remove obstruction.

50950298/AP0517

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

ENGINE

Engine Components and Engine Controls - DPF Models

24

1

20 8

14

25

21 REMOVED DPF LIFT HOOK TO CLEAR ROOM FOR HEATER TUBE ROUTING

31

1

31

6

28

30 24

26 37 NOTES #1 & #4 34

NOTE #2

13

2

NOTES #1 & #4 37

43

32

1

15

27

7

1

35

12

36 21

42

23 42

35

22

1

24

29

19

3 40

NOTE #1

38

NOTE #1

39 NOTE #1 42

41

38

9 16

NOTE #1

17

42 NOTES #1 & #4

42

NOTES: 1. APPLY LOCTITE 242 OR EQUIVALENT.

18

7

10 NOTE #1 38

5 NOTE #1

34 NOTE #2

4

38

11

37

37 33 NOTE #3

GOVERNED ENGINE SPEED SPECIFICATIONS SPEED SETTING RPM TOLERANCE LOW IDLE, NO LOAD 1500 10 RPM 2830 10 RPM HIGH IDLE, NO LOAD 10 RPM MANUFACTURER'S RATING* 2800 *THE FULL LOAD GOVERENED SPEED THAT THE ENGINE PASSES U.S. EPA EMISSIONS STANDARDS

2. TORQUE TO 110 FT/LBS 3. TORQUE TO 55 FT/LBS 4. TORQUE TO 39 FT/LBS

1 2 3 4 5 6 7 8 9 10 11

CLAMP/HOSE LN LN LN HFS CS FL LOCK LN FL SERR CLAMP/HOSE ISOLATOR PLATE/PUMP MOUNT ENGINE MOUNT

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12 13 14 15 16 17 18 19 20 21 22

HOSE-FUEL BRACE/ENGINE TOP LN FL SERR DRIVE PLATE WASHER WASHER/FLAT ENGINE MOUNT ENGINE SUPPORT ASSY/DIPSTICK ENGINE HOSE/FUEL

23 NYLON SLEEVE 24 HOSE/FUEL 25 NYLON SLEEVE 26 HOSE/FUEL 27 NYLON SLEEVE 28 NYLON SLEEVE 29 HOSE/FUEL 30 HOSE/FUEL 31 NYLON SLEEVE 32 BRACKET/HOSE 33 CS

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CS CB CB CS CS CS FW FW LW CLAMP/HOSE

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Engine Components and Engine Controls - Non-DPF Models SEE NOTE #2 27 FUEL RETURN 30

13 SEE NOTE #2

3

38

FUEL SUPPLY 3

32

28

ELECTRIC FUEL PUMP (REF) TO WELD STUDS ON CHASSIS INNER RISER

3 11

25

19 17

1 49

3

36 32

49

28 50

SEE NOTE #3 40

30

4

SEE NOTES #1 & #5 43 23

SEE NOTES #1 & #5 43

5

17

3

3

52 A

46

20

SEE ENGINE SPEED CHART

3

51 51

41

8

31

DETAIL A

6

24 47 44 51

48

45 SEE NOTES #1 & #6

44 SEE NOTE #1 USED WITH GROUND CABLES

40 SEE NOTE #3

14

SEE NOTES44 #1 & #5

42 9 SEE NOTE #1

12

35

39

33

15 16

36 44

34

51

7

44

21

10

18

51

39

26

SEE NOTES 43 #1 & #5 37 SEE NOTE #4

22 39

1

NOTES: 1. APPLY LOCTITE 242 OR EQUIVALENT.

2 32

2. APPLY PIPE THREAD SEALANT

29

3. TORQUE TO 110 FT/LBS 4. TORQUE TO 55 FT/LBS 5. TORQUE TO 39 FT/LBS 6. TORQUE TO 14 FT-LBS GOVERNED ENGINE SPEED SPECIFICATIONS SPEED SETTING RPM TOLERANCE 1500 LOW IDLE, NO LOAD 25 RPM 2800 10 RPM HIGH IDLE, NO LOAD HIGH, NO LOAD (EU ONLY) 2600 10 RPM 10 RPM MANUFACTURER'S RATING* 3000 *THE FULL LOAD GOVERENED SPEED THAT THE ENGINE PASSES U.S. EPA EMISSIONS STANDARDS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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BUSHING/OILITE BALL/JOINT ASSY CLAMP/HOSE LN LN LN LN CS FL LOCK HFS FW CABLE LN FL SPIRALOCK FITTING/ST ISOLATOR SCREW/SHOULDER PUMP MOUNT HOSE/FUEL BRACKET/THROTTLE

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

HOSE/FUEL HOSE/FUEL ENGINE MOUNT ROD/THROTTLE BRACE/ENGINE TOP ENGINE MOUNT PIVOT/THROTTLE HAND PIVOT THROTTLE FOOT VALVE/FUEL SHUT OFF YOKE/CLEVIS NUT/FLRCL PIN/CLEVIS DRIVE PLATE WASHER WASHER WASHER/FLAT ENGINE MOUNT BUSHING

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CS CS HN CS CB CS CS CS CS CS FW FW CP EPSC HN LW ENGINE

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GEHL R105 / MUSTANG 1050R

ENGINE

Air Cleaner and Exhaust Components - DPF Models 50352362 BOTTOM HOUSING FOR REPLACEMENT PURPOSES ONLY

188814 PRIMARY ELEMENT FOR REPLACEMENT PURPOSES ONLY 188817 SECONDARY ELEMENT FOR REPLACEMENT PURPOSES ONLY

15

11

14

4

12 2

3

2

13

6

10

8 7

9

2 13

2

NOTE 1 5

6

1

NOTE: 1. IF PRE CLEANER OPTION IS ORDERED WITH UNIT, SOUND DIFFUSER 192848 IS NOT USED.

1 2 3 4 5 6 7 8

CLAMP/HOSE CLAMP/HOSE TUBE-HOSE CONNECTOR CLAMP/FILTER SOUND DIFFUSER NUT/FLRSUF FITTING/DIRT INDICATOR GAUGE/RESTRICTION

PRINTED IN USA

9 10 11 12 13 14 15

HOSE/INTAKE 200 SERIES ELBOW TUBE/EXHAUST CLEANER/AIR CB HN LW

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Air Cleaner and Exhaust Components - Non-DPF Models NOTE: IF PRE CLEANER OPTION IS ORDERED WITH UNIT, (192848) SOUND DIFFUSER CANNOT BE USED, RETURN TO INVENTORY

8

15

9

14

13

7

3

SEE COMPLETING KIT FOR APPROPRIATE MUFFLER

14 10 4

18

3

17

6

16

12

2

5 11 SEE NOTE 1

1 2 3 4 5 6 7 8 9

156

HFS CLAMP/HOSE CLAMP/HOSE TUBE-HOSE CONNECTOR MUFFLER MOUNT 200 SERIES ELBOW CLAMP/FILTER ELEMENT/PRIMARY ELEMENT/SECONDARY

REMOVE BOLT FROM ENG/ALT ASSEMBLY AND REPLACE AFTER MUFFLER MOUNT HAS BEEN PLACED

10 11 12 13 14 15 16 17 18

HOSE/ MOLDED/AIR FILTER SOUND DIFFUSER NUT/FLRSUF GAUGE/RESTRICTION CLEANER/AIR HOUSING/BOTTOM CB LW HN

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ENGINE

Radiator/Cooler Components - DPF Models 9

15

6

22

22

5

27

10

33 23 5

15 4

22

9

7

14 NOTE 1

3 31 12

19

28

SUPPLIED WITH ENGINE 8

22

34

17

18

1

37

24

1 26

29

21

35 36

20

1 10 26

13

8 35

1 30

16

15

2 32

25

TO TANK 11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CLAMP/HOSE CLAMP/HOSE CLAMP/HOSE TEE FITTING/TUBE FITTING/90 LN LG FL SERR CS FL LOCK LN FL SERR CLAMP/HOSE SEAL-SHROUD RELIEF VALVE COOLER/HOC/RAD HOSE RAD SUPPORT LN FL CTR COOLER MOUNTING PLATE SUPPORT/SHROUD LH SUPPORT/SHROUD RH

PRINTED IN USA

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

NOTE: 1. IF SELF-LEVEL OPTION IS USED, SHIFT BRACKET FROM TOWER TO OUTSIDE OF SELFLEVEL VALVE.

