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Cpt Track Loader (CTL55/CTL65/CTL75/CTL85)

1. 139 Replacing the Travel Motor Gear Oil 135 Replacing the Travel Motor Gear Oil 139 Park 26 Retightening the Engine Cylinder Head Bolts 46 Parkings scandit tpi 90 Right Control Lever 60 Parking the Machine s 90 Perform inspection and maintenance daily 16 Place heavy objects in a stable position 30 S Precautions ern 93 SAFETY s 1 Precautions on Installing Attachments 180 SafeyBar s 59 Precautions on Operating Attachments 18 Safetysigns iss 24 Precautions on Safety 197 AN INDEX S W Safety Signs Decals 35 Transporting Precautions 27 seat mt 48 Travel in narrow Congested places 24 Seat lt CTL65 CTL75 CTL85 gt s 50 Travel Speed Button 58 Seat and Seat Bell eet eae 48 TROUBLESHOOTING zones 155 Seat Belt lt CTL55 49 Seat lt CTL65 CTL75 CTL85 gt 51 Secure the rear door when opened 30 U Securely block the machine or any component that may Use a signal person and flagman
2. 19 Every 100 Hours nnn Every 1000 Hours Every 1500 Hours Every 2000 Hours Every 250 HOUS iizians Every 3000 Hours es Every SO aiite aceti Every 500 Exhaust fumes from the engine can kill 13 Expendables uecae tetti 106 F Fan Switch 184 Fire prevention e 10 Float uiridi an 54 Fuel Filler testabatur 47 195 G Cc e 102 General 8 General Precautions e 180 H Handling asbestos dust s 13 Handling Of hoses natnra 31 Handling of poisonous chemicals 34 Have a Gehl technician repair weld cracks or other damage itii tait 34 Heating and Dehumidifying in cold weather or when the humidity is high 185 High flow Hydraulic System If Equipped 63 Hoisting the Machine 96 Hoisting the machine 5 27 54 Ifa Fuse BIOWS csset 160 If a Warning Lamp Flashes 162 If the
3. Rescue vehicle battery Problem machine battery 2 1 VF 1 ol 3 T block E4J005 158 Connect the clip of jumper cable R to the problem machine s positive terminal Connect the other clip of jumper cable R to the rescue vehicle s positive 4 terminal Connect the clip of jumper cable B to the rescue vehicle s negative terminal Connect the other clip of jumper cable B to the problem machine s engine block Connect the clip as far from the battery as possible Starting the engine 1 Check that the clips are securely connected to the terminals 2 Startthe rescue machine s engine and run it at high speed 3 Start the problem machine s engine TROUBLESHOOTING If the Battery Goes Dead TROUBLESHOOTING After the Fuel Runs Out Disconnecting the jumper cables After the engine starts disconnect the jumper cables following the connection procedure in reverse order Rescue vehicle battery Problem machine battery 1 4 006 Disconnect the clip of jumper cable B from the problem machine s engine block Disconnect the other clip of jumper cable B from the rescue vehicle s negative terminal Disconnect the clip of jumper cable R from the rescue vehicle s positive terminal Disconnect the other clip of jumper cable R from the problem machine s positive termin
4. 146 Every 2000 Hours 147 Every 3000 Hours 147 When Required ennn 148 Long term Storage 153 101 s MAINTENANCE n General Maintenance Description For long term use of the machine under good conditions perform the inspection and maintenance procedures properly and safely as recommended in this manual The inspection and maintenance items are divided according to the machine s total operating time inspection and maintenance to be performed every 10 hours walk around and daily inspection every 50 hours every 250 hours Refer to the hour meter to determine when it is time to perform inspection and maintenance Items for which itis not possible to determine the inspection and maintenance interval are included under When Required When operating the machine in extremely harsh environments with high dust levels or high temperatures inspection and maintenance should be performed earlier than the times indicated on the Maintenance Chart 102 Cautions on Maintenance Do not perform inspection and maintenance procedures not prescribed in this manual Have inspection and maintenance procedures not prescribed in this manual performed by a Gehl dealer Always keep the machine clean Always keep the machine clean and wash it before perfo
5. COOL WARM T9LOOS Use this dial to adjust the air temperature COOL To lower the temperature WARM To increase the temperature Note No warm air is emitted if the temperature of the engine coolant is low Fan Switch o OFF Es M 91004 Use this switch to adjust the fan speed in three steps At the OFF position the air conditioner is also OFF OPP uos Fan and air conditioner off Low M Medium Qnis High OPTIONS Air Conditioner CTL55 gt Outlets Move the louvers up and down or left and right to adjust the air flow direction and amount OPERATION Heating and Dehumidifying in cold weather or when the humidity is high AC T9LOO7 After starting the engine turn the air conditioner ON and adjust the switches as shown in the diagram above The outflow slot of the defroster can be directed at the cab door Warm dehumidified air blows on the cab door preventing fogging Set the temperature control dial and fan switch to the desired positions 185 Cooling Excessive cooling can be harmful to your health It is best to keep the air inside the cab only about 5 to 6 C 9 to 11 F cooler than the outside air If the loader has been parked in the sun open the windows or door to let the hot air out of the cab before using the air conditioner o
6. Auxiliary Hydraulic Lines 62 Cleaning the Condenser s Auxiliary Hydraulic Switches 56 Cleaning the Condenser lt CTL55 Option gt 137 Avoid battery hazards 33 Cleaning the Engine Cooling System 142 Avoid fire and explosion hazards 10 Cleaning the Filter e 188 Avoid overloading and off center loads 23 Cleaning the Radiator Fins and Oil Cooler Fins 137 Cleaning the Water Separator 134 Clear the area of other persons before starting the B MACHINE 17 Be careful not to get crushed or Condition of the refrigerant ss 190 Be careful with fluids under pressure elo 39 Be careful with grease under 185 Be careful with hot and pressurized components 34 Crush Hazard FOPS 9 Be careful with hot cooling systems 32 Be sure to raise the safety bar before leaving the operator s 1 9 Before Starting O
7. doo yo T 140 Caution on refrigerant gas After Cold Weather is Over 91 Cautions after Completing Operations After First 250 Hours New Machines Only 135 Cautions on Maintenance After First 50 Hours New Machines Only 122 Cautions on Operating After starting the engine 18 Cautions on tilting up the After the Fuel Runs Out s 159 Cautions on towing nnn Air Conditioner CTL55 gt 182 Cautions on Transporting 100 Air Conditioner Switch 184 Cautions on traveling and turning 20 Always clean the machine 29 Cautions on traveling on 5 21 Always keep the machine 15 Cautions on Traveling on Slopes 86 Always maintain good visibility 182 Check for safety in the surrounding area before starting 19 Anti explosive lighting 28 Check the strength of the bridge Attach a DO NOT OPERATE 28 Checks after maintenance
8. 170033 e Allowable water depth In water only use the machine up to a depth at which the water comes up to the bottom of the chassis When greasing places used under water for long periods of time apply enough grease so that the old grease is expelled Never submerge the main chassis in water or sand If the main chassis becomes submerged contact a Gehl dealer for inspection 85 OPERATION Operating Procedures Cautions on Traveling on Slopes Never exceed the machine s stability capabilities maximum gradeability 30 lateral tipping angle 15 Also note that when actual working area conditions are poor the machine s stability capabilities may be lower e When traveling on slopes or grades lower the bucket to a height of 20 to 30 cm 8 to 12 in off the ground In emergencies lower the bucket to the ground and stop the machine Travel at slow speeds on slopes Especially when going down slopes reduce the engine r p m speed and set the position of the left control lever to half orless before going down Going down a slope too fast will lead to loss of control e When going up or down slopes having a gradient of 15 degrees or more travel up and down slope with the heavy end of the machine pointed up hill e When traveling on a slope be cautious of tipping over or sliding sideways Do not travel down slopes in reverse except for with bucket full V
9. Use this lever to operate the lift arms and bucket Refer to page 74 Lever Pattern Refer to page 80 Operating the Right Control Lever 60 CONTROLS Accessories ee Interior Light Option IMPORTANT The battery charge will decrease if the interior light is left on for long periods of time with the engine stopped Turn the light off when leaving the machine LR TR SSS WES f ADS DRESS PAPAS Mi 7780271 61 CONTROLS Accessories Auxiliary Hydraulic Lines Oil may spray out if caps or filters are removed or pipes disconnected before releasing the pressure in the hydraulic system e When removing plugs or disconnecting hoses release the internal pressure before removing e Hydraulic fluid tubes fittings and quick couplers can get hot when running machine and attachments Be careful when connecting and disconnecting quick couplers These lines deliver the hydraulic oil necessary for operating other attachments Auxiliary hydraulic flow rate and rated pressure Flow Rate CTL55 57 L min 15 1 US gpm CTL65 70 L min 18 4 US gpm CTL75 75 L min 19 8 US gpm CTL85 89 L min 23 4 US gpm Rated Pressure 20 6 MPa 2987 psi Quick Couplers Connecting Remove dirt or debris from the surface of both the male and female couplers and from the outside diameter of the mal
10. 1 Inspecting the Fusible Link Inspecting the Hydraulic Oil Level and Replenishing 119 Inspecting the Refrigerant gas Level 188 Inspecting the Rubber Tracks 152 Inspecting the Turbocharger Blower wash as necessary CTL55 CTL75 CTL85 s 1 Inspecting the Water Separator Inspecting While Sitting in the Operator s Seat 1 Inspection After Warm up s Inspection and Checks After Stopping the Engine Instrument Panel Interior Light Option INTRODUGTION tte Keep a safe distance from electrical power lines Keep your body inside the operator s cab Know the working area nnnnn L Lapping the Engine Valve 147 Left Control Lever Let hot air out first Lever Pattefti sec ac aote ten Levers and Pedals 59 t AMN 46 Light SWItCTIeS cicer 58 Load and unload the machine safely 27 Loaders are NOT designed for lifting loads 25 Loading and Unloading 98 Long term Storage 153 Lubricant and Fuel Chart ss 104 Lubricating the Levers 150
11. TYPE ROPS MASS Ma nine mass kg b Rubber tracks 3635 8015 not including operator PERFORMANCE Bucket capacity m cu ft Heaped 0 351 12 4 standard bucket Struck 0 260 9 18 1st 7 3 4 54 Travel speed km h mph d sa racs 2nd 10 9 6 77 Gradeability degrees 30 Ground pressure kPa psi Rubber tracks 35 7 5 18 Noise level dB A Sound power level Lwa 103 lt For EU gt Sound pressure level Lpa 85 ENGINE Manufacturer and model Yanmar 4TNV98 ZNTBL Rated output kW min hp rpm 50 1 2500 67 1 2500 Displacement ml cu in 3319 203 Starter V kW 12 3 0 Alternator V kW 12 0 48 Battery V Ah 12 80 171 SPECIFICATIONS Main Specifications TYPE ROPS MASS Machine mass kg 6 Rubber tracks 4400 9700 not including operator 4450 9810 PERFORMANCE Bucket capacity m cu ft Heaped 0 458 16 17 standard bucket Struck 0 335 11 8 1st 7 6 4 72 Travel speed km h mph Rubber tracks 2nd 11 6 7 21 Gradeability degrees 30 Rubber tracks 28 9 4 2 Ground pressure kPa psi 28 8 4 18 Noise level Sound power level Lwa 104 For EU Sound pressure level Loa 85 ENGINE Manufacturer and model Yanmar 4TNV98T ZNTBL Rated output kW min hp rpm 61 9 2500 83 2500 Displacement ml cu in 3319 203 Starter V kW 12 3 0 Alternator V kW 12 0 48 Battery V Ah 12 80 f
12. U1B009 Press the travel speed button on the left control lever to switch to 2nd high speed and press it again to return to 1st speed low speed T7D0161 gt To spin left Tilt the left control lever to the left gt To spin right Tilt the left control lever to the right 78 OPERATION Machine Operation Stopping Travel Park the machine on firm level ground and apply the parking brake If you must park on a slope or incline park across the slope and block the machine securely to prevent movement If any controls are touched accidentally when the safety bar is lowered the machine will move suddenly and may cause serious injury or death Never bring the machine to a sudden stop except in the case of a true emergency Stop as gently as possible d 10007 1 Slowly set the left control lever to the neutral position The machine stops Braking is automatically applied by the hydrostatic drive system when the left control lever is returned to the neutral position Full braking is achieved when the safety bar is raised 79 24 OPERATION Machine Operation Operating the Right Control Lever e Be careful to check which pattern of lever control arrangement you are operating with before beginning operations e Make sure the bucket is lowered to the ground before floating the lift arms Floating the lift arms while they are raised wil
13. i b Tightening TOQUES rrara 108 Wiper Switches Option 58 Tilting Up the ROPS s 151 To Lower the Lift Arms 166 M 107 TOWING 167 TRANSPORT eet ia 95 Transport the machine 5 27 198 GEHL COMPANY WARRANTY GEHL COMPANY hereinafter referred to as Gehl warrants new Gehl equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve 12 months from the Warranty Start Date GEHL WARRANTY SERVICE INCLUDES Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer s business location GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND EXPRESS OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL BE DEEMED DELETED FROM THIS WARRANTY ALL OTHER TERMS WILL CONTINUE TO APPLY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW GEHL WARRANTY DOES NOT INCLUDE 1 Transportation to selling dealer s business location or at the option of the Original Retail Purchaser the cost of a ser
14. 7 Remove the inner element 5 8 Install the new elements Press the elements firmly into the body 4 9 Install the dust cup 2 with the UP mark at the top then fasten it with the clamps 1 2 Push down the lever 6 to tilt up the air cleaner 016009 10 Push down the air cleaner and securely lock it Every 250 Hours Cleaning the Radiator Fins and Oil Cooler Fins Wear required appropriate equipment such as safety glasses and filter mask when using compressed air because metal fragments or other objects can fly and cause serious personal injury IMPORTANT Be careful not to damage the radiator fins and oil cooler fins when cleaning them When using compressed air pressurized water make sure the pressure is no higher than 200 kPa 28 psi and hold the nozzle sufficiently away from the fins IMPORTANT When using water cover the electrical system to prevent water from getting in IMPORTANT When operating the machine in very dusty places inspection and maintenance should be performed every day 1 Open the rear door 2 Blow compressed air on the radiator fins and oil cooler fins to remove mud and dirt stuck on them 137 Replacing the Engine Oil and Oil Filter Refer to page 123 Replacing the Engine Oil and Oil Filter Inspecting and Adjusting the Fan Belt Refer to page 125
15. To prevent overheating and reduce the risk of fire the machine should be cleaned daily The standard cooling package is not permitted for use in high airborne debris applications such as mulching or land clearing Operating attachments in these environments could cause the warranty to be denied IMPORTANT Operation over long periods with Detent mode switch pressed will cause the hydraulic oil temperature to rise and will shorten the life of the hydraulic units 64 65 66 67 68 24 OPERATION Before Starting Operation 70 Starting and Stopping the Engine 71 Machine Operation 74 Operating Procedures 82 Parking the Machine 90 Operating in Cold Weather 91 Using Rubber Tracks 92 69 OPERATION mS Before Starting Operation Mounting and Dismounting Do not jump on or off the machine Never attempt to mount or dismount a moving machine e When mounting and dismounting the cab first open the door fully to the locked position and check that it does not move for machines with front door 170001 Always face the access system and maintain a three point contact with the handholds and steps while getting o
16. Working Lithium Daily or every equipment pd grease 10 hrs As required Levers and 5 i Pedal NLGI No 2 When required s MAINTENANCE 2 Service Data gear oil earlier than the specified time For water use tap water soft Do not use well or river water If the percentage of the traveling time within the total operating time is high replace the When the ambient temperature drops below 0 add coolant antifreeze Follow the coolant manufacturer s instructions to determine the mixture ratio Fuel Diesel Fuel Specifications Diesel fuel should comply with the following specifications The table lists several worldwide specifications for diesel fuels Diesel Fuel Specification Location Diesel Fuel Specification Location ASTM D975 USA ISO 8217 DMX International No 1D 15 S500 No 2D 15 S500 EN590 96 European BS 2869 A1 or A2 United Union Kingdom Capacity L Part Type US gal Use a clean quality fuel for good performance and optimum engine life To prevent fuel flow problems in cold weather use diesel fuel with a pour point of at least 12 10 F below the lowest expected ambient temperature CTL55 57 e Minimum cetane number is 45 Low 15 1 US gal temperature or high altitude operation may CTL65 75 require the use of fuel with a higher cetane 19 8 US gal Fuel tank Diesel fuel number CTL75 90 e Use fuel with sulfur content of less than 0 05 23 8 US gal by volume
17. 9 30 Use caution when floating the lift arms 21 Securely block the raised lift 30 Use caution when fueling 81 Securing the 99 Use 28 Service Data 04 Using optional products vss 14 Side Window lt CTLSS gt 43 Using Rubber Tracks 92 SPECIFICATIONS nnns 169 Start the engine from the operator s seat 17 Starting and Stopping the 71 Starting Precautions Starting the Engine caeterae M seh Starting with jumper cables 18 Vibrations to which the operator is subjected 34 Stay clear of moving parts 29 Stop the engine before performing maintenance 29 W Stopping Precautions Stopping the Engine ts Walk Around Inspection 70 Walk Around Inspection 114 Symptoms that Are Not Malfunctions 156 Warming Up the Engine 73 Warming Up the Hydraulics 75 Warning LAMPS 52 Watch out for hazardous working conditions 24 Temperature Control Dial 184 Wear appropriate clothing and personal protective Throttle LiGuar mta 59 equipment
18. Air strength High e Engine speed 1500 rpm Air conditioner On Inspect by watching the flow of air bubbles in the refrigerant through the sight glass 2 Refer to page 190 Condition of the refrigerant The high pressure pipe becomes hot 80 to 120 C 176 to 248 F so be careful not to burn yourself when inspecting the refrigerant level 4 Open the radiator Refer to page 125 Inspecting and Adjusting the Fan Belt 5 Also check the temperature of the compressor s high pressure pipe 1 and low pressure pipe 2 Refer to page 184 Condition of the refrigerant 189 Off Season Inspection Even off season run the cooler for 3 to 5 minutes at least once a week to maintain oil in the various parts of the compressor OPTIONS d Air Conditioner lt CTL55 gt Condition of the refrigerant Sight glass refrigerant High low pressure pipe connection temperature Normal Almost transparent with High pressure pipe 1 hot No irregularities some bubbles but fully 80 to 120 C 176 to 248 transparent when the low pressure pipe 2 cold engine speed is increased 8 to 15 C 46 to 59 F or decreased Clear difference in temperature between the pipes Flow of bubbles can be High pressure pipe Seen constantly Refrigerant warm low pressure pipe is sometimes transparent or somewhat cool No great has white bubbles difference in
19. CTL85 108 A higher sulfur content fuel may cause sulfuric 28 5 US gal acid corrosion in the cylinders of the engines e NEVER mix kerosene used engine oil or residual fuels with the diesel fuel Poor quality fuel can reduce engine performance and or cause engine damage Fuel additives are not recommended Some fuel additives may cause poor engine performance 105 s MAINTENANCE 2 Service Data Expendables Replace wear out items such as filters and elements periodically referring to the table below Replacement interval Item Part name Part No Hydraulic oil return filter Element 195564 After first 50 hrs Pilot line filter Element 180324 Every 500 hrs Fuel filter Cartridge CTL55 195566 Every 500 hrs CTL65 195566 CTL75 195566 CTL85 195567 Engine oil filter Cartridge CTL55 195568 After first 50 hrs CTL65 194315 Every 250 hrs CTL75 194315 CTL85 195569 Air cleaner Outer Element CTL55 195570 CTL65 195570 CTL75 195571 CTL85 195571 Every 250 hrs or when the air cleaner warning lamp lights Do not clean Inner Element CTL55 195573 CTL65 195573 CTL75 195574 CTL85 195574 106 Every 250 hrs or when the air cleaner warning lamp lights Do not clean s MAINTENANCE A Service Data Tools 1 2 3 5 6 7 9 10 11 12 13 14 15 16 17 Q 18 21 T7G0013 Partname Part
20. Consult a Gehl dealer Hoisting 1 Lower the bucket to the ground 2 Raise the safety bar to engage the lock 3 Stop the engine and remove the starter key and get off the machine 4 Install the sling as shown on the diagram Suspend in such a way that the sling and lifting tool do not touch the chassis 5 Hoist slowly until the machine just leaves the ground 6 Stop hoisting until the machine is stable and hoist again slowly 96 Hoisting position CTL55 CTL65 gt Mi VR i Rear L H Rear T7FO05E Lifting tool T7FOO4E TRANSPORT ems Hoisting the Machine CTL55 CTL65 1555 61 3 1675 65 9 930 36 7 1005 39 6 1525 60 1590 62 6 D 950 37 4 960 37 8 E 575 22 6 635 25 F 585 23 1 440 17 3 G 425 16 7 600 23 6 Units mm inches CTL75 CTL85 1660 65 3 1705 67 1 B 940 37 1 950 37 4 1720 7 7 1895 74 6 D 985 38 8 1110 43 7 E 735 28 9 785 30 9 F 880 34 7 880 34 6 G 630 24 7 615 24 2 Units mm inches TRANSPORT Loading and Unloading The machine may roll or tip over or fall while loading or unloading it Take the following precautions Select a firm level surface and keep sufficient distance from road shoulders Use loading ramps of adequate strength and size Maintain the slope of loading ramp
21. Inspecting and Adjusting the Fan Belt Cleaning the Condenser lt CTL55 Option gt Refer to page 187 the Condenser Cleaning Inspecting and Adjusting the Air Conditioner Belt lt CTL55 Option gt Refer to page 187 Inspecting and Adjusting the Air Conditioner Belt MAINTENANCE 2 Every 500 Hours pan under the filter 1 3 Using a filter wrench turn the filter 1 counterclockwise and remove it WARNING 4 Clean the surface of installation of the Replacing the Fuel Filter Do not smoke or permit open flames filter stand while handling fuel or working on the 5 Apply a thin layer of oil to the packing of fuel system the new filter Stop the engine in a well ventilated Install the new filter by hand place and allow it to cool before 7 Tighten one more turn after the filter performing maintenance packing comes in contact with the surface Clean up spilled fuel immediately of installation 8 Bleed the air CTL55 CTL65 CTL 75 Refer to page 159 Bleeding the Air from the Fuel System ES ZAN s ANA 016019 16012 1 Tilt up the ROPS 138 MAINTENANCE 2 Every 500 Hours Replacing the Hydraulic Oil Return Filter Refer to page 122 Replacing the Hydraulic Oil Return Filter Replacing the Pilot Line Filter Refer to page 126 Replacing the Pilot Line Filter Replacing the Trave
22. Lubricating the Working Equipment 120 M MACHINE DESCRIPTION 3 Machine Dimensions ennt 174 Machine Operation es 74 Main Specifications 170 Maintain three point contact when mounting and dismounting ttt 17 MAINTENANCE Maintenance Chart e Maintenance Description s Maintenance Logistic enn Maintenance Precautions MELONS e Mounting and Dismounting R INDEX N S N Precautions when passing through tunnels or near high Uc 24 Names of Components n Prepare the Work area 29 Never disassemble the track adjuster Preparing for Cold Weather s 91 Never modify the Preparing Precautions 15 Never remove safety equipment 9 Product Usage tc 14 Prohibited Actions s 92 Prohibited Operations 82 o Provide a fire extinguisher and first aid Kit 8 Observe all safety rules Off Season Inspection es Operate on snow or ice with extra caution 22 R Operate th
23. a ie T7D0032 If a lamp does not light or the alarm is not sounded the bulb may be burned out or a wire may be damaged Contact a Gehl dealer for repairs OPERATION A p amp 3 Starting and Stopping the Engine Starting the Engine Clear the area of all persons Sound horn to alert everyone around the machine IMPORTANT Donotrun the starter motor for more than 15 consecutive seconds If the engine fails to start wait for 30 seconds to protect the battery and then try again to start the engine Normal Starting ce 2 s EC is 010002 1 Pull the throttle lever to the middle position 20003 2 the key to the START position and start the engine 3 Once the engine starts release the key The key automatically returns to the ON position Check that the warning lamps are off 5 Return the throttle lever to idle position and warm up the engine Refer to page 73 Warming Up the Engine A Starting in Cold Weather V 010002 1 Pull the throttle lever to the middle position Te PREHEAT J2DOO4E 2 Turn the key to the PREHEAT position and hold it there while the glow lamp is lit about 15 seconds CTL85 25 seconds 3 After the glow lamp turns off then turn the key to the START position and start the engine 4 Once the engine starts release
