Gehl CTL55, CTL65, CTL75, CTL85 Operator's Manual

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CTL55

CTL65 CTL75 CTL85

Compact

Track Loader

OPERATOR’S MANUAL

Revision E

09/10

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.

� 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.

� All operators must be instructed on the proper functions of the loader before running

the machine.

� Learn and practice correct use of the machine controls in a safe, clear area before

operating this machine on a job site.

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.

� 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, 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.

CAUTION

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.

 EXPLANATION OF GRAPHICAL SYMBOLS

Following is an explanation of symbols used in this manual.

, X .........prohibition

/ .......Lock

/ ......Unlock

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.

 SlGNAL 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” indicates an imminently hazardous situation, which, if not avoided, can result in serious injury or death.

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

The word “CAUTlON” indicates a potentially hazardous situation, which, if not avoided, may result in injury.

CAUTION WARNING DANGER

INTRODUCTION

T7A002

for Cab

T9A002

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.

 Serial numbers

Check the serial numbers of the machine and the engine and write them in the spaces provided below.

Machine number :

Engine number :

 Manual storage

A 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

Type B

T7A0012

MACHINE DESCRIPTION

 Front, rear, Ieft 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.

 Designated operations

Use this machine primarily for the following operations:

 Carrying  Leveling  Loading

 Features

 Hydrostatic drive system  Roll Over / Falling Object Protective Structure (ROPS/FOPS), tilt-up ROPS  Low engine noise and exhaust emissions  Two-way auxiliary hydraulics  Pilot-operated joystick controls 

 Break-in period

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.

 Warm up the engine and hydraulic oil sufﬁciently.  Avoid heavy loads and rapid operations. Operate with a load of about 80% of the maximum

load.

 Do not start up, accelerate, change directions, or stop abruptly unless necessary.

RIGHTLEFT

REAR

FRONT

T7A004E

CONTENTS

Introduction ..........................................2

Machine Description ..........................

Safety ....................................................

Controls ............................................. 39

Operation ........................................... 69

Transport ........................................... 95

Maintenance ................................... 101

Troubleshooting .............................. 155

Speciﬁcations ................................. 169

Options ............................................ 179

Index ................................................. 193

General Precautions ......................................... 8

Preparing Precautions ...................................15

Starting Precautions .......................................17

Operating Precautions ...................................19

Stopping Precautions .....................................26

Transporting Precautions ..............................27

Maintenance Precautions ..............................28

Safety Signs (Decals) ......................................35

SAFETY

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

 Do not wear loose clothing or any

accessory that can catch on controls or in moving parts.

 Do not wear oily or fuel-stained 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.

 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°F) or lower than –15°C (+5°F).

 If operated at an ambient temperature of

higher than +45°C (+113°F), the engine may overheat and cause the engine oil to degrade.

 If 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.

 If 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

 Know where a ﬁre extinguisher and ﬁrst

aid kit are located and understand how to use them.

 Know how to contact emergency

assistance and ﬁrst aid help.

SAFETY

General Precautions

Never remove safety equipment

 Make sure all protective guards, canopies,

doors, etc., are in place and secure. Repair or replace damaged components before operating the machine.

 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:  Level 1 ...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 your dealer or the manufacturer concerning the possible availability of such protection.

T7A005

Use a signal person and ﬂagman

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 in a clearly

visible location when giving signals.

Be sure to raise the safety bar before leaving the operator’s seat

 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.

 If any controls are touched accidentally

when the safety bar is lowered, the machine will move suddenly, and cause serious injury or death.

SAFETY

General Precautions

Avoid ﬁre and explosion hazards

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 with

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 wellventilated 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.

Fire prevention

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 guidelines 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.

2. 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.

3. Blow off all accumulated debris near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and mufﬂer) at the completion of each work shift or more frequently when

AU1E001

SAFETY

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.

4. 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.

5. 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 equipment.

6. Clean up any grease, diesel fuel, hydraulic and lubricating oil accumulation and spillage immediately.

7. Steam clean the engine, and belly pan areas at least once a month or more frequently when working in sever conditions where large amounts of combustible debris are present.