BRACE/COOLER COOLER MOUNTING PLATE FAN CS FL LOCK WASHER HOSE/UPPER RADIATOR HOSE/LOWER RADIATOR WELDMENT/FAN SHROUD FAN SHROUD GUARD BRKT/DIP STICK HOSE/HYD HOSE/HYD HOSE/RADIATOR OVERFLOW CB CB CB HWHTRS TAP/R CS FL

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Radiator/Cooler Components - Non-DPF Models 9

7

6

23 18

9

22

5

22 20

26

3

29

SUPPLIED WITH ENGINE

33 1

10

31

17

13

12

8 NOTE 1 15 21 32

22

4 5

1

1 24 16

14

10

18

8

28 1

25

33 2 19

30

27 TO TANK

11

NOTES: 1. IF SELF LEVEL OPTION IS USED, SHIFT BRACKET FROM TOWER TO OUTSIDE OF SELF LEVEL VALVE. 2. DISCARD FAN SPACERS THAT COME WITH THE ENGINE. 3. USE EXISTING FAN BOLTS THAT COME WITH THE ENGINE TO MOUNT THE FAN.

1 2 3 4 5 6 7 8 9 10 11

158

CLAMP/HOSE CLAMP/HOSE CLAMP/HOSE TEE FITTING/TUBE FITTING/90 LN LG FL SERR CS FL LOCK LN FL SERR CLAMP/HOSE SEAL-SHROUD RELIEF VALVE

12 13 14 15 16 17 18 19 20 21 22

COOLER/HOC/RAD HOSE/UPPER RADIATOR HOSE RAD SUPPORT FAN SHROUD FAN LN FL CTR COOLER MOUNTING PLATE BRACE/COOLER COOLER MOUNTING PLATE CS FL LOCK

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WASHER HOSE/HYD HOSE/HYD HOSE/RADIATOR OVERFLOW HOSE/RADIATOR/LOWER SUPPORT/SHROUD LH SUPPORT/SHROUD RH CB CB CB HWHTRS TAP/R

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

ENGINE

Oil Filter Element Removal and Installation The engine oil filter is located on the left side of the engine and can be accessed through a belly pan in the chassis.

4. Turning counterclockwise, loosen the oil filter element with a filter wrench.

5. Turn the filter element by hand until it is free of the oil filter mating surface.

Installation Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

Removal Procedure 1. Remove two capscrews on the rearmost belly pan and remove the pan.

1. Clean oil filter mating surface of any debris before installing new element.

2. Apply a thin film of oil to seal on filter element before installing.

3. Hand-tighten filter element, turning it clockwise, until gasket contacts filter mating surface, then turn element another 3/4 turn to seat gasket.

4. If old oil has been removed, fill crankcase with 7.6 qts. (7,2 L) of oil. (See Lubrication chapter.)

5. Start engine and check for leaks near oil filter. Shut off engine, recheck oil level, and fill as needed.

6. Replace the belly pan.

2. Place a suitable container beneath the oil filter to catch any leaking oil.

Engine Oil Filter Location

3. Clean the area around the oil filter element.

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GEHL R105 / MUSTANG 1050R

Air Cleaner Assembly Removal and Installation

4. Loosen the hose clamp on the sound diffuser and remove the diffuser.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Open the engine access cover and lock open the rear grille.

2. Clean the area around the hose connection.

3. At the front of the air cleaner assembly, loosen the hose clamp securing the air filter hose to the assembly and pull the hose away from the air cleaner. Cover the air cleaner hose opening to help prevent contamination.

5. Remove the top capscrew and locknut securing the air cleaner bracket to the left riser to release the air cleaner canister.

6. Pull up on the bracket until it releases from itself and slide the air cleaner out of the bracket.

7. Remove the lower capscrew and locknut on the air cleaner bracket and remove the bracket.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

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Air Filter Element Removal and Installation Service the air filter element when the restriction gauge shows in the red zone. The red zone indicates a clogged air filter. If the gauge shows red with the engine stopped, replace the air filter element. After fitting a clean element, push the gauge reset button.

3. Pull the primary and secondary air filters from the air cleaner assembly.

Primary Air Filter

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

Secondary Air Filter

1. Open the engine access cover and lock open the rear grille.

2. Release the metal clips securing the air cleaner cover and remove the cover. Clean out any dirt build-up in the end cap.

4. Replace both air filter elements, if needed. (See Service chapter of the Operator's Manual.)

5. Check the condition of the dust ejector.

Installation Procedure - Follow all warnings first, then reverse the removal steps.* * Clean the radial seal surfaces of the mating plastic body.

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161

ENGINE

GEHL R105 / MUSTANG 1050R

Fuel Filter Removal and Installation

Adding Fuel

The fuel filter is a maintenance item in the fuel system.

The fuel tank is filled at the factory with United States off-road grade diesel fuel, dyed red for identification.

Removal Procedure 1. Shut off the fuel supply by turning a valve on the water separator.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Keep open flames and sparks away from fuel. 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.

2. Remove the fuel filter.

■ 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.

1. Perform the “Mandatory Safety Shutdown Procedure” found in the Safety Chapter.

Installation Procedure 1. Lubricate the new fuel filter gasket with diesel fuel.

2. Install and turn the filter one-half turn past the point where the gasket contacts the filter head.

3. Turn the valve on the water separator to allow the diesel fuel to flow through the filter.

2. Open the engine access cover and lock open the rear grille. The fuel cap is located under the engine cover.

3. Use the ignition key to unlock fuel cap and remove the fuel cap from the fuel filler neck.

NOTE: When the fuel filter is changed, the system MUST BE primed.

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ENGINE

4. Fill the fuel tank by adding fuel through the fuel filler neck opening.

If the indicator ring (M) is floating off the bottom of the cup, water is present and needs to be drained.

5. When the tank if full, replace and lock the fuel cap in the fuel filler neck opening.

2. If water needs to be drained, position a suitable collection container underneath the water separator drain.

IMPORTANT: To provide for proper fuel system venting, do not top off the fuel tank.

3. Turn the fuel valve lever (V) on the water separator to the OFF position.

4. Loosen drain plug (N) at the bottom of the water separator. Allow water to drain until indicator ring falls to the bottom of the cup.

Water Separator Maintenance

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Shut off the engine and allow to cool.

■ NEVER service the fuel system while smoking, while near an open flame, or if the engine is hot.

(For detailed instructions, refer to the Safety chapter of this manual.)

5. Tighten drain plug (N) and discard fuel/water according to environmental laws.

IMPORTANT: Dispose waste fuel according to environmental laws. DO NOT pour fuel onto the ground or down a drain.