24. b T7E007 Avoid traveling with one track on a slope or projecting object and the other track on a flat surface with the machine at a tilt of 10 or greater Travel with both tracks on flat surfaces OPERANON Using Rubber Tracks T7E008 e Do not change directions when the tracks are slack as shown in the diagram 94 TRANSPORT Hoisting the Machine 96 Loading and Unloading 98 Securing the Machine 99 Cautions on Transporting 100 95 TRANSPORT ems Hoisting the Machine e Know and use correct crane signals Inspect the hoisting equipment daily for damaged or missing parts e When hoisting use a wire rope with sufficient strength for the machine s weight Do not hoist with the machine in a position other than the one described in the procedure below Doing so is dangerous because it may result in the machine losing its balance e Do not hoist the machine with an operator on it When hoisting hoist slowly so that the machine does not tip e Keep all other persons out of the area when hoisting Do not move the machine over the heads of the persons IMPORTANT This hoisting method applles to machines with standard specifications The center of gravity differs according to the attachments and options that are mounted
25. it may not have the safety devices or meet the safety standards required for use in your country If you have any question about whether your machine complies with the regulations and standards of your country contact a Gehl dealer Please note that the contents and diagrams included in this manual may not match your machine exactly It is your responsibility to observe all pertinent laws and regulations and to follow the manufacturer s instructions on machine operation inspection and maintenance Virtually all accidents occur as the result of a failure to observe basic safety rules and precautions An accident can often be avoided by recognizing potentially hazardous situations beforehand Read and understand all of the safety messages which explain how to prevent these accidents from occurring Do not operate the machine until you are sure that you have gained a proper understanding of its operation inspection and maintenance ESIGNAL WORDS Safety messages appearing in this manual and on machine decals are identified by the words DANGER WARNING and CAUTION These signal words mean the following The word DANGER The word WARNING The word CAUTION indicates an imminently hazardous situation which if not avoided can result in serious injury or death indicates a potentially hazardous situation which if not avoided could result in serious injury or death indicates a potentially hazardous situation
26. shut off and the line is visibly grounded Use a signal person to observe the approach of any part of the machine or load to the power line Caution all ground personnel to stand clear of the machine and the load at all times If the machine should come in contact with a live electrical source do not leave the operator s seat Do not allow anyone to approach or touch the machine Be especially careful of buried high voltage power lines Operating Precautions Watch out for hazardous working conditions Precautions when passing through tunnels or near high walls T7A021 Neverundercutahigh bank Be particularly alert for the possibility of a cave in Do not operate in places where there is a danger of falling rocks Do not approach unstable surfaces cliffs road shoulders deep trenches etc The ground may give way under the machine s weight or vibrations causing the machine to tip over e The ground is weak after rain or explosions The ground is also unstable on banks and near dugout trenches Travel in narrow or congested places T7A023 Careless entry into tunnels or places with high walls can lead to serious accidents such as contact accidents etc Check height and width limits in advance and verify that the machine is within the limits Do not drive on soft ground T7A022 To avoid contact accidents pay attention to the surroundings at
27. which if not avoided may result in injury IMPORTANT The word IMPORTANT is used to alert operators and maintenance personnel about situations that can result in possible damage to the machine and its components It is impossible to foresee every possible circumstance that might involve a potential hazard The warnings in this manual or on the machine can not cover all possible contingencies You must exercise all due care and follow normal safety procedures when operating the machine to ensure that no damage occurs to the machine its operators or other persons E EXPLANATION OF GRAPHICAL SYMBOLS Following is an explanation of symbols used in this manual O prohibition a E Lock 9 jd Unlock INTRODUCTION Foreword This manual describes operation inspection and maintenance of the machine as well as safety instructions to be heeded during these operations If you have any questions about the machine please contact a Gehl dealer Manual storage compartment for storing this manual is provided at the position shown in the diagram below 1 Insert the starter key and turn it counterclockwise to unlock the cover 1 2 Open the cover 1 3 After using the manual place it in the plastic pouch and store it in the manual storage Type A Serial numbers Check the serial numbers of the machine and the engine and write them in the spaces p
28. 114 Inspecting by walking around the machine 115 Inspecting while sitting in the operator s seat 115 Daily Inspection Every 10 Hours Inspecting and replenishing the coolant 116 Inspecting and replenishing the engine oil 117 Inspecting the water separator 117 Inspecting the fuel level 118 Inspecting the hydraulic oil level and replenishing 119 Lubricating the working equipment 120 After First 50 Hours New Machines Only Replacing the hydraulic oil return filter 122 Replacing the engine oil and oil filter 123 Inspecting and adjusting the fan belt 125 Replacing the pilot line filter 126 Every 50 Hours Inspecting and adjusting the track tension 128 Inspecting the battery fluid level and replenishing 130 Draining the fuel tank 132 Inspecting the bucket stoppers bolts nuts 133 Every 100 Hours Cleaning the water separator 134 After First 250 Hours New Machines Only Replacing the travel motor gear oil 135 If the percentage of the travel time within the total operating time is high replace the gear oil earlier than the specified time 110 MAINTENANCE Maintenance Chart Maintenance Items Page Every 250 Hours Replacing the air cleaner elements 136 Cleaning the radiator fins and oil cooler fins 137 Replacing the engine oil and oil filter 137 Inspecting and adjusting the fan belt 137 Cleaning the condenser CTL55 Option gt 137 Inspecting and adjusting the air conditioner bel
29. Battery Goes 158 If the Engine Overheats s 157 lghition Ignition Switch Important Parts In cold weather partite RR e Inspecting and Adjusting the Air Conditioner Belt 87 Inspecting and Adjusting the Air Conditioner Belt Option ctt ttr tos 137 Inspecting and Adjusting the Engine Valve Clearance 146 Inspecting and Adjusting the Fan Belt 1 Inspecting and Adjusting the Fan Belt INDEX I M Inspecting and Adjusting the Track 128 Inspecting and Cleaning the EGR Valve Lead Valve and i 147 Inspecting and Cleaning the Engine Fuel Injectors 146 Inspecting and Replacing 160 Inspecting and Replenishing the Coolant 116 Inspecting and Replenishing the Engine Oil 117 Inspecting and Replenishing the Windshield Washer ui 150 Inspecting by Opening the Engine Hood and Rear DOOM Rn RU 1 Inspecting by Walking Around the Machine Inspecting the Battery Fluid Level and Replenishing 130 Inspecting the Bucket Stoppers bolts nuts 133 Inspecting the Crankcase Breather System 146 Inspecting the Fuel
30. a concentration of 50 Refer to page 104 Lubricant and Fuel Chart Battery As the temperature drops the battery performance decreases Inspect the battery If the charge is low contact a Gehl dealer to have the battery charged Refer to page 130 Inspecting the Battery Fluid Level and Replenishing 91 Cautions after Completing Operations Heed the following to prevent dirt water or other objects being stuck on the machine as well as the lower chassis from freezing Remove any dirt or water from the chassis In particular water droplets on the hydraulic cylinder rod surfaces could freeze and if dirt and ice enter into the seals the seals could break Park the machine on a dry hard surface If no appropriate place can be found put boards down and park on the boards Drain any water from the fuel tank to prevent freezing Refer to page 132 Draining the Fuel Tank Topreventdecreasedbattery performance place a cover over the battery or remove it from the machine and store it warm place Also add battery fluid before starting the next morning If battery fluid is added after completing operations the distilled water may not mix resulting in freezing After Cold Weather is Over Perform the following after cold weather is over e Change the fuel and the oils for those specified on the Fuel and Lubricant Chart Refer to page 104 Lubricant and Fuel Chart When using o
31. and the stopper bolt 8 so that they evenly contact each other Start the engine retract the bucket cylinders to the minimum length and then stop the engine 019025 12 Adjust the height of the stopper bolts 8 so that they protrude 1 mm 2 3 turn and tighten them with the lock nuts 7 Stopper bolt lock nut ThreeBond 1324 Tightening torque Lock nut 416 N m 306 7 ft lb U1G0261 13 14 15 Start the engine lift the lift arm until the lift arm stop 2 is disconnected and then stop the engine Disengage the locking pin 3 and then remove the lift arm stop 2 Start the engine lower the lift arm to its lowest position and then stop the engine Every 1000 Hours Cleaning the Engine Cooling System Stop the engine and allow the machine to cool before performing maintenance The engine muffler radiator and many other parts of the machine are hot directly after the engine is stopped Touching these parts will cause burns The engine coolant is also hot and under high pressure Be careful when loosening caps and plugs Working on the machine under these conditions could result in burns or injuries due to the hot coolant spurting out If maintenance must be performed with the engine running always work asatwo person team with one person sitting in the operator s seat while the other works on the machine When performing
32. and the hydraulic flow switches from two way to one way and the built in lamp and flow selector switch lamp green come on Press this switch again to deactivate the high flow hydraulics and the hydraulic flow switches from one way back to two way and the lamps go out Refer to page 63 High Flow Hydraulic System OFF harsi ON CONTROLS e Switches Travel Speed Button Wiper Switches Option IMPORTANT If no washer fluid is discharged do not operate the washer I Doing so may damage the pump U1B009 Press this button to set the travel speed to 2nd speed high speed while travel speed lamp lights Press again to return to 1st speed low speed and travel speed lamp turns off Travel speed always begins in 1st speed when starting the engine Refer to page 53 Travel Speed Lamp Light Switches L3B028 When this switch is turned on while the ignition switch is ON the lights turn on as follows Front light switch Instrument lights and front lights turn on Tail light switch inei Tail lights turn on 58 IMPORTANT Operating the wiper with no moisture on the windshield will scratch the glass Apply water or washer fluid when operating the wiper IMPORTANT In cold seasons the wiper blade may freeze to the glass Operating the wiper forcibly may damage the wiper motor L3B029 Front wiper switch O Off Wi
33. button is released the Float mode is canceled Setting the arm float to the detent mode To set to the detent mode press and hold the arm float button and move the right control lever forward once To turn off the detent mode move the right control lever rearward T8B0091 When in the Float mode the bucket can follow the contour of the ground without movement of the control lever 55 CONTROLS Switches gt Auxiliary Hydraulic Switches Auxiliary Hydraulic Buttons A B Jew Press these buttons to control the flow of the oil in the auxiliary hydraulic circuit U1B004 A Hydraulic oil flows to auxiliary hydraulic line a B Hydraulic oil flows to auxiliary hydraulic line b kx U1BOOSE The button turns on the flow when it is pressed and turns off the flow when it is released e When one way flow is selected by turning on the flow selector switch C the auxiliary hydraulic button only functions when button A is pressed Refer to page 81 Operating the Auxiliary Hydraulics Slider Switch Proportional control Proportional control allows for slow to fast movement of auxiliary functions 56 Example If you move the slider switch half way the auxiliary function will move at approximately one half speed C T9B012 Move this switch to c
34. clothing that can catch fire Wear a hard hat safety shoes safety glasses filter mask heavy gloves ear protection and other protective equipment as required by job conditions Wear required appropriate equipment such as safety glasses and filter mask when using grinders hammers or compressed air because metal fragments or other objects can fly and cause serious injury P dn E3A040 Use hearing protection when operating the machine Loud prolonged noise can cause hearing impairment even the total loss of hearing Operating temperature range To maintain the performance of machine and to prevent it from early wear observe the following operating conditions Do not operate the machine if the ambient temperature is higher than 45 C 113 or lower than 15 C 5 f operated at an ambient temperature of higher than 45 113 the engine may overheat and cause the engine oil to degrade operated at an ambient temperature of lower than 15 C 5 F the parts made of rubber such as gaskets may get hardened to cause an early wear or damage to the machine e f the machine is to be used outside the ambient temperature range described above consult your sales or a service dealer Provide a fire extinguisher and first aid kit E3A080 Know where a fire extinguisher and first aid kit are located and understand how to use them e Know how to contac
35. equipment Clean up any grease diesel fuel hydraulic and lubricating oil accumulation and spillage immediately Steamcleantheengine andbelly panareas at least once a month or more frequently when working in sever conditions where large amounts of combustible debris are present Use only nonflammable solutions for cleaning the machine and components Inspect the exhaust system daily for any signs of leakage Check for worn cracked broken or damaged pipes or muffler Also check for missing or damaged bolts or clamps Should any exhaust leaks or defective parts be found repairs must be made immediately Engine exhaust leaks can cause fires Do not operate the machine until the exhaust leak is repaired 10 During daily operation of the machine the occurrence of exhaust leaks are usually accompanied by a change or 11 increase in engine exhaust noise levels These audible warnings cannot be ignored Should any exhaust leaks occur during operation the machine must be shut down immediately and not put back to work until the necessary repairs have been completed 11 Before starting repair work such as welding the surrounding area should be cleaned and a fire extinguisher should be close by 12 Do not use the machine on top of or to push piles of burning timber A machine fire will likely result What to do to prepare for a machine fire e Prevent the fire from happening in the first place by ensuring th
36. humidity is high If this happens turn on the air conditioner and use outside air and the defroster to get rid of the fog If the air conditioner is set too high when using the defroster the difference between the external and internal temperatures increases and fog may form on the outside of the windows If this happens either turn off the air conditioner or turn the temperature control dial clockwise to increase the inside temperature Mist may blow out of the air outlets This is not a malfunction When moist air passes through the air conditioner unit s evaporator water particles in the air freeze and are emitted as mist 182 Do not overcool For health purposes the air inside the cab should be kept at a temperature at which you feel a little cool when entering the cab from outside a difference of 5 to 6 C 9 to 11 F Be careful to adjust the temperature properly Do not turn the air conditioner on until the engine is started To avoid placing an excessive load on the compressor wait until the engine is started and is running smoothly before turning on the air conditioner Let hot air out first If the loader has been parked in the sun open the windows or door to let the hot air out of the cab before using the air conditioner Caution on refrigerant gas Exposure of the eyes or hands to the air conditioner s refrigerant could result in blindness or frostbite Never touch the refrigerant or loosen the
37. machine set the bucket against the ground or in the lowermost position Securely block the tracks e f you must work beneath the raised machine or equipment always use lift arm stop jack stands or other rigid and stable supports Never get under the machine or working equipment if they are not sufficiently supported This procedure is especially important when working on hydraulic cylinders Securely block the raised lift arms f you must work beneath the raised lift arms securely engage the lift arm stop Never get under the lift arms and bucket if they are not sufficiently supported Disconnecting or loosening any hydraulic line hose fitting or component or a parts failure can cause the lift arms to drop 30 Service the lift arm stop if damaged or if parts are missing Using a damaged lift arm stop or with missing parts can cause the lift arms to drop causing injury or death Secure the rear door when opened Be sure to secure the rear door when opening it Do not open the rear door on slopes or in strong wind Cautions on tilting up the ROPS e Raising or lowering the ROPS while the engine is running may cause the machine to move and cause serious injury or death Lower the working equipment to the ground and stop the engine before raising or lowering the ROPS When the ROPS is tilted up support it firmly with the stop to prevent it from falling Place heavy objects in a s
38. narrow sites indoors and congested places and operate at speeds at which the machine can be safely operated 24 T7A024 Driving onto soft ground can result in the machine tilting on its own weight tipping over or falling in Do not enter weak ground such as that following back filling Operating Precautions Loaders are NOT designed for lifting loads gt ps T7A0261 The machine is NOT specifically designed for lifting loads and has no safety devices for crane operation Danger of flying objects This machine is not equipped with protective guards to protect the operator from flying objects Do not use the machine in places where there are risks of the operator being hit by flying objects 25 Cautions on towing 30 or less 30 ou moins weniger als 30 30 menos 1 T9A0071 When towing selecting the wrong wire rope inspecting improperly or towing in the wrong manner could lead to accidents resulting in serious injury or death The wire rope breaking or coming detached could be extremely dangerous Use a wire rope suited for the required tractive force Do not use a wire rope that is kinked twisted or otherwise damaged Do not apply strong loads abruptly to the wire rope Use safety gloves when handling the wire rope Make sure there is an operator on the machine being towe
39. page 142 If the problem persists after the above procedures are taken contact a Gehl dealer for repairs TROUBLESHOOTING If the Battery Goes Dead The following symptoms indicate that the battery is dead The starter motor does not turn or turns weakly and the engine does not start The horn is weak Procedure Use jumper cables and start the engine using the rescue vehicle s battery Use jumper cables only in the recommended manner Improper use of jumper cables can result in battery explosion or unexpected machine motion Do not let the problem machine and rescue vehicle touch each other Donotletthe positibe and negative clips of the jumper cables touch each other Connect the jumper cables to the positive terminals first and disconnect them from the negative terminals ground first Connect the final clip of the jumper cable to a point as far away from the battery as possible Use safety glasses when using jumper cables to start the machine IMPORTANT Usejumper cables and clips of a size suited to the battery s capacity Do notused damaged or corroded jumper cables and clips IMPORTANT The rescue vehicle s battery must have the same capacity as the problem machine s battery IMPORTANT Connect the clips securely Connecting the jumper cables IMPORTANT Setthe ignition keys of both the rescue vehicle and problem machine to the OFF position
40. posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling battery Ciz HL Gehl Company 143 Water Street P O Box 179 West Bend WI 53095 0179 U S A www gehl com 917299 EP0910 2010 GEHL COMPANY PRINTED IN JAPAN Rights Reserved
41. properly utilized 1 Pull out the locking pin D from the lift arm stop 2 Hook the end part of the spring 3 onto tne hook of the ift arm stop 3 Sit in the seat fasten the seat belt start the engine and lower the safety bar 4 Raise the lit arms slowly until the spring wil lift the lit arm stop 2 off the e cylinder rod tar i 5 Lower the Ift arms slowly to the ground and stop the engine 5 Sitin ten t 5 Raise the lift arms slowly until the lit arm stop 2 drops onto the cylinderr rod 6 Raise the I arm stop into storage position and insert the locking pin D through 7 Lower the lift arms slowly until the lift arm stop Mt arm stop and bracket n the lift arm and the end of the cylinder tube 6693 001100 U1AG031 37 Safety Signs Decals 16 No 08800 31018 17 No 137637 EMERGENCY 19 No 03993 00400 Position of Fire extinguisher A WARNING ALWAYS keep legs arms and body out from between lift arm and machine 08810 31551 21 03593 06600 20 08810 31549 Diesel fuel Tie down point Diesel Fuel Only 22 No 03593 06700 23 No 06693 00014 Hydraulic oil A CAUTION A sure to unlock the air cleaner before cleaning replacing the elements sure to lock the air cleaner after completing the maintenance 06693 00014 24 No 03993 00500 25 No 08710 86051 26
42. rapidly and is dangerous Do not drive the loader forward with the lift arms in Float position 7700411 Lower the bucket onto the ground then put the lift arms Float position Tilt the bucket forward to stand it on its cutting edge then level the loose material while driving rearward Loading p T7D0421 Approach the truck and stop then raise the bucket until its lower edge clears the truck bed Drive the loader slowly forward stop at the position where the bucket is to be tilted forward then tilt the bucket forward releasing the material in the bucket into the truck bed When the truck is half loaded use the bucket to spread the load evenly 89 ZA OPERANON R3 Parking the Machine Parking T7A027 T7A028 e Park the machine on firm level ground and apply the parking brake If you must park on a slope or incline park across the slope and block the machine securely to prevent movement e When parking on streets use barriers caution signs lights etc so that the machine can easily be seen even at night to avoid collision with other vehicles Before leaving the operator s seat set the safety bar to the lock position and stop the engine Never leave the machine with the engine running or the lift arms raised unattended If arms are left in raised position they MUST be restrained by the lift arm stop Before l
43. seat rearward or forward to bring it to the optimum position for operating the machine 2 Release the lever 2 at the desired position and the seat will be locked there Adjustment range 15 steps 150 mm 5 9 in G4B0071 C Weight adjustment 1 Turn handle 8 until the indicator 4 will show the operator s weight May be set to any value 10 kg steps from 50 to 130 kg 110 to 287 Ibs D Vertical adjustment Upward Lift the seat to first or second position click stop Downward First lift the seat to highest position then the seat can be lowered to lowest position E Headrest adjustment Option The position of the headrest can be adjusted in the vertical and front rear directions 1 To adjust in the vertical direction grasp the headrest with both hands and move it upward or downward 2 To adjust in the front rear direction grasp the headrest with both hands and move it forward or rearward CONTROLS Seat and Seat Belt Hem Seat Belt lt CTL65 CTL75 CTL85 gt Always fasten the seat belt securely before starting the engine Fastening the seat belt 1 Adjust the seat to the optimum position for operating raise your torso and sit back firmly into the seat 2 Pull the seat belt to the desired length 3 Make sure that the belt is not twisted and then insert the tongue plate A into the buckle B of the seat belt until you hear a cl