8. Use only nonﬂammable solutions for cleaning the machine and components.

9. 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

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

 Prevent the ﬁre from happening in the

ﬁrst place by ensuring that all machine systems are frequently inspected and always well maintained.

 Ensure that any hand held ﬁre extinguishers

are charged and in working order. Fire extinguishers require routine care. Follow the manufacturer’s instructions for 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.

SAFETY

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.

2. Shut the engine off.

3. Exit the machine. Call for help. Be certain to report a ﬁre immediately.

4. 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.

Before deciding to ﬁght the ﬁre, be certain that:

1. The ﬁre is small and not rapidly spreading.

2. There is always a clear, safe escape route.

3. You have received training in the use of the available ﬁre extinguishing devices and are conﬁdent that you can operate them effectively.

 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.

•

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 at the base of the 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.

•

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 and 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 after a machine ﬁre has occurred

 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.

SAFETY

Exhaust fumes from the engine can kill

 Do not operate the engine in an enclosed

area without adequate ventilation.

 If 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.

General Precautions

SAFETY

General Precautions

Be careful not to get crushed or cut

 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 operating lift arms and bucket, the gap between the moving parts will be changing, and getting caught in between can cause serious injury or death .

 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.

 The lift arms move close to the ROPS;

therefore, do not stand or lean on the machine.

T7A007

T7A008

T8A006

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 to 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.

 Note and avoid all hazards and obstructions

such as ditches, underground lines, trees, cliffs, overhead electrical wires and areas where there is danger of a slide.

 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.

 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.

Check the strength of the bridge

When travelling over a bridge or other structure, check the permissible load. If the strength is insufﬁcient, reinforce it.

Always keep the machine clean

 Clean windows, mirrors and lights to

ensure good visibility.

 Wipe off any oil, grease, mud, snow and

ice, to prevent accidents 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.

T7A009

T7A025

T3A004

SAFETY

Preparing Precautions

Perform inspection and maintenance daily

Failure to notice and repair machine malfunctions or damage can lead to accidents.  Before operating, perform the prescribed

inspections and make repairs immediately if any malfunctions are found.

 If 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.

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.

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).

E X I T

T8B001

SAFETY

Starting Precautions

Maintain three-point contact when mounting and dismounting

 Do not jump 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.

 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.

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 operator’s

seat.

 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 persons.  Start and operate the engine from the

operator’s seat only.

 Never attempt to start the engine by

shorting across the starter terminals.

SAFETY

Starting Precautions

Starting with jumper cables

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.

 Warm up the engine and hydraulics.  Observe all gauges and warning

instruments for proper operation.

 Listen for unusual noises.  Test engine speed control.  Operate each control to ensure proper

operation.

In cold weather

 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.

SAFETY

Operating Precautions

Ensure good visibility

 When 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

 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

Operate all the controls only from the operator’s seat. Failure to do so can cause serious injury or death.

Check for safety in the surrounding area before starting

 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

Keep your body inside the operator’s compartment while operating the loader. Never work with your arms, feet or legs beyond the operator’s compartment.

T7A010

T7A011

SAFETY

Operating Precautions

Cautions on traveling and turning

 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.

 Before backing up, visually check for

safety to the rear. Backing up without checking could result in contact with a worker or obstacle.

 If the working equipment must be operated

while traveling, do so with extra care.

 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

obstacle with the 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.

T7A013

T7A012E

30 cm

(12 in.)

SAFETY

Operating Precautions

Cautions on traveling on slopes

Work 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.

 Travel at 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.

 Sudden stopping on a sloped road may

lead to loss of stability and the machine could tip over.

 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

 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.

T7A015E

With bucket empty

T8A0051

T7A0161

SAFETY

Operating Precautions

Do not drive into materials at high speeds

Driving at high speed into the materials you are handling can lead to your body striking the machine or being thrown from the machine. Check the conditions surrounding the area in front of the material you are handling and work at low speeds.

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.

Do not carry the bucket over the heads of people

Carrying the bucket over the heads of people entails the danger of the load spilling or the bucket suddenly dropping.

Caution against falling unstable loads

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 bucket too high or tilting it too far rearward.