6. Turn the fuel valve lever (V) on the water separator to the ON position.

7. Prime the fuel system by turning the ignition key to the ON position without starting the engine for 30 seconds. Repeat this step 3 times to ensure the fuel system is completely primed.

CAUTION

IMPORTANT: Water in the fuel system can cause severe engine damage. Drain the water from the fuel filter/water separator whenever water is present.

1. Inspect the water separator for the presence of water.

Do not use the starter motor to crank the engine to prime the fuel system. Damage to the engine starter motor, coils, pinion/ring gear could result.

8. Start the engine and check for leaks.

V

M

N

If the indicator ring (M) is at the bottom of the cup, no action is required.

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163

ENGINE

GEHL R105 / MUSTANG 1050R

Changing the Water Separator Filter

Changing the Fuel Filter

WARNING

WARNING

BEFORE beginning this service procedure, perform the following SAFETY procedures:

BEFORE beginning this service procedure, perform the following SAFETY procedures:

■ Shut off the engine and allow to cool.

■ Shut off the engine and allow to cool.

■ NEVER service the fuel system while smoking, while near an open flame, or if the engine is hot.

■ NEVER service the fuel system while smoking, while near an open flame, or if the engine is hot.

(For detailed instructions, refer to the Safety chapter of this manual.)

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Turn the fuel valve lever (V) on the water separator to the OFF position.

2. Unscrew the separator bowl from the housing and pull down on the existing filter to release it from the housing.

3. Install a new filter and reinstall the bowl.

4. Turn the fuel valve lever (V) on the water separator to the ON position.

5. Prime the fuel system by turning the ignition key to the ON position without starting the engine for 30 seconds. Repeat this step 3 times to ensure the fuel system is completely primed.

CAUTION Do not use the starter motor to crank the engine to prime the fuel system. Damage to the engine starter motor, coils, pinion/ring gear could result.

IMPORTANT: Change the fuel filter every 250 hours of operation.

1. Turn fuel valve lever (V) on the water separator to the OFF position.

2. Remove the fuel filter (W) using a filter wrench if necessary. Carefully clean the filter head mounting surface with a clean cloth.

3. Apply a coating of clean diesel fuel on the new fuel filter gasket. Install the filter and tighten 3/4 rotation past the point where the gasket contacts the filter head.

4. Turn fuel valve (V) on the water separator to the ON position.

5. Prime the fuel system by turning the ignition key to the ON position without starting the engine for 30 seconds. Repeat this step 3 times to ensure the fuel system is completely primed.

CAUTION

6. Start the engine and check for leaks.

Do not use the starter motor to crank the engine to prime the fuel system. Damage to the engine starter motor, coils, pinion/ring gear could result.

6. Start the engine and check for leaks.

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ENGINE

Electric Fuel Pump Removal and Installation The electric fuel pump is located between the water separator and the fuel filter on the left inside riser, very close to the water separator.

Removal Procedure 1. Unplug the electrical connector on the fuel pump.

Priming the Diesel Fuel System When the fuel filter is changed or if the diesel engine runs out of fuel, the system MUST BE primed.

Priming Procedure 1. Turn the keyswitch to the ON position to charge the electric fuel pump.

2. Air is vented through the excess fuel return line to the fuel tank. There is not vent plug to open.

3. Leave the keyswitch in the ON position until air is no longer heard being released in the fuel tank.

Electric Fuel Pump

2. Shut off the fuel supply by turning the fuel shutoff valve on top of the water separator.

3. Loosen two small hose clamps at the top and bottom of the fuel pump.

4. Remove two locknuts securing the fuel pump to the chassis.

5. Slip the fuel hoses off of the fuel pump and plug the hoses.

Installation Procedure 1. Slip the new electric fuel pump (with the electrical connector positioned lower) over the bolts in the chassis and tighten with locknuts.

2. Unplug the fuel hoses and connect at top and bottom of the fuel pump and secure with hose clamps.

3. Plug the fuel pump’s electrical connector at its connection in the engine harness.

4. Turn the valve on the water separator to allow the diesel fuel to flow through the filter.

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165

ENGINE

GEHL R105 / MUSTANG 1050R

Battery Removal and Installation

2. First, disconnect and remove the negative (-) battery cable and then disconnect the positive (+) battery cable from the battery.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

WARNING

3. Remove the locknut from the battery clamp rod securing the battery clamp to the chassis.

Review the following safety considerations before working on or around the battery: ■ Keep sparks and flames away from battery.

Gas given off by the battery’s electrolyte solution is extremely explosive.

■ Avoid contact with battery electrolyte; wash off any electrolyte immediately.

■ Wear safety glasses when working near battery.

■ Do not tip battery more than 45° to avoid spilling electrolyte solution.

■ To avoid injury from spark or short circuit, disconnect negative (-) battery cable before servicing electrical system.

1. Open the engine access cover and lock open the rear grille.

166

4. Lift the battery up and out of the chassis.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

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ENGINE

Starter Removal and Installation For wiring connections to the starter and solenoid, refer to the Electrical System chapter of this manual.

4. Remove the two capscrews securing the starter to the engine.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Remove attachment from lift arm.

■ Raise lift arm, engage lift arm support device.

■ Shut off the engine.

5. Remove the starter from the engine.

■ Tilt back ROPS/FOPS until lock engages.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

˘ (For detailed instructions, refer to the Safety chapter of this manual.)

1. Open the engine access cover and lock open the rear grille.

2. Disconnect and remove the negative (-) battery cable from the battery.

3. On the starter solenoid, remove the nut that secures the positive (+) battery cable and a smaller wire.

Also, disconnect the push-on connector attached at the solenoid.

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ENGINE

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Exhaust Assembly Removal and Installation - Non-DPF Models

Installation Procedure - Follow all warnings first, then reverse the removal steps.*

Removal Procedure

*Tighten the mounting hardware only after checking the alignment of the exhaust assembly so that the tailpipe is centered in the opening on the engine cover when closed.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures:

Exhaust Tube Removal and Installation DPF Models Removal Procedure

■ Lower the lift arm completely.

■ Shut off the engine and allow to cool.

WARNING

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Open the engine access cover and lock open the rear grille.

2. Remove the capscrew securing the bottom of the muffler to the muffler mount.

BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Lower the lift arm completely.

■ Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. The exhaust tube is connected to the DPF cannister.

3. Remove four locknuts securing the muffler to four studs on the engine.

2. Remove the four hex nuts and washers that connect the exhaust tube to the DPF cannister and remove the exhaust tube.

Installation Procedure - Follow all warnings first, then reverse the removal steps.* *Tighten the mounting hardware only after checking the alignment of the exhaust assembly so that the tailpipe is centered in the opening on the engine cover when closed.

4. Lift the muffler up and remove it from the loader.

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ENGINE

Fan Belt Adjustment

4. Rotate the alternator in a clockwise direction (viewed from the engine end) until the correct belt tension is achieved.

Adjustment Procedure

5. Retighten the bolts.

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Open the engine access cover and lock open the rear grille.

2. Test the fan belt tension by pushing on the belt midway between the alternator and the engine crankshaft pulley. The belt should deflect about ½" (13 mm) under a load of 20 lbs. (90 N). If adjustment is needed, follow the next steps.

3. Loosen the two bolts on the alternator, one at the low pivot area and one on top in the slide bracket.

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ENGINE

GEHL R105 / MUSTANG 1050R

Radiator/ Oil Cooler Removal and Installation

connect the hose clamps on the radiator hoses and the hydraulic oil lines from their fittings.