44. selecting the wrong wire rope inspecting improperly or towing incorrectly could lead to accidents resulting in serious injury or death The wire rope breaking or detaching could be extremely dangerous Use a wire rope suitable for the required tractive force Do not use a wire rope that is kinked twisted or otherwise damaged Do not apply strong loads abruptly to the wire rope Use safety gloves when handling the wire rope Make sure there is an operator on the machine being towed as well as on the machine that is towing Never tow on slopes Do not let anyone near the wire rope while towing Towing the Machine Use the procedure described below to tow light weight objects or the machine itself if it is stuck in the mud and not able to get out on its own IMPORTANT Do not tow a machine if its engine does not start or if the machine does not run Doing so could damage the machine being towed IMPORTANT Be sure to follow all the steps below closely when towing Failure to heed even one of the steps may cause damage to the hooks 1 167 232 2000mm 78 7in bow A Maximum tractive force CTL55 42 0 kN 9450 Ibf or less CTL65 56 8 kN 12780 Ibf or less CTL75 68 4 15370 Ibf or less CTL85 78 9 kN 17750 Ibf or less 30 or less 30 moins weniger als 30 30 menos T9A0071 Attach the wi
45. side window close it until a Click is heard 43 NTROL Doors and Covers Engine Hood Rear Door Before opening the engine hood be sure e When opening the rear door open it to stop the engine If your hands or tools firmly to the locked position get caught in the fan or fan belt while the e When opening and closing the rear engine is running they may be severely door be careful not to get your hands injured or other parts of your body caught Opening Opening 1 Insert the ignition key and turn it 1 Open the engine hood counterclockwise to unlock the engine 2 Lift the lever 1 and open the rear door hood 1 2 2 Remove the key and pull the lever 2 3 Release the stay 3 then insert and secure backward it into the stay hole of the rear door 2 3 Lift the engine hood 1 Closing Closing 1 Support the rear door 2 by hand remove 1 Close the engine hood and press it down stay 3 and secure it in the original until a click is heard at the front position 2 Insertthe ignition key and turn it clockwise 2 Close the rear door 2 and press it until a to lock the engine hood click is heard at the front 44 NTROL Doors and Covers Emergency Exit If you become trapped inside the cab remove the rear window to get out There are two ways to remove the rear window n case of emergency Kick out the r
46. storage If the machine is to be stored for 30 days or more store it indoors If it must be stored outdoors park it on wood laid out on a flat surface and place a waterproof cover over it So that it stays dry 1 Clean the machine 2 Inspect for oil leakage water leakage and loose nuts and bolts Add fuel and replace the hydraulic oil and oil To prevent rusting and freezing replace the engine coolant with long life coolant LLC Refer to page 142 Cleaning the Engine Cooling System Usethe grease gun to apply grease to the grease fittings Fully retract the bucket cylinders and ground the bucket Apply rust prevention oil to the hydraulic cylinder rods Disconnect the cable from the battery s negative terminal and cover the battery to prevent freezing 3 158 During storage e Donotoperatetheengineinanenclosed area without adequate ventilation e If natural ventilation is poor install ventilators fans exhaust extension pipes other artificial venting devices 1 To prevent rusting operate the machine once a month so that the oil is fully circulated 2 Inspect the battery and recharge it if necessary Starting the machine after storage IMPORTANT the Procedures for storage have not been performed and the machine has been stored for a long period of time consult a Gehl dealer before reusing the machine 1 Wipe off the rust prevention oil that was applied
47. thermostat open MAINTENANCE 2 Every 1000 Hours 10 11 12 13 14 15 16 17 18 19 Stop the engine let the coolant temperature lower then loosen the drain plug 4 and drain the coolant After draining the coolant clean using cleaning agent Follow the instructions included with the cleaning agent you are using Repeat steps 4 to 8 to flush the cooling System Tighten the drain plug 4 then install the under cover 5 Slowly add the new coolant mixture of antifreeze and tap water through the radiator s filler neck up to the top of the filler neck Take your time doing this Close the radiator cap 3 Warm up the engine Use the instruments to check that there are no irregularities in the cooling system at this time Raise the coolant temperature to at least 90 195 then run the engine for about 10 minutes Stop the engine let the coolant temperature lower then check the level of coolant in the radiator and replenish it up to the top of the filler neck Close the radiator cap 3 Clean the interior of the reserve tank 1 then add coolant to the upper limit H After replacing the coolant inspect the coolant level once again after operating the machine The coolant permeates the entire system during operation so the level decreases Replenish by the amount the level has decreased 143 Every 1000 Hours Replacing the H
48. to which they have deteriorated during periodic service To maintain their proper function at all times therefore replace them with new ones after using them for a specific period of time even if no abnormality is found with the parts If you find abnormalities in these parts before their scheduled replacement time is reached repair or replace them immediately If a hose clamp is deformed or cracked replace it immediately When replacing the important parts please contact a Gehl dealer Also check the hydraulic hoses other than the above important parts If any abnormality is found in them retighten them or replace them immediately When replacing the hydraulic hoses replace the O rings and seals at the same time Check the fuel and hydraulic hoses according to the periodic schedule described below Refer to Maintenance Type of inspection Inspection item Daily inspection Leakage from joints hydraulic or fuel hoses Monthly inspection Leakage from joints hydraulic or fuel hoses Damaged hydraulic or fuel hoses cracks wear and tear Annual inspection Leakage from joints hydraulic or fuel hoses Deteriorated twisted damaged hydraulic or fuel hoses cracks wear and tear or hoses in contact with other parts of the machine 109 Maintenance Chart Maintenance Items Page Walk Around Inspection Inspecting by opening the engine hood and rear door
49. while traveling operate at T7D023 speeds slow enough so you have complete control at all times e Travel ata speed that is appropriate for the conditions Travel at low speeds when the field of view is obstructed and take extra precautions with hazardous materials T7D021 Work should not be performed on a slope because the stability of the machine can be reduced when operating the working equipment and there is the danger of the Do not use this loader in areas where machine tipping over there is danger of explosion from volatile gases Also avoid using the loader where the exhaust gases could come in contact with flammable items T7D022 Keep the bucket as low as possible during travel Do not travel or attempt to change directions with the bucket raised 82 Seed OPERATION I amp 3 Operating Procedures Do not attempt a spin turn or pivot turn at high speeds Doing so may cause extreme wear and or the tracks to come off Do not cut across a slope Doing so may cause extreme wear and or the tracks to come off Do not exceed the loader s rated operating capacity Do not use buckets or attachments that exceed the loader s operating capacity 83 Do not use the downward force of the bucket to drive piles T7D030 Do not dig down deeply with
50. 0 4 153 3 7 7 27 30 M20 X 2 5 410 9 20 5 303 1 15 1 12 13 M8 X 1 0 24 5 1 2 18 1 0 9 14 17 M10 X 1 25 50 2 5 36 9 1 8 Fine 17 19 12 1 5 87 3 4 3 64 4 3 2 19 22 M14 X 1 5 135 3 6 8 99 8 5 0 22 24 16 1 5 220 6 11 162 7 8 1 27 30 M20 X 1 5 452 1 22 6 333 4 16 6 108 MAINTENANCE Important Parts For safe use the machine must be serviced periodically To increase safety periodically replace the parts listed in the following Table of Important Parts Serious injury or a fire could result if they deteriorate or are damaged Table of Important Parts Unit Important parts to be replaced periodically Replacement Interval Fuel hoses Packing in fuel filler cap Engine connection Engine oil filter hoses Heater hoses Air conditioner hoses Hydraulic hoses Pump delivery Hydraulic hoses Pump suction Every 2 years Hydraulic hoses Travel motor Hydraulic hoses Lift arm cylinder lines Working Hydraulic hoses Bucket cylinder lines equipment Hydraulic hoses Quick hitch cylinder lines Hydraulic hoses Pilot valve Hydraulic hoses Auxiliary lines Seat belt Every 3 years Fuel system Heater amp AC systems Machine body Hydraulic system Above important parts are vulnerable to aging and wear or deterioration and it is difficult to determine the degree
51. 1 e Make sure the bucket is lowered to the ground before actuating the lift arms Float control Actuating the Float control when the lift arms are raised will cause the bucket to fall rapidly and is extremely dangerous Do not drive the loader forward with the lift arms in Float position Operating Precautions Do not drive into materials at high speeds Do not carry the bucket over the heads of people j T7A017 T7A018 Driving at high speed into the materials you are handling canleadto your body striking the machine or being thrown from the machine Carrying the bucket over the heads of people entails the danger of the load spilling or the bucket suddenly dropping Check the conditions surrounding the area in front of the material you are handling and work at low speeds Caution against falling unstable loads Operate on snow or ice with extra caution When traveling on snow or frozen surfaces keep the machine travel speed down and avoid accelerating stopping and changing directions abruptly Remember that the road shoulder fences etc may be buried in the snow and not visible Lower the bucket when parked on unsure ground conditions T7A019 Unstable loads such as round items cylindrical items and stacked plates entail the possibility of falling from the bucket When handling unstable loads operate carefully to avoid raising the b
52. 3 Machine Operation Inspection After Warm up After warming up the engine and hydraulic oil perform the checks and inspections described below and repair if there is a problem 3 Bea T7D0122 1 Check that the warning lamps and instruments are as follows Are all the warning lamps off s the water temperature gauge needle within the green range 2 Check that there are no irregularities in the exhaust color sound and vibrations T7B015 3 Set the safety bar to the locked position and check that the control levers and pedal are locked 76 24 OPERATION amp 3 Machine Operation Operating the Left Control Lever Never allow anyone to enter the turning radius and machine path Signal your intention to move by sounding the horn Traveling and turning should be performed with the bucket cylinder fully retracted and the bucket at a height of approximately 30 cm 12 in from the ground Avoid sudden stops start or turns Do not raise the safety bar while traveling This is dangerous because raising the safety bar will cause the parking brakes of the travel motors to operate and apply the brakes abruptly Do not switch off the ignition switch while traveling Doing so will cause sudden braking and is dangerous Before backing up visually check for safety to the rear Backing up without checking could result in contact with a wor
53. 73 2 G 300 11 8 320 12 6 450 17 7 450 17 7 H 1360 53 5 1430 56 3 1500 59 1 1570 61 8 J 925 36 4 980 38 6 985 38 7 985 38 7 K 1600 63 1675 66 0 1880 74 0 1960 77 2 L 495 19 5 510 20 0 535 21 1 580 22 8 M 30 30 30 30 175 SPECIFICATIONS pnm 54 kg Operating Range T7K0021 176 rpm SPECIFICATIONS TY Operating Range Units mm inches Standard Bucket Rubber Tracks A 3725 146 7 3905 153 8 4080 160 7 4245 167 2 B 2905 114 4 3030 119 3 3120 122 9 3205 126 1 Cc 2275 89 5 2370 93 4 2405 94 8 2430 95 7 D 590 23 1 730 28 8 875 34 4 985 38 8 E 1995 78 6 2080 82 0 2295 90 4 2435 95 8 F 1320 52 1375 54 1 1500 59 1 1560 61 4 G 1470 67 9 1590 62 7 1670 65 7 1755 69 1 H 30 30 31 31 177 178 OPTIONS General Precautions nns Air Conditioner lt CTL55 gt 179 OPTIONS General Precautions Precautions on Safety Heed the following when removing or installing an attachment or option Consult with a Gehl dealer before installing optional attachments Do not use attachments that have not been approved by Gehl Doing so may compromise safety or adversely affect the machine s operation or service life Gehl will not be held responsible for any injuries acci
54. 99 OFF M T9L008 After starting the engine turn the air conditioner ON and adjust the switches as shown in the diagram above Set the temperature control dial and fan Switch to the desired positions Quick cooling o 99 ii OFF AC 79009 To cool the cab quickly set the temperature control dial to Cool and the fan switch to High as shown on the diagram above OPTIONS a Air Conditioner lt CTL55 gt Defogging the Windows If the air conditioner is set too high when usingthe defroster the difference between the outside and inside temperatures increases and fog may form on the outside of the windows this happens either turn the air conditioner OFF or turn the temperature control dial clockwise WARM OFF 20 xt AC T9LOO8 After starting the engine turn the air conditioner ON and adjust the switches as shown in the diagram above The outflow slot of the defroster can be directed at the cab door 186 OPTIONS Air Conditioner CTL55 gt INSPECTION AND MAINTENANCE Inspection and maintenance interval Every 250 hours Cleaning the Condenser IMPORTANT Cleaning the condenser with high pressured water may damage it Clean the condenser gently T9LO10 Ifthecondenseris dirty heat will not discharge properly Wash dirt off the condenser with water 1 Open the rear door 2 C
55. CTL55 CTL65 CTL75 CTL85 Compact Track Loader SalolV i3idO SAFETY ALERT SYMBOL This symbol means Attention Be Alert Your Safety Is Involved The message that follows this symbol contains important safety information Read and understand the message to avoid personal injury or death H it is the owner s or employer s responsibility to fully instruct each operator in the proper and safe operation of all equipment All persons using this machine should thoroughly familiarize themselves with the following sections Wi All operators must be instructed on the proper functions of the loader before running the machine Wi Learn and practice correct use of the machine controls in a safe clear area before operating this machine on a job site A CAUTION Improper operation inspection and maintenance of this machine can cause injury or death Read and understand this manual before performing any operation inspection or maintenance on this machine E3A010 Always store this manual where it is ready available preferably on the machine itself If it is lost or damaged immediately order a new one from your Gehl dealer When transferring ownership of this machine be sure to provide this manual to the new owner Gehl Company supplies machines complying with the local regulations and standards If your machine has been purchased in another country or from a person or company of another country
56. Chart Use different lubricants greases and fuels according to the temperature referring to the chart below e Change the lubricant earlier than as shown in the table if it is extremely dirty or its performance has deteriorated severely Whenever possible use the same brand of lubricant as before If changing with a different brand replace the entire quantity do not mix different brands Lubricants and greases 104 Type by temperature n Part Type 22 4 14 32 50 68 86104r Replacement Capacity 30 20 10 0 10 20 3040 interval US at Upper limit CTL55 7 4 7 8 CTL65 10 2 10 8 Engine Diesel engine Loro ro d After first 50 CTL75 10 2 10 8 oil API CF or SAE 10W 30 hrs CTL85 13 2 13 9 higher SAE 15W 40 Every 250 hrs System CTL55 45 11 9 US gal CTL65 58 15 3 US gal CTL75 75 Biss US gal iesel engine TL85 95 Hydraulic 10W 30 Every 1000 hrs 25 1 US gal tank oil API CD CE Tank 7 7 US gal CTL65 39 10 2 US gal CTL75 49 12 8 US gal CTL85 60 15 9 US gal CTL55 11 11 6 Engine Cooling 50 coolant mixture coolin ater water Bi 30 coolant mixture Every 1000 hrs 174 CTL85 16 5 17 4 Travel After first 250 CTL55 1 0 1 06 Gear oil CTL65 1 0 1 06 reduction ansa SAB 99 CTL75 1 6 1 69 gear Every 500 hrs cras 6 169
57. No Remarks Partname Part No Remarks 1 Wrench 10 12 12 Hammer 3 4 2 Wrench 11 13 13 Allen wrench 5mm 3 Wrench 14 17 14 Allen wrench 6 4 Wrench 19 22 15 Allen wrench 8 5 Wrench 24 27 16 Allen wrench 10 mm 6 Wrench 30 17 Allen wrench 14 mm 7 Wrench 41 18 Grease gun 600 cc 8 Screwdriver 90 19 Tool case 9 L type wrench 19 20 Drain connector 10 Adjustable wrench 250 mm 21 Case 11 Pliers 200 mm 107 s MAINTENANCE 2 Service Data Tightening Torques Nuts and Bolts for ISO strength category 10 9 Tighten nuts and bolts at the torques shown on the table below unless otherwise specified in the text e Tightening torques when mounting plastic covers differ from the values on the table below Consult a Gehl dealer Tightening too forcefully will break the cover When replacing nuts and bolts replace them with nuts and bolts of the same size and standards e Tighten nuts and bolts alternately top bottom left then right or in 2 or 3 times so that they are tightened uniformly e e 5 4 E4G003 0506010 Head width Size a X Pitch b General Connection Points mm mm N m ft Ib 10 M6 X 1 0 9 8 0 5 7 2 0 4 12 13 M8 X 1 25 22 6 1 1 16 6 x 0 8 14 17 M10X 1 5 47 1 2 4 34 7 1 7 Coarse 17 19 M12 X 1 75 83 4 4 1 61 5 3 0 19 22 M14 X 2 0 134 4 6 7 99 1 4 9 22 24 M16 X 2 0 207 9 1
58. No 08820 31159 Position of Position of Emergency Exit 7 Safety Distance Hoisting Do not get near or stand within the machine working area U1AG04 38 CONTROLS Names of Components 40 Doors and Covers eere 42 Seat and Seat Belt 48 Instrument Panel 52 Switches enses nennen tna 54 Levers and Pedals 59 61 39 CONTROLS Names of Components O OY 5 7 8 CE WR B NR EE T9B006 1 Tail light 10 Bucket cylinder 2 Hydraulic tank 11 Bucket 3 ROPS FOPS 12 Fuel filler cap 4 Safety bar 13 Arm cylinder 5 Front light 14 Travel motor 6 Lift arm stop 15 Rubber track 7 Left control lever 16 Track roller 8 Auxiliary hydraulic lines 17 Idler 9 Lift arm 40 CONTROLS Names of Components U1B0013 1 Left control lever 12 Float button 2 Travel speed button 13 Horn button 3 Slider switch for auxiliary hydraulic 14 Right control lever 4 Detent mode switch 15 Ignition switch for auxiliary hydraulic switches 16 High flow switch option 5 Flow selector switch 2 way 1 way 17 Throttle lever 6 Front wiper switch option 18 Thr
59. O ring and if there are any scratches or other irregularities replace it Assemble the indicator ring 6 case 4 and element 5 and tighten the ring 3 Open the valve 2 Loosen the vent plug 8 and bleed the air Tighten the vent plug 8 Refer to page 159 Bleeding the Air from the Fuel System 134 916003 Open the rear door Close the valve 2 Loosen the ring 3 then remove the case 4 element 5 and indicator ring 6 and clean them Inspect the O ring and if there are any scratches or other irregularities replace it Assemble the indicator ring 6 case 4 and element 5 and tighten the ring 3 Open the valve 2 and bleed the air Refer to page 159 Bleeding the air from the fuel system MAINTENANCE 2 After First 250 Hours New Machines Only Replacing the Travel Motor Gear 5 Tighten plug 1 e Tightening torque 22 N m 15 9 ft lb 6 Supply through the hole for plug 3 until oil flows out of the hole of plug 2 7 Tighten plugs 2 and 3 e Stop the engine and allow the e Tightening torque 22 N m 15 9 ft lb machine to cool before performing maintenance e The travel motors are hot directly after the engine is stopped Touching them will cause burns The gear oil is also hot and under high pressure Be careful when loosening plugs Working on the machine under these conditions could res
60. Replace the fuel e f the Engine Overheats Refer to page 157 e Replace the muffler Request at a Gehl dealer Po TROUBLESHOOTING To Lower the Lift Arms If the lift arms must be lowered to the ground while the engine is stopped use the following procedure to do so WARNING This operation is dangerous and requires experience Have it performed by a Gehl dealer Procedure Donot approach the area where the lift arms are to be lowered You may be hit by dirt falling out of the bucket or the lift arms as it drops Turn the port relief valve s set screw slowly so that the lift arms lowers slowly Do not turn the screw more than the specified amount lt CTL55 CTL65 CTL75 gt 1 Tilt up the ROPS 166 Put mark M on the plug of the port relief valve 1 and set screw 2 Gripping the set screw 2 with ahexagonal wrench so that it does not turn together with the lock nut 3 loosen the lock nut 3 Turn the set screw 2 slowly 1 and 1 2 turns to lower the lift arms Check for safety and machine stability Turn the set screw 2 back to its original position Gripping the set screw 2 with ahexagonal wrench so that it does not turn together with the lock nut 3 tighten the lock nut 3 Tightening torque 20 x 1 N m 14 5 0 7 ft lb Lower the ROPS TROUBLESHOOTING Towing When towing
61. al Recharging As necessary have a Gehl dealer recharge any dead batteries 159 Bleeding the Air from the Fuel System IMPORTANT NEVER use the starter motor to crank the engine in order to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or ring gear 1 Add fuel 2 Open the water separator valve 2 J2D002E 3 Turn the ignition key to the ON position and hold it there for about 10 to 15 seconds The automatic air bleeder bleeds the air from the fuel system 4 Start the engine and inspect for fuel leakage Note Air in the fuel system can make it difficult to start the engine and cause engine problems Also bleed the air when the fuel tank is emptied TROUBLESHOOTING If a Fuse Blows If a light does not turn on or the electric System does not operate a fuse may be blown Inspect the fuses Inspecting and Replacing Fuses If the fuse blows as soon as it is replaced there is a problem with the electric system Continued use may lead to fire Consult a Gehl dealer 1 Turn the ignition key to the OFF position and stop the engine 2 Open the fuse box cover 1 3 Inspect for any blown fuses Normal E4J007 4 fuse is blown replace it with a spare fuse of the same capacity 160 Fuse Layout and Circuits P
62. an the filter installation surface on the filter stand 11 Apply a thin layer of oil to the packing of the new filter 12 Install the new filter by hand 13 Tighten one more turn after the filter packing comes in contact with the surface 14 Supply oil up to the upper limit H of the dipstick 1 Problems could arise if the oil level is either too low or too high 15 Tighten the oil supply cap 2 16 Lower the ROPS 17 Start the engine run it at low idle for about 3 minutes then stop it 18 After about 10 minutes inspect the oil level 124 After First 50 Hours New Machines Only Inspecting and Adjusting the Fan Belt Stop the engine and allow the machine to cool before performing inspection and maintenance e The engine muffler radiator hydraulic lines sliding parts and many other parts of the machine are hot directly after the engine is stopped Touching these parts will cause burns Inspection 1 Open the rear door 2 Remove the bolts a and open the radiator b 7 10mm 0 28 0 4in L3G0292E 3 Press the fan belt midway between the fan pulley 2 and alternator pulley 3 and check the tension about 98N or 22 Ibs The slack A should be about 7 to 10 mm 0 28 to 0 4 in 4 Inspect the fan belt 4 and replace it if e there are cuts or cracks 125 t
63. ard from the air conditioner unit Removing the filters Outer filter T9L012 1 Remove the cover 1 2 Remove the filter 2 Inner filter Cleaning Wear safety glasses when using compressed air 1 Blow dry compressed air 138 kPa 20 psi or less directly on the filter from the inside moving up and down along the creases Be sure to keep the nozzle at an adequate distance from the filter For difficult to remove dirt wash the filter 3 with neutral detergent and water Dry the filter 3 completely after washing it Inspecting the Refrigerant gas Level Exposure of the eyes or hands to the coolers refrigerant could result in blindness or frostbite Never touch the refrigerant or loosen the parts of the cooling circuit If the refrigerant gas leaks keep flames away The cooling capacity will decrease if the amount of refrigerant is insufficient VA a TSLO02 1 Lift the filter 8 upwards and off 2 Use compressed air or water to clean the filter depending on how dirty it is 188 1 Loosen the bolts and remove the cover 3 OPTIONS Air Conditioner CTL55 gt Inspect the refrigerant level using the sight glass 2 on the top of the receiver drier 1 2 Inspect under the following conditions Cab door Fully open Temperature control dial Fully to the COOL side