T7A017

T7A018

T7A019

SAFETY

Operating Precautions

Do not suddenly stop or lower the working equipment

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 lbs.); CTL65: 835 kg (1841 lbs.); CTL75: 945 kg (2083 lbs.); CTL85: 1190 kg (2624 lbs.).

Keep a safe distance from electrical power lines

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.  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 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.

T7A020

T7A029

SAFETY

Operating Precautions

Watch out for hazardous working conditions

 Never undercut a high 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.

• 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

To avoid contact accidents, pay attention to the surroundings at narrow sites, indoors, and congested places and operate at speeds at which the machine can be safely operated.

Precautions when passing through tunnels or near high walls

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

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.

T7A021

T7A023

T7A022

T7A024

SAFETY

Operating Precautions

Loaders are NOT designed for lifting loads

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.

Cautions on towing

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 towed as well as on the machine that is towing.

 Never tow on slopes.  Do not let anyone near the wire rope while

towing.

T7A0261

SAFETY

Stopping Precautions

Park safely

 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.

 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.

 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.

T7A027

T7A028

T7A031

SAFETY

E4F001

Transporting Precautions

Load and unload the machine safely

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 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.

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.

Fasten to the suspension ﬁtting

Ramp

15° or less

Distance between ramps

Stopper

SAFETY

Maintenance Precautions

Attach a “DO NOT OPERATE” tag

Severe injury could result if an unauthorized person starts the engine or touches controls during inspection or maintenance.  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

Do not use damaged or weakened tools, or tools designed for other purposes. Use tools suited for the operation.

Replace important safety parts periodically

 Replace fuel hoses periodically. Fuel

hoses become weaker over time, even if they appear to be in good condition.

 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

Use anti-explosive electrical ﬁxtures and lights when inspecting fuel, oil, coolant, battery ﬂuid, etc. If lighting that is not antiexplosive 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.

SAFETY

Maintenance Precautions

Prepare the work area

 Select a ﬁrm, level work area. Make sure

there is adequate light and, if indoors, ventilation.

 Clear obstacles and dangerous objects.

Eliminate slippery areas.

Always clean the machine

 Clean the machine before performing

maintenance.

 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.

Stop the engine before performing maintenance

 Avoid lubrication or mechanical

adjustments with the machine in motion or with the engine running while stationary.

 If maintenance must be performed with

the engine running, always work as a twoperson 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

 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.

SAFETY

Maintenance Precautions

Securely block the machine or any component that may fall

 Before performing maintenance or repairs

under the machine, set the bucket against the ground or in the lowermost position.

 Securely block the tracks.  If 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

 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.

 Disconnecting or loosening any hydraulic

line, hose, ﬁtting or component or a parts failure can cause the lift arms to drop.

 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

 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 stable position

When removing or installing the bucket or attachment, place it in a stable position so that it does not tip over.

T7A031

SAFETY

Maintenance Precautions

Use caution when fueling

 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 manufacturer’s 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.

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

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 after 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.

SAFETY

Maintenance Precautions

Be careful with hot cooling systems

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.  Release all pressure before working on

the hydraulic system.

 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.

Release all pressure before working on the hydraulic system

Oil may spray out if caps or ﬁlters are removed or pipes disconnected before releasing the pressure in the hydraulic system.  When removing plugs and screws and

disconnecting hoses, stand to the side and loosen slowly to gradually release the internal pressure before removing.

Be careful with grease under pressure

The track 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

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

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

 Batteries contain sulfuric acid, which will

damage eyes and skin on contact.

• If acid contacts eyes, ﬂush immediately with clean water and get prompt medical attention.

• If acid is accidentally swallowed, drink large quantities of water or milk and call a physician immediately.

• If acid contacts skin or clothing, wash off immediately with clean water.

 Wear safety glasses and gloves when

working with batteries.

 Batteries generate ﬂammable and

explosive gases. Keep arcs, sparks, ﬂames and lighted tobacco away.

 Use a 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 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.  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.) / s

, while the seated part of the

body is subjected to vibrations lower than

0.5 m (1.64 ft.) / s

Checks after maintenance

 Gradually raise the engine speed from low

idle to maximum speed and check that no oil or water is leaking from serviced parts.

 Move the controls and check that the

machine is operating properly.

Disposing of wastes

 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

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.

