Gehl CTL55, CTL65, CTL75, CTL85 Operator's Manual
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
1
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
2
INTRODUCTION
T7A002
for Cab
T9A002
1
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
1
T7A0012
3
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
4
5
CONTENTS
Introduction ..........................................2
Machine Description ..........................
3
Safety ....................................................
7
Controls ............................................. 39
Operation ........................................... 69
Transport ........................................... 95
Maintenance ................................... 101
Troubleshooting .............................. 155
Specifications ................................. 169
Options ............................................ 179
Index ................................................. 193
6
7
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
SAFETY
8
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.
9
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
10
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
11
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
12
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.
13
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
14
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.
15
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
16
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
A
B
17
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
18
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.
19
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
20
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.)
21
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
22
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
23
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
24
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
25
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
26
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
27
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
28
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.
Loading...