64. at Belt Hem Seat Belt lt CTL55 gt Always fasten the seat belt securely before starting the engine Fastening the seat belt 1 Adjust the seat to the optimum position for operating raise your torso and sit back firmly into the seat 2 2 Pull on adjuster A in the manner shown in the diagram to adjust the seat belt to the desired length C4C010 4 011 3 Make sure that the belt is not twisted and then insert the tongue plate B into the buckle C of the seat belt until you hear a clicking sound as it locks in place 4 Pull the belt until you can feel the pressure on your pelvis with the belt firmly in place CONTROLS Seat and Seat Belt Hem Seat lt CTL65 CTL75 CTL85 gt Adjust secure and latch the operator s seat G4B0061 A Seatback angle adjustment Donotsetthe seat back to its maximum reclining position and slide the seat backwards at the same time Doing so may break the rear window glass resulting in injury Be careful not to allow the force of the spring to bring the seat back sharply forward 1 Raise your torso and sit down firmly in the seat 2 Pull on lever 1 to use the force of the springs in the seatback to adjust the reclining angle Release the lever 1 at the desired angle and the seatback will be locked in that position 50 B Fore and aft adjustment 1 Pull on lever 2 and slide the
65. at all machine Systems are frequently inspected and always well maintained Ensurethatany handheldfire extinguishers are charged and in working order Fire extinguishers require routine care Follow the manufacturers instructions inspection and maintenance shown on the label of the fire extinguisher and in the extinguisher manufacturer s manual Ensure that you follow all national state provincial and local regulations dealing with fire fighting in effect in your specific geographic region Ensure that all information necessary for you to immediately contact all sources of help local fire department etc in the event of a fire emergency is recorded and readily available at all times General Precautions What to do if a machine fire occurs If operating the machine when a fire occurs 1 Lower all working attachments to the ground Shut the engine off Exit the machine Call for help Be certain to report a fire immediately At all times ensure your own personal safety and the safety of anyone that may be in the area Approach any fire with extreme caution All fires can be very dangerous and life threatening 2 3 Before deciding to fight the fire be certain that 1 The fire is small and not rapidly spreading There is always a clear safe escape route You have received training in the use of the available fire extinguishing devices and are confident that you can operate them effe
66. ator cap or drain plugs when the coolant is hot Stop the engine let the engine and radiator cool and loosen the radiator cap or drain plugs slowly Stop the engine and allow the machine to cool before performing inspection and maintenance The following symptoms indicate overheating 170012 An alarm is sounded and the coolant temperature warning lamp flashes The coolant temperature gauge shows the red zone The engine slows down and the power decreases Steam comes compartment from engine 157 Procedure 1 2 If there Park the machine in a safe place Inspect whether the coolant temperature warning lamp is flashing or if there is steam coming out when the engine hood is closed is steam stop the engine immediately and contact a Gehl dealer for repairs If the coolant temperature warning lamp is run the engine at low idle and let the coolant temperature decrease After the coolant temperature gauge drops to the green zone stop the engine After the engine is cool perform the following inspections and procedures Fan belt slack Adjust Refer to page 125 Coolant level Refer to page 116 Coolant leakage Repair o Radiator fins Clean Refer to page 137 e Sediment in cooling system Clean Refer to
67. contact are damaged consult a Gehl dealer Seals and split pins e Replace removed seals and split pins with new ones e When mounting be careful not to damage or twist the seal Sealing tape Sealing tape Leave 1 or 2 threads free E4G001 When wrapping sealing tape around plugs etc remove any old sealing tape from the threads and clean the threads e Wrap the sealing tape tight leaving 1 or 2 threads at the tip free 103 Disposing of wastes Collect waste fluids from the machine in containers Disposing of wastes irresponsibly damages the environment Dispose of oil fuel cooling water coolant filters batteries other harmful substances as prescribed by law Check after maintenance e Gradually increase the engine speed from a low idle to maximum speed and check that there is no oil or water leaking from serviced parts Operate all the control levers and check that the machine is operating properly Cautions on handling of battery cables e Disconnect the battery cables before working on the electrical system or doing any welding Remove the negative battery cable first When reconnecting the battery connect the negative battery cable last Do not disconnect the battery cables while the engine is running Doing so could damage the electronic circuitry of the alternator and other parts 7 MAINTENANCE Service Data Lubricant and Fuel
68. cracks or other damage If welding must be performed make sure that it is done by a qualified person in a properly equipped workplace To prevent any part from breaking down or be being damaged due to overcurrent or sparks observe the following e Disconnect the wiring from the battery before doing electric welding Do not continuously apply 200V or more The earth ground must be connected within one meter from the welding section Do not connect the earth ground near to an electronically controlled device instrument or connectors Make sure that there are no seals or bearings between the welding section and the earth ground Do not connect the earth ground around the pins for working equipment or hydraulic cylinders When welding is to be done on the machine body disconnect the connectors for the electronically controlled devices before working Safety signs Keep all safety signs clean and legible Replace all missing illegible or damaged safety and warning signs Vibrations to which the operator is subjected According to the results of the tests carried out to determine the vibrations transmitted to the operator by the machine the upper limbs are subjected to vibrations lower than 2 5 m 8 2 ft 5 while the seated part of the body is subjected to vibrations lower than 0 5 m 1 64 ft s 34 Checks after maintenance e Gradually raise the engine speed from low idle to maximum speed and check that no
69. ctively 2 Be aware that engine coolant diesel fuel or hydraulic hoses could fail during a fire If this happens hot coolant fuel or oil could possibly be ignited by the fire If in any doubt about whether or not to fight the fire DON T Instead stand well clear of the fire and wait for help to arrive Use the PASS method This is the most effective use of a fire extinguisher e Pull the pin at the top of the extinguisher that keeps the handle from being pressed Break the plastic seal as the pin is pulled Aim the nozzle atthe base ofthe fire Do not aim the nozzle at the flames In order to put out the fire you must extinguish the fuel not the flames Hose nozzles are often clipped to the extinguisher body Release the hose before taking aim 12 e Squeeze the handle to release the pressurized extinguishing agent The handle can be released at any time to stop the discharge Sweep from side to side at the base of the fire until the fire is completely out or the fire extinguisher is empty Only if you can safely do so open the access panels to the machine in the area of the fire Failing all attempts to access the machine compartment discharge the extinguisher through the mesh or any available openings on the machine Ensure that the machine all components have cooled down sufficiently after a fire so that re ignition does not occur Remain in the area until help arrives What to do a
70. d The traction force will apply extremely heavy loads on the bucket cylinders and this may damage them Scooping 2X T7D0371 Lower the lift arms and bring the bucket down to the ground with the front end tilted slightly forward then drive the loader forward until the bucket is filled with the material Next tilt the bucket rearward and scoop up the material Grading 1700381 Tilt the front edge the bucket down at angle that is appropriate for the ground hardness then drive the loader forward slowly digging into the ground with the cutting edge of the bucket When the bucket is full tilt it rearward Leveling T7D0391 Raise the lift arms and tilt the bucket forward then release it as the loader is driven forward Next tilt the bucket forward and lower the front edge until it is slightly above the ground surface then back the loader over the load that was just released 88 OPERATION 45 Operating Procedures Backfilling gt Se With the bucket lowered drive near the hole and tilt the front edge of the bucket downward as soon as it passes over the near side of the hole Raise the bucket and empty the load only when necessary Leveling Operation using the Float position A WARNING e Make sure the bucketis lowered to the ground before floating the lift arms Floating the lift arms while they are raised will cause the bucket to fall
71. d as well as on the machine that is towing Never tow on slopes Do not let anyone near the wire rope while towing SAFETY Stopping Precautions Park safely T7A027 T7A028 Park the machine on firm level ground and apply the parking brake If you must park on a slope or incline block the machine securely to prevent movement When parking on streets use barriers caution signs lights etc so that the machine can easily be seen at night to avoid collisions with other vehicles 8 E3A070 Before leaving the machine do the following 1 Lower the bucket to the ground 2 Set the safety bar in the lock raised position 3 Stop the engine and remove the key 4 Lock the covers 26 Never leave the machine with the engine running or the lift arms raised unattended If lift arms are left in a raised position they MUST be supported by the lift arm stop SAFETY Transporting Precautions Load and unload the machine safely lt A Fasten to the suspension fitting Distance between ramps 15 or less E4F001 The machine may roll or tip over or fall while loading or unloading it Take the following precautions Select a firm level surface and keep sufficient distance from road shoulders Use loading ramps of adequate strength and size Maintain the slope of loading ramps to 15 degrees or less Secure the ramps to
72. dents or damage to products caused by the use of a non approved attachment Choose a flat hard surface to perform the operations Also make sure there is enough light and good ventilation Clean the area remove any articles that may get in the way or be dangerous and remove any spilled oil or grease When removing or installing a backhoe attachment place it in a stable position so that it does not tip over Due to the risk of loads falling and or hitting people do not allow unauthorized personnel in the work area Use a crane to carry heavy objects 25 kg 55 Ib or greater When removing heavy parts be sure to prop them up before removing them When lifting them with a crane be careful to balance them properly Operating with loads suspended with the crane is dangerous Place loads on a stand and check for safety When attaching the attachments failure to follow proper procedures could result in serious damage Consult a Gehl dealer beforehand Precautions on Installing Attachments After replacing optional attachments or other special attachments test run them then inspect the hydraulic oil level and add oil if necessary In addition consult a Gehl dealer for details of removal and installation procedures 180 OPTIONS General Precautions Precautions on Operating Attachments A WARNING Long attachments reduce machine stability When traveling down steep slopes or turning on slopes the machine may lo
73. dicator ring 6 is sunk to the bottom of the case 4 no water is mixed in If the red indicator ring 6 is floating there is water up to the bottom of the ring Drain the water and clean Place a pan under the drain valve 7 Open the drain valve 7 and drain the water If the water does not drain easily loosen the vent plug 8 Close the drain valve 7 and vent plug 8 Refer to page 134 Cleaning the Water Separator Daily Inspection Every 10 Hours TL U1G003 1 Open the rear door 2 Inspect the water separator 1 If the red indicator ring 6 is sunk to the bottom of the case 4 no water is mixed in If the red indicator ring 6 is floating there is water up to the bottom ofthe ring Drain the water and clean Refer to page 134 Cleaning the Water Separator 118 Inspecting the Fuel Level e Do not smoke or permit flames while fueling or near fueling operations Stop the engine in a well ventilated place when adding fuel Clean up spilled fuel immediately Do not fill the fuel tank to capacity Allow room for expansion Tighten the fuel filler cap securely 1 Check the fuel level using the fuel gauge 1 F full E empty 2 If the level is low add fuel from the fuel port 2 while watching the fuel gauge 1 Refer to page 47 Fuel Filler Cap Daily Inspection Every 10 Ho
74. due to slipping Remove all loose objects stored in the machine and all objects that do not belong in or on the machine and its equipment Remove any dirt oil and grease from the engine area to prevent fires Clean the area around the operator s seat removing any potential obstacles Preparing Precautions Perform inspection and maintenance daily E3A520 Failure to notice and malfunctions or damage can accidents e Before operating perform the prescribed inspections and make repairs immediately if any malfunctions are found e f a failure that causes loss of control Such as steering service brakes or engine occurs stop the machine motion as quickly as possible follow the shutdown procedure and keep machine securely parked until the malfunction is corrected repair machine lead to 16 Emergency Exit If you become trapped inside the cab remove the rear window to get out MET me There are two ways to remove the rear window In case of emergency Kick off the rear window Note that the glass may break Be careful not to get injured In case of need 1 Pull off ring A and remove the tip of the rubber wedge 2 Grasp the tip pull and remove the entire rubber wedge 3 Pull inside knob B Starting Precautions Maintain three point contact when mounting and dismounting Do not j
75. e and Cooler This operation requires experience Have it performed by a Gehl dealer s MAINTENANCE 2 When Required Replacing the Bucket or Attachment Read the manufacturer s instructions manual for attachments not included in this manual DO NOT use attachments that are not approved by Gehl e Before performing maintenance repairs under the machine set all working equipment against the ground or in the lowermost position Installation IMPORTANT Before installing a bucket or attachment make sure the mounting area of the bucket 1 and the quick hitch 3 are clean 1 Make sure the quick hitch 3 lock levers 2 are in the unlocked position 2 While sitting in the operator s seat with the safety bar down start the engine and tilt the quick hitch 3 forward T9GO10 3 Move the machine slowly forward and raise the loader lift arms The wedge shaped top edge of the quick hitch 3 must engage in the upper mounts of the bucket or attachment T9GO011 4 Roll the quick hitch 3 back while lifting the bucket or attachment off the ground The quick hitch 3 will slide into position 5 Lower the bucket or attachment until it is 25 to 50 mm 1 to 2 in off the ground 6 Stop the engine and raise the safety bar NN Vax 8 A H il 44 799012 7 Push both quick hitch 3 lock levers 2 down securing
76. e coupler Visually check the couplers for corrosion cracks damage or excessive wear If any of these conditions exist the coupler s must be replaced Install the male coupler into the female coupler Full connection is made when the ball release sleeve slides forward on the female coupler Disconnecting Hold the male coupler Retract the sleeve on the female coupler until the couplers disconnect Releasing Residual Pressure Connecting Push the quick couplers tightly together and hold for five seconds the pressure is automatically released as the couplers are installed Disconnecting Push the quick couplers tightly together and hold for five seconds then retract the sleeve until the couplers disconnect Connecting the Hydraulic Circuits To connect attachment hydraulic lines use the following procedures 1 Connect the attachment hydraulic lines to ports a and b When fitted with a hydraulic breaker a Connect the return circuit to port b and the supply circuit to port a b Turn on the flow selector switch Refer to page 56 Flow Selector Switch Some attachments may have a case drain which needs to be the connected to the small port T 2 When connecting is complete purge air from the hydraulic lines a Start and run the engine at low idle with no load for 10 minutes b With the engine running at low idle operate the auxiliary hydraulics switch repeatedly approx 10 times to purge ai
77. e engaged Stop engine 5 No 08800 31005 E A WARNING AR ARMS MOVE NEAR CANOPY FRAME 3 No 06593 00013 NEVER STAND OR AVOID INJURY LEAN ANYWHERE Loader can move suddenly and violently 08800 31005 Always wear seat belt 6 No 08810 30026 Operator must have proper instructions WARNIN prior to operating loader Failure to obey warnings can cause serious injury or even death 08810 30026 4 No 06593 0001 1 AVOID INJURY Lift arms move 7 No 03593 13700 close by window opening Never place through A WARNING Screen opening 1 This machine if improperly operated or maintained can cause bodily harm or even DEATH Read and understand the owners manual supplied with this machine before operating Keep all safety devices in place and functional Do not operate the machine unless the seat belt is properly fastened around you Follow the instructions in the Operator s Manual when hoisting the machine or fastening it to the transport vehicle U1AG021 36 Safety Signs Decals 8 No 08820 31135 9 No 08810 30020 Sign indicates a burn hazard from spurting hot water or oil A WARNING if radiator or hydraulic tank is AVOID INJURY uncapped while hot G Read operator s manual Jj Allow radiator or hydraulic tank peaton and fungtienf to cool before removing cap K
78. e fluid to swell and the plate appears distorted Level too low The fluid does not reach up to the bottom edge ofthe sleeve 3 so the plate appears laminar not distorted 4 Also check the terminals for looseness and dirt Replenishing When adding distiled water do so before starting operations in order to prevent freezing U1G006 1 Remove the bolts a and open the radiator b 131 2 Remove the indicator 1 and caps 2 and add distilled water up to the upper level 3 Tighten the indicator 1 which then turns blue 4 Clean the cap s exhaust hole then tighten the caps 2 securely MAINTENANCE 2 Every 50 Hours Draining the Fuel Tank Do not smoke or permit open flames while handling fuel or working on the fuel system Stop the engine in a well ventilated place and allow it to cool before performing maintenance Clean up spilled fuel immediately Do this before operating the machine 1 fuel filler cap 2 2 Place a pan under the drain plug 3 3 Remove the cover 4 4 Remove the drain plug 3 and drain the water and sediment from the bottom of the tank 5 Tighten the drain plug 3 6 While watching the fuel gauge 1 add fuel 7 Tighten the fuel filler cap 2 and lock it with the key Bleeding the air from the fuel system Refer to page 159 Bleeding the Air from the Fuel Sy
79. e fuel tank to capacity Allow room for expansion Tighten the fuel filler cap securely Opening 1 Open the key cover insert the key and turn it counterclockwise to unlock the fuel cap 2 Turn the fuel cap counterclockwise and remove it Closing 1 Set the fuel cap in place and turn it clockwise 2 Turn the key clockwise to lock the fuel cap then remove the key CONTROLS Seat and Seat Belt Seat lt CTL55 gt Adjust secure and latch the operator s seat A Seatback angle adjustment T3B001 1 Raise your torso and sit down firmly in the seat Pull on lever 1 to use the force of the springs in the seatback to adjust the reclining angle Release the lever 1 at the desired angle and the seatback will be locked in that position Adjustment range B Fore and aft adjustment T3B002 1 Pull on lever 2 and slide the seat rearward or forward to bring it to the optimum position for operating the machine Release the lever 2 at the desired position and the seat will be locked there Adjustment range 130 mm 5 1 in 48 C Weight adjustment T3B003 1 Pull on and shift the lever 3 to right side or left side to adjust the seat suspension according to the operator s weight e Right Light operator e Middle Medium weight operator Left Heavy operator CONTROLS Seat and Se
80. e machine only from the operator s seat 19 Rea DOON 2 A n 44 Operating Cold Weather 91 Release all pressure before working on the hydraulic Operating Precautions 19 32 Operating 82 Replace important safety parts periodically 28 Operating Range 176 Replacing the Air Cleaner Elements 36 Operating temperature 8 Replacing the Bucket or Attachment 48 Operating the Auxiliary Hydraulics 81 Replacing the Engine Oil and Oil Filter 123 Operating the Left Control Lever T Replacing the Engine Oil and Oil Filter 137 Operating the Right Control 80 Replacing the Fuel 38 OPERATION anite ai 69 Replacing the Hydraulic Oil and Cleaning the Suction Operations Possible with this Machine 88 aTe 144 O9 rem 179 Replacing the Hydraulic Oil Return Filter 22 Other Symptoms nnns 164 Replacing the Hydraulic Oil Return Filter 39 OU T D n 185 Replacing the Pilot Line 126 Replacing the Pilot Line
81. ear window Note that the glass may break Be careful not to be injured n case of need 1 Pull off ring and remove the tip of the rubber wedge 2 Grasp the tip pull and remove the entire rubber wedge 3 Pull inside knob B 45 CONTROLS Doors and Covers Lift Arm Stop If you must work beneath the raised lift arms securely engage the lift arm stop Never get under the lift arms and bucket if they are not sufficiently supported Service the lift arm stop if damaged or if parts are missing Using a damaged lift arm stop or with missing parts can cause the lift arms to drop causing injury or death Maintenance and service work can be done with the lift arms lowered If the lift arms are raised use the following procedures to engage and disengage an approved lift arm stop Engagement 1 Park the machine on level ground and remove the bucket or attachment 2 Lower the lift arms to the ground and stop the engine T9B0011 T9B020 3 Align the hook 4 on the tip of the locking pin 1 with the locking pin 46 4 Support the lift arm stop 2 by hand and pull out the locking pin 1 T9B002 5 Check that the spring 3 moves freely i e is disengaged from the hook 5 and place the lift arm stop 2 on the cylinder 6 Sit in the seat fasten the seat belt start the engine and lower the safety bar 7 Raise the lift arms slowly un
82. eaving the machine do the following 1 Set the control levers and pedal to the neutral position 2 Return the throttle lever to idle position and idle the engine at low speed 3 Lower the bucket to the ground 4 Set the safety bar to the lock position 5 Stop the engine and remove the key Refer to page 73 Stopping the Engine Inspection and Checks After Stopping the Engine 1 Check for oil and water leakage and inspect the working equipment covers and chassis If any irregularities are found repair 2 Fill the fuel tank Refer to page 118 Inspecting the Fuel Level 3 Remove any debris and dirt from the engine compartment 4 Remove any mud from the chassis Locking Be sure to lock the following places E3A070 Fuel filler cap Engine hood Manual storage e Cab door Seed OPERATION gt nue Operating in Cold Weather Preparing for Cold Weather In cold weather it may be difficult to start the engine and the coolant may freeze Make the preparations described below Changing the Fuel and Lubricant Change the fuel hydraulic oil and engine oil to types suited for cold conditions Refer to page 104 Lubricant and Fuel Chart Engine Coolant The coolant is combustible Keep flames away Use long life coolant antifreeze and tap water for the engine coolant Supplement New machines are delivered with JIS Type 2 long life coolant antifreeze at
83. eep safety devices working Keep screens and windows in place 08820 31135 Keep children and others away Never carry riders Lower lift arms stop engine and remove key before leaving G Keep cab clean lt CTL55 gt lt CTL65 gt lt CTL75 gt lt CTL85 gt 10 No 06593 00009 10 No 06693 00009 10 08820 30009 10 No 06993 00009 A CAUTION A CAUTION A CAUTION CAUTION AVOID OVERTURN AVOID OVERTURN AVOID OVERTURN AVOID OVERTURN Carry load low Carry load low Carry load low Carry load low Avoid steep slopes and Avoid steep slopes and Avoid steep slopes and Avoid steep slopes and high speed turns high speed turns high speed turns Never carry more than Never carry more than Never carry more than high speed turns Never carry more than 565kg 1246LBS 835kg 1841LBS 945kg 2083LBS 1190kg 2624LBS 11 No 08800 30015 13 No 06893 00035 Sign indicates a crush hazard A CAUTION from falling off of working device Keep away when the working device is raised ALWAYS INSPECT COUPLER LATCHES PIN ENGAGEMENT BEFORE OPERATING VEHICLE 12 No 03393 75040 CAUTION 14 03793 66006 DO NOT USE ETHER Hazard of rotating parts USAGE OF ETHER FOR STARTING PURPOSES MAY CAUSE INTERNAL Turn off before inspection and maintenance ENGINE DAMAGE Death can occur if lift arm stop is not