SAFETY

Safety Signs (Decals)

SAFETY

Safety Signs (Decals)

SAFETY

Safety Signs (Decals)

Names of Components ..................................40

Doors and Covers ...........................................42

Seat and Seat Belt ..........................................48

Instrument Panel .............................................52

Switches ...........................................................54

Levers and Pedals ...........................................59

Accessories .....................................................61

CONTROLS

Names of Components

1. Tail light

2. Hydraulic tank

3. ROPS / FOPS

4. Safety bar

5. Front light

6. Lift arm stop

7. Left control lever

8. Auxiliary hydraulic lines

9. Lift arm

10. Bucket cylinder

11. Bucket

12. Fuel ﬁller cap

13. Arm cylinder

14. Travel motor

15. Rubber track

16. Track roller

17. Idler

T9B006

2 3 4 5 6 7 8

CONTROLS

Names of Components

1. Left control lever

2. Travel speed button

3. Slider switch (for auxiliary hydraulic)

4. Detent mode switch (for auxiliary hydraulic switches)

5. Flow selector switch (2-way

1-way)

6. Front wiper switch (option)

7. Rear wiper switch (option)

8. Safety bar

9. Seat

10. Auxiliary hydraulic buttons

11. Instrument panel

12. Float button

13. Horn button

14. Right control lever

15. Ignition switch

16. High-ﬂow switch (option)

17. Throttle lever

18. Throttle pedal

19. Front light switch

20. Tail light switch

21. Multifunction buttons

U1B0013

1218

CONTROLS

Ignition Key

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  Engine hood  Cab door  Manual storage

Doors and Covers

E4B003

Cab Door < CTL55 >

WARNING

 When mounting and dismounting the

cab, ﬁrst open the door fully to the stopped position and check that it does not move.

 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.

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

1. Insert and turn the ignition key.

Opening

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 (3) and slowly close the door.

T3B004

T3B005

T3B006

CONTROLS

Doors and Covers

Side Window < CTL55 >

1. Grasp the catch (8), unlock it and open the side window.

2. To close the side window, close it until a click is heard.

T9C010

CONTROLS

Rear Door

CAUTION

 When opening the rear door, open it

ﬁrmly to the locked position.

 When opening and closing the rear

door, be careful not to get your hands or other parts of your body caught.

Opening

1. Open the engine hood.

2. Lift the lever (1) and open the rear door (2).

3. Release the stay (3), then insert and secure it into the stay hole of the rear door (2).

Closing

1. Support the rear door (2) by hand, remove stay (3), and secure it in the original position.

2. Close the rear door (2) and press it until a click is heard at the front.

Doors and Covers

Engine Hood

WARNING

Before opening the engine hood, be sure to stop the engine. If your hands or tools get caught in the fan or fan belt while the engine is running they may be severely injured.

Opening

1. Insert the ignition key and turn it counterclockwise to unlock the engine hood (1).

2. Remove the key and pull the lever (2) backward.

3. Lift the engine hood (1).

Closing

1. Close the engine hood and press it down until a click is heard at the front.

2. Insert the ignition key and turn it clockwise to lock the engine hood.

T8B003

T7B003

CONTROLS

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:

— In case of emergency

Kick out the rear window. Note that the

glass may break. Be careful not to be 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).

Doors and Covers

E X I T

T8B001

CONTROLS

Doors and Covers

Lift Arm Stop

WARNING

 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.

3. Align the hook (4) on the tip of the locking pin (1) with the locking pin.

4. Support the lift arm stop (2) by hand and pull out the locking pin (1).

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 until the lift arm stop (2) drops onto the cylinder rod.

8. Lower the lift arms slowly until the lift arm stop is held between the lift arm and the end of the cylinder tube.

9. 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.

T9B002

CONTROLS

Doors and Covers

Disengagement

1. Align the hook (4) on the tip of the locking pin (1) with the locking pin.

2. Pull out the locking pin (1) from the lift arm stop (2).

3. Hook the end part of the spring (3) onto the hook (5) of the lift arm stop (2).

4. Sit in the seat, fasten the seat belt, start the engine and lower the safety bar.

5. Raise the lift arms slowly until the spring (3) will lift the lift arm stop (2) off the cylinder rod.

6. Lower the lift arms slowly to the ground and stop the engine.

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.