The radiator/oil cooler is mounted on a shroud located just behind the engine.

Removal Procedure Right Side Lines

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. If necessary, drain the oil from the hydraulic reservoir per the procedure in the Lubrication chapter.

2. If necessary, drain the engine coolant from the radiator per the procedure in the Lubrication chapter.

NOTE: Hydraulic oil lines should be plugged to prevent contaminants from entering the hydraulic system. If the hydraulic oil lines are plugged after removal to prevent oil leakage, it should not be necessary to drain the hydraulic reservoir.

Left Side Hoses

3. Open the engine access cover and lock open the rear grille.

4. Disconnect the recovery tanks hose leading to the overflow bottle at the radiator cap.

NOTE: BE SURE to use two wrenches on the hydraulic oil lines, one on the oil cooler fitting and the other on the hydraulic oil line to prevent damage to the oil cooler.

6. Remove remote radiator overflow line at the top of the radiator.

5. Remove coolant hoses and hydraulic oil lines from the inlets and outlets of the radiator/oil cooler. Dis-

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7. Remove three locking capscrews on each side securing the radiator/oil cooler tab to the shroud.

Fan Shroud and Support Brackets Removal and Installation Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

8. Using a suitable hoist of adequate capacity and a positive locking mechanism able to support the radiator/oil cooler or equivalent, remove the radiator/oil cooler from the skid-steer loader.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

WARNING DO NOT attempt to service any part of radiator/oil cooler system until engine has been allowed to cool. Serious injury may result from high temperature oil or water coolant or high pressure.

1. Remove the hydraulic reservoir drain plug and drain the hydraulic oil into a suitable container.

Refer to the procedure in the Lubrication chapter.

NOTE: Hydraulic oil lines should be plugged after disconnecting to prevent contaminants from entering the hydraulic system. If the hydraulic lines are plugged after disconnecting to prevent leakage, it should not be necessary to drain the hydraulic reservoir.

2. Remove the radiator/oil cooler per the procedure in this chapter.

3. Underneath the skid-steer loader there is space to access and remove two locknuts securing the

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

9. ALWAYS check for hydraulic fluid leaks after installing any components of the hydraulic system.

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shroud support brackets to a bracket on the floor of the chassis, on each side of the skid-steer loader.

Fan Shroud Adjustment Adjustment Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

4. Remove the fan shroud assembly with the shroud supports still attached.

5. Unbolt the shroud supports at this time, if necessary.

1. Loosen, but do not remove, the two locking capscrews on the shroud support connected to the shroud.

2. Move the shroud and radiator/oil cooler assembly up or down until the fan is centered in the shroud opening.

Installation Procedure - Follow all warnings first, then reverse the removal steps.* * BE SURE and uncap/unplug the hydraulic oil lines prior to reconnecting them to the radiator/oil cooler.

3. Tighten the locking capscrews on the fan shroud supports to secure the height adjustment.

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Fan Removal and Installation

Fuel Tank Removal

Removal Procedure

The welded-steel fuel tank on Gehl R105 and Mustang 1050R skid-steer loaders is nestled in a chassis crossmember behind the ROPS/FOPS.

WARNING

Removal Procedure

BEFORE beginning this service procedure, perform the following SAFETY procedure:

WARNING

■ Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. If necessary, drain the oil from the hydraulic reservoir per the procedure in the Lubrication chapter.

2. If necessary, drain the engine coolant from the radiator per the procedure in the Lubrication chapter.

NOTE: Hydraulic oil lines should be plugged to prevent contaminants from entering the hydraulic system. If the hydraulic oil lines are plugged after removal to prevent oil leakage, it should not be necessary to drain the hydraulic reservoir.

3. Remove the radiator/oil cooler per the procedure in this chapter.

4. Unbolt four nuts securing the fan to the engine.

5. Carefully pull the fan out the rear of the skid-steer loader.

6. Repair or replace the engine fan.

Installation Procedure - Follow all warnings first, then reverse the removal steps.

BEFORE beginning this service procedure, perform the following SAFETY procedure: ■ Remove attachment from lift arm.

■ Raise lift arm; engage lift arm support device.

■ Shut off the engine and allow to cool.

■ Tilt back ROPS/FOPS until lock engages.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Open the engine access cover and lock open the rear grille.

2. Remove the air cleaner assembly per the procedure found in this chapter.

3. Turn the water separator fuel shut off valve to its OFF position.

4. Loosen the clamp on the fuel supply hose on the outside of the water separator. Place the hose end in an approved container with enough capacity (9.5 gal.) (36 L) to hold a full tank of fuel.

5. Loosen the fuel cap on the fuel tank and drain the diesel fuel into the approved container.

6. Reinstall the fuel supply hose to the water separator.

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GEHL R105 / MUSTANG 1050R

7. Loosen the hose clamps on two hose lines at the top and bottom of the fuel tank and pull the hoses off the barbed fittings.

10. Remove two nuts holding the fuse panel at the right side of the fuel tank.

NOTE: Cap or plug all hydraulic hoses and tubes immediately after they are disconnected to prevent fluid loss and contamination of the hydraulic system.

11. Remove the capscrews securing the hydraulic filter assembly to the fuel tank welded tab.

12. Remove locknuts on carriage bolts securing the fuel tank bracket to the left side of the chassis riser.

8. Remove the fuel sender wiring and fuel sender per the procedure in the Mainframe chapter.

9. Remove one hydraulic hose and tube attached to either side of the oil filter assembly.

13. Remove locking capscrews at the front of the fuel tank securing the tank to the chassis crossmember.

14. Maneuver the tank out of the chassis.

Installation Procedure* - Follow all warnings first, then reverse the removal steps. * Perform the “Priming Diesel Fuel System” procedure in this chapter after the re-connection of the fuel tank.

174

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PRINTED IN USA

GEHL R105 / MUSTANG 1050R

ENGINE

Engine Removal and Installation

10. Disconnect fuel lines from the fuel filter.

The following procedure allows removal of the diesel engine without removing the hydrostatic pump assembly. Some hydraulic hoses/oil lines need to be disconnected in this procedure, and if they cannot be capped/plugged to prevent fluid loss, the hydraulic reservoir should be drained BEFORE disconnecting any hydraulic hoses/oil lines.

Removal Procedure

WARNING BEFORE beginning this service procedure, perform the following SAFETY procedures: ■ Raise lift arm; engage lift arm support device.

11. Turn the fuel shut off petcock valve at the top of the water separator to its OFF position. Disconnect fuel lines from the water separator.

■ Shut off the engine.

(For detailed instructions, refer to the Safety chapter of this manual.)

1. Drain the hydraulic oil reservoir and the engine oil.

2. Remove the floor covers and kickplate per the procedure in the Mainframe chapter.

3. Remove the rear grille per the procedure in the Mainframe chapter.

4. Remove the ROPS/FOPS per the procedure found in the Mainframe chapter.

5. Remove the battery per the procedure in this chapter.

6. Remove the air cleaner assembly per the procedure in this chapter.

12. Disconnect the fuel line in front of the fuel pump and unplug the electrical connector on the fuel pump.

WARNING DO NOT PROCEED with the following steps unless engine has completely cooled and is safe to touch.