84. eling is not possible or not smooth Stones or foreign objects are Stuck Remove the foreign object Machine does not travel Stones or foreign objects are Remove the foreign object temperature is too high 164 straight forward Stuck Operation is not e Fuse is blown e Replace the fuse possible with the Refer to page 160 various switches e Safety bar is raised Lower the safety bar Refer to page 59 Travel speed cannot be e Fuse is blown e Replace the fuse changed Refer to page 160 Hydraulic oil e Insufficient hydraulic oil e Replenish to the prescribed level Refer to page 119 TROUBLESHOOTING Other Symptoms Symptoms Main cause Procedure Starter motor turns but e Insufficient fuel e Add fuel engine does not start Refer to page 118 Air in fuel system Bleed the air Refer to page 159 Water in fuel system e Drain the water Refer to page 132 Crawlers slip off Engine exhaust is white or bluish Crawlers are too loose Excessive engine oil Insufficient fuel e Adjust the tension Refer to page 128 Adjust to the prescribed level Refer to page 117 e Replace the fuel Engine exhaust is occasionally black Air cleaner is clogged e Replace the air cleaner Refer to page 136 Irregular noise is produced from the engine combustion or mechanical noise Low quality fuel is being used Engine is overheating Damage in muffler 165 e
85. en working in dark places turn on the machine s working lights and headlights and or provide extra stationary lighting if necessary When visibility is poor due to severe weather fog snow or rain stop operating the machine and wait until conditions improve Do not permit riders on the machine Ya T E3A180 Do not allow anyone to ride on any part of the machine at any time while traveling Do not allow anyone to be on any part of the machine while operating Operate the machine only from the operator s seat T8A002 Operate all the controls only from the operator s seat Failure to do so can cause serious injury or death 19 Check for safety in the surrounding area before starting A T7A010 Understand the machine limitations Use a signal person where clearances are close or your vision is obstructed Never allow anyone to enter the turning radius and machine path Signal your intention to move by sounding the horn There are blind spots to the rear of the machine If necessary before backing up check that the area is safe and clear Keep your body inside the operator s cab 4 T7A011 Keep your body inside the operators compartment while operating the loader Never work with your arms feet or legs beyond the operator s compartment Operating Precautions Cautions on traveling and turning obstacle with the
86. eneath the raised machine or equipment always use wood blocks jack stands or other rigid and stable supports Never get under the machine or working equipment if they are not sufficiently supported This procedure is especially important when working on hydraulic cylinders The track adjuster contains highly pressurized grease the tension is adjusted without following the prescribed procedure the grease discharge valve may fly off resulting in injury Loosen the grease discharge valve slowly Do not put your face arms legs or body in front of the grease discharge valve no grease is expelled when the grease discharge valve is loosened there is a problem Contact your Gehl dealer for repairs DO NOT disassemble because this is very dangerous Inspection CTL55 gt lt CTL65 CTL75 gt 786012 7700141 136005 Lower the lift arm tilt the bucket forward to raise the front of the loader off the ground as far as it will go Measure the clearance between the center track roller and the surface of the track where it makes contact with the roller The gap A should be within the following range 25 to 50 mm 1 to 2 in Adjustment Increasing the tension T7G015 1 Remove the cover MAINTENANCE 2 Every 50 Hours 2 Use the grease gun to insert grease through the grease nipple in the grease dischar
87. erious problem can occur When the ignition switch is turned to the ON position the lamp lights up and stays on for 2 seconds and then goes out If a problem arises in the engine or controls the lamp starts flashing with the flashing pattern corresponding to the type of problem CONTROLS Switches Ignition Switch PREHEAT J2B009E IMPORTANT Do not repeatedly switch the key from OFF to ON and ON to OFF over a short period Doing so will cause engine breakdown Position for preheating the engine OEP ie Position for stopping the engine and inserting and removing the key ON ini Position in which the engine is running In this position all the electrical equipment is functional START Positionforstartingtheengine When the key is released the switch automatically returns to the ON position Horn Button U1B002 Press the right button on the right control lever to blow the horn 54 Float Button e Make sure the bucket is lowered to the ground before putting the lift arms in the Float mode Putting the lift arms in the Float mode while they are raised will cause the bucket to fall and is extremely dangerous Do not drive the loader forward with the lift arms in the Float mode This button sets the lift arms to the Float mode The lift arms are put to the Float mode while this button is pressed in When the
88. es will help to keep your equipment up and running efficiently and keep the risk of fire to a minimum 1 Maintain a CHARGED fire extinguisher on or near the machine at all times and KNOW HOW TO USE IT Remove debris and blow out dust regularly from side air intake areas engine radiator hydraulic oil cooler air conditioning condenser core to prevent overheating of the engine and hydraulics and to maintain efficient operation of the machine Blow off all accumulated debris near hot engineexhaustcomponents turbocharger and exhaust manifold as well as exhaust pipes and muffler at the completion of each work shift or more frequently when General Precautions working in severe conditions where large amounts of combustible debris are present Engine exhaust systems provide numerous small pockets where flammable debris can gather Even small accumulations close to hot exhaust components can ignite and smolder Clean out all accumulated debris twigs pine needles branches bark leaves saw dust small wood chips and any other combustible materials from inside the machine belly pans or lower machine structures as well as from areas in proximity to the engine fuel and hydraulic oil systems no less frequently than at the completion of each work shift Inspect the machine regularly for any signs of diesel fuel or hydraulic system leakage Check for worn or damaged fuel or hydraulic lines before starting up any
89. filter Install the flange 4 Inspect the level with the sight gauge 2 and replenish if the level is low Refer to page 119 Inspecting the Hydraulic Oil Level and Replenishing After First 50 Hours New Machines Only Replacing the Engine Oil and Oil Filter Stop the engine and allow the machine to cool before performing maintenance e The engine muffler radiator and many other parts of the machine are hot directly after the engine is stopped Touching these parts will cause burns e The engine oil is also hot Be careful when loosening caps and plugs Working on the machine under these conditions could result in burns 6 Remove cap A install connector B and drain the oil The oil comes out when the Screw is tightened 7 Remove connector B and install cap A IMPORTANT Check the waste oil If it contains large amounts of metal powder consult a Gehl dealer 8 Install the under cover 3 1 Open the engine hood 2 Tilt up the ROPS Refer to page 151 Tilting Up the ROPS 3 Remove the oil supply cap 2 U1G004 T7G0111 4 Place a pan under the under cover 3 5 Loosen the bolts and remove the under cover 3 123 U1G005 9 Using a filter wrench turn the filter 4 counterclockwise and remove it MAINTENANCE 2 After First 50 Hours New Machines Only 10 Cle
90. fter a machine fire has occurred e Before returning the machine to work 1 Ensure that the cause of the fire is determined and all appropriate repairs are completed 2 Ensure that all extinguishers used in fighting the fire are replaced or recharged Notify your equipment dealer and or GEHL Manufacturing General Precautions Exhaust fumes from the engine can kill E3A090 Do not operate the engine in an enclosed area without adequate ventilation e f natural ventilation is poor install ventilators fans exhaust extension pipes or other artificial venting devices Handling asbestos dust Inhaling asbestos dust has been linked to lung cancer When handling materials which may contain asbestos take the following precautions Never use compressed air for cleaning Avoid brushing or grinding of the materials For clean up use wet methods or a vacuum equipped with a high efficiency particulate air HEPA filter Wear an approved respirator if there is no other way to control the dust When working indoors install a ventilation system with a macro molecular filter 13 General Precautions Be careful not to get crushed or cut 9 T7A007 T7A008 T8A006 Your body hands and feet must not enter between moving parts such as between lift arms and main body or between lift arms and bucket When operatin
91. fter the engine is stopped Touching these parts will cause burns The engine coolant oil and hydraulic fluid are also hot and under high pressure Be careful when loosening caps and plugs Working on the machine under these conditions could result in burns or injuries due to the hot oil spraying out Maintenance Precautions Be careful with hot cooling systems 540 Do not remove the radiator cap or drain plugs when the coolant is hot Stop the engine let the engine and radiator cool and loosen the radiator cap or drain plugs slowly Be careful with fluids under pressure Pressure can be retained in the hydraulic circuit long after the engine has been shut down e Release all pressure before working on the hydraulic system N d e Hydraulic fluid under pressure can penetrate the skin and eyes and cause injury blindness or death Fluid escaping from a small hole can be almost invisible Wear safety goggles and heavy gloves and use a piece of cardboard or wood to search for suspected leaks If fluid is injected into the skin it must be removed within a few hours by a doctor familiar with this type of injury E3A600 32 Release all pressure before working on the hydraulic system Oil may spray outif caps orfilters are removed or pipes disconnected before releasing the pressure in the hydraulic system When removing plugs and screws and disconnecting h
92. g lift arms and bucket the gap between the moving parts will be changing and getting caught in between can cause serious injury or death e The lift arms move close to the outside of the side screens never stick out arms or other portions of your body from the side Screens e The lift arms move close to the ROPS therefore do not stand or lean on the machine 14 Using optional products Consult with a Gehl dealer before installing optional attachments Do not use attachments that have not been approved by Gehl Doing so may compromise safety or adversely affect the machine s operation or service life Gehl will not be responsible for any injuries accidents or damage to its products caused by the use of a non approved attachment Product usage Keep in mind that the use of high output brush cutter attachments on this unit can only be used in part time lighter duty brush clearing applications with appropriate cooling system care and in moderate ambient temperatures Care with respect to usage and prevention of track damage must also be adhered to This usage notice also applies to all other high performance high demand attachments Never modify the machine Unauthorized modifications to this machine can cause injury or death Never make unauthorized modifications to any part of this machine SAFETY Preparing Precautions Know the working area Before starting operation know the working area t
93. ge valve 1 3 Check the track tension Decreasing the tension T7G016 1 Remove the cover 2 Use the wrench to slowly loosen the grease discharge valve 1 and drain the grease If the grease does not drain easily move the machine forward or rearward 3 Tighten the grease discharge valve 1 e Tightening torque 59 N m 43 4 ft lb 129 Every 50 Hours Inspecting the Battery Fluid Level and Replenishing Do not use the battery when the fluid level is below the lower level Doing so will hasten the deterioration of the internal portions of the battery and shorten the battery life and can also cause rupturing or an explosion e Batteries generate flammable and explosive gases Keep arcs sparks flames and lighted tobacco away Use adampened cloth to clean the area of the fluid level lines and check the fluid level Note that if this area is cleaned with a dry cloth static electricity could cause ignition or explosion Do not fill the battery above the upper level Doing so could cause the fluid to leak contact and damage the skin or cause parts to corrode e Batteries contain sulfuric acid which will damage eyes or skin on contact elf acid contacts eyes flush immediately with clean water and get prompt medical attention elf acid is accidentally swallowed drink large quantities of water or milk and call a physician immediately e If acid contacts
94. h Operating the Auxiliary Hydraulic Switches Ou To deliver hydraulic oil to port a Depress A When using a hydraulic breaker or other one way flow attachment gt To deliver hydraulic oil to port b Depress B 81 When using a hydraulic breaker or other 1 way flow attachment Two Way Flow One Way Flow 7880111 Change the direction the hydraulic oil flow by setting flow selector switch C ON to return the oil in the b port line directly to the hydraulic tank Refer to page 56 Flow Selector Switch When using detent mode switch D IMPORTANT Operation overlong periods with Detent mode switch pressed will cause the hydraulic oil temperature to rise and will shorten the life of the hydraulic units Pressing the detent mode switch D lights the orange lamp and the auxiliary hydraulic Switch A changes to detent mode Detent mode r 1 01 008 One press of the auxiliary hydraulic switch sets it to ON and one more press sets it to OFF There is no need to continue pressing the switch Refer to page 57 Detent Mode Switch Operating the High Flow Hydraulics Refer to page 63 High Flow Hydraulic System OPERATION 45 Operating Procedures Prohibited Operations Do not operate on base rock hard or soft AN eet If you must operate the lift arms and bucket
95. he belt is worn and touches the bottom of the V groove in the pulley ethe belt stretches cannot be adjusted Adjustment 1 Loosen the locking nuts 6 2 Turn the adjusting bolt 5 and adjust the fan belt 4 Tighten Clockwise e Loosen Counterclockwise 3 Tighten the locking nuts 6 Note When replacing with a new belt new belt slack 5 to 8 mm run the engine at low idle speed for about three to five minutes to break in the new belt before adjusting the tension MAINTENANCE 2 After First 50 Hours New Machines Only Replacing the Pilot Line Filter Stop the engine and allow the machine to cool before performing maintenance Oil may spray out if caps or filters are removed or pipes disconnected before releasing the pressure in the hydraulic system When removing plugs or screws or disconnecting hoses stand to the side and loosen slowly to gradually release the internal pressure before removing 1 Tilt up the ROPS Refer to page 151 Tilting Up the ROPS 2 Turn the case 1 counterclockwise and remove it Remove the element 2 and O ring 3 Clean the inside of the case 1 Install the new element in the case 1 Install the new O ring then tighten the case 1 oak WwW 126 127 2 Every 50 Hours Inspecting and Adjusting the Track Tension If you must work b
96. he rearview mirrors for dirt damage and angle adjustment 11 Check the decals for dirt and damage 12 Inspect the bucket stops for damage or looseness 9 115 Inspecting While Sitting in the Operator s Seat 13 Check the windshield for dirt or damage for machines with cab door 14 Check the seat and seat belt for dirt and damage Check the operator s compartment for dirt oil and other combustible materials 15 Check the monitor instruments and Switches for dirt and damage F3 MAINTENANCE Daily Inspection Every 10 Hours Perform the following inspections once every day before starting the engine the first time e Before operating perform the daily inspections and make repairs immediately if any irregularities are found e Be sure to secure the engine hood or rear door when opening it Do not open the engine hood or rear door on slopes or in strong winds Inspecting and Replenishing the Coolant Do not remove the radiator cap or drain plugs when the coolant is hot Stop the engine let the engine and radiator cool and loosen the radiator cap or drain plugs slowly Inspection 1 Open the rear door 2 Inspect the quantity of coolant in the reserve tank 1 The level should be between the upper limit H and lower limit L If itis below the lower limit L replenish 116 Replenishing 1 Remove the reserve tank cap 2 2 Add coolan
97. icking sound as it locks in place Releasing the seat belt To remove the seat belt simply press the button C located on the buckle The seat belt is automatically retracted 51 CONTROLS Instrument Panel SEDE k E NES LL Ny 1780062 Warning Lamps IMPORTANT If a warning lamp flashes and an alarm is sounded stop all operations immediately and inspect and maintain the appropriate parts Refer to page 162 Troubleshooting 1 Engine Oil Pressure Warning Lamp This lamp flashes and an alarm is sounded if the lubricant oil pressure drops 1 abnormally while the engine is running 2 Coolant Temperature Warning Lamp This lamp flashes and an alarm is sounded if the engine coolant temperature rises abnormally while the engine is running C4B012 3 Battery Charge Warning Lamp This lamp flashes and an alarm is sounded if a problem arises in the charging system while the engine is running C4B030 4 Air Cleaner Warning Lamp This lamp flashes and an gt alarm is sounded if the air 2 cleaner filter is clogged 9481 while the engine is running 5 Pilot Line Filter Warning Lamp L This lamp flashes and an alarm is sounded if the pilot line filter is clogged while the engine is running This lamp may flashes directly afte
98. id is accidentally swallowed drink large quantities of water or milk and call a physician immediately f acid contacts skin or clothing wash off immediately with clean water Wear safety glasses and gloves when working with batteries Batteries generate flammable explosive gases Keep arcs sparks flames and lighted tobacco away flashlight to check battery electrolyte level Stop the engine and shut off electrical equipment while inspecting or handling the battery Do not short circuit the battery posts with metal items Always unfasten the negative battery cable first when disconnecting the battery cable Always connect the negative battery cable last when fastening the battery cable Loose battery terminals may result in sparks Be sure to fasten terminals tightly Make sure the vent caps are tightened securely Do not charge a battery or jump start the engine if the battery is frozen Warm to 15 C 60 F or the battery may explode Do not use the battery when the fluid level is below the lower level Doing so will hasten the deterioration of the internal portions of the battery and shorten the battery life and can also cause rupturing or an explosion Do not fill the battery above the upper level Doing so could cause the fluid to leak contact and damage the skin or cause parts to corrode SAFETY Maintenance Precautions Have a Gehl technician repair weld
99. ker or obstacle If unavoidable while traveling when operating the working equipment do so with care Avoidcrossingoverobstacleswhenever possible If you must do so keep the bucket close to the ground and travel slowly Never cross obstacles if they will seriously tilt the machine to an angle of 15 or greater When traveling on rough terrain or when carrying a load lower the load and travel slowly Remove any obstacles in the machine s path Use the left control lever to operate the crawler tracks Return the left control lever to the neutral position to stop the tracks 77 010006 170008 2 the safety bar to the released position 30 cm 12 in T7A012E 3 Roll back the bucket fully and liftthe bucket to 30 cm 12 in above the ground OPERATION amp 3 Machine Operation Forward and Reverse Travel Pivot Turn To move forward Turning to the left Push the left control lever forward gt To turn forward to the left c To move backward Tilt the left control lever forward to the Pull the left control lever rearward left c To turn rearward to the left Tilt the left control lever rearward to the Traveling in 2nd High Speed right To turn to the right operate the left control c lever in the opposite way Spin Turn
100. ket Dump Left Pivot Turn Lift Arm Float Right Pivot Turn Neutral Right Pivot Turn Reverse Left Pivot Turn Reverse 4 OPERATION amp 3 Machine Operation Warming Up the Hydraulics Operating the working equipment without warming up the hydraulics is dangerous because response will be slow and the equipment may move in unexpected ways Be sure to sufficiently warm up the hydraulics IMPORTANT Do not operate the levers suddenly when the hydraulic oil temperature is below 20 C 68 F The proper hydraulic oil temperature during operation is 50 to 80 C 122 to 176 F but if operations must be performed at lower temperatures heat up the hydraulic oil to at least 20 C 68 F Normal Warm up z X Me i 910002 1 Run the engine at medium speed for about 5 minutes with no load T7D008 2 Set the safety bar to the released position and lift the bucket from the ground T7D009 3 Extend and retract each of the cylinders several times with no load 170010 4 Travel slowly forward and backward several times Warming Up in Cold Weather 1 Perform the normal warm up procedure 770011 2 Set the bucket at the stroke end and keep it there Do not do this for more than 30 seconds 3 Repeat step 2 until the bucket operating speed is normal OPERATION amp
101. l T7A016 Do not change directions or cross slopes sideways First return to a flat surface then redirect the machine 86 On grass dead leaves wet metal or frozen surfaces the machine may slide sideways even on very gentle slopes Make sure the machine is never sideways with respect to the slope Position for traveling on slopes With bucket full a T7A014E With bucket empty e T7A015E OPERATION I Operating Procedures Braking when traveling down slopes Braking 770034 Braking is automatically applied by the hydrostatic drive system when the left control lever is returned to the neutral position Full braking is achieved when the safety bar is raised If the engine stops Descending T7D035E If the engine stops when traveling down a slope set the control levers and pedal to the neutral position stop the machine and re start the engine 87 Do not open the front door while traveling on slopes if equipped 170036 Opening the front door while traveling slopes can be hazardous because the force required to open and close the door changes abruptly Always keep the door closed when traveling on slopes OPERATION I Operating Procedures Operations Possible with this Machine IMPORTANT Do not perform scooping or grading operations with the bucket cylinders fully extende
102. l Motor Gear Refer to page 135 Replacing the Travel Motor Gear Oil 139 Every 500 Hours Adjusting or Replacing the Bucket Stoppers bolts nuts If you must work beneath the raised lift arms securely engage the lift arm stop Never get under the lift arms and bucket if they are not sufficiently supported Service the lift arm stop if damaged or if parts are missing Using a damaged lift arm stop or with missing parts can cause the lift arms to drop causing injury or death e Park the machine on solid flat ground for work Work as a 2 person team and stay in communication with each other One person must sit at the operator s seat and stop the engine whenever necessary and must take care not to touch the lever or pedal unless necessary Set the engine speed to low when operating the control lever The one who performs maintenance must make sure to keep their body or clothing away from the moving parts of the machine For the adjustment of the bucket stopper install the lift arm stop 2 used for the lift arm adjustment on the lift arm cylinder while the pin hole 1 ofthe lift arm should be positioned atthe height of approximately 1500 mm 59 1 in or 1600 mm 63 in above the ground as shown in the figure on the right Adjustment work should be done while maintaining the machine at this attitude To perform the inspection safely obtain the lift arm stop 2 and the locking pi