Fuel Filler Cap

WARNING

 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 the 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.

T7B005E

Close Open

CONTROLS

Seat and Seat Belt

Seat < CTL55 >

WARNING

Adjust, secure and latch the operator’s seat.

(A) Seatback angle adjustment

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.

Adjustment range ..................... 15 deg.

(B) Fore-and-aft adjustment

1. Pull on lever (2) and slide the 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: 130 mm (5.1 in.)

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.

• Right .............Light operator

• Middle ..........Medium weight operator

• Left ...............Heavy operator

CONTROLS

Seat Belt < CTL55 >

CAUTION

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 on adjuster (A) in the manner shown in the diagram to adjust the seat belt to the desired length.

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.

Seat and Seat Belt

C4C010

90°

C4C011

CONTROLS

Seat and Seat Belt

Seat < CTL65 / CTL75 / CTL85 >

WARNING

Adjust, secure and latch the operator’s seat.

(A) Seatback angle adjustment

WARNING

 Do not set the 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.

(B) Fore-and-aft adjustment

1. Pull on lever (2) and slide the 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.)

1. Turn handle (3) 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 lbs.)

(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

Seat Belt < CTL65 / CTL75 / CTL85 >

CAUTION

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 clicking 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.

E4B023

E4B024

CONTROLS

Instrument Panel

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 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.

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.

4. Air Cleaner Warning Lamp

This lamp ﬂashes and an alarm is sounded if the air cleaner ﬁlter is clogged while the engine is running.

5. Pilot Line Filter Warning Lamp

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 after the engine in started in cold weather. This is not a malfunction. The lamp will turn off as the engine warms up.

C4B012

G4B010

T7B008

C4B030

C4B031

CONTROLS

Instrument Panel

Indicators

6. Glow Lamp

This lamp turns off when engine preheating is completed.

7. Travel Speed Lamp

This lamp lights when the travel speed button is set to 2nd (high speed).

Meters

8. Hour meter

This displays the total engine running time in hours. The rightmost digit indicates 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

coolant.

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.

Be sure to top off the tank

before running out of fuel.

C4B013

C4B014

L3B019

L3B020

L3B021

Engine Fault Warning Lamp < CTL55 / CTL65 / CTL75 >

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 serious 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

Float Button

WARNING

 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 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.

When in the Float mode, the bucket can follow the contour of the ground without movement of the control lever.

Ignition Switch

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.

PREHEAT ....... Position for preheating the

engine.

OFF ................ Position for stopping the

engine and inserting and removing the key.

ON .................. Position in which the engine

is running. In this position, all the electrical equipment is functional.

START ............ Position for starting the engine.

When the key is released, the switch automatically returns to the ON position.

Horn Button

Press the right button on the right control lever to blow the horn.

MEMO

Multifunction Buttons

These buttons are used to operate various optional functions.

1. Turn the cap (1) counterclockwise and

remove it.

2. To install the female connector or the cap

(1), align the notches and turn it clockwise

to tighten. <14P connector M> HDB34-18-14PN-059 Total max. working current: 20A Max. working current at each terminal:

13A

U1L008

14P Connector M

ACC

U1L009

CONTROLS

Switches

Auxiliary Hydraulic Switches

Auxiliary Hydraulic Buttons (A), (B)

Press these buttons to control the ﬂow of the oil in the auxiliary hydraulic circuit.

(A) .............Hydraulic oil ﬂows to auxiliary

hydraulic line (a)

(B) .............Hydraulic oil ﬂows to auxiliary

hydraulic line (b)

The button turns on the ﬂow when it is pressed, and turns off the ﬂow when it is released.  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.

Example: If you move the slider switch half way, the auxiliary function will move at approximately one-half speed.

Move this switch to control the ﬂow of the oil in the ﬁrst auxiliary hydraulic lines.

Flow Selector Switch (C)

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 oneway back to two-way and the lamp turns off.

OFF(O) ......Two-way ﬂow

ON ( I ) .....One-way ﬂow

The oil in line (b) returns to the

hydraulic tank.

T9B012

CONTROLS

Switches

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 and the hydraulic ﬂow switches from two-way to one-way and the builtin 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”.