7. Remove the exhaust assembly per the procedure in this chapter.

8. Remove the radiator/oil cooler per the procedure in this chapter.

Electric Fuel Pump

9. Remove the fan shroud and support brackets per the procedure in this chapter.

PRINTED IN USA

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ENGINE

GEHL R105 / MUSTANG 1050R

13. Non-DPF Models Only: Remove the hand throttle cable and engine throttle cable per the “Handle Throttle, Hand Throttle Cable and Throttle Rod Removal and Installation” procedure in the Controls chapter.

14. Unplug engine harness connectors located in several areas on the engine and attached to the chassis.

ECU Connection

Block Heater Plug

176

50950298/AP0517

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

ENGINE 17. On the starter solenoid, remove the nut that secures the positive (+) battery cable and a smaller wire.

Also, disconnect the push-on connector attached at the solenoid.

NOTE: The following step includes disconnection of hydraulic hoses. If hoses cannot be capped/plugged to prevent fluid loss, the hydraulic reservoir should be drained BEFORE disconnecting hoses. Refer to the Hydraulic System chapter for the procedure.

NOTE: ALWAYS clean area around hydraulic fittings BEFORE disconnecting any hydraulic hose or tube.

15. Label and disconnect all the hydraulic hoses connected to the hydrostatic pump. Refer to the “Hydrostatic Pump Removal” procedure in the Hydrostatic System chapter for hydraulic hose removal procedure on the pump.

18. Attach lift hooks to engine lifting locations on the front and rear of the cylinder head.

19. Remove one capscrew, lock nut (110 ft-lbs) (149 N•m) and three washers on two forward engine mounts.

16. Disconnect the negative (-) battery cable from the engine, located beneath the engines starter.

Engine Mount

Engine Mount

PRINTED IN USA

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ENGINE

GEHL R105 / MUSTANG 1050R

20. Remove one capscrew, locknut (55 ft-lbs) (75 N•m) and two washers on the rear engine mount.

WARNING NEVER use your hands to search for hydraulic fluid leaks.

Use a piece of cardboard or paper. Escaping fluid under pressure can be invisible and penetrate the skin causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

21. Using a suitable hoist of adequate capacity and a positive locking mechanism able to support the engine, lift slightly and pull the engine rearward.

Continue pulling the engine rearward until the pump is free from the drive coupling, then remove the engine from the chassis.

WARNING ALWAYS wear safety glasses when checking for hydraulic fluid leaks. Escaping fluid under pressure can be invisible and can cause permanent eyesight damage if safety glasses are not worn.

ALWAYS check for hydraulic fluid leaks after installing any components of the hydraulic system.

Engine Diagnostic Chart (DPF Models) When detecting faults, the information center electronic display 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 underneath an electrical cover, right of the seat.

Installation Procedure - Follow all warnings first, then reverse the removal steps.* * Bleed the fuel system. Also check engine oil and hydraulic oil levels prior to starting the engine. * If the diesel fuel was drained, add fuel, then prime the fuel system according to the “Priming Diesel Fuel System” procedure in this chapter. * Safely check for hydraulic fluid leaks observing the correct procedure in doing so (refer to Hydraulic System chapter). * Perform the neutral centering adjustment procedure found in the Controls chapter.

178

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

50950298/AP0517

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

ENGINE

Engine Diagnostic Trouble Codes (DTC) Table 1: Yanmar Engine Diagnostic Trouble Codes (DTC)

DTC SPN

28

29

FMI 0 1 2 3 4

P-Code P1126 P1125 P0224 P0223 P0222

15

P1228

3 4 2 3 4 1 4

P02E9 P02E8 P0124 P0123 P0122 P1198 P1192

Part Acceleration Sensor 3 Acceleration Sensor 3 Acceleration Sensor 3 Acceleration Sensor 2 Acceleration Sensor 2 Accelerator Pedal Position Sensor "B" Accelerator Pedal Position Sensor "B" Acceleration Sensor 3 Acceleration Sensor 3 Acceleration Sensor 3 Accelerator Pedal Position Sensor "B” Accelerator Pedal Position Sensor "B" Intake Throttle Opening Sensor Intake Throttle Opening Sensor Acceleration Sensor 1 Acceleration Sensor 1 Acceleration Sensor 1 Oil Pressure Switch Oil Pressure Switch

0

P1226

1

P1225

3

P0238

EGR Low Pressure Side Sensor

4 13 3 4 2 3 4 10

P0237 P0236 P040D P040C P2230 P2229 P2228 P1231

0

P0217

2

P0119

3

P0118

4

P0117

EGR Low Pressure Side Sensor EGR Low Pressure Side Sensor Intake Air Temperature Sensor Intake Air Temperature Sensor Barometric Pressure Sensor Atmospheric Pressure Sensor Atmospheric Pressure Sensor Atmospheric Pressure Sensor Cooling Water Temperature Sensor Cooling Water Temperature Sensor Cooling Water Temperature Sensor Cooling Water Temperature Sensor

3 8

51 91 100

102

105

108

Error Item

P0227 P0228 P1127 P1227

110

PRINTED IN USA

50950298/AP0517

State Sensor failure (foot pedal in open position) Sensor failure (foot pedal in closed position) Intermittent fault Acceleration sensor 2 fault (high voltage) Acceleration sensor 2 fault (low voltage) Above normal operation range Below normal operation range Acceleration sensor 3 fault (high voltage) Acceleration sensor 3 fault (high voltage) Sensor failure (pulse communication) Communication fault Not available Intake throttle opening sensor fault (high voltage) Intake throttle opening sensor fault (low voltage) Intermittent Fault Acceleration sensor 1 fault (high voltage) Acceleration sensor 1 fault (low voltage) Low oil pressure fault alarm Oil pressure switch open circuit EGR low pressure side sensor fault (high voltage) EGR low pressure side sensor fault (low voltage) Abnormal learning value Intake air temperature sensor fault (high voltage) Intake air temperature sensor fault (low voltage) Intermittent fault Atmospheric pressure sensor fault (high voltage) Atmospheric pressure sensor fault (low voltage) Atmospheric pressure sensor characteristic fault Cooling water temperature sensor temperature abnormally high (overheat) Intermittent fault Cooling water temperature sensor fault (high voltage) Cooling water temperature sensor fault (low voltage)

179

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GEHL R105 / MUSTANG 1050R

Table 1: Yanmar Engine Diagnostic Trouble Codes (DTC)

DTC SPN

157

158 167 172

FMI

Error Item

0 3 4

P-Code P0088 P0193 P0192

Part Abnormal Rail Pressure Rail Pressure Sensor Rail Pressure Sensor

15

P0093

Abnormal Rail Pressure

16

P000F

18

P0094

0 1 1 5 3 4

P0563 P0562 P1568 P1562 P0113 P0112

3

P0546

4

P0545

0

P0168

3 4 16 13 31 3 4

12 2 12 3 5 6 2

P0183 P0182 P0219 U3002 U0168 P041D P041C P1605 P1606 P0605 P1601 P0601 P0629 P0627 P1642 P1214

3

P1213

4

P1212

7

P1211

173

174 190 237 412 628 630 633

638

180

2

State Actual rail pressure rise error Rail pressure sensor (high voltage) Rail pressure sensor (low voltage) Rail pressure deviation error during the actual rail pressure rise

PLV (Common Rail Pressure Limit PLV open valve Value) Rail pressure deviation error during the actual rail Abnormal Rail Pressure pressure drop System Voltage Too high System Voltage Too low Charge Switch Charge alarm Charge Switch Charge switch open circuit New Air Temperature Sensor New air temperature sensor fault (high voltage) New Air Temperature Sensor New air temperature sensor fault (low voltage) Exhaust air temperature sensor fault (high Exhaust Air Temperature Sensor voltage) Exhaust air temperature sensor fault (high Exhaust Air Temperature Sensor voltage) Fuel temperature sensor temperature abnormally Fuel Temperature Sensor high Fuel Temperature Sensor Fuel temperature sensor fault (high voltage) Fuel Temperature Sensor Fuel temperature sensor fault (low voltage) Overspeed Overspeed CAN 2 VI (CAN message) reception data fault CAN 2 VI (CAN message) reception time-out error EGR Gas Temperature Sensor EGR gas temperature sensor fault (high voltage) EGR Gas Temperature Sensor EGR gas temperature sensor fault (low voltage) ECU Internal Fault FlashROM checksum error (data sheet 1) ECU Internal Fault FlashROM checksum error (data sheet 2) ECU Internal Malfunction FlashROM checksum error (main software) ECU Internal Fault EEPROM error EEPROM EEPROM memory deletion error SCV (MPROP) SCV (MPROP) high side VB short-circuit SCV (MPROP) SCV (MPROP) open circuit SCV (MPROP) SCV (MPROP) high side GND short-circuit Engine Malfunction Engine Fuel Rack Position Shorted to high source Actuator Engine Fuel Rack Position Shorted to low source Actuator Engine Fuel Rack Position Mechanical malfunction Actuator

50950298/AP0517

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

ENGINE

Table 1: Yanmar Engine Diagnostic Trouble Codes (DTC)

DTC SPN 639

651

Error Item

FMI 12 3

P-Code U0001 P1271

5

P0204

6 11

P0271 P0272 P1262 P1268

3

P0203 5 P0203

652

3

P0268 P0268 P1263 P1269 P1265

5

P0202

6 11 3

P0265 P1266 P1262

5

P0201

6 11 4 2 3 4 0 2 3 4 2

P0262 P1263 P0340 P1644 P0643 P0642 P0634 P1664 P0669 P0668 U423

3

P0473

4 13 3 4

P0472 P0471 P1203 P1202

6 11

653

654

1078 1079

1136 1202 1209

1210

PRINTED IN USA

Part High Speed CAN Injector 1 (Cylinder Number 4)

State

Communication fault Injector 1 short-circuit Injector 1 open circuit (inherent location of the Injector 1 (Cylinder Number 4) injector) Injector 1 (Cylinder Number 4) Injector 1 coil short-circuit Injector 1 (Cylinder Number 4) Injector 1 unclassified Injector 1 (Cylinder Number 3) Injector 1 short circuit Injector 4 (Cylinder Number 3) Injector 4 short-circuit Injector 1 open circuit (inherent location of the Injector 1 (Cylinder Number 3)) Injector) Injector 4 open circuit (inherent location of the Injector 4 (Cylinder Number 3) injector) Injector 1 (Cylinder Number 3) Injector 1 coil short circuit Injector 4 (Cylinder Number 3) Injector 4 coil short-circuit Injector 1 (Cylinder Number 3) Injector 1 unclassified Injector 4 (Cylinder Number 3) Injector 4 unclassified Injector 2 (Cylinder Number 2) Injector 2 short-circuit Injector 2 open circuit (inherent location of the Injector 2 (Cylinder Number 2) injector) Injector 2 (Cylinder Number 2) Injector 2 coil short-circuit Injector 2 (Cylinder Number 2) Injector 2 unclassified Injector 3 (Cylinder Number 1) Injector 3 short-circuit Injector 3 open circuit (inherent location of the Injector 3 (Cylinder Number 1) injector) Injector 3 (Cylinder Number 1) Injector 3 coil short-circuit Injector 3 (Cylinder Number 1) Injector 3 unclassified Fuel Injection Pump Speed Sensor Shorted to low source Sensor 5V Intermittent fault Sensor 5V Shorted to high source Sensor 5V Shorted to low source ECU Internal Temperature Too high ECU Internal Temperature Sensor Intermittent fault ECU Internal Temperature Sensor Shorted to high source ECU Internal Temperature Sensor Shorted to low source Immobilizer System fault EGR low pressure side sensor fault (high EGR High Pressure Side Sensor voltage) EGR High Pressure Side Sensor EGR low pressure side sensor fault (low voltage) EGR High Pressure Side Sensor Abnormal learning value Engine Fuel Rack Position Sensor Shorted to high source Engine Fuel Rack Position Sensor Shorted to low source

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GEHL R105 / MUSTANG 1050R

Table 1: Yanmar Engine Diagnostic Trouble Codes (DTC)

DTC SPN 2

P068A

Main Relay

4 7 0 1 7 9 12

P0686 P068B P0404 P1404 P1409 U0401 P0403

ECU Main Relay Main Relay EGR Valve EGR Valve EGR Valve EGR Valve EGR Valve

2797

6

P1146

Injector (Common)

2798

6

P1149

Injector (Common)

3

P1658

Intake Throttle Drive Circuit

4

P1659

Intake Throttle Drive Circuit

5

P0660

Intake Throttle Drive Circuit

6

P1660

Intake Throttle Drive Circuit

3

P1661

Intake Throttle Drive Circuit

4

P1662

Intake Throttle Drive Circuit

0

P1436

DPF Inlet Temperature Sensor

3 4

P1428 P1427

DPF Inlet Temperature Sensor DPF Inlet Temperature Sensor

0

P1426

DPF Intermediate Temperature Sensor

1

P0420

3

P1434

4

P1435

0

P2452

DPF Differential Pressure Sensor

3

P2455

DPF Differential Pressure Sensor

4

P2454

DPF Differential Pressure Sensor

13

P2453

DPF Differential Pressure Sensor

State Power off without main relay self-holding / Main relay early opening Shorted to low source Main relay contact stuck EGR over-voltage malfunction EGR low voltage malfunction EGR feedback malfunction EGR ECM data fault Open circuit between the EGR motor coils Injector drive circuit (bank 1) short-circuit (common circuit for number 1, number 4) Injector drive circuit (bank 2) short-circuit (common circuit for number 2, number 3) Power short-circuit of throttle valve drive H bridge output 1 GND short-circuit of throttle valve drive H bridge output 1 No-load of throttle valve drive H bridge circuit Overload on the drive H bridge circuit of the throttle valve VB power short-circuit of throttle valve drive H bridge output 2 GND short-circuit of throttle valve drive H bridge output 2 DPF inlet temperature sensor temperature abnormally high DPF inlet temperature sensor fault (high voltage) DPF inlet temperature sensor fault (low voltage) DPF intermediate temperature sensor temperature abnormally high (post-injection failure) DPF intermediate temperature sensor temperature abnormally low DPF intermediate temperature sensor fault (high voltage) DPF intermediate temperature sensor fault (low voltage) DPF differential pressure sensor differential pressure abnormally high DPF differential pressure sensor fault (high voltage) DPF differential pressure sensor fault (low voltage) Abnormal learning value

50950298/AP0517

PRINTED IN USA

1485

2791

2950

FMI

Error Item P-Code

Part

2951

3242

3250

3251

182

DPF Intermediate Temperature Sensor DPF Intermediate Temperature Sensor DPF Intermediate Temperature Sensor

GEHL R105 / MUSTANG 1050R

ENGINE

Table 1: Yanmar Engine Diagnostic Trouble Codes (DTC)

DTC SPN 3

P1455

DPF High Pressure Sensor

4257

4 0 7 9 16 0 16 12

P1454 P1424 P1446 P1445 P1421 P1420 P242F P0611

DPF High Pressure Sensor DPF OP Interface DPF OP Interface DPF OP Interface DPF OP Interface DPF OP Interface DPF OP Interface Injector (Common)

37251

16

P1437

DPF

2 3 4 7 2 3 4 2 3 4 5 6 3 4 3 4 3 4 3 4 0 0 0 2 5 2 5 7 4 12

P1224 P1223 P1222 P1221 P1244 P1243 P1242 P1234 P1233 P1232 P0543 P0541 P1403 P1402 P1413 P1412 P1423 P1422 P1433 P1432 P1217 P1101 P1151 P0336 P0037 P0341 P0342 P1341 P1340 U1401

Engine Fuel Rack Actuator Relay Engine Fuel Rack Actuator Relay Engine Fuel Rack Actuator Relay Reserved Cold Start Device Cold Start Device Cold Start Device Air Heater Relay Air Heater Relay Air Heater Relay Start Auxiliary Relay Start Auxiliary Relay EGR Stepping Motor "A" EGR Stepping Motor "A" EGR Stepping Motor "B" EGR Stepping Motor "B" EGR Stepping Motor "C" EGR Stepping Motor "C" EGR Stepping Motor "D" EGR Stepping Motor "D" Engine Coolant Temperature Air Cleaner Switch Oil/Water Separator switch Crank Sensor Crank Sensor Cam Sensor Cam Sensor Cam Sensor Aux Speed Sensor EGR

State DPF high pressure side sensor fault (high voltage) DPF high pressure side sensor fault (low voltage) Backup mode Recovery regeneration prohibition Recovery regeneration failure Stationary regeneration standby Ash cleaning request 2 Ash cleaning request 1 Injector drive IC error Maintenance (maintenance not performed for a given period of time) Intermittent fault Circuit fault B Circuit fault A N/A Intermittent fault Circuit fault B Circuit fault A Intermittent fault Circuit fault B Circuit fault A Start auxiliary relay interrupted Start auxiliary relay GDN interrupted Circuit fault B Circuit fault A Circuit fault B Circuit fault A Circuit fault B Circuit fault A Circuit fault B Circuit fault A Abnormal temperature Air cleaner clogged alarm Oil/water separator alarm Crank signal malfunction No crank signal Cam signal malfunction No cam signal Angle offset failure Shorted to low source EGR target value out of range

50950298/AP0517

183

3609

3719

3720

522241

522242

522243

522251 522252 522253 522254 522314 522323 522329 522400 522401 522402 522567

FMI

Error Item

PRINTED IN USA

P-Code

Part

ENGINE

GEHL R105 / MUSTANG 1050R

Table 1: Yanmar Engine Diagnostic Trouble Codes (DTC)

DTC SPN 3 6

P-Code P1641 P1643

SCV (MPROP) SCV (MPROP)

6

P062A

SCV (MPROP)

11

P1645

SCV (MPROP)

522573 522574

0 0

P2463 P1463

DPF DPF

522575

7

P2458

DPF

522576

12

P160E

EEPROM

522577

11

P2459

DPF

522578 522579 522580 522581 522582 522583 522584 522585 522588 522589 522590 522591 522592 522593 522594 522595 522596 522597 522598

12 12 12 7 7 1 1 12 12 12 12 12 12 12 3 3 9 9 11 9 11 9 11 9 12 12 9 12 9 9

P160F P1405 P0488 P148A P049D P1410 P1411 P1613 P1608 P1617 P1609 P1618 P1619 P1624 P160A P1625 U0292 U1301 P160B U1292 P1636 U1293 P1637 U1294 P160D P1639 U1296 P1640 U1298 U1300

EEPROM EGR EGR EGR EGR EGR EGR ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction CAN 2 CAN 2 ECU Internal Malfunction CAN 2 ECU Internal Malfunction CAN 2 ECU Internal Malfunction CAN 2 ECU Internal Malfunction ECU Internal Malfunction CAN 2 ECU Internal Malfunction CAN 2 CAN 2

522571

FMI

Error Item Part

522572

522599 522600 522601 522602 522603 522605 522609 184

50950298/AP0517

State SCV (MPROP) low side VB short-circuit SCV (MPROP) low side GND short-circuit High-pressure pump drive circuit (drive current [high level]) High-pressure pump drive circuit (pump overload error) Over-accumulation (method C) Over-accumulation (method P) Regeneration defect (stationary regeneration failure) EEPROM memory read error Regeneration defect (stationary regeneration not performed) EEPROM memory write error Short-circuit between the EGR motor coils EGR position sensor malfunction EGR stuck open valve malfunction EGR initialization malfunction EGR high temperature thermistor malfunction EGR low temperature thermistor malfunction CY146 SPE/SPI communication error Excessive supply 1 voltage error Dropped/Insufficient supply 1 voltage error Sensor supply voltage error 1 Sensor supply voltage error 2 Sensor supply voltage error 3 Power for sensor SRC low error Actuator drive circuit 1 VB short-circuit Actuator drive circuit 2 VB short-circuit TSC1 (CAN message) reception time out (SA1) TSC1 (CAN message) reception time out (SA2) SW reset (recovery) execution 1 Y_ECR1 (CAN message) reception time out error SW reset (recovery) execution 2 Y_EC (CAN message) reception time out error SW reset (recovery) execution 3 Y_RSS (CAN message) reception time out error WDA/ABE shut off due to dropped voltage WDA/ABE shut off due to excessive voltage VH (CAN message) reception time out WDA/ABE shut off due to unknown cause Y_ECM3 (CAN message) reception time out Y_ETCP1 (CAN message) reception time out PRINTED IN USA

GEHL R105 / MUSTANG 1050R

ENGINE

Table 1: Yanmar Engine Diagnostic Trouble Codes (DTC)

DTC SPN 522610

9 19

P-Code U101B U040C

522611

9

U1107

522617 522618 522619 522623 522624

523249

12 9 9 7 7 12 12 12 12 8 12 4 12 12 12 12 12 19 4 12 12 12 5

U1401 U1302 U1303 P1647 P1646 P1610 P1611 P1612 P1620 U1167 U0167 P1626 P1438 P1439 P1440 P1441 P1442 P1443 P1633 P1607 P1615 P1616 P0008

523460

7

P1670

523462 523463 523464 523465

13 13 13 13

P1648 P1649 P1650 P1651

523468

9

P1665

523469 523470 523471 523473 523474 523475 523476 523477

0 0 6 12 12 12 12 12

P1666 P1667 P1467 P1469 P1470 P1471 P1472 P1473

522727 522728 522730 522744 522746 522747 522748 522749 522750 522751 522994

FMI

Error Item

PRINTED IN USA

Part

State CAN 1 CAN1 (for EGR): Reception time out error EGR CAN1 (for EGR): Reception data length error Exhaust throttle (CAN message from the exhaust CAN1 / Exhaust Throttle throttle time out) EGR Valve EGR target value out of range CAN 2 EBC1 (CAN message) Reception time out error CAN 2 Y_DPFIF (CAN message) reception time out Acceleration Sensor 1/2 Dual accelerator sensor (open position) Acceleration Sensor 1/2 Dual accelerator sensor (closed position) ECU Internal Fault Sub-CPU error A ECU Internal Fault Sub-CPU error B ECU Internal Fault Sub-CPU error C ECU Internal Fault Engine map data version error Immobilizer Pulse communication fault Immobilizer Communication fault ECU Internal Malfunction Actuator drive circuit 1 GND short-circuit Exhaust Throttle Voltage fault Exhaust Throttle Motor fault Exhaust Throttle Sensor system fault Exhaust Throttle MPU fault Exhaust Throttle PCB fault Exhaust Throttle CAN fault ECU Internal Malfunction Actuator drive circuit 2 GND short-circuit ECU Internal Malfunction WDA/ABE communication error ECU Internal Malfunction CY320 SPI communication error ECU Internal Malfunction MSC communication error of R2S2 Cam Sensor No signal from both sensors Rail pressure fault (operation time error during Rail Pressure Control/Sensor RPS limp mode) Injector (Correction Value) IQA corrected injection amount for injector 1 Injector (Correction Value) IQA corrected injection amount for injector 2 Injector (Correction Value) IQA corrected injection amount for injector 3 Injector (Correction Value) IQA corrected injection amount for injector 4 PLV (Common Rail Pressure Limit Rail pressure fault (controlled rail pressure error Value); Rail Pressure Sensor after PLV valve opening) Rail Pressure Sensor Rail pressure fault (PLV opening timing error) Rail Pressure Sensor Rail pressure fault (PLV opening timing error) ECU Internal Malfunction Actuator drive circuit 3 GND short-circuit ECU Internal Malfunction AD converter fault 1 ECU Internal Malfunction AD converter fault 2 ECU Internal Malfunction External monitoring IC and CPU fault 1 ECU Internal Malfunction External monitoring IC and CPU fault 2 ECU Internal Malfunction ROM fault 50950298/AP0517

185

ENGINE

GEHL R105 / MUSTANG 1050R

Table 1: Yanmar Engine Diagnostic Trouble Codes (DTC)

DTC

Error Item

SPN 523478 523479 523480 523481 523482 523483 523484 523485 523486 523487 523488

FMI 12 12 12 12 12 12 12 12 12 12 0

P-Code P1474 P1475 P1476 P1477 P1478 P1479 P1480 P1481 P1482 P1483 P1484

523489

0

P1668

543491

0

P1669

186

Part ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction ECU Internal Malfunction PLV (Common Rail Pressure Limit Value); Rail Pressure Sensor Rail Pressure Control/Sensor

50950298/AP0517

State Shutoff path fault 1 Shutoff path fault 2 Shutoff path fault 3 Shutoff path fault 4 Shutoff path fault 5 Shutoff path fault 6 Shutoff path fault 7 Shutoff path fault 8 Shutoff path fault 9 Shutoff path fault 10 Recognition error of engine speed Rail pressure fault (the actual rail pressure is too high during PRV limp mode) Rail pressure fault (injector B/F temp error during PLV4 limp home)

PRINTED IN USA

GEHL R105 / MUSTANG 1050R

INDEX

INDEX A Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Additional Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air Cleaner and Exhaust Components - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Air Cleaner and Exhaust Components - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Air Cleaner Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Air Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 All-Tach® Hitch Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 All-Tach® Hitch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Auxiliary Hydraulics Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Auxiliary Hydraulics Cable Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Axle and Wheel Bearing Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Axle Housing Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

B Battery Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

C Chaincases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Changing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Changing the Water Separator Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Charge Pressure Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Chassis Electrical Schematic - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Control Handle Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Control Handle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Control Locations - T-Bar and Hand/Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Cooling System Drain Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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D Description of Operation - Instrument Panel - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Description of Operation - Instrument Panel - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Diesel Particulate Filter (DPF) Regeneration Procedures - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Dome Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 DPF Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Drive Chain Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Drive Chain Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Drive Motor Hot-Oil Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Drive Motor Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

E Electric Foot Throttle Pedal Removal and Installation - DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Electric Fuel Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Electrical Chassis Components - DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Electrical Chassis Components - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Electrical Lights Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Electrical ROPS/FOPS Components - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Electrical ROPS/FOPS Components - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Electrical Schematic - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Engine Access Cover - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine Components and Engine Controls - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Engine Components and Engine Controls - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Engine Diagnostic Chart (DPF Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Engine Diagnostic Trouble Codes (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Exhaust Assembly Removal and Installation - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Exhaust Tube Removal and Installation - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

F Fan Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Fan Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Fan Shroud Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Fan Shroud and Support Brackets Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Floor Covers and Kickplate Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Foot Throttle Adjustment - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Foot Throttle and Foot Throttle Cable Removal and Installation - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Forcing Stationary Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Front and Rear Work Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Fuel Filter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Fuel Sensor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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G Gear Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Grease Fitting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

H Hand Throttle Adjustment - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Hand Throttle Tension Adjustment - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Handle Throttle, Hand Throttle Cable and Throttle Rod Removal and Installation - Non-DPF Models . . . . . . . . . . . . . . . . . 64 Hydraulic Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulics - Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Hydraulics - Chassis Components - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Hydraulics - Chassis Components - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Hydraulics - Lift Arm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Hydraulics - Self Level Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Hydraulics - Standard Auxiliary Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Hydrostatic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Hydrostatic Pump Assembly and Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Hydrostatic Pump Flexible Drive Coupling Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Hydrostatic Pump Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Hydrostatic Pump Removal / Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Hydrostatic/Hydraulic Schematic - Gehl R105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Hydrostatic/Hydraulic Schematic - Mustang 1050R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

I Interlock Control Module Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Interlock Control Module Truth Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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L Lift Arm Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Lift Arm Components - Gehl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Lift Arm Components - Mustang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Lift Arm Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Lift Arm Stop Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lift Arm Support Device Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Lift Arm Support Device Engagement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lift Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Lift Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Lift, Tilt and Brake Solenoid Valves - Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Lift/Tilt Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Lift/Tilt Controls Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Lift/Tilt Cylinder Disassembly / Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Loader Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Loader Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

M Main Control Valve Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Main Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Mainframe (Chassis) - DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Mainframe (Chassis) - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Mainframe Components - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Mainframe Components - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Mandatory Safety Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

N Neutral Centering Device Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Neutral Centering Device and Pump Arm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

O Oil Filter Element Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

P Pivot Tube Weldment Removal and Installation - T-Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Power Distribution Module Test and Operation - DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Pressure Tests, Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Priming the Diesel Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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R Radiator/ Oil Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Radiator/Cooler Components - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Radiator/Cooler Components - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Rear Grille Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Rear Grille Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Relay Test and Operation - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Relieving Hydraulic Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Reset Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Reset Regeneration Inhibit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Restraint Bar Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Restraint Bar Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Restraint Bar Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Restraint Bar Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Roll-Over and Falling Object Protective Structure Components - ROPS/FOPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ROPS – Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ROPS – Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ROPS/FOPS Electrical Schematic - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 ROPS/FOPS Rear Window Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 ROPS/FOPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

S Safety Lock Valves - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Seat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Seat Slide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Seat Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Seats - Standard and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Self-Leveling Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Self-Leveling Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Self-Leveling Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Solenoid Valve Test - Tilt, Lift, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Starter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Stationary Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

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T Tilt Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Tilt Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Tilt Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

W Water Separator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Wheel Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Wheel Drives, Auxiliary Hydraulics and Lift Tilt Components - Hand/Foot Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Wheel Drives, Foot Throttle and Lift Tilt Components - Parts Listing - T-Bar - DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . 49 Wheel Drives, Foot Throttle and Lift Tilt Components - Parts Listing - T-Bar - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . 51 Wheel Drives, Foot Throttle and Lift Tilt Components - T-Bar - DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Wheel Drives, Foot Throttle and Lift Tilt Components - T-Bar - Non-DPF Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Y Yanmar Engine Diagnostic Trouble Codes (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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