103. l cause the bucket to fall rapidly and is extremely dangerous Do not drive the loader forward with the lift arms in Float position At times of combined operation of bucket and lowering tilting the lift arms continuation of the combined operation after the bucket cylinder has reached fall stroke will result in the lift arms rising or stopping without going lower Be cautious of any unexpected movement of the lift arms Operating the Lift Arms U1D008 To lower the lift arms Push the right control lever forward c To raise the lift arms Pull the right control lever rearward Operating the Bucket 010009 110001 Use the right control lever to operate the lift arms and bucket Return the right control lever to the neutral position to stop the lift arms and bucket Set the safety bar to the released position To roll back Tilt the right control lever to the left c To dump Tilt the right control lever to the right Operating the Lift Arms Float U1D010 To float the lift arms Press the float switch on the right control lever OPERATION amp 3 Machine Operation Operating the Auxiliary Hydraulics Use the auxiliary hydraulics to operate a breaker angle bucket or other approved attachments Two methods of operation are permitted operation with the auxiliary hydraulic buttons and operation with the slider switc
104. l work area Make sure there is adequate light and if indoors ventilation Clear obstacles and dangerous objects Eliminate slippery areas Always clean the machine Stop the engine before performing maintenance Avoid lubrication mechanical adjustments with the machine in motion or with the engine running while stationary f maintenance must be performed with the engine running always work as a two person team with one person sitting in the operator s seat while the other works on the machine When performing maintenance be sure to keep your body and clothing away from moving parts Stay clear of moving parts lt lt 580 eS E3A630 Clean the machine before performing maintenance e Stop the engine before washing the machine Cover the electrical parts so that water cannot enter Water on electrical parts could cause short circuits or malfunctions Do not use water or steam to wash the battery electronic control components sensors connectors or the operator s compartment 29 Stay clear of all rotating and moving parts Wrapping or entanglement may result in serious injury or death Keep hands clothing and tools away from the rotating fan and running fan belts Maintenance Precautions Securely block the machine or any component that may fall E3A570 Before performing maintenance or repairs under the
105. lean the condenser 1 Inspecting and Adjusting the Air Conditioner Belt IMPORTANT Do not let any oil or grease get on the belt because it will cause the belt to slip shortening its service life and reducing the air conditioner s cooling capacity If the belt is slack it will slip and vibrate shortening its service life and reducing the air conditioner s cooling capacity The belt should also not be too tight Adjust the belt tension to the standard value approximately 8 mm or 0 3 in 187 011001 Inspection 1 Open the radiator door 2 Press on the center of the belt 1 with a finger The belt s tension is normal if it deflects about 8 mm 0 3 in when pressed with a force of about 98 N 22 Ibs Adjustment If the belt s tension is not normal adjust it with the adjust bolt 3 1 Loosen the nut 4 2 Tighten the bolt 3 to decrease the tension Loosen the bolt 8 to increase the tension After adjusting is completed tighten the nut 4 OPTIONS Air Conditioner CTL55 gt Replace Replace the belt in the following cases e f it stretches and its tension cannot be adjusted e f it is cut or cracked f the fan belt is worn and the pulley is touching the bottom of the V groove Cleaning the Filter Clean the filter more often when operating in dusty places If the filter is clogged the air becomes weak and a muted booming sound is he
106. machine body on an extreme slope of 15 degrees or more When traveling on rough terrain or when carrying a load lower the load and travel slowly 30 cm 12 in T7A012E e Traveling and turning should be performed with the bucket cylinder fully retracted and the bucket at a height of approximately 30 cm 12 in from the ground Avoid sudden stops starts and turns Do not raise the safety bar while traveling This is dangerous because raising the safety bar will cause the parking brakes of the travel motors to operate and apply the brakes abruptly Do not switch off the ignition switch while traveling Doing so will cause sudden braking and is dangerous e Before backing up visually check for safety to the rear Backing up without checking could result in contact with a worker or obstacle e ftheworking equipment must be operated while traveling do so with extra care T7A013 When traveling try not to cross over obstacles When crossing over something cannot be avoided keep the bucket close to the ground and travel slowly Also note that the machine must not cross over an 20 Operating Precautions Cautions on traveling on slopes With bucket full e T7A014E Sudden stopping on a sloped road may lead to loss of stability and the machine could tip over T7A0161 With bucket empty T7A015E Work
107. maintenance be sure to keep your body and clothing away from moving parts Standing at the back of the machine while the engine is running is extremely dangerous because the machine could move suddenly Never stand at the back of the machine while the engine is running Do not remove the radiator cap or drain plugs when the coolant is hot Stop the engine let the engine and radiator cool and loosen the radiator cap or drain plugs slowly 142 When cleaning if the temperature of the coolant is low the thermostat will be closed and the coolant will not circulate in the radiator Heat the coolant to at least 90 195 F before cleaning OA mu T7G022 A o Open the rear door and remove the under cover 5 Gradually loosen the radiator cap 3 to release the internal pressure then remove the cap Place a pan to catch the waste coolant under the drain plug 4 then loosen the drain plug 4 and drain the coolant Tighten the drain plug 4 Add tap water through the radiator s coolant supply port up to the top of the port Take your time doing this adding the water slowly to avoid any air entering the radiator Close the radiator cap 3 Start the engine and run it at a speed slightly above low idling Raise the coolant temperature to at least 90 C 195 F then run the engine for about 10 minutes with the
108. me A WARNING e Before operating perform the walk around inspections and make repairs immediately if any irregularities are found Be sure to secure the engine hood or rear door when opening it Do not open the engine hood or rear door on slopes or in strong winds Before starting the engine look around the machine and lower chassis clean any combustible materials off high temperature parts of the engine and inspect for irregularities such as oil leakage water leakage and loose nuts and bolts 2 7 LECT 2 7790031 Inspecting by Opening the Engine Hood and Rear Door 1 Check for any twigs leaves oil or other 3 Check for oil leakage from the hydraulic combustible materials around the engine tank hydraulic devices hoses and and battery connections 2 Check for oil and engine coolant water leakage around the engine 114 s MAINTENANCE Walk Around Inspection Inspecting by Walking Around the Machine Check lights for dirt damage and burned out bulbs Check attachments hoses for damage Check the bucket for wear damage and looseness Check the handrail and step for damage and loose bolts Check the tracks track rollers idlers and sprockets for damage wear and loose bolts Check for oil leakage from the travel motor 10 Check the ROPS cab and guard for damage and loose nuts and bolts Check t
109. n 3 in advance The work should be done by two people One of them must sit at the operator s seat and stop the engine whenever necessary while the other person installs removes the lift arm stop 2 and adjusts the bucket stopper 1500mm 1600mm CTL55 CTL65 CTL75 CTL85 U1GG20 1 Park the machine on solid flat ground and remove the bucket 2 Lower the lift arm to its lowest position and stop the engine 010021 3 Hook the lift arm stop 2 on the steel bar 4 of the lift arm and place it on the cylinder A BN 019022 Every 500 Hours Start the engine and raise the lift arm until the lift arm stop 2 falls on the cylinder rod Slowly lower the lift arm until the lift arm stop 2 hits against the edge of the cylinder tube and becomes fixed and then stop the engine U1G0231 U1G027 6 Insert the locking pin 3 in the front hole of the lift arm stop 2 and pass it through under the cylinder rod to the back hole 7 To prevent the locking pin 3 from falling off set the hook 5 at a right angle to the locking pin U1G024 8 Loosen the lock nuts 7 and fully screw in the stopper bolts 8 141 9 10 11 Start the engine extend the bucket cylinders to the maximum length and then stop the engine Adjust each plate 9 right left
110. n and off the machine Keep steps and platform clean Never use the control levers as hand holds Walk Around Inspection Perform the walk around inspection before starting the engine the first time each day Perform the inspection as described under Maintenance Walk Around Inspection pages 114 and 115 Daily Inspection Perform the daily inspection once a day before starting the engine the first time each day Perform the inspection as described under Maintenance Daily Inspection pages 116 to 120 OPERATION A p amp 3 Starting and Stopping the Engine Before Starting the Engine 1 Adjust the seat for a comfortable operating position 2 Fasten the seat belt IUGERA T7B015 3 Check that the safety bar is in the locked position U1D001 4 Check that the control levers and pedal are in the neutral position J2D002E 5 Insert the key into the ignition switch turn it to the ON position then perform the following inspection fs Sl e All the warning lamps flash and an alarm is sounded for 2 seconds The instruments also start functioning After 2 seconds only the battery charge warning lamp 3 and engine oil pressure warning lamp 1 flash and the other lamps turn off e Turn the light switch to check that the front lights tail lights and instruments lights turn on Check the fuel level e
111. nce 101 HONS 3 2 a Troubleshooting 155 Specifications 169 HE p Options ence tnn usan vane anii 179 SAFETY General Precautions s 8 Preparing Precautions 15 Starting Precautions 17 Operating Precautions 19 Stopping Precautions 26 Transporting Precautions 27 Maintenance Precautions 28 Safety Signs Decals 35 General Precautions Observe all safety rules Operation inspection and maintenance of this machine must be performed only by trained and qualified persons All rules regulations precautions and safety procedures must be understood and followed when performing operation inspection and maintenance of this machine Do not perform any operation inspection and maintenance of this machine when under the adverse influence of alcohol drugs medication fatigue or insufficient sleep Wear appropriate clothing and personal protective equipment 2 8 7 A afla Do not wear loose clothing or any accessory that can catch on controls or in moving parts Do not wear oily or fuel stained
112. nce Precautions Attach a NOT OPERATE tag Severe injury could result if an unauthorized person starts the engine or touches controls during inspection or maintenance e Stop the engine and remove the key before performing maintenance Attach a DO NOT OPERATE tag to the ignition switch or control lever Use the correct tools Je Do not use damaged or weakened tools or tools designed for other purposes Use tools suited for the operation E3A530 Replace important safety parts periodically e Replace fuel hoses periodically Fuel hoses become weaker over time even if they appear to be in good condition e Replace important safety parts whenever an malfunction is found even if it is before the normal time for replacement Refer to the section titled Important Parts for further details Anti explosive lighting M r nt E3A550 Use anti explosive electrical fixtures and lights when inspecting fuel oil coolant battery fluid etc If lighting that is not anti explosive breaks the substance could ignite resulting in serious injury or death Do not allow unauthorized personnel in the work area Do not allow unauthorized personnel in the work area Chips or other debris can fly off machine parts when grinding welding or using a hammer E3A140 Maintenance Precautions Prepare the work area Select a firm leve
113. ne season type antifreeze coolant completely drain the antifreeze coolant carefully clean the inside of the coolant system then add tap water Refer to page 142 Cleaning the Engine Cooling System OPERANON amp 3 Using Rubber Tracks Rubber tracks have an inherent weakness due to their use of rubber Be sure to follow the prohibitions and cautions below to prevent damage to the tracks and track slippage Prohibited Actions Do not travel or operate the machine in the following places T7E001 e Traveling or slewing on broken stone jagged base rock iron rods iron scraps or the edges of iron sheets may damage or cut the tracks T7E002 e Traveling on riverbeds or places with many soft rocks may cause the tracks to slip off or be damaged due to rocks getting stuck in them Do not use on the seashore The salt may corrode the metal cores of the tracks 92 7 003 e Donotletfuel salt or chemical solvents get on the tracks These substances may corrode the couplings of the tracks metal cores resulting in rust or peeling If these substances get on the tracks wipe them off immediately using water T7E004 Traveling on roads directly after asphalting or on hot surfaces such as over fires or on iron sheets under strong sunlight may result in irregular wear or damage to the lugs Do not move earth in places where the rubber
114. ngine and remove the ignition key 3 Set the safety bar securely to the locked position 4 Set stoppers in front and behind the tracks 5 Put a chain or wire rope over the lower frame and fasten it securely to prevent sideways slippage 6 Secure the bucket with a chain or wire rope 99 P TRANSPORT um Cautions on Transporting e Know and follow the safety rules vehicle code and traffic laws when transporting the machine Consider the length width height and weight of the truck with the machine loaded on it when determining the best route 100 General 102 Service Data eese 104 Important Parts esses 109 Maintenance Chart 110 Maintenance Log nnna 112 Walk Around Inspection 114 Daily Inspection Every 10 Hours 116 A New Machines 122 Every 50 Hours ener 128 Every 100 Hours ees 134 After First 250 Hours New Machines Only 135 Every 250 Hours eese 196 Every 500 Hours ess 138 Every 1000 Hours 142 Every 1500 Hours
115. o ensure safety Check the topography and ground condition of the working area or the structure of the building when working indoors and take the necessary safety measures in dangerous spots Noteandavoidallhazardsandobstructions Such as ditches underground lines trees cliffs overhead electrical wires and areas where there is danger of a slide T7A009 Check with the local utilities for the locations of buried gas and water pipes and buried power cables Determine jointly what specific precautions must be taken to ensure safety When working on roads be sure to take into account the safety of pedestrians and vehicles Use a flagman and or signals Fence off the working area and prohibit entry to unauthorized persons e When working in water or crossing shallow Streams or creeks check the depth of the water the firmness of the ground and the speed of the current beforehand Make sure the water is not deeper than the allowable depth Refer to the section titled Cautions on Use in Water for further instructions 15 Check the strength of the bridge rf T7A025 When travelling over a bridge or other structure check the permissible load If the strength is insufficient reinforce it Always keep the machine clean T3A004 Clean windows mirrors and lights to ensure good visibility Wipe off any oil grease mud snow and ice to prevent accidents
116. ody s holder and insert an R pin into the stopper pin s hole to fasten it in place If you need to run the engine while the ROPS is raised follow these steps 7 Make sure that all levers and pedal are in neutral positions 8 Push the throttle lever to the low idle position 9 Start the engine 10 Besureto stop the engine after inspection and maintenance Lowering 1 Remove the stopper pin B 2 Lower the ROPS 3 Tighten the lock bolts A 4 Reinsertthe stopper pin B into the body s holder s MAINTENANCE 2 When Required Inspecting the Rubber Tracks Repair or replace the rubber tracks if their conditions are as described below Consult a Gehl dealer about repairs or replacement Rubber track Replace the track if the entire track is stretched and cannot be adjusted 1 Lug 779032 Replace if the height of the lugs A is 5 mm 0 2 in or less 2 Steel cord E4G063 Replace if the steel cord is exposed over 2 or more links Replace if half or more of the steel cords on one side are cut 152 8 Metal core E4G064 Replace if even one metal core is missing 4 Rubber 60 mm or greater E4G065 Replace if there are cracks of 60 mm 2 4 in or greater in length If the steel cord is visible replace as soon as possible regardless of the length of the crack MAINTENANCE Long term Storage Procedures for
117. of the boot 1 and turn it upwards 2 Wipe off the old grease 3 Apply grease to points A and B 4 Re install the boot 1 150 Inspecting and Replenishing the Windshield Washer Fluid Use a windshield washer fluid intended specifically for motor vehicles Follow the instructions included with the washer fluid 786004 Inspection 1 Open the cab door 2 Inspect the washer tank 1 and add washer fluid if the level is low Replenishing 1 Mix the washer fluid to the prescribed concentration 2 Remove the cap 2 and add washer fluid 3 Reinstall the cap 2 s MAINTENANCE 2 When Required Tilting Up the ROPS For inspection and maintenance the ROPS is designed so that it can be tilted up e Raising or lowering the ROPS while the engine is running may cause the machine to move and cause serious injury or death Lower the working equipment to the ground and stop the engine before raising or lowering the ROPS When the ROPS is tilted up support it firmly with the stopper to prevent it from falling Raising Tilt up 1 Select a firm level surface lower the working equipment to the ground and stop the engine 2 Set the safety bar to the lock position 1760301 3 Remove R pin and remove the stopper pin B 4 Remove the lock bolts A 151 T7G081 5 Slowly raise the ROPS 6 Insert the stopper pin B into the b
118. oil or water is leaking from serviced parts Move the controls and check that the machine is operating properly Disposing of wastes E3A640 Pour waste fluids from the machine into containers Disposing of fluids improperly destroys the environment Follow the prescribed regulations when disposing of oil fuel engine coolant refrigerant solvents filters batteries and other harmful substances Handling of poisonous chemicals Poisonous chemicals will cause serious injury if directly contacted Poisonous chemistry used in this machine includes grease battery solution coolant paint and adhesive agent Safety Signs Decals The following safety signs decals have been placed on the machine in the areas indicated They are intended for the personal safety of the operator and co workers Please take this manual walk around the machine and note the content and location of these safety signs Review these signs and the operating instructions in this manual with all machine operators Keep the safety signs legible If they are not obtain replacements from your Gehl dealer U1AGO11 35 Safety Signs Decals 1 No 06593 00012 2 No 08800 30010 AVOID DEATH Before removing seat belt A DANGER and leaving seat e Lower lift arms to ground or AVOID DEATH rest lift arms on stops Lift arm stop must b
119. ole re install the plug 1 Every 1000 Hours MAINTENANCE Every 1500 Hours E Cylinders Start the engine and run it at low idle for 10 minutes Set the engine to a low idle then extend and retract all the cylinders 4 or 5 times without going to the stroke ends Runthe engine at high speed then extend and retract all the cylinders 4 or 5 times without going to the stroke ends Set the engine back to a low idle then extend and retract all the cylinders 4 or 5 times to the stroke ends Inspecting and Adjusting the Engine Valve Clearance This operation requires experience Have it performed by a Gehl dealer Retightening the Engine Cylinder Head Bolts This operation requires experience Have it performed by a Gehl dealer 146 Inspecting and Cleaning the Engine Fuel Injectors This operation requires experience Have it performed by a Gehl dealer Inspecting the Crankcase Breather System This operation requires experience Have it performed by a Gehl dealer Every 2000 Hours MAINTENANCE Every 3000 Hours E Lapping the Engine Valve Seats This operation requires experience Have it performed by a Gehl dealer 147 Inspecting the Turbocharger Blower wash as necessary CTL55 CTL75 CTL85 gt This operation requires experience Have it performed by a Gehl dealer Inspecting and Cleaning the EGR Valve Lead Valv
120. ontrol the flow of the oil in the first auxiliary hydraulic lines Flow Selector Switch C N IN 7880111 The flow of the auxiliary hydraulic system lines a and b can be set to either one way or two way flow When the switch is pressed the flow switches from two way to one way and the built in lamp green lights When pressed again the flow switches from one way back to two way and the lamp turns off OFF O Two way flow A One way flow The oil in line b returns to the hydraulic tank CONTROLS Switches gt Detent Mode Switch D This switch changes the function of auxiliary hydraulic button Normally auxiliary hydraulic flow is on while button A is pressed and turns off when it is released If pressed again after pressing this switch then auxiliary hydraulic button A turns on and stays on when it is pressed and only turns off when it is pressed again The built in lamp orange lights when the switch is on Thus there is no need to hold the switch in When this switch is pressed again the function of the auxiliary hydraulic switch returns to normal and the lamp turns off 57 High Flow Switch E If equipped This switch controls the ON OFF function of the high flow auxiliary hydraulics Press this switch to activate the high flow hydraulics
121. or High flow hydraulic system 172 SPECIFICATIONS Main Specifications TYPE ROPS MASS Machine mass kg Ib Rubber tracks 5090 11220 not including operator 5155 11365 PERFORMANCE Bucket capacity m cu ft Heaped 0 579 20 45 standard bucket Struck 0 426 15 04 1st 7 8 4 85 Travel speed km h mph Rubber tracks 2nd 12 0 7 46 Gradeability degrees 30 Rubber tracks 31 0 4 5 Ground pressure kPa psi 31 6 4 58 Noise level dB A Sound power level Lwa 105 lt For EU gt Sound pressure level Lpa 85 ENGINE Manufacturer and model KUBOTA V3800DI T E3B TLTU 1 Rated output kW min hp rpm 68 3 2600 91 6 2600 Displacement ml cu in 3769 230 Starter V kW 12 3 0 Alternator V kW 12 0 72 Battery V Ah 12 92 for High flow hydraulic system 178 SPECIFICATIONS pnm 54 kg N Machine Dimensions T7K0012 174 rpm mm kg om SPECIFICATIONS Machine Dimensions Units mm inches CTL55 CTL65 CTL75 CTL85 Standard Bucket Rubber Tracks A 3220 126 9 3430 135 1 3740 147 2 3985 156 9 B 2580 101 7 2740 107 8 2980 117 3 3135 123 5 Cc 1240 48 9 1390 54 7 1495 58 9 1595 62 9 D 1970 77 6 2130 83 9 2270 89 4 2320 91 3 E 250 9 8 310 12 1 325 12 8 345 13 5 F 1470 57 9 1580 62 2 1770 69 7 1860
122. ose its balance and tip over The following operations are particularly dangerous Do not perform them Traveling down slopes with e Traveling across slopes Turning on slopes the attachment lifted T K E When heavy attachments are installed the overrun the distance from where the control movement to stop traveling is performed until traveling stops completely increases and mistakes in judgment may result in the attachment hitting surrounding objects Allow for plenty of room between the attachment and obstacles In addition the natural drop the gradual dropping of the attachment under its own weight when it is stopped in midair also increases when heavy attachments are installed 770021 181 OPTIONS Air Conditioner CTL55 gt CAUTIONS ON USE Ventilate periodically When using the air conditioner over an extended period of time open the windows about once each hour to let in fresh air Your eyes may become irritated if you smoke while using the air conditioner If this happens open the windows to let in fresh air Cigarette smoke particularly irritates the eyes when using the air conditioner because the humidity in the cabin drops and the eyes membranes tend to become dry Always maintain good visibility Working with the windows dirty or fogged restricts visibility and is dangerous Always clean dirt and moisture off the windows before working The windows tends to get foggy when the
123. oses stand to the side and loosen slowly to gradually release the internal pressure before removing Be careful with grease under pressure a m e Ms E3A620 Thetrack adjuster contains highly pressurized grease If the tension is adjusted without following the prescribed procedure the grease discharge valve may fly off resulting in injury Loosen the grease discharge valve slowly Do not put your face arms legs or body in front of the grease discharge valve If no grease is expelled when grease discharge valve is loosened there is a problem Contact your nearest service outlet for repairs DO NOT disassemble because this is very dangerous SAFETY Maintenance Precautions Never disassemble the track adjuster U1A005 There is very strong spring contained in the track adjuster If the track adjuster is accidentally disassembled the spring can pop out resulting in serious injury never disassemble the track adjuster Disconnect the battery E3A590 Disconnect the battery before working on the electrical system or doing any welding Remove the negative battery cable first When reconnecting the battery connect the negative battery cable last Avoid battery hazards e Batteries contain sulfuric acid which will damage eyes and skin on contact e f acid contacts eyes flush immediately with clean water and get prompt medical attention f ac
124. ot line filter This indicates the hydraulic oil pilot line filter is clogged 2 warning lamp Stop the engine and replace the filter Replace the filter immediately if the lamp flashes Refer to page 126 Replacing the Pilot Line Filter T7B008 IMPORTANT Continuing to operate the machine while the lamp is lit could damage the line filter and hydraulic equipment Cold weather operation Hydraulic oil is not heated Refer to page 75 Warming up the hydraulics 163 TROUBLESHOOTING Other Symptoms For symptoms not included on the table below or if the problem persists after the proper procedures have been taken consult a Gehl sales or service outlet Symptoms Main cause Procedure Left and right control levers do not move smoothly Insufficient grease on left and right control levers Add grease Refer to page 150 Lift arms bucket e Safety bar is raised Lower the safety bar auxiliary hydraulics or Refer to page 59 traveling operation not e Fuse is blown e Replace the fuse possible Refer to page 160 Scooping or lifting force e Insufficient hydraulic oil level Replenish to the prescribed is insufficient level Refer to page 119 e Hydraulic oil is not heated e Perform the warm up procedure Air cleaner is clogged Hydraulic oil is not of suitable type Refer to page 75 Replace the air cleaner Refer to page 136 Replace the hydraulic oil Refer to page 144 Trav
125. otects the electrical parts and wiring from damage due to abnormally large currents 161 TROUBLESHOOTING If a Warning Lamp Flashes If an alarm is sounded or a warning lamp starts flashing during operation park the machine in a safe place and perform the procedures described below Warning lamp Lamp name Procedure Engine oil Inspect the engine oil level If the lamp is flashing even pressure though the levels are normal or if it continues flashing after warning oil added consult a Gehl dealer lamp Refer to page 117 Inspecting and Replenishing the OSOBO70 Engine Oil Coolant This indicates the coolant temperature has risen irregularly temperature and the engine is overheating warning Refer to page 157 If the Engine Overheats lamp C4B012 Battery This indicates there is a problem with the fan belt or charge charger Inspect the fan belt for slack or breakage and warning adjust as necessary If the lamp continues flashing after lamp maintenance there is a problem with the charger Consult a Gehl dealer UM Refer to page 125 Inspecting and Adjusting the Fan Belt Air cleaner This indicates the air cleaner filter is clogged P warning If the air cleaner warning lamp lights replace the elements lamp immediately 948010 Refer to page 136 Replacing the Air Cleaner Elements 162 TROUBLESHOOTING If a Warning Lamp Flashes Warning lamp Lamp name Procedure Pil
126. ottle pedal 7 Rear wiper switch option 19 Front light switch 8 Safety bar 20 Tail light switch 9 Seat 21 Multifunction buttons 10 Auxiliary hydraulic buttons 11 Instrument panel 41 CONTROLS Doors and Covers Ignition Key E4B003 The Ignition key is used not only to start and stop the engine but also to lock and unlock the following places Fuel filler cap e Engine hood e Cab door e Manual storage Cab Door CTL55 e When mounting and dismounting the cab first open the door fully to the stopped position and check that it does not move e When opening and closing the door grasp the handle securely and move the door slowly Opening the door suddenly could result in it hitting your head or your hands or feet could get caught T3B004 42 Preparation before Opening and Closing the Cab Door 1 Park the machine on a level surface and stop the engine 2 Raise the safety bar Lock and unlock V 7 KO Ne 138005 1 Insert and turn the ignition key Opening T3B006 1 Turn the handle 2 clockwise and open the door fully To open the door from inside the cab 1 Turn the handle 2 counterclockwise and open the door fully Closing 1 Grasp the handle 2 or 8 and slowly close the door NTROL Doors and Covers Side Window CTL55 side window 2 To close the
127. parts of the cooling circuit If the refrigerant gas leaks keep flames away OPTIONS a Air Conditioner lt CTL55 gt NAMES OF COMPONENTS EI M U1L007 1 Defroster 2 Condenser Control Pannel 3 Receiver drier a 4 Foot outlets O o gt 5 Rear outlets OFF o 6 Control panel NN m 7 Compressor 8 Air conditioner unit 9 Inner filter d 10 Outer filter 0021 11 Air conditioner switch 12 Temperature control dial 13 Fan switch 183 OPTIONS Air Conditioner CTL55 gt Air Conditioner Switch IMPORTANT avoid placing an excessive load on the compressor wait until the engine is started and is running smoothly before turning on the air conditioner EN L3TO06 Use this switch to turn the air conditioner ON and OFF When this switch is pressed while the engine is running and the fan switch is ON the air conditioner turns on Press the Switch again or turn the fan switch OFF to stop the air conditioner Note To prevent leakage of refrigerant gas from the compressor s seal operate the air conditioner at least once a week regardless of the season Note The air conditioner will not function if the temperature in the cab is too low about 3 38 or lower 184 Temperature Control Dial o 0 O M
128. per operates PUSH Washer fluid is squirted from the nozzle while pressed and stops when released Rear wiper switch Quos Off Landes Wiper operates Washer fluid is squirted from the nozzle while pressed and stops when released NTROL CONTROLS Levers and Pedals Safety Bar Throttle Lever Before leaving the operators seat raise the safety bar to engage the lock and stop the engine If any controls are touched accidentally when the safety bar is lowered the machine will move suddenly and cause serious injury or death e Be careful not to touch the control This lever controls the engine speed levers and pedal when lowering eee Low idle raising the safety bar B Maximum speed U1B012 Throttle Pedal T7B015 This device is for locking the control levers pedal and selector detent mode and high flow switches When the safety bar is lifted the levers pedal and switches are locked Low idle 59 NTROL Levers and Pedals Right Control Lever Left Control Lever Be sure to check which pattern of lever control arrangement you are operating with before beginning operations Use this lever to move forward and rearward and to change directions Refer to page 74 Lever Pattern Refer to page 77 Operating the Left Control Lever
129. peration ss 70 Daily Inspection senses 70 Before Starting the 71 Daily Inspection Every 10 116 Bleeding the Air from the Fuel System 159 Danger of flying objects 25 Defogging the Windows 186 Disconnect the battery s 33 Disposing of wastes n 34 INDEX D I Do not allow unauthorized personnel the work 28 Do not carry the bucket over the heads of people 22 Do drive into materials at high speeds 22 Do not drive on soft ground sss 24 Do notovercool acttbinett rers 182 Do not permit riders on the machine 19 Do not suddenly stop or lower the working equipment 23 Do not turn the air conditioner on until the engine is 182 Doors and Covers nnn 42 Draining the Fuel Tank 132 E Emergency 16 Emergency 45 Engine Fault Warning Lamp CTE65 CULTS gt 53 Engine ood cuc ttr aon 44 Ensure good visibility
130. pment iN SS T9G001 1 Setthe machine to the lubrication position shown in the diagram above ground the bucket then stop the engine 2 Use the grease gun to lubricate the grease fittings 3 Wipe off the expelled grease 120 121 MAINTENANCE A After First 50 Hours New Machines Only Replacing the Hydraulic Oil Return Filter Stop the engine and allow the machine to cool before performing maintenance The engine hydraulic lines and many other parts of the machine are hot directly after the engine is stopped Touching these parts will cause burns The hydraulic fluid is also hot and under high pressure Be careful when loosening caps and plugs Working on the machine under these conditions could result in burns or injuries due to hot oil spraying out Oil may spray out if caps or filters are removed or pipes disconnected before releasing the pressure in the hydraulic system e When removing plugs or screws or disconnecting hoses stand to the side and loosen slowly to gradually release the internal pressure before removing T3G0011 1 Loosen the bolts and remove the cover 3 7300021 Loosen the bolts and remove the flange 4 Remove the return filter 5 Install the new return
131. r b and remove it T3G0011 T3G0021 THs Refer to page 122 Replacing the Hydraulic Oil Return Filter Loosen the hose clip and remove the hose 8 Loosen the bolts and remove the flange 9 Remove the suction strainer 10 and clean it Clean the inside of the hydraulic tank Install the new return filter Refer to page 122 Replacing the Hydraulic Oil Return Filter Install the suction strainer 10 to the flange 9 18 Install the flange 9 19 Install the hose 8 to the flange 9 20 Tighten the drain plug 7 12 13 14 15 16 17 145 21 Replenish hydraulic up to the middle of the sight gauge 2 through the port for plug 1 Tighten the plug 1 Follow the procedure Bleeding the air below to bleed the air from the hydraulic oil circuit Set the machine to the hydraulic oil level inspection position and inspect the level after the temperature of the oil has dropped Refer to page 119 Inspecting the Hydraulic Oil Level and Replenishing 22 23 24 Bleeding the air IMPORTANT Afterreplacingthe hydraulic oil bleed the air from the hydraulic circuit and hydraulic devices Failure to do so may damage the hydraulic devices e Hydraulic pump CTL55 CTL65 gt 1 Tilt up the ROPS 2 Remove the plug 1 from the hydraulic pump 3 After hydraulic oil overflows from the plug h
132. r from the hydraulic lines c Stop the engine and wait for more than 5 minutes until bubbles escape from the hydraulic oil in the tank CONTROLS Accessories IMPORTANT Follow the procedures for purging air as instructed by the attachment manufacturer if specified to do so 3 Check for leaks High flow Hydraulic System If Equipped The High flow function provides additional flow to the system to operate attachments that require more hydraulic flow EXAMPLE Cold planer This system can be used only for one way flow attachments Auxiliary hydraulic flow rate and rated pressure Flow Rate CTL75 138 L min 36 3 US gpm CTL85 152 L min 40 1 US gpm Rated Pressure 20 6MPa 2987 psi A 178030 1 Connect the attachment hydraulic lines to ports a and b Refer to page 62 Hydraulic Circuits Some attachments may have a case drain which need to be connected to the small port T D Connecting the 63 2 Turn on the High Flow switch E green light is ON T9B018 Press the auxiliary hydraulic switch A or slide the slider switch to the left side A Refer to page 81 Operating the Auxiliary Hyaraulics Note Running the high flow hydraulics for extended periods of time could cause damage to the hydraulics or other systems of the machine due to overheating
133. r the engine in started in cold weather This is not a malfunction The lamp will turn off as the engine warms up T7B008 52 CONTROLS Instrument Panel Indicators 6 Glow Lamp C4B013 7 Travel Speed Lamp This lamp lights when the travel speed button is set to C4B014 This lamp turns off when engine preheating is completed 2nd high speed Meters 8 Hour meter This displays the total engine H running time in hours The rightmost digit indicates 1 1 tenths of hours 6 minutes Set the inspection and maintenance intervals according to the time displayed on the hour meter 9 Coolant Temperature Gauge This gauge indicates the temperature of the engine Vei coolant g 38020 The needle should be within the green range during machine operation The red range indicates overheating 10 Fuel Gauge This gauge indicates the amount of fuel in the tank L Be sure to top off the tank before running out of fuel 53 Engine Fault Warning Lamp CTL55 CTL65 CTL75 gt U1B013 IMPORTANT If the lamp flashes check the flashing pattern stop the engine and then contact a Gehl sales or service outlet for help Do not run the engine while the lamp is flashing Otherwise the specified engine performance cannot be obtained or more s
134. re ropes 2 to the hooks 1 as shown in the figure Make the wire rope horizontal and line up straight with the travel frame Move the machine to tauten the wire rope 4 Move the machine slowly and tow Applicable machine models CTL55 222000440 or later CTL65 223000838 or later CTL75 224000543 or later CTL85 225000633 or later 168 SPECIFICATIONS Main Specifications M 170 Machine Dimensions 174 Operating 176 169 D SPECIFICATIONS Main Specifications TYPE MASS Machine mass kg Ib not including operator PERFORMANCE Bucket capacity m cu ft standard bucket Travel speed km h mph Rubber tracks Heaped CAB 2720 5995 2780 6130 0 298 10 52 Struck Rubber tracks 0 223 7 88 9 3 5 78 Gradeability degrees 30 Ground pressure kPa psi Rubber tracks 32 1 4 65 32 8 4 75 Noise level dB A Sound power level Lwa 103 For EU Sound pressure level Lpa 81 ENGINE Manufacturer and model Yanmar 4TNV841 ZKTBL Rated output kW min hp rpm 38 2 2800 51 2 2800 Displacement ml cu in 1995 121 7 Starter V kW 12 2 3 Alternator V kW 12 0 48 Battery V Ah 12 72 170 D SPECIFICATIONS Main Specifications
135. rming inspection and maintenance When washing the machine with water stop the engine and cover the electrical system with plastic to protect it from water Exposing the electrical system to water is dangerous and could result in short circuits or malfunction Do not wash the battery sensors electoronic control components connectors or the inside of the cab with water or steam Fuel lubricant and grease For fuels lubricant and grease follow the instructions on the Lubricant and Fuel Chart Use pure fuels lubricants and greases that do not contain water and be careful to keep dirt out when changing or replenishing fuel lubricant or grease Store fuels lubricants and greases in the prescribed places and in such a way that no water or dirt can get in them Cautions on fueling f the fill pipe includes a strainer do not remove the strainer when fueling e After fueling be sure to securely tighten the cap etc Do not add more than the prescribed amount of fuel s MAINTENANCE n General Do not clean parts with fuel Do not use fuel to clean parts Use a non combustible cleaning agent Keep dirt out When mounting and removing parts do so in a place where there is no dust clean the working area and the part and keep dirt out Clean mounting surfaces When mounting and removing parts be sure that the surfaces of contact of the parts are clean If the sealing grooves of the surface of
136. rotected CTL55 CTL65 CTL75 gt Capacity Protected circuit capacity Protected circuit 15A Front light 30A Lever lock Radio ACC 10A Instrument 30A Air conditioner cluster OPT 10A Immobilizer 20A Reserve ACC Multifunction 5A Controller 10A Reverse alarm Service tool 10A Feed pump 15A Rear light Sensor 10A Controller 15A Main relay Ignition switch 20A External power socket OPT 10A Solenoid 10A Horn Radio Spare 20A Wiper 10A Immobilizer OPT Spare lt CTL85 gt Capacity Protected circuit Capacity Protected circuit 30A Air conditioner External power Socket OPT 20A Rear light 20A Reserve Multifunction 20A Front light 20A Instrument cluster 30A Lever lock 10A Safety relay Solenoid Air heater Radio ACC controller 10A Rear wiper 30A Stop solenoid 10 Front wiper 20A Horn Radio B TROUBLESHOOTING If a Fuse Blows Inspecting the Fusible Link U1J001G If the power is not switched on after turning the ignition switch to the ON position the cartridge type fusible links 1 might be blown Open the rear door and inspect If the fusible link is blown please contact your dealer Note A fusible link is a large piece of fuse wiring that is mounted in a circuit that carries a large electrical current Like a regular fuse the fusible link pr
137. rovided below Machine number E3A030 MACHINE DESCRIPTION lll Front rear left and right This manual refers the front rear left and right of the machine as seen when sitting in the operator s seat with the bucket visible to the front E Designated operations Use this machine primarily for the following operations e Carrying Leveling Loading Features e Hydrostatic drive system Low engine noise and exhaust emissions Two way auxiliary hydraulics Pilot operated joystick controls Break in period LEFT FRONT RIGHT REAR T7A004E Roll Over Falling Object Protective Structure ROPS FOPS tilt up ROPS When the machine is new follow the instructions below when operating the machine for the first 100 hours as indicated on the hourmeter Using a new machine roughly without breaking it in will lead to quicker deterioration of machine performance and may shorten the machine s service life e Warm up the engine and hydraulic oil sufficiently Avoid heavy loads and rapid operations Operate with a load of about 8096 of the maximum load Do not start up accelerate change directions or stop abruptly unless necessary CONTENTS Introduction erre 2 Machine Description 3 Controls isis eiisse 39 rris sacra saga naa 69 Maintena
138. s to 15 degrees or less Keep the truck bed and loading ramps clean of oil clay ice snow and other materials that can become slippery Clean the tracks e Never change course on the ramp When loading or unloading the machine be sure to use ramps and follow the procedure below Fasten to the suspension fitting 15 or less Distance between ramps E4F001 98 1 Apply the truck s parking brake and place chocks stoppers against its tires Fasten the ramps securely to the truck bed so that they will not come off Set the ramps to an angle of 15 or less Move the machine up or down the ramps with the bucket end facing downward Line up the center of the truck bed with the center of the machine and the center of the ramps with the center of the crawlers Make sure the bucket does not hit the ramps Lower the engine speed T7F001 Determine the direction on the ramps then slowly travel up or down the ramps in 1st speed low speed following the signals of a flagman Load the machine properly at the prescribed position on the bed Refer to page 99 Transporting Position TRANSPORT emacs Securing the Machine After loading the machine in the designated position secure it as described below Transporting Position T7F0021 1 Lower the bucket 2 Stop the e
139. should not be performed on a slope because the stability of the machine can be adversely affected when operating the working equipment and there is the possibility of the machine tipping over When traveling on a slope be cautious of tipping over or sliding sideways When traveling on a slope position the heavier end of the machine front or back whichever is heavier pointing up the slope When going up or down slopes having a gradient of 15 degrees or more travel up and down slope with the heavy end of the machine pointed uphill When traveling on a slope lower the bucket to a height of 20 to 30 cm 8 to 12 in above the ground and in case of an emergency lower the bucket to the ground and stop the machine e Travelat slow speeds on slopes Especially when going down slopes reduce the engine r p m speed and set the stroke of the left control lever to half or less before going down Going down a slope too fast will lead to loss of control e Traveling across an inclined surface at an angle or traveling straight across an inclined surface could result in slipping sideways or tipping over Travel straight up and down the slope When traveling over grass or fallen leaves wet iron plates or frozen surfaces the machine might unexpectedly slide sideways when on even a slight slope Do not allow the machine to become positioned across the slope Use caution when floating the lift arms T8A005
140. skin or clothing wash off immediately with clean water Inspection IMPORTANT Check the fluid level of all cells even when the fluid level can be checked by indicator Note Under normal operating conditions the maintenance free battery does not require addition of water because of the special plate designed to minimize fluid loss However for those machines that are heavily used or operated under severe conditions for example in high ambient temperature the fluid level often becomes low If that is the case check the fluid level of the maintenance free battery and add water as needed lt CTL55 gt T8GO0031 1 Open the rear door 2 Inspect the indicator 1 Blue Charging complete e White OK e Red center White Insufficient battery fluid e Red center Red Charging needed 3 Inspect the fluid level The fluid level should be between the lines indicating the upper level H and lower level L If not add distilled water up to line H Every 50 Hours e f the fluid level can not be checked by fluid level lines NOGO301E Remove the caps 2 and look into the fluid supply holes to check the fluid level If the fluid is below the sleeve 3 be sure to add distilled water up to the bottom edge of the sleeve 3 Proper amount A The fluid reaches up to the bottom edge of the sleeve 3 so the surface tension causes th
141. sons Start and operate the engine from the operator s seat only Never attempt to start the engine by shorting across the starter terminals Starting Precautions Starting with jumper cables In cold weather E3A200 280 Use jumper cables only in the recommended manner Improper use of jumper cables can result in battery explosion or unexpected machine motion Refer to the section titled If the Battery Goes Dead for proper instructions After starting the engine After starting the engine perform the following operations and checks in a safe place with no persons or obstacles in the area If any malfunctions are found follow the shutdown procedure and report the malfunction e Warm up the engine and hydraulics Observe al gauges warning instruments for proper operation e Listen for unusual noises Test engine speed control Operate each control to ensure proper operation 18 Be careful of slippery conditions on freezing ground steps and hand holds In severe cold weather do not touch any metal parts of the machine with exposed flesh because flesh can freeze to the metal and cause injury Do not use ether or starting fluids on this engine These starting aids can cause explosion and serious injury or death Warm up the engine and hydraulic fluid before operating Operating Precautions Ensure good visibility Wh
142. stem Note Air in the fuel system can make it difficult to start the engine and cause engine problems Also bleed the air when the fuel tank is emptied 132 MAINTENANCE 9 Every 50 Hours Inspecting the Bucket Stoppers bolts nuts Before performing maintenance repairs under the machine set all working equipment against the ground or in the lowermost position A 10 Parallel T8G006E 1 Park the machine on firm level ground and remove the bucket 2 Retract the bucket cylinders and lift arm cylinders to the minimum length 3 Inspect the adjusting bolts 1 and lock nuts 2 for bending denting deformation and looseness 4 If there any irregularities with the adjusting bolts 1 and lock nuts 2 Refer 140 Adjusting or Replacing the Bucket Stoppers bolts nuts 133 Every 100 Hours Cleaning the Water Separator Do not smoke or permit open flames while handling fuel or working on the fuel system Stop the engine in a well ventilated place and allow it to cool before performing maintenance Clean up spilled fuel immediately CTL55 CTL65 CTL75 gt 019002 1 2 3 Tx 8 Closed Open the rear door Close the valve 2 Loosen the ring 3 then remove the case 4 element 5 and indicator ring 6 and clean them Inspect the
143. t CTL55 Option gt 137 Every 500 Hours Replacing the fuel filter 138 Replacing the hydraulic oil return filter 139 Replacing the pilot line filter 139 Replacing the travel motor gear oil 139 Adjusting or replacing the bucket stoppers bolts nuts 140 Every 1000 Hours Cleaning the engine cooling system 142 Replacing the hydraulic oil and cleaning the suction strainer 144 Inspecting and adjusting the engine valve clearance 146 Retightening the engine cylinder head bolts 146 Every 1500 Hours Inspecting and cleaning the engine fuel injectors 146 Inspecting the crankcase breather system 146 Every 2000 Hours Lapping the engine valve seats 147 Every 3000 Hours Inspecting the turbocharger Blower wash as necessary CTL55 CTL75 CTL85 147 Inspecting and cleaning the EGR valve lead valve and cooler 147 When Required Replacing the bucket or attachment 148 Lubricating the levers 150 Inspecting and replenishing the windshield washer fluid 150 Tilting up the ROPS 151 Inspecting the rubber tracks 152 111 Maintenance Log Service Procedure 112 MAINTENANCE Maintenance Log Service Procedure 113 s MAINTENANCE Walk Around Inspection Perform the following inspections once every day before starting the engine the first ti
144. t assistance and first aid help emergency General Precautions Never remove safety equipment e Make sure all protective guards canopies doors etc are in place and secure Repair or replace damaged components before operating the machine Use a signal person and flagman T7A005 E3A050 e Know how to use the safety bar seat belt and other safety equipment and use them properly Never remove any safety equipment except for service Keep all safety equipment in good operating condition Crush Hazard FOPS Limitations Various classes and sizes of off road equipment operate in a wide variety of applications and environmental conditions With the intention of providing operators with reasonable protection from falling objects two levels of FOPS Falling Object Protective Structure acceptance criteria have been developed based on end use Level1 protection from falling bricks small concrete blocks and hand encountered in operations such as highway maintenance landscaping and other construction site services Level 2 protection from falling trees or rocks for machines involved in site clearing overhead demolition or forestry This machine is equipped with a Level 1 FOPS as standard equippment DO NOT use this machine in an application that may involve the hazards of falling trees or rocks If Level 2 FOPS protection is required in your application contact
145. t up to the upper limit H of the reserve tank 1 If the reserve tank is empty inspect for fluid leakage then inspect the radiator 3 coolant level If it is low add coolant to the radiator 3 first then to the reserve tank Install the cap 2 Daily Inspection Every 10 Hours Inspecting and Replenishing the Engine Oil Stop the engine and allow the machine to cool before performing inspection and maintenance Inspection TuS 176005 Open the engine hood Pull out the dipstick 1 and wipe off the oil with a rag Fully reinsert the dipstick 1 then pull it back out Check the oil on the dipstick 1 The level should be between the upper limit H and lower limit L If itis below the lower limit L replenish Replenishing 1 Remove the oil supply cap 2 2 Add oil up to the upper limit H of the dipstick 1 Problems could arise if the oil level is either too low or too high Tighten the oil supply cap 2 Start the engine run it at low idle for about 3 minutes then stop it After about 10 minutes inspect the oil level 117 Inspecting the Water Separator Stop the engine and allow the machine to cool before performing inspection and maintenance CTL55 CTL65 CTL75 016002 Closed 1 Open the rear door 2 Inspect the water separator 1 If the red in
146. table position 560 When removing or installing the bucket attachment place it in a stable position so that it does not tip over SAFETY Maintenance Precautions Use caution when fueling i E3A100 Do not smoke or permit open flames while fueling or near fueling operations Never remove the fuel cap or refuel with the engine running or hot Never allow fuel to spill on hot machine components Maintain control of the fuel filler nozzle when filling the tank Do not fill the fuel tank to capacity Allow room for expansion Clean up spilled fuel immediately Tighten the fuel tank cap securely If the fuel cap is lost replace it only with the original manufacturers approved cap Use of a non approved cap without proper venting may result in pressurization of the tank Never use fuel for cleaning purposes Use the correct fuel grade for the operating season 31 Handling of hoses Fuel oil and hydraulic fluid leaks can cause a fire Do not twist bend or hit the hoses Never use twisted bent or cracked hoses tubes and pipes They may burst Retighten loose connections Be careful with hot and pressurized components Saas E3A110 Stop the engine and allow the machine to cool down before performing inspection and maintenance The engine muffler radiator hydraulic lines sliding parts and many other parts of the machine are hot a
147. temperature Refrigerant may be leaking between the pipes Almost no Some mist like refrigerant Almost no difference in Some heavily refrigerant be barely seen flowing temperature between the oily places Refrigerant has leaked and high and low pressure almost none is left pipes Excess bubbles can be seen High pressure pipe is No irregularities refrigerant even when the fan is set hot low pressure pipe is to high and the engine is somewhat cool idling There is a difference in temperature between the pipes If the air conditioner does not function If the air conditioner does not cool or heat the air set the fan switch to OFF and contact a Gehl dealer for inspection and or repairs IMPORTANT Continued use of the air conditioner when it is not functioning properly may damage its various parts IMPORTANT Using the air conditioner when there is no refrigerant will damage the compressor Be particularly careful not to do this IMPORTANT Always have a Gehl dealer add or replace the refrigerant Be sure to use R134a refrigerant 800 g or 1 76 Ibs 190 191 192 AY INDEX INDEX M a A 61 Cab Door C TL55 5 42 Adjusting or Replacing the Bucket Stoppers Caution against falling unstable loads
148. th the engine running or hot Never allow fuel to spill on hot machine components Clean up spilled fuel oil and other flammable fluids immediately Check for fuel oil and hydraulic fluid leaks Stop all leaks and clean the machine before operating Do not cut or weld on pipes or tubes that contain flammable fluids Clean thoroughly with nonflammable solvent before cutting or welding Remove all trash and debris from the machine Make sure that oily rags and other flammable material are not stored on the machine Handle all solvents and dry chemicals according to procedures identified on manufacturers containers Work in a well ventilated area Never use fuel for cleaning purposes Always use a nonflammable solvent Store all flammable fluids and materials in a safe fireproof and well ventilated place 10 When working in a certain environment it is impossible to prevent combustible debris from collecting in the machine This debris in itself may cause a fire however when mixed with fuel oil or grease in a hot or confined place the danger of fire is greatly increased The following fire prevention guidelines should be used to supplement the operator s fire prevention efforts In no case should the guidelines be used or assumed as replacements for diligent operator efforts at preventing fires that include regular schedule of cleaning and inspecting the machine as conditions require The following guidelin
149. the bucket Doing so could damage the bucket and lift arms T7D029 e Hitting the bucket against rocks etc could damage the bucket or the bucket cylinders OPERATION amp 3 Operating Procedures T7DO43E Do not conduct operations with the cylinders fully extended or retracted Doing so applies excessive force on the cylinders and may damage them T7D044 Do not perform scooping or grading operations with the bucket cylinders fully extended The traction force will apply extremely heavy loads on the bucket cylinders and this may damage them 84 Cautions on Operating Cautions on Traveling T7A013 Traveling over obstacles rocks stumps etc may subject the machine to strong shocks and result in damage Avoid traveling over obstacles whenever possible If you must do so keep the bucket near the ground travel at low speed and go over the obstacle at the center of the crawler Cautions on Traveling in 2nd High Speed 770031 On uneven ground travel at low speeds and avoid accelerating stopping or changing directions abruptly OPERATION I Operating Procedures Cautions on Use in Water T7D032 If you leave water at a sharp angle the rear of the machine may be submerged exposing the radiator fan to water and damaging it Do not let the rear of the machine become submerged
150. the bucket or attachment in position s MAINTENANCE 2 When Required 186007 IMPORTANT Before operating the machine always inspect the quick hitch latch pins 4 engagement by raising the loader arms high enough to view the latch pins 4 engagement from the operator s seat Note If the quick hitch 3 latch pins 4 do not lower into the LOCKED position remove the attachment and investigate the cause 149 Removal 1 Raise the bucket 1 or attachment 25 to 50 mm 1 to 2 in off the ground 2 Stop the engine raise the safety bar and release the seat belt Pull both attachment lock levers 2 upward to disengage the bucket 1 or attachment Return to the operator s seat lower the safety bar fasten the seat belt and start the engine T9G014 Rotate the quick hitch 3 out bucket dump function allowing the bucket or attachment to slide off the top edge of the quick hitch 3 s MAINTENANCE 2 When Required Lubricating the Levers Set the machine in the parking position stop the engine remove the ignition key and store it Failure to do so may result in the machine moving abruptly leading to serious injury or death If the levers or pedal no longer move smoothly apply grease Control levers E4G058 1 Remove the lower mount section
151. the key The key automatically returns to the ON position 5 Check that the warning lamps are off 6 Return the throttle lever to idle position and warm up the engine Refer to page 73 Warming Up the Engine OPERATION gt amp 3 Starting and Stopping the Engine Warming Up the Engine IMPORTANT Avoid racing the engine until it is warmed up Do not warm up the engine for long periods of time 20 minutes or more 1 Return the throttle lever to idle position and idle the engine for about 5 minutes with no load Stopping the Engine IMPORTANT Do not stop the engine suddenly when operating with heavy loads or at maximum speed Doing so may cause the engine to overheat or seize Never bring the engine to a sudden stop except in the case of a true emergency E 2277 elis TSIEN 1 010004 1 Idle the engine for about 5 minutes to gradually let it cool ot PREHEAT J2D005E 2 Turn the key to the OFF position to stop the engine OPERATION Machine Operation Lever Pattern Be careful to check which pattern of lever control arrangement you are operating with before beginning operations The explanations in this manual are for this pattern a ON Nu Crawler Forward Lift Arm Lower Crawler Reverse Lift Arm Raise Left Spin Turn Bucket Rollback Right Spin Turn Buc
152. the truck bed Keep the truck bed and loading ramps clean of oil clay ice snow and other materials that can become slippery Clean the tracks Block the transport vehicle so it cannot move Use a signal person when loading and unloading the machine and travel slowly in first gear low speed Never change course on the ramp Do not turn on the ramps The machine may tip over Block both tracks and secure the machine to the truck bed with load binders 27 Transport the machine safely Know and follow the safety rules vehicle code and traffic laws when transporting the machine Consider the length width height and weight of the truck with the machine loaded on it when determining the best route Hoisting the machine safely Know and use correct crane signals Inspect the hoisting equipment daily for damaged or missing parts When hoisting use a wire rope with sufficient strength with respect to the machine s weight Do not hoist the machine with an operator on it When hoisting hoist slowly so that the machine does not tip Keep all other persons out of the area when hoisting Do not move the machine over the heads of the persons Do not hoist with the machine in a position other than the one described in the procedure below Doing so is dangerous because it may result in the machine losing its balance Refer to the section titled Hoisting the Machine for further details Maintena
153. til the lift arm stop 2 drops onto the cylinder rod Lower the lift arms slowly until the lift arm stop is held between the lift arm and the end of the cylinder tube Stop the engine 10 Install the locking pin 1 into the rear of the lift arm stop 2 below the cylinder rod 11 To prevent the locking pin 1 from falling off set the hook 4 at a right angle to the locking pin CONTROLS Doors and Covers Disengagement 1 Align the hook 4 on the tip of the locking pin 1 with the locking pin Pull out the locking pin 1 from the lift arm stop 2 Hook the end part of the spring 3 onto the hook 5 of the lift arm stop 2 Sit in the seat fasten the seat belt start the engine and lower the safety bar Raise the lift arms slowly until the spring will lift the lift arm stop 2 off the cylinder rod Lower the lift arms slowly to the ground and stop the engine T9B0051 7 Raise the lift arm stop 2 into storage position and insert the locking pin 1 through lift arm stop and bracket 8 To prevent the locking pin 1 from falling off set the hook 4 at a right angle to the locking pin 47 Fuel Filler Cap Do not smoke or permit open flames while fueling or near fueling operations Supply fuel in a well ventilated place and with the engine stopped Clean up spilled fuel immediately Do not fill th
154. to the hydraulic oil cylinder piston rods Add fuel oil and grease to all parts 154 TROUBLESHOOTING Symptoms that Are Not Malfunctions 156 If the Engine Overheats 157 If the Battery Goes Dead 158 After the Fuel Runs Out 159 If a Fuse Blows eene 160 If a Warning Lamp Flashes 162 Other Symptoms cess 164 To Lower the Lift Arms 166 TOWING P 167 155 TROUBLESHOOTING Symptoms that Are Not Malfunctions The following symptoms not malfunctions e The travel motor produces noise when stopped suddenly during high speed travel The control valve produces noise if excessive force is applied to the working equipment and when the stroke end is reached e Attimes of combined operation of bucket and lift arm lowering continuation of the combined operation after the bucket has reached the stroke end will result in the lift arm rising or stopping without going lower Performance decreases when an attachment weighing more than a standard bucket is mounted 156 TROUBLESHOOTING If the Engine Overheats Do not open the engine hood when there is steam coming from the engine compartment The steam or hot water may spray out resulting in burns Do not remove the radi
155. tracks may slip Doing so may increase lug wear ZA OPERANON amp 3 Using Rubber Tracks Precautions Follow the following precautions when operating the machine Avoid changing course abruptly and spinning on concrete surfaces whenever possible Doing so may wear or damage the rubber tracks Avoid drops that may expose the rubber tracks to strong shocks Salt potassium chloride ammonium sulfate potassium sulfate and triple superphosphate of lime can damage the tracks If any of these substances get on the tracks wash them off thoroughly with water Do not let the sides of the rubber tracks rub against concrete or walls Be especial careful in the winter on snowy or frozen surfaces as the tracks tend to slip Use rubber tracks only at temperatures between 25 C to 55 14 F to 131 When storing the rubber tracks for long periods of time 3 months or more do so indoors in a place not exposed to direct sunlight or rain 93 Preventing the Rubber Tracks from Slipping Off Heed the following to prevent the rubber tracks from slipping off Always keep the tracks at the proper tension T7E005 When traveling up large cobblestone or rock steps 20 cm 8 in or greater climb up the steps at a straight angle and do not change course on top of the step T7E006 When climbing in reverse do not change course at the point where the slope starts
156. ucket too high or tilting it too far rearward 22 Operating Precautions Do not suddenly stop or lower the working equipment T7A020 Keep a safe distance from electrical power lines X T7A029 Sudden lowering or stopping of the working equipment could cause the machine to tip bowed forward Operate the working equipment carefully especially when the bucket is loaded Avoid overloading and off center loads Filling the bucket in excess of the maximum load and loading an off center load will cause the machine to become unstable and could result in the machine tipping over Loading should be done evenly should be less than the CTL55 565 kg 1246 Ibs CTL65 835 kg 1841 lbs CTL75 945 kg 2083 Ibs CTL85 1190 kg 2624 Ibs 23 Never approach power lines with any part of the machine and its load unless all local and national required safety precautions have been taken Electrocution and death can result from arcing touching or even being close to a machine that is in contact with or near an electrical source e Maintain the maximum possible distance from power lines and never violate the minimum clearance Always contact the nearest electric utility and determine jointly what specific precautions must be taken to ensure safety Consider all lines to be power lines and treat all power lines as energized even if it is known or believed that the power is
157. ult in burns or injuries The pressure in the travel motor reduction gears case may cause oil or the plug to fly out Loosen the plug slowly to release the pressure IMPORTANT If the percentage of the travel time within the total operating time is high replace the gear oil earlier than the specified time 9 799015 1 Set the travel motor so that plug 1 is at the very bottom 2 Place a pan for catching the waste oil under plug 1 3 Remove plugs 1 2 and 3 and drain the oil 4 Wrap new sealing tape around the plugs 135 Every 250 Hours Replacing the Air Cleaner Elements Stop the engine and allow the machine to cool before performing maintenance The engine muffler radiator and many other parts of the machine are hot directly after the engine is stopped Touching these parts will cause burns IMPORTANT Do not use an element if its flutes gaskets or seals are damaged IMPORTANT Be sure to install the element and dust cap securely If not dust could be drawn into the cylinder damaging the engine IMPORTANT Besuretolocktheaircleaner after completing the maintenance 1 Open the engine hood 016017 16008 3 Loosen the clamps 1 and remove the dust cup 2 4 Clean the inside of the dust cup 2 5 Remove the outer element 3 Do not yet remove inner element 5 6 Clean the inside of the body 4
158. ump on or off the machine Never attempt to mount or dismount a moving machine For machines with cab when mounting and dismounting the cab first open the door fully to the locked position and check that it does not move E3A160 Always face the access system and maintain a three point contact with the recommended handrails and steps while getting on and off the machine Keep steps and platform clean Never use the control levers as hand holds Do not go under the raised lift arms if they are not sufficiently supported Lower the lift arms to the ground before mounting or dismounting the cab 17 Clear the area of other persons before starting the machine Do not start the engine until you are sure it is safe Before starting check or perform the following Walk around the machine and warn all personnel who may be servicing the machine or are in the machine path Do not start until all personnel are clearly away from the machine Check for any DO NOT OPERATE tags or similar warning notices on the cab door controls and ignition switch Sound horn to alert everyone around the machine Start the engine from the operator s seat Adjust secure and latch the operators Seat E3A190 Fasten the seat belt Check that the parking brake is applied and place all controls in the neutral position Check that the safety bar is in the lock position Clear the area of all per
159. urs Inspecting the Hydraulic Oil Level and Replenishing e Stop the engine and allow the machine to cool before performing maintenance Oil may spray out if caps or filters are removed or pipes disconnected before releasing the pressure in the hydraulic system When removing plugs or screws or disconnecting hoses stand to the side and loosen slowly to gradually release the internal pressure before removing Inspection The oil level changes according to the oil temperature Inspect the oil level in the hydraulic oil level inspection position shown in the diagram e Hydraulic oil level inspection position 1 Start the engine and run it at low speed 2 Fully retract the lift arms and bucket cylinders and ground the bucket 3 Stop the engine 4 Inspect the oil level using the sight gauge 2 When the oil temperature is about 20 68 F The level should be halfway between the upper limit H and lower limit L If it is below the lower limit L replenish 119 e When the oil temperature is about 50 to 80 C 122 to 176 F The level should be near the upper limit H Replenishing T3G0011 Loosen the bolts and remove the cover 3 Remove the plug 1 Add hydraulic oil up to the middle of the sight gauge 2 Tighten the plug 1 Install the cover 3 MAINTENANCE 2 Daily Inspection Every 10 Hours Lubricating the Working Equi
160. vice call 2 Used equipment 3 Components covered by their own non Gehl warranties such as tires batteries trade accessories and engines 4 Normal maintenance service and expendable high wear items 5 Repairs or adjustments caused by improper use failure to follow recommended maintenance procedures use of unauthorized attachments accident or other casualty 6 Liability for incidental or consequential damages of any type including but not limited to lost profits or expenses of acquiring replacement equipment No agent employee or representative of Gehl has any authority to bind Gehl to any warranty except as specifically set forth herein Ad WARNING THIS OPERATOR S MANUAL IS PROVIDED FOR OPERATOR USE DO NOT REMOVE FROM THIS MACHINE Do not start operate or work on this machine until you carefully read and thoroughly understand the contents of this operator s manual Failure to follow safety operating and maintenance instructions can result in serious injury to the operator or bystanders poor operation and costly breakdowns If you have any questions on proper operation adjustment or maintenance of this machine contact your dealer or the Gehl Company Service Department before starting or continuing operation California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer and birth defects or other reproductive harm Battery
161. ydraulic Oil and Cleaning the Suction Strainer Stop the engine and allow the machine to cool before performing maintenance The engine hydraulic lines and many other parts of the machine are hot directly after the engine is stopped Touching these parts will cause burns The hydraulic fluid is also hot and under high pressure Be careful when loosening caps and plugs Working on the machine under these conditions could result in burns or injuries due to hot oil spraying out Oil may spray out if caps or filters are removed or pipes disconnected before releasing the pressure in the hydraulic system e When removing plugs or screws or disconnecting hoses stand to the side and loosen slowly to gradually release the internal pressure before removing Open the rear door 2 Drain the coolant Refer to page 142 Cleaning the Engine Cooling System U1G014 3 Place a pan for catching the waste oil under the drain plug 7 4 Loosen the drain plug 7 and drain the hydraulic oil P i rg 010006 5 Remove the bolts and open the radiator oil cooler b SC 5 SSN U1G013 6 Disconnect the hoses that are connected to the radiator oil cooler b 7 Temporarily suspend the radiator oil cooler b MAINTENANCE Every 1000 Hours 8 Remove the split pin and pull out pins 6 9 Lift out the radiator oil coole
162. your dealer or the manufacturer concerning the possible availability of such protection Know and use the hand signals required for particular jobs and make sure who has the responsibility for signaling All personnel must fully understand all the signals The operator shall respond to signals only from the appointed signal person but shall obey a stop signal at any time from anyone The signal person must stand a clearly visible location when giving signals Be sure to raise the safety bar before leaving the operator s seat 7 e Before leaving the operator s seat Lower the lift arms to the ground or engage the lift arm stop Stop the engine Raise the safety bar to engage the lock Remove the key and take it with you e any controls are touched accidentally when the safety bar is lowered the machine will move suddenly and cause serious injury or death General Precautions Avoid fire and explosion hazards Fire prevention n E3A100 AU1E001 Keep flames away from fuel hydraulic fluid oil grease and antifreeze Fuel is particularly flammable and dangerous When handling these combustible materials keep lit cigarettes matches lighters and other flames or sources of flames away Do not smoke or permit open flames while fueling or near fueling operations Never remove the fuel cap or refuel wi

Cpt Track Loader (CTL55/CTL65/CTL75/CTL85)

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