O .........OFF

I ..........ON

Detent Mode Switch (D)

This switch changes the function of auxiliary hydraulic button (A). 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.

T9B0151

CONTROLS

Travel Speed Button

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

When this switch is turned on while the ignition switch is ON, the lights turn on as follows: Front light switch

O ...............Off

I ................Instrument lights and front lights

turn on.

Tail light switch

O ...............Off

I ................Tail lights turn on.

Wiper Switches (Option)

IMPORTANT: If no washer ﬂuid is discharged, do not operate the washer. Doing so may damage the pump. 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.

Front wiper switch

O ...............Off

I ................Wiper operates.

PUSH .......Washer ﬂuid is squirted from the

nozzle while pressed, and stops when released.

Rear wiper switch

O ...............Off

I ................Wiper operates.

PUSH .......Washer ﬂuid is squirted from the

nozzle while pressed, and stops when released.

Switches

L3B028

L3B029

PUSH

CONTROLS

Safety Bar

WARNING

 Before leaving the operator’s 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.  Be careful not to touch the control

levers and pedal when lowering or

raising the safety bar.

This device is for locking the control levers, pedal and selector, detent mode and highﬂow switches. When the safety bar is lifted, the levers, pedal and switches are locked.

Throttle Lever

This lever controls the engine speed.

(A) ............Low idle

(B) ...........Maximum speed

Throttle Pedal

This pedal controls the engine speed.

(A) ............Low idle

(B) ...........Maximum speed

Levers and Pedals

T7B015

U1B014

CONTROLS

Left Control Lever

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.”

Levers and Pedals

Right Control Lever

WARNING

Be sure to check which pattern of lever control arrangement you are operating with before beginning operations.

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.”

CONTROLS

Accessories

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.

O .........Off

I ..........On

T7B0271

CONTROLS

Accessories

Auxiliary Hydraulic Lines

WARNING

 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 disconnecting hoses, release the internal pressure before removing.

 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 male 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 air 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)

1. Connect the attachment hydraulic lines to

ports (a) and (b). Refer to page 62, “Connecting the

Hydraulic Circuits”. Some attachments may have a case drain,

which need to be connected to the small

port (T).

2. Turn on the High-Flow switch (E) (green light is ON).

3. Press the auxiliary hydraulic switch (A) or slide the slider switch to the left side (A).

Refer to page 81, “Operating the Auxiliary

Hydraulics”.

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. 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.

T9B018

T9B0151

MEMO

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

OPERATION

Before Starting Operation

Mounting and Dismounting

WARNING

 Do not jump on or off the machine.

Never attempt to mount or dismount a moving machine.

 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).

 Always face the access system and

maintain a three-point contact with the handholds and steps while getting on 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).

T7D001

OPERATION

Starting and Stopping the Engine

Before Starting the Engine

1. Adjust the seat for a comfortable operating position.

2. Fasten the seat belt.

3. Check that the safety bar is in the locked position.

4. Check that the control levers and pedal are in the neutral position.

5. Insert the key into the ignition switch, turn it to the ON position, then perform the following inspection:

• 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.

• Turn the light switch to check that the front lights, tail lights and instruments lights turn on.

• Check the fuel level.

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.

T7B015

OPERATION

Starting and Stopping the Engine

Starting the Engine

WARNING

 Clear the area of all persons.  Sound horn to alert everyone around

the machine.

IMPORTANT: Do not run 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

1. Pull the throttle lever to the middle position.

2. Turn 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.

4. 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.”

Starting in Cold Weather

1. Pull the throttle lever to the middle position.

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 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

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.

1. Idle the engine for about 5 minutes to gradually let it cool.

2. Turn the key to the OFF position to stop the engine.

OPERATION

Machine Operation

Lever Pattern

WARNING

 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.

Crawler Forward

Crawler Reverse

Left Spin Turn

Right Spin Turn

Left Pivot Turn

Right Pivot Turn

Right Pivot Turn Reverse

Left Pivot Turn Reverse

Lift Arm Lower

Lift Arm Raise

Bucket Rollback

Bucket Dump

Lift Arm Float

Neutral

OPERATION

Machine Operation

Warming Up the Hydraulics

WARNING

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

1. Run the engine at medium speed for about 5 minutes with no load.

2. Set the safety bar to the released position and lift the bucket from the ground.

3. Extend and retract each of the cylinders several times with no load.

4. Travel slowly forward and backward several times.

Warming Up in Cold Weather

1. Perform the normal warm-up procedure.

2. Set the bucket cylinder 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

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.

1. Check that the warning lamps and instruments are as follows:

• Are all the warning lamps off?

• Is the water temperature gauge needle

within the green range?

2. Check that there are no irregularities in the exhaust color, sound and vibrations.

3. Set the safety bar to the locked position and check that the control levers and pedal are locked.

T7B015

OPERATION

Machine Operation

Operating the Left Control Lever

WARNING

 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 worker or obstacle.

 If unavoidable while traveling, when

operating the working equipment, do so with care.

 Avoid crossing over obstacles whenever

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.

1. Increase the engine speed.

2. Set the safety bar to the released position.

3. Roll back the bucket fully and lift the bucket to 30 cm (12 in.) above the ground.

T7A012E

30 cm

(12 in.)

OPERATION

Machine Operation

Forward and Reverse Travel

To move forward:

Push the left control lever forward.

To move backward:

Pull the left control lever rearward.

Traveling in 2nd (High) Speed

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).

Pivot Turn

Turning to the left:

To turn forward to the left:

Tilt the left control lever forward to the

left.

To turn rearward to the left:

Tilt the left control lever rearward to the

right. To turn to the right, operate the left control lever in the opposite way.

Spin Turn

To spin left:

Tilt the left control lever to the left.

To spin right:

Tilt the left control lever to the right.

T7D0161

OPERATION

Machine Operation

Stopping Travel

WARNING

 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.

CAUTION

Never bring the machine to a sudden stop except in the case of a true emergency. Stop as gently as possible.

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.

OPERATION

Machine Operation

Operating the Right Control Lever

WARNING

 Be careful to check which pattern

of lever control arrangement you are operating with before beginning operations.

 Make sure the bucket is lowered to

the ground before ﬂoating the lift arms. Floating the lift arms while they 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.

 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.

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.

Operating the Lift Arms

To lower the lift arms:

Push the right control lever forward.

To raise the lift arms:

Pull the right control lever rearward.

Operating the Bucket

To roll back:

Tilt the right control lever to the left.

To dump:

Tilt the right control lever to the right.

Operating the Lift Arms Float

To ﬂoat the lift arms:

Press the ﬂoat switch on the right control

lever.

OPERATION

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 switch.

Operating the Auxiliary Hydraulic Switches

To deliver hydraulic oil to port (a):

Depress (A).

• When using a hydraulic breaker or other

one-way ﬂow attachment.

To deliver hydraulic oil to port (b):

Depress (B).

When using a hydraulic breaker or other 1way ﬂow attachment:

Change the direction of 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 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.

Pressing the detent mode switch (D) lights the orange lamp and the auxiliary hydraulic switch (A) changes to detent mode.

Detent mode

One press of the auxiliary hydraulic switch (A) 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

Operating Procedures

Prohibited Operations

WARNING

 Do not operate on base rock (hard or

soft).

 If you must operate the lift arms and

bucket while traveling, operate at speeds slow enough so you have complete control at all times.

 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 machine tipping over.

 Keep the bucket as low as possible during

travel. Do not travel or attempt to change directions with the bucket raised.

 Travel at a 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.

 Do not use this loader in areas where

there is danger of explosion from volatile gases. Also avoid using the loader where the exhaust gases could come in contact with ﬂammable items.

T7D021

T7D022

T7D023

OPERATION

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.

 Do not use the downward force of the

bucket to drive piles.

 Do not dig down deeply with the bucket.

Doing so could damage the bucket and lift arms.

 Hitting the bucket against rocks, etc.,

could damage the bucket or the bucket cylinders.

T7D025

T7D026

T7D027

T7D028

T7D030

T7D029

OPERATION

Operating Procedures

 Do not conduct operations with the

cylinders fully extended or retracted. Doing so applies excessive force on the cylinders and may damage them.

 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.

Cautions on Operating

Cautions on Traveling

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

On uneven ground, travel at low speeds and avoid accelerating, stopping or changing directions abruptly.

T7D043E

Leave some play

T7D044

T7A013

T7D031

OPERATION

Cautions on Use in Water

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.

 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.

Operating Procedures

T7D032

T7D033

OPERATION

Operating Procedures

Cautions on Traveling on Slopes

WARNING

 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.

 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 or less before going down. Going down a slope too fast will lead to loss of control.

 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.

 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).

 Do not change directions or cross

slopes sideways. First return to a ﬂat surface, then redirect the machine.

 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

T7A016

T7A015E

With bucket empty

OPERATION

Braking when traveling down slopes

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

If the engine stops when traveling down a slope, set the control levers and pedal to the neutral position, stop the machine and restart the engine.

Do not open the front door while traveling on slopes (if equipped)

Opening the front door while traveling on 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.

Operating Procedures

T7D036

T7D035E

Descending

OPERATION

Operations Possible with this Machine

IMPORTANT: 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.

Scooping

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

Tilt the front edge of the bucket down at an 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

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.

Operating Procedures

T7D0371

T7D0381

T7D0391

OPERATION

Backﬁlling

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

WARNING

 Make sure the bucket is lowered to the ground before ﬂoating the lift arms. Floating the

lift arms while they are raised will cause the bucket to fall rapidly and is dangerous.

 Do not drive the loader forward with the lift arms in Float position.

Lower the bucket onto the ground, then put the lift arms in Float position. Tilt the bucket forward to stand it on its cutting edge, then level the loose material while driving rearward.

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.

Operating Procedures

T7D0401

T7D0411

T7D0421

OPERATION

Parking

WARNING

 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.

 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 leaving 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:

 Fuel ﬁller cap  Engine hood  Manual storage  Cab door

Parking the Machine

T7A027

T7A028

OPERATION

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

WARNING

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 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.”

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.”

 To prevent decreased battery performance,

place a cover over the battery or remove it from the machine and store it in a 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:  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 one-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.”

OPERATION

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:

 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.

 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.

 Do not let fuel, oil, 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.

 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 tracks may slip. Doing so may increase lug wear.

OPERATION

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 especially 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°C (–14°F to 131°F).

 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.

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.

 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.

 When climbing in reverse, do not change

course at the point where the slope starts.

 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.

T7E005

T7E007

OPERATION

Using Rubber Tracks

 Do not change directions when the tracks

are slack, as shown in the diagram.

T7E008

Hoisting the Machine ....................................96

Loading and Unloading ..................................98

Securing the Machine ....................................99

Cautions on Transporting ............................100

TRANSPORT

WARNING

 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 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.

 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.

IMPORTANT: This hoisting method applles to machines with standard speciﬁcations. The center-of-gravity differs according to the attachments and options that are mounted. 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.

Hoisting position

< CTL55 / CTL65 >

< CTL75 / CTL85 >

T3F001

Hoisting the Machine

TRANSPORT

Hoisting the Machine

Units : mm (inches)

CTL55 CTL65

A 1555 (61.3) 1675 (65.9)

B 930 (36.7) 1005 (39.6)

C 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)

CTL75 CTL85

A 1660 (65.3) 1705 (67.1)

B 940 (37.1) 950 (37.4)

C 1720 (67.7) 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)

TRANSPORT

WARNING

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.

 Keep the truck bed and loading ramps

clean of oil, clay, ice, snow, and other materials that can become slippery. Clean the tracks.

 Never change course on the ramp.

When loading or unloading the machine, be sure to use ramps and follow the procedure below:

1. Apply the truck’s parking brake and place chocks (stoppers) against its tires.

2. 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.

3. Move the machine up or down the ramps with the bucket end facing downward.

4. 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.

5. Make sure the bucket does not hit the ramps.

6. Lower the engine speed.

7. 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.

8. Load the machine properly at the prescribed position on the bed.

Refer to page 99, “Transporting

Position.”

T7F001

E4F001

Loading and Unloading

Fasten to the suspension ﬁtting

Ramp

15° or less

Distance between ramps

Stopper

Gehl CTL55, CTL65, CTL75, CTL85 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual