Gehl CTL 60
Gehl CTL 60
Gehl CTL 60
CTL70
CTL80
Compact
Track Loader
OPERATORS MANUAL
SAFETY ALERT SYMBOL
This symbol means Attention! Be Alert! Your Safety Is Involved.
The message that follows the symbol contains important information
about safety.
Read and understand the message to avoid personal injury or death.
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.
CAUTION
Always store this manual near at hand preferably on the machine itself. If it should be 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 next
owner.
Gehl Company supplies machines complying to the local regulations and standards of the
country of export. 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 safety standards
required for use in your country. Should you have any question about whether your machine
complies with the regulations and standards of your country, contact a Gehl dealer.
Please note that the contents and diagrams included in this manual may not match your
machine exactly.
It is your responsibility to observe all pertinent laws and regulations and to follow the
manufacturers 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:
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
so as to ensure that no damage occurs to the machine, its operators or other persons.
/ ....... Lock
/ ...... Unlock
1
INTRODUCTION
Foreword
This manual describes operation, inspection
and maintenance of the machine, as well as
safety instructions to be heeded during these
operations.
If you have any questions about the machine,
please contact a Gehl sales or service outlet.
1
T7A002
Engine number :
T7A0012
2
MACHINE DESCRIPTION
LEFT RIGHT
Designated operations
Use this machine primarily for the following
operations:
Carrying
Leveling
Loading
REAR
T7A004E
Features
Hydrostatic drive system.
Roll Over / Falling Object Protective Structure (ROPS/FOPS) tilt-up ROPS.
Rubber crawlers combine the capabilities of a crawler loader.
Low engine noise and exhaust emissions.
Two-way auxiliary hydraulics.
Pilot operated joystick controls.
Engine emergency stop system.
Break-in period
When the machine is new, heed the instructions below when operating the machine for the
first 100 hours (as indicated on the hour meter).
Using a new machine roughly without breaking it in will lead to quicker deterioration of machine
performance and may shorten the machines service life.
Warm up the engine and hydraulic oil sufficiently.
Avoid heavy loads and rapid operations. Operate with a load of about 80% the maximum
load.
Do not start up, accelerate, change directions, or stop abruptly unless necessary.
3
4
CONTENTS
Introduction .................................... 2
Machine Description ...................... 3
Safety .............................................. 7
Controls .........................................35
Operation .......................................57
Transport .......................................83
Maintenance ..................................87
5
6
SAFETY
General Precautions .................................... 8
Preparing Precautions ............................... 12
Starting Precautions .................................. 14
Operating Precautions ............................... 16
Stopping Precautions ................................ 23
Transporting Precautions .......................... 24
Maintenance Precautions .......................... 25
Safety Signs (Decals) ................................. 32
7
SAFETY
General Precautions
Do not wear loose clothing or any Know where a fire extinguisher and first
accessory that can catch on controls or in aid kit are located and understand how to
moving parts. use them.
Do not wear oily or fuel stained clothing Know how to contact emergency
that can catch fire. assistance and first aid help.
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, as
metal fragments or other objects can fly
and cause serious injury.
8
SAFETY
General Precautions
T7A005
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, Know and use the hand signals required for
two levels of FOPS (Falling-Object Protective particular jobs and make sure who has the
Structure) acceptance criteria have been responsibility for signaling.
developed based on end use: All personnel must fully understand all the
Level 1 ...... protection from falling bricks, signals.
small concrete blocks and The operator shall respond to signals only
hand encountered in from the appointed signal person, but shall
operations such as highway obey a stop signal at any time from
maintenance, landscaping anyone.
and other construction site The signal person must stand in a clearly
services. visible location when giving signals.
9
SAFETY
General Precautions
Avoid fire and explosion hazards Exhaust fumes from the engine
can kill
10
SAFETY
General Precautions
T8A006
11
SAFETY
Preparing Precautions
12
SAFETY
Preparing Precautions
B
A
T8B001
Failure to notice or repair machine
irregularities or damage can lead to There are two ways to remove the rear
accidents. window.
Before operating, perform the prescribed
inspections and make repairs immediately In case of emergency
should any irregularities be found. 1. Kick off the rear window. Note that the
If a failure that causes loss of control such glass may break. Be careful not to get
as steering, service brakes or engine injured.
occurs, stop the machine motion as
quickly as possible, follow the shutdown In case of need
procedure, and keep machine securely 1. Pull off ring (A) and remove the tip of the
parked until the malfunction is corrected. rubber wedge.
2. Grasp the tip, pull, and remove the entire
rubber wedge.
3. Pull inside knob (B).
13
SAFETY
Starting Precautions
Always face the access system and Start the engine from the
maintain a three point contact with the operators seat
recommended handrails and steps while
getting on and off the machine. Keep steps Adjust, secure and latch the operators
and platform clean. seat.
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.
14
SAFETY
Starting Precautions
15
SAFETY
Operating Precautions
T7A011
16
SAFETY
Operating Precautions
30 cm
(12 in.)
T7A012E
T7A013
17
SAFETY
Operating Precautions
T7A014E
T7A016
18
SAFETY
Operating Precautions
Do not drive into materials at Do not carry the bucket over the
high speed heads of people
T7A017 T7A018
Driving at high speed into the materials you Carrying the bucket over the heads of people
are handling can lead to your body bumping entails the danger of the load spilling or the
into the machine or being thrown from the sudden dropping of the bucket.
machine. Check the conditions surrounding
the area in front of the material you are
handling and work at low speeds.
19
SAFETY
Operating Precautions
T7A020 T7A029
Sudden lowering or stopping of the working Never approach power lines with any part of
equipment could cause the machine to tip the machine and its load unless all local and
over due to the reaction. national required safety precautions have
Especially when the bucket is loaded, been taken. Electrocution and death can
operate the working equipment carefully. 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 insure safety.
Consider all lines to be power lines and
treat all power lines as energized even
though it is known or believed that the
Avoid overloading and off-center power is shut off and the line is visibly
loads grounded.
Use a signal person to observe the
Filling the bucket in excess of the maximum approach of any part of the machine or
load and loading an off-center load will cause load to the power line.
the machine to become unstable and could Caution all ground personnel to stand
result in the machine tipping over. Loading clear of the machine and the load at all
should be less than the maximum load times.
(CTL60: 735 kg or 1620 lb. / CTL70: 945 kg If the machine should come in contact with
or 2083 lb. / CTL80: 1120 kg or 2470 lb.) and a live electrical source, do not leave the
should be done evenly. operators seat. Do not allow anyone to
approach or touch the machine.
Be especially careful of buried high voltage
power lines.
20
SAFETY
Operating Precautions
T7A021 T7A023
Never undercut a high bank. Be Careless entry into tunnels or places with
particularly alert for the possibility of a high walls can lead to serious accidents such
cave-in. as contact accidents, etc. Check height and
Do not operate in places where there is a width limits in advance and verify that the
danger of falling rocks. machine is within the limits.
Do not approach unstable surfaces (cliffs,
road shoulders, deep trenches, etc.). The
ground may give way under the machines
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.
T7A024
T7A022
Entry onto soft ground can result in the
To avoid contact accidents, pay attention to machine tilting on its own weight, tipping over,
the surroundings at narrow sites, indoors, or falling in.
and congested places and operate at a Do not enter weak ground such as that
speed at which the machine can be safely following back-filling.
operated.
21
SAFETY
Operating Precautions
1 2
1 T9A007
T7A0261
When towing, selecting the wrong wire rope,
The machine is NOT specifically designed inspecting improperly, or towing in the wrong
for lifting loads work and has no safety way could lead to accidents resulting in
devices for crane operation. serious injury or death.
The wire rope breaking or coming
detached could be extremely dangerous.
Use a wire rope suited for the required
Danger of flying objects towing force.
Do not use a wire rope that is kinked,
This machine is not equipped with twisted or otherwise damaged.
protective guards to protect the operator Do not apply strong loads abruptly to the
from flying objects. Do not use the wire rope.
machine in places where there are risks Use safety gloves when handling the wire
of the operator being hit by flying objects. 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.
22
SAFETY
Stopping Precautions
Park safely
T7A031
T7A028
23
SAFETY
Transporting Precautions
15 or less
Distance between ramps E4F001
24
SAFETY
Maintenance Precautions
25
SAFETY
Maintenance Precautions
Clean the machine before performing Stay clear of all rotating and moving parts.
maintenance. Wrapping or entanglement may result in
Stop the engine and cover electrical parts serious injury or death.
when washing the machine. Water on Keep hands, clothing and tools away from
electrical parts could cause short-circuits the rotating fan and running fan belts.
or malfunctions.
Do not use water or steam to wash the
battery, sensors, connectors or the
operators compartment.
26
SAFETY
Maintenance Precautions
Securely block the machine or Service the lift arm stop if damaged or if
parts are missing. Using a damaged lift
any component that may fall
arm stop or with missing parts can cause
the lift arms to drop causing injury or death.
T7A031
27
SAFETY
Maintenance Precautions
28
SAFETY
Maintenance Precautions
29
SAFETY
Maintenance Precautions
30
SAFETY
Maintenance Precautions
31
SAFETY
Safety Signs (Decals)
The following safety signs (decals) have been placed on your machine in the areas indicated.
They are intended for the personal safety of you, and those working with you. Please take
this manual, walk around your machine and note the content and location of these safety
signs. Review these signs and the operating instructions in this manual with your machine
operators.
Keep the signs legible. If they are not, obtain replacements from your Service outlet.
CTL60 CTL60
CTL70 CTL80 CTL80
23 13 15 13 9 2 19 12 14 7
4
5 18
21
16
6
3 17 20
1 8
22
5
21
10 11
6
T8A008G
32
SAFETY
Safety Signs (Decals)
08800-30010
4.No.08800-31003
AVOID DEATH
WARNING AVOID INJURY
Loader can move
Before removing seat belt AVOID INJURY suddenly and violently
and leaving seat Always wear seat belt
LIFT ARMS MOVE
Lower lift arms to ground or CLOSE BY WINDOW
08800-30011
rest lift arms on stops. OPENING
Stop engine. NEVER PLACE
08800-30009 HANDS OR ARMS,
THROUGH SCREEN
OPENING
08800-31003
T8A012E
33
SAFETY
Safety Signs (Decals)
08800-30016
15.No.03593-07400 16.No.08810-30110
Engagement Disengagement
CAUTION WARNING 2 1
BEFORE OPENING
03593-07400
08810-30100
17.No.08800-31018 18.No.137637
EXIT DANGER
SECONDARY EMERGENCY
08800-31018
1 2 3
PULL
INSIDE
19.No.08810-31551 20.No.03993-00400
Position of
WARNING
ALWAYS keep legs, arms and
Fire extinguisher
body out from between lift arm
and machine.
08810-31551
T8A015E
34
CONTROLS
Names of Components .............................. 36
Doors and Covers ...................................... 38
Seat and Seat Belt ...................................... 42
Instrument Panel ........................................ 44
Switches ..................................................... 46
Levers and Pedals ..................................... 50
Accessories ............................................... 52
35
CONTROLS
Names of Components
1 2 3 4 5 6 7 8
12
10
13
11
14
15
16
17
T9B006
36
CONTROLS
Names of Components
3 2 1 9 10 11 12 13 14
15
4
16
5
17
6
18
3 1 2 13 15 14
19
20
7
21
8 If Equipped If Equipped
T9B007
37
CONTROLS
Doors and Covers
WARNING
Before opening the engine hood, be sure
to stop the engine. If your hands or tools
should get caught in the fan or fan belt
while the engine is running they may be
severed.
E4B003
Opening
The starter 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 1 2
Cab door
Manual storage
T8B003
Closing
1. Close the engine hood and press it down
until a click is heard at the front.
2. Insert the starter key and turn it clockwise
to lock the engine hood.
38
CONTROLS
Doors and Covers
2 1
T8B001
In case of emergency
1. Kick off the rear window. Note that the
T7B003
glass may break. Be careful not to get
Opening injured.
1. Open the engine hood.
2. Lift the lever (1) and open the rear door In case of need
(2). 1. Pull off ring (A) and remove the tip of
3. Release the stay (3), then insert and fix it the rubber wedge.
into the stay hole of the rear door (2). 2. Grasp the tip, pull, and remove the
entire rubber wedge.
Closing 3. Pull inside knob (B).
1. Support the rear door (2) by hand, remove
stay (3), and fix it to the original position.
2. Close the rear door (2) and press it until a
click is heard at the front.
39
CONTROLS
Doors and Covers
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 T9B002
Engagement
1. Park the machine on level ground and
remove the bucket.
2. Lower the lift arms to the ground and stop T9B003
the engine. 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. Install the R-pin (4) to the locking pin (1).
T9B001
40
CONTROLS
Doors and Covers
Disengagement
Fuel Filler Cap
2 1
WARNING
Do not smoke or permit open flames
5 while fueling or near fueling
operations.
Supply fuel in a well ventilated place
3 4 and with the engine stopped.
T9B004
Clean up spilled fuel immediately.
1. Remove the rear R-pin (4) from the locking Do not fill the fuel tank to capacity.
pin (1). Allow room for expansion.
2. Pull out the locking pin (1) from the lift arm Tighten the fuel filler cap securely.
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 Close Open
rod.
6. Lower the lift arms slowly to the ground
and stop the engine. T7B005E
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
T9B005 1. Set the fuel cap in place and turn it
clockwise.
7. Raise the lift arm stop (2) into storage 2. Turn the key clockwise to lock the fuel cap,
position and insert the locking pin (1) then remove the key.
through lift arm stop and bracket.
8. Install the R-pin (4) to the locking pin (1).
41
CONTROLS
Seat and Seat Belt
A E
3 3 4
C
1
4 2 G4B006 G4B007
42
CONTROLS
Seat and Seat Belt
Seat Belt
CAUTION
Always fasten the seat belt securely
before starting the engine.
B E4B023
E4B024
43
CONTROLS
Instrument Panel
1
4
2
10
3
5
11
6
7
9
8
T7B0061
44
CONTROLS
Instrument Panel
Indicators Meters
7. Glow Lamp 9. Hour Meter
This lamp turns off when This displays the total engine
engine preheating is running time in hours.
completed. The rightmost digit indicates
C4B013 L3B019
tenths of hours (6 minutes).
Set the inspection and maintenance intervals
8. Travel Speed Lamp according to the time displayed on the hour
This lamp lights when the meter.
travel speed switch is set to
2nd (high speed). 10. Water Temperature Gauge
C4B014
This gauge indicates the
temperature of the engine
coolant water.
L3B020
The needle should be within
the green range during machine operation.
The red range indicates overheating.
45
CONTROLS
Switches
OFF WARNING
PREHEAT ON
START Make sure the bucket is lowered to the
ground before putting the lift arms in
the Float position. Putting the lift arms
in the Float position while they are
raised will cause the bucket to fall and
E4B010 is extremely dangerous.
Do not drive the loader forward with
IMPORTANT: Do not repeatedly switch the lift arms in the Float position.
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 or
removing the key.
ON ................ Position in which the engine If Equipped
T9B010
is running. At this position, all
the electrical equipment is This switch sets the lift arms to the Float
functional. position. The lift arms are put to the Float
START .......... Position for starting the engine. position while this switch is pressed in. When
When the key is released, the the switch is released, the Float position is
switch automatically returns to canceled.
the ON position.
Horn Switch
If Equipped
T9B009
46
CONTROLS
Switches
If Equipped
T9B012
Press those buttons to control the flow of the Flow Selector Switch (C)
oil in the auxiliary hydraulic circuit.
(A) .......... Hydraulic oil flows to auxiliary
hydraulic line (a)
(B) .......... Hydraulic oil flows to auxiliary
hydraulic line (b)
If Equipped
T9B013
47
CONTROLS
Switches
If Equipped
If Equipped
T9B014
T9B016
48
CONTROLS
Switches
L3B029
49
CONTROLS
Levers and Pedals
WARNING
A
B
Before leaving the operators seat,
raise the safety bar to engage the lock
and stop the engine.
If any controls should be touched
accidentally when the safety bar is
lowered, the machine will move T7B016
suddenly, and cause serious injury or
death. This controls the engine speed.
Be careful not to touch the control (A) .......... Low idling
levers and pedal when lowering or (B) .......... Maximum speed
raising the safety bar.
T7B015 WARNING
This device is for locking the control levers, Be careful to check which pattern of lever
pedal and selector, detent mode and high control arrangement you are operating
flow switches. with before beginning operations.
When the safety bar is lifted, then levers,
pedal and switches are locked.
T7B017
50
CONTROLS
Levers and Pedals
T7B018
) 6%*'
Use this lever to move forward and backward Use this pedal to operate the auxiliary
and to change directions. hydraulics circuit.
Refer to page 62 Lever Pattern. (A) .......... Hydraulic oil flows to auxiliary
Refer to page 65 Operating the Left hydraulic line (a)
Control Lever. (B) .......... Hydraulic oil flows to auxiliary
hydraulic line (b)
Refer to page 69 Operating the Auxiliary
Hydraulics.
51
CONTROLS
Accessories
Fan Switch
T7B0211
O ............ Off
I ............. Heater fan rotates at low speed.
I I ............ Heater fan rotates at high speed.
52
CONTROLS
Accessories
53
CONTROLS
Accessories
T7B0281
54
CONTROLS
Accessories
O I
T7B0231 T7B0272
55
56
OPERATION
Before Starting Operation ......................... 58
Starting and Stopping the Engine ............. 59
Machine Operation ..................................... 62
Operating Procedures ............................... 70
Parking the Machine .................................. 78
Handling in Cold Weather .......................... 79
Handling Rubber Crawlers ........................ 80
57
OPERATION
Before Starting Operation
Daily Inspection
Perform the daily inspections once a day
before starting the engine the first time that
day.
Perform the inspections as described under
T7D001
Maintenance - Daily Inspection (pages 102
Always face the access system and to 106).
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.
58
OPERATION
Starting and Stopping the Engine
T7D0031
N N
If a lamp does not light or the alarm is not
sounded, the bulb may be burnt out or a wire
B
may be damaged. Contact a Gehl sales or
A
service outlet for repairs.
T7D002
OFF
PREHEAT ON
START
E4D002
59
OPERATION
Starting and Stopping the Engine
WARNING
Clear the area of all persons.
Sound horn to alert everyone around
the machine.
E4D060
T7D0051
OFF
PREHEAT ON
START
E4D007
61
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.
N N
T7D007
62
OPERATION
Machine Operation
WARNING
Operating the working equipment without
warming up the hydraulics is dangerous,
as response will be slow and the
equipment may move in unexpected 6%,'
ways. Be sure to sufficiently warm up the 3. Extend and retract each of the cylinders
hydraulics. several times with no load.
T7D004
6%,
63
OPERATION
Machine Operation
T7D0121
T7B015
64
OPERATION
Machine Operation
WARNING
Never allow anyone to enter the turning
radius and machine path.
Signal your intention to move by
sounding the horn. T7D005
whenever possible. If you must do so, 3. Rollback the bucket fully and lift the bucket
keep the bucket close to the ground to 30 cm (12 in.) above 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
machines path.
6%," 6%,#
Spin Turn
If Equipped
T9B016
66
OPERATION
Machine Operation
Stopping Travel
WARNING
Park the machine on firm, level ground
and apply the parking device. If you
must park on a slope or incline, block
the machine securely to prevent
movement.
If any controls should be touched
accidentally when the safety bar is
lowered, the machine will move
suddenly, and 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.
N N
T7D017
67
OPERATION
Machine Operation
WARNING N N
T7D020
a To rollback:
N N Tilt the right control lever to the left.
e To dump:
B
Tilt the right control lever to the right.
A
68
OPERATION
Machine Operation
aTo deliver hydraulic oil to port (a): One press of the auxiliary hydraulic switch
Depress (A). (A) sets it to ON and one more press sets it
When using a hydraulic breaker or other to OFF. There is no need to continue pressing
1-way flow attachment. the switch.
eTo deliver hydraulic oil to port (b): Refer to page 48 Detent Mode Switch.
Depress (B).
69
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 T7D023
speeds slow enough so you have Travel at a speed which is appropriate for
complete control at all times. the conditions. Travel at low speed when
the field of view is obstructed and take
extra precautions with hazardous
materials.
T7D021
T7D022
70
OPERATION
Operating Procedures
T7D025 T7D028
Do not attempt a spin turn or pivot turn at Do not use the downward force of the
high speeds. bucket to drive piles.
Never do this since it may cause the
crawler to fall off, extreme wear, etc.
T7D030
T7D029
71
OPERATION
Operating Procedures
Cautions on Operating
Leave some play Cautions on Traveling
T7D043E
T7D031
72
OPERATION
Operating Procedures
T7D032
T7D033
73
OPERATION
Operating Procedures
T7A016
74
OPERATION
Operating Procedures
Braking when traveling down slopes Do not open the front door (if equipped)
while traveling on slopes
Braking
T7D034
T7D036
Braking is automatically applied by the
hydrostatic drive system when the left control Opening the front door while traveling on
lever is returned to the neutral position. Full slopes can be hazardous, because the force
braking is achieved when the safety bar is required to open and close the door changes
raised. abruptly. Always keep the door closed when
traveling on slopes.
If the engine stops
Descending
T7D035E
75
OPERATION
Operating Procedures
Scooping
T7D0371
Lower the lift arms and bring the bucket down to the ground with the front end tilted slightly
forward, then drive the loader forward until the bucket is filled with the material. Next tilt the
bucket backward and scoop up the material.
Grading
T7D0381
Tilt the front edge of the bucket down at an angle which 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 backward.
Leveling
T7D0391
Raise the lift arms and tilt the bucket forward, then release it as the loader is driven forward.
Next tilt the bucket forward and lower the front edge until it is slightly above the ground
surface, then back the loader over the load which was just released.
76
OPERATION
Operating Procedures
Backfilling
T7D0401
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.
WARNING
Make sure the bucket is lowered on the ground before floating the lift arms. Floating the
lift arms 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 Float position.
T7D0411
Lower the bucket onto the ground, then put the lift arms in a Float position. Tilt the bucket
forward to stand it on its cutting edge, then level the loose material while driving backward.
Loading
T7D0421
Approach the truck and stop, then raise the bucket until its lower edge clears the truck bed.
Drive the loader slowly forward, stop at the position where the bucket is to be tilted forward,
then tilt the bucket forward, releasing the material in the bucket into the truck bed. When the
truck is half loaded, use the bucket to spread the load evenly.
77
OPERATION
Parking the Machine
T7A027
Inspection and Checks After
Stopping the Engine
1. Check for oil and water leakage and
inspect the working equipment, covers
and lower body. If any irregularities are
found, repair.
2. Fill the fuel tank.
Refer to page 101 Inspecting the Fuel
T7A028 Level.
3. Remove any paper scraps or dirt from the
Park the machine on firm, level ground
engine room.
and apply the parking device. If you 4. Remove any mud from the lower body.
must park on a slope or incline, block
the machine securely to prevent Locking
movement. Be sure to lock the following places:
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 operators 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, Fuel filler cap
unattended. If arms are left in raised Engine hood
position, they MUST be restrained by Manual storage
the lift arm stop. Cab door
78
OPERATION
Handling in Cold Weather
79
OPERATION
Handling Rubber Crawlers
6%-!
6%-
6%-
80
OPERATION
Handling Rubber Crawlers
T7E007
81
OPERATION
Handling Rubber Crawlers
T7E008
82
TRANSPORT
Loading and Unloading ............................. 84
Securing the Machine ................................ 85
Cautions on Transporting .......................... 86
83
TRANSPORT
Loading and Unloading
84
TRANSPORT
Securing the Machine
T7F0021
85
TRANSPORT
Cautions on Transporting
WARNING
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.
86
MAINTENANCE
General ....................................................... 88
Service Data ............................................... 90
Important Parts .......................................... 94
Maintenance Chart ..................................... 96
Maintenance Log ....................................... 98
Walk-Around Inspection .......................... 100
Daily Inspection (Every 10 Hours) ........... 102
After First 50 Hours
(New Machines Only) ............................ 107
Every 50 Hours ......................................... 111
Every 100 Hours ....................................... 114
Every 250 Hours ....................................... 115
After First 500 Hours
(New Machines Only) ............................ 116
Every 500 Hours ....................................... 117
Every 1000 Hours ..................................... 120
Every 2000 Hours ..................................... 125
When Required ........................................ 126
Long-term Storage ................................... 131
87
MAINTENANCE
General
Cautions on fueling
If the port includes a strainer, do not
remove the strainer when fueling.
After fueling, be sure to securely tighten
the cap, etc.
Do not add more than the prescribed
amount of fuel.
88
MAINTENANCE
General
89
MAINTENANCE
Service Data
90
MAINTENANCE
Service Data
* If the percentage of the traveling time within the total operating time is high, replace the
gear oil earlier than the specified time.
** For water, use tap water (soft). Do not use well or river water.
*** When the ambient temperature drops below 0C, add coolant (antifreeze). Follow the
coolant manufacturers instructions to determine the mixture ratio.
Expendables
Replace expendables such as filters and elements periodically, referring to the table below.
91
MAINTENANCE
Service Data
Tools
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17
18 19 20 21 22
T7G0011
No. Part name Part No. Remarks No. Part name Part No. Remarks
1 Spanner 10-12 12 Hammer 3/4
2 Spanner 11-13 13 Hex. wrench 5mm
3 Spanner 14-17 14 Hex. wrench 6mm
92
MAINTENANCE
Service Data
Tightening Torques
Nuts and Bolts (for ISO strength category 10.9)
Tighten nuts and bolts at the torques shown on the table below, unless otherwise specified in
the text.
Tightening torques when mounting plastic covers differ from the values on the table below.
Consult a Gehl sales or service outlet. Tightening too strongly will break the cover.
When replacing nuts and bolts, replace them with nuts and bolts of the same size and
standards.
Tighten nuts and bolts alternately (top, bottom, left then right) or in 2 or 3 times so that they
are tightened uniformly.
3 6
5 4
2 E4G003
93
MAINTENANCE
Important Parts
For safe use, the machine must be serviced periodically. To increase safety, periodically
replace the parts listed in the following table of important parts.
Serious injury or a fire could result if they deteriorate or are damaged.
Above important parts are vulnerable to aging and wear or deterioration and it is difficult to
determine the degree to which they have deteriorated on the occasion of periodic service. To
maintain their proper function at all times, therefore, replace them with new ones after using
them for a specific period of time even if no abnormality is found with the parts. If you find
abnormalities in these parts before their scheduled replacement time is reached, repair or
replace them immediately. If a hose clamp is deformed or cracked, replace it immediately.
When replacing the important parts, please contact a Takeuchi sales or service outlet .
Also check the hydraulic hoses other than the above important parts. If any abnormality is
found in them, retighten them or replace them immediately.
When replacing the hydraulic hoses, replace the O-rings and seals at the same time.
Check the fuel and hydraulic hoses according to the periodic schedule described below.
Refer to Maintenance.
94
MEMO
95
MAINTENANCE
Maintenance Chart
96
MAINTENANCE
Maintenance Chart
* If the percentage of the traveling time within the total operating time is high, replace the
gear oil earlier than the specified time.
97
MAINTENANCE
Maintenance Log
98
MAINTENANCE
Maintenance Log
99
MAINTENANCE
Walk-Around Inspection
Perform the following inspections once every day before starting the engine the first time.
WARNING
Before operating, perform the walk-around inspections and make repairs immediately
should any irregularities be found.
Be sure to secure the engine hood or rear door when opening it. Do not open the
engine hood or rear door on slopes or in strong wind.
Before starting the engine, look around the machine and lower body, clean any combustible
materials off high temperature parts of the engine, and inspect for such irregularities as oil
leakage, water leakage and looseness of nuts and bolts.
13 10 4 12 1 2 11
14 3
9
6
T7G0031
100
MAINTENANCE
Walk-Around Inspection
101
MAINTENANCE
Daily Inspection (Every 10 Hours)
Perform the following inspections once every day before starting the engine the first time.
WARNING
Before operating, perform the Daily inspections and make repairs immediately should
any irregularities be found.
Be sure to secure the engine hood or rear door when opening it. Do not open the
engine hood or rear door on slopes or in strong wind.
Inspection
2 1
H
L
T7G004
102
MAINTENANCE
Daily Inspection (Every 10 Hours)
T7G005
< CTL60 / CTL80 >
1. Open the engine hood.
2. Pull out the dipstick (1) and wipe off the 2 8 1
ON
103
MAINTENANCE
Daily Inspection (Every 10 Hours)
3
2 4
T7G0071
104
MAINTENANCE
Daily Inspection (Every 10 Hours)
T7G0081 T7G0091
1. Start the engine and run it at low speed. 1. Remove the plug (1).
2. Fully retract the lift arms and bucket 2. Add hydraulic oil up to the middle of the
cylinders and ground the bucket. sight gauge (2).
3. Stop the engine. 3. Tighten the plug (1).
4. Inspect the oil level using the sight gauge
(2).
When the oil temperature is about 20C
(68F):
The level should be halfway between the
upper limit (H) and lower limit (L).
If it is below the lower limit (L), replenish.
When the oil temperature is about 50 to
80C (122 to 176F):
The level should be near the upper limit
(H).
105
MAINTENANCE
Daily Inspection (Every 10 Hours)
T9G001
1. Set the machine to the lubrication posture shown in the diagram above, ground the bucket,
then stop the engine.
2. Use the grease gun to lubricate the grease nipples.
3. Wipe off the expelled grease.
106
MAINTENANCE
After First 50 Hours (New Machines Only)
WARNING 2
4
5
T8G0011
107
MAINTENANCE
After First 50 Hours (New Machines Only)
Replacing the Engine Oil and Oil 7. Remove connector (B) and install cap (A).
Filter
IMPORTANT: Check the spent oil. If it
contains large amounts of metal powder,
WARNING
consult a Gehl sales or service outlet.
Stop the engine and allow the machine to
cool down before performing maintenance. 8. Install the under cover (3).
The engine, muffler, radiator and many
other parts of the machine are hot < CTL70 >
directly after the engine is stopped.
Touching these parts will cause burns.
The engine oil is also hot.
Be careful when loosening caps and 4
plugs. Working on the machine under
these conditions could result in burns.
T8G002
2
< CTL60 / CTL80 >
L H 1
T7G005
4
1. Open the engine hood.
2. Tilt up the ROPS. T7G0121
Refer to page 129 Tilting Up the ROPS.
3. Remove the oil supply cap (2). 9. Using a filter wrench, turn the filter (4)
counterclockwise and remove it.
3 10. Clean the surface of installation of the
filter stand.
11. Apply a thin layer of oil to the packing of
the new filter.
12. Install the new filter by hand.
B A 13. Tighten 3/4 (CTL70: 1 and 1/4) more
turns with the filter wrench after the filter
T7G0111 packing comes in contact with the surface
4. Place a pan under the under cover (3). of installation.
5. Loosen the bolts and remove the under 14. Supply oil up to the upper limit (H) of the
cover (3). dipstick (1). Problems could arise if the
6. Remove cap (A), install connector (B) and oil level is either too low or too high.
drain the oil. (The oil comes out when the 15. Tighten the oil supply cap (2).
screw is tightened.) 16. Lower the ROPS.
108
MAINTENANCE
After First 50 Hours (New Machines Only)
17. Start the engine, run it at low idle for about Inspecting and Adjusting the Fan
3 minutes, then stop it.
Belt
18. After about 20 minutes, inspect the oil level.
WARNING
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 directly
after the engine is stopped. Touching
these parts will cause burns.
Inspection
a
b
T9G006
3
A
2
10mm
(0.4in.)
4
L3G029
109
MAINTENANCE
After First 50 Hours (New Machines Only)
5 8 T7G013
110
MAINTENANCE
Every 50 Hours
Inspection
1
T7G016
111
MAINTENANCE
Every 50 Hours
WARNING
Do not fill the battery above the upper
level. Doing so could cause the fluid
a
to leak, contact and damage the skin,
or cause parts to corrode. b
Batteries contain sulfuric acid which
T9G006
will damage eyes or skin on contact.
If acid contacts eyes, flush 1. Remove the bolts (a) and open the radiator
immediately with clean water and get (b).
prompt medical attention. 2. Remove the indicator (1) and caps (2), and
If acid is accidentally swallowed, add distilled water up to the upper level.
drink large quantities of water or milk 3. Tighten the indicator (1) then it turns green.
and call a physician immediately. 4. Clean the caps exhaust hole, then tighten
If acid contacts skin or clothing, wash the caps (2) securely.
off immediately with clean water.
Inspection
1 2
2
Upper Limit
T8G003E
112
MAINTENANCE
Every 50 Hours
WARNING
Do not smoke or permit open flames
while handling fuel or working on the
fuel system.
Stop the engine in a well-ventilated
place and allow it to cool down before
performing maintenance.
Clean up spilled fuel immediately.
3
2 4
T7G0071
113
MAINTENANCE
Every 100 Hours
WARNING
Do not smoke or permit open flames
while handling fuel or working on the
fuel system.
Stop the engine in a well-ventilated
place and allow it to cool down before
performing maintenance.
Clean up spilled fuel immediately.
2 8 1
ON
S OFF
3
5
4
6
7
T7G0062
S : Closed
1. Open the rear door.
2. Close the valve (2).
3. Loosen the ring (3), then remove the case
(4), element (5) and indicator ring (6) and
clean them.
4. Inspect the O-ring, and if there are any
scratches or other irregularities, replace
it.
5. Assemble the indicator ring (6), case (4)
and element (5) and tighten the ring (3).
6. Open the valve (2).
7. Loosen the vent plug (8) and bleed the
air.
8. Tighten the vent plug (8).
Refer to page 137 Bleeding the Air from the
Fuel System.
114
MAINTENANCE
Every 250 Hours
115
MAINTENANCE
After First 500 Hours (New Machines Only)
WARNING 3
OIL.L.
after the engine is stopped. Touching 1. Set the travel motor so that plug (1) is at
them will cause burns. the very bottom.
The gear oil is also hot and under 2. Place a pan for catching the spent oil
high pressure. under plug (1).
Be careful when loosening plugs. 3. Remove plugs (1), (2) and (3) and drain
Working on the machine under these the oil.
conditions could result in burns or 4. Wrap new sealing tape around the plugs.
injuries. 5. Tighten plug (1).
The pressure in the travel motor 6. Supply oil through the hole for plug (3) until
reduction gears case may cause oil or oil flows out of the hole of plug (2).
the plug to fly out. Loosen the plug 7. Tighten plugs (2) and (3).
slowly to release the pressure.
116
MAINTENANCE
Every 500 Hours
T7G021
T7G020
117
MAINTENANCE
Every 500 Hours
6. Install the new filter by hand. Replacing the Feed Pump Filter
7. Tighten 2/3 more turn with the filter wrench
(CTL70)
after the filter packing comes in contact
with the surface of installation.
WARNING
8. Bleed the air.
Refer to page 137 Bleeding the Air from Do not smoke or permit open flames
the Fuel System. while handling fuel or working on the
fuel system.
Stop the engine in a well-ventilated
place and allow it to cool down before
performing maintenance.
Clean up spilled fuel immediately.
a
b
T9G006
1 4 3 4 2
T9G0071
118
MAINTENANCE
Every 500 Hours
119
MAINTENANCE
Every 1000 Hours
Cleaning the Engine Cooling 1. Open the rear door and remove the cover (5).
System
3
WARNING
Stop the engine and allow the machine 2 1
to cool down before performing
maintenance. H
The engine, muffler, radiator and
L
many other parts of the machine are T7G004
hot directly after the engine is
stopped. Touching these parts will 2. Gradually loosen the radiator cap (3) to
cause burns. release the internal pressure, then remove.
The engine coolant is also hot and
under high pressure. Be careful when
loosening caps and plugs. Working
on the machine under these 4
conditions could result in burns or
injuries due to the hot coolant
spurting out.
If maintenance must be performed with 5
the engine running, always work as a T7G022
two-person team with one person
sitting in the operators seat while the 3. Place a pan for catching the spent coolant
other works on the machine. under the drain plug (4), then loosen the
When performing maintenance, be drain plug (4) and drain the coolant.
sure to keep your body and clothing 4. Tighten the drain plug (4), then add a little
away from moving parts. cleaning agent and tap water to the
Standing at the back of the machine radiator until it is full. Take your time doing
while the engine is running is extremely this.
dangerous, as the machine could move Follow the manufacturers instructions
suddenly. Never stand at the back of when using the cleaning agent.
the machine while the engine is 5. Run the engine at a low idle for about 30
running. minutes. For the first 5 minutes after
Do not remove the radiator cap or drain starting it, pay attention to the level of the
plugs when the coolant is hot. Stop the cleaning fluid, and add tap water if the level
engine, let the engine and radiator cool drops.
and loosen the radiator cap or drain 6. Stop the engine and drain the cleaning
plugs slowly. fluid.
7. Tighten the drain plug (4), add tap water,
run the engine at a low idle for about 10
minutes, then stop the engine and drain
the water.
Clean repeatedly until the drained water
is clear.
120
MAINTENANCE
Every 1000 Hours
4 3
1
2
5
T7G019
121
MAINTENANCE
Every 1000 Hours
The engine, hydraulic lines and many 1. Open the rear door
other parts of the machine are hot 2. Drain the coolant
directly after the engine is stopped. Refer to page 120 Cleaning the Engine
Touching these parts will cause Cooling System.
burns. 3. Remove the bolts (4) and open the radiator
The hydraulic fluid is also hot and (5).
under high pressure. 4. Disconnect the hoses that are connected
Be careful when loosening caps and to the radiator (5).
plugs. Working on the machine under 5. Temporarily suspend the radiator (5).
these conditions could result in 6. Remove the split pin and pull out pins (6).
burns or injuries due to the hot oil 7. Lift out the radiator and remove it.
spurting out.
Oil may spurt out if caps or filters are
removed or pipes disconnected before 1
releasing the pressure in the hydraulic
system.
When removing plugs or screws or 2
disconnecting hoses, stand to the
side and loosen slowly to gradually
release the internal pressure before
removing. 3
1 4
9
3 5
8
4 7
5 T7G0091
122
MAINTENANCE
Every 1000 Hours
11. Loosen the bolts, and remove the flange Bleeding the air
(8).
12. Remove the suction strainer (9) and IMPORTANT: After replacing the hydraulic
clean it. oil, bleed the air from the hydraulic circuit
13. Clean the inside of the hydraulic tank. and hydraulic devices. Failure to do so
14. Install the new return filter. may damage the hydraulic devices.
Refer to page 107 Replacing the
Hydraulic Oil Return Filter. Hydraulic pump
15. Install the suction strainer (9) to the flange
(8). 1
16. Install the flange (8).
17. Tighten the drain plug (7).
18. Add hydraulic oil up to the middle of the
sight gauge (2) from the hole of plug (1).
19. Tighten the plugs (1).
20. Follow the procedure next Bleeding the
T7G024
air to bleed the air from the hydraulic oil
circuit. 1. Tilt up the ROPS.
21. Set the machine to the hydraulic oil level 2. Remove the plug (1) from the hydraulic
inspection posture and inspect the level pump.
once the temperature of the oil has 3. Once hydraulic oil overflows from the plug
dropped. hole, connect the plug (1).
Refer to page 105 Inspecting the
Hydraulic Oil Level and Replenishing. Cylinders
1. Start the engine and run it at low idle for
10 minutes.
2. Set the engine to a low idle, then extend
and contract all the cylinders 4 or 5 times,
without going to the stroke end.
3. Run the engine at high speed, then extend
and contract all the cylinders 4 or 5 times,
without going to the stroke end.
4. Set the engine back to a low idle, then
extend and contract all the cylinders 4 or
5 times to the stroke ends.
123
MAINTENANCE
Every 1000 Hours
124
MAINTENANCE
Every 2000 Hours
125
MAINTENANCE
When Required
WARNING
Before performing maintenance or
repairs under the machine, set all working
equipment against the ground or in the T9G010
lowermost position.
3. Move the machine slowly forward and
raise the loader lift arms. The wedge
Installation
shaped top edge of the quick attachment
(3) must engage in the upper mounts of
IMPORTANT: Read the manufacturers
the bucket or attachment.
instructions manual for attachments not
included in this manual. DO NOT use
attachments that are not approved by
Gehl.
IMPORTANT: Before installing a bucket
or attachment, make sure the mounting
area of the bucket (1) and the quick
attachment (3) are clean. 1
3
1. Make sure the quick attachment (3) lock T9G011
2 3
T9G009
126
MAINTENANCE
When Required
2
1
T9G013
3 1
T9G014
127
MAINTENANCE
When Required
Control levers
G4G030
Inspection
A 1 1. Open the front door.
2. Inspect the washer tank (1) and add
washer fluid if the level is low.
B
Replenishment
E4G058
1. Mix the washer fluid to the prescribed
1. Remove the lower mount section of the concentration.
boot (1) and turn it upwards. 2. Remove the cap (2) and add washer fluid.
2. Wipe off the old grease. 3. Reinstall the cap (2).
3. Supply grease to points (A) and (B).
4. Set the boot (1) back as it was.
Auxiliary pedal
A
B B
T7G027
128
MAINTENANCE
When Required
WARNING
Raising or lowering the ROPS while the
engine is running may cause the
machine to move, and cause serious
injury or death. Lower the working
equipment to the ground and stop the
engine before raising or lowering the
ROPS.
When the ROPS is tilted up, support it
firmly with the stopper to prevent it T7G031
from falling.
6. Insert the stopper pin (B) into the bodys
Raising (Tilt up) holder and insert a R-pin into the stopper
1. Select a firm, level surface, lower the pins hole to fasten it in place.
working equipment to the ground, and stop If you need to run the engine while the
the engine. ROPS is raised follow these steps.
2. Set the safety bar to the lock position. 7. Make sure that all levers and pedal are in
neutral positions.
8. Push the throttle lever to the low idling
B A position.
9. Start the engine.
10. Be sure to stop the engine after
inspection and maintenance.
Lowering
1. Remove the stopper pin (B).
2. Lower the ROPS.
3. Tighten the lock bolts (A).
4. Reinsert the stopper pin (B) into the bodys
holder.
T7G0301
129
MAINTENANCE
When Required
Rubber crawler
Replace the crawler if the entire crawler is 3 E4G064
stretched and cannot be adjusted.
Replace if even one metal core is off.
(1) Lug
(4) Rubber
60 mm or greater
4 3
A
1 2 E4G062
E4G065
Replace if the height of (A) is 5 mm (0.2 in.)
or below. Repair if there are cracks of 60 mm (2.4 in.)
or greater in length.
(2) Steel cord If the steel cord is visible, repair as soon as
possible, regardless of the length of the
crack.
2
E4G063
130
MAINTENANCE
Long-term Storage
Cranking
IMPORTANT: When the engine is being
used for the first time or after a long
period of storage, perform the cranking
operation first in accordance with the
procedure shown below in order to
distribute lube oil to all of the parts. Using
an engine which has been stored for a
long period of time without the cranking
procedure may result in engine seizure,
since there will no longer be oil on the
moving parts after storage.
131
MAINTENANCE
Long-term Storage
132
TROUBLESHOOTING
Symptoms that are not Malfunctions ...... 134
If the Engine Overheats ........................... 135
If the Battery Goes Dead .......................... 136
After the Fuel Runs Out ........................... 137
If a Fuse Blows ......................................... 138
If a Warning Lamp Flashes ...................... 140
Other Symptoms ...................................... 142
To Lower the Lift Arms ............................ 144
Towing ...................................................... 145
133
TROUBLESHOOTING
Symptoms that are not Malfunctions
134
TROUBLESHOOTING
If the Engine Overheats
Procedure
WARNING
1. Park the machine in a safe place.
Do not open the engine hood when 2. Inspect whether the engine oil pressure/
there is steam coming from the engine coolant level warning lamp is flashing or if
room. The steam or hot water may there is steam coming out when the
spurt out, resulting in burns. engine hood is closed.
Do not remove the radiator cap or drain 3. If there is steam, stop the engine
plugs when the coolant is hot. Stop the immediately and contact a Gehl sales or
engine, let the engine and radiator cool service outlet for repairs.
and loosen the radiator cap or drain If the engine oil pressure/coolant level
plugs slowly. warning lamp is off, run the engine at low
Stop the engine and allow the machine idle and let the water temperature
to cool down before performing decrease.
inspection and maintenance. 4. Once the water temperature gauge drops
to the green zone, stop the engine.
The following symptoms indicate 5. Once the engine is cool, perform the
overheating: following inspections and procedures:
Fan belt slack ......................... Adjust.
Refer to page 109.
Coolant level .............................. Add.
Refer to page 102.
Water leakage ........................ Repair.
Radiator fins ............................ Clean.
Refer to page 117.
Sediment in cooling system ..... Clean.
Refer to page 120.
T7J0011 If the problem persists after the above
An alarm is sounded and the coolant procedures are taken, contact a Gehl sales
temperature warning lamp, engine or service outlet for repairs.
emergency lamp flashes.
When the engine oil pressure/coolant level
warning lamp is flashing simultaneously,
the coolant level is low.
The water temperature gauge shows the
red zone.
The engine slows down and the power
decreases.
Steam comes from the engine room.
135
TROUBLESHOOTING
If the Battery Goes Dead
The following symptoms indicate that the Connecting the jumper cables
battery is dead:
The starter motor does not turn or turns IMPORTANT: Set the starter keys of both
weakly, and the engine does not start. the rescue vehicle and problem vehicle
The horn is weak. to the OFF position.
WARNING
3 To engine block
Use jumper cables only in the B
4
recommended manner. Improper use E4J005
of jumper cables can result in battery 1. Connect the clip of jumper cable (R) to
explosion or unexpected machine the problem vehicles + terminal.
motion. 2. Connect the other clip of jumper cable (R)
Do not let the problem vehicle and to the rescue vehicles + terminal.
rescue vehicle touch each other. 3. Connect the clip of jumper cable (B) to
Do not let the + and clips of the the rescue vehicles terminal.
jumper cables touch each other. 4. Connect the other clip of jumper cable (B)
Connect the jumper cables to the + to the problem vehicles engine block.
terminals first, and disconnect them Connect the clip as far from the battery as
from the terminals (ground) first. possible.
Connect the final clip of the jumper
cable to a point as far away from the Starting the engine
battery as possible. 1. Check that the clips are securely
Use safety glasses when using jumper connected to the terminals.
cables to start the machine. 2. Start the rescue vehicles engine and run
it at high speed.
IMPORTANT: Use jumper cables and 3. Start the problem vehicles engine.
clips of a size suited to the batterys
capacity. Do not used damaged or
corroded jumper cables and clips.
IMPORTANT: The rescue vehicles
battery must have the same capacity as
the problem vehicles battery.
IMPORTANT: Connect the clips securely.
136
TROUBLESHOOTING TROUBLESHOOTING
If the Battery Goes Dead After the Fuel Runs Out
Disconnecting the jumper cables Bleeding the Air from the Fuel
Once the engine starts, disconnect the
System
jumper cables following the connection
procedure in reverse order. 1. Add fuel.
Rescue vehicle battery Problem vehicle battery
3 4
R OFF
PREHEAT ON
START
E4D002
1. Disconnect the clip of jumper cable (B)
from the problem vehicles engine block. 2. Turn the starter key to the ON position and
2. Disconnect the other clip of jumper cable hold it there for about 20 seconds.
(B) from the rescue vehicles terminal. The automatic air bleeder bleeds the air
3. Disconnect the clip of jumper cable (R) from the fuel system.
from the rescue vehicles + terminal.
4. Disconnect the other clip of jumper cable Supplement: Air in the fuel system can
(R) from the problem vehicles + terminal. make it difficult to start the engine and cause
engine problems. Also bleed the air when
Recharging the fuel tank is emptied or air in the fuel
Have a Gehl sales or service outlet recharge system.
batteries that have gone dead.
137
TROUBLESHOOTING
If a Fuse Blows
If a light does not turn on or the electric Fuse Layout and Circuits Protected
system does not operate, a fuse may be Capacity Protected circuit Capacity Protected circuit
blown. Inspect the fuses.
30A External power
socket (option)
Inspecting and Replacing the Fuse Heater (option)
20A Tail light 20A Reserve
WARNING
20A Front light 20A Instrument panel
If the fuse blows as soon as it is replaced, Feed pump
there is a problem with the electric 30A Arm float, Lever lock 10A Safety relay
system. Continued use may lead to fire. Auxiliary Generator
Consult a Gehl sales or service outlet. 10A Rear wiper (option) 30A Engine
stop-solenoid
1. Turn the starter key to the OFF position 10A Front wiper (option) 20A Horn
and stop the engine. Interior light (option)
1
T7J002
Blown Normal
E4J007
138
TROUBLESHOOTING
If a Fuse Blows
1
1 CTL60
CTL80 CTL70
T9J0011
139
TROUBLESHOOTING
If a Warning Lamp Flashes
If an alarm is sounded or a warning lamp starts flashing during operation, park the machine
in a safe place and perform the procedures described below.
Engine oil Inspect the engine oil level or coolant level. If the lamp is
pressure/ flashing even though the level is normal or if it continues
coolant level flashing after oil or coolant are added, consult a Gehl
warning sales or service outlet.
L3J004 lamp Refer to page 102 or 103 Inspecting and replenishing the
coolant or Inspecting and Replenishing the Engine Oil.
G4B010
140
TROUBLESHOOTING
If a Warning Lamp Flashes
141
TROUBLESHOOTING
Other Symptoms
For symptoms not included on the table below or if the problem persists after the proper
procedures have been taken, consult a Gehl sales or service outlet.
Lift arms, bucket, Safety bar is raised Lower the safety bar.
auxiliary hydraulics or Refer to page 50.
traveling operation not Fuse is blown Replace the fuse.
possible Refer to page 138.
Scooping or lifting force Insufficient hydraulic oil level Replenish to the prescribed
is insufficient level.
Refer to page 105.
Hydraulic oil is not heated Perform the warm-up
procedure.
Refer to page 63.
Air cleaner is clogged Clean the air cleaner.
Traveling is not possible Stones or foreign objects are Remove the foreign object.
or not smooth stuck
Machine does not travel Stones or foreign objects are Remove the foreign object.
straight forward stuck
142
TROUBLESHOOTING
Other Symptoms
Crawlers slip off Crawlers are too loose Adjust the tension.
Refer to page 111.
Irregular noise is Low quality fuel is being used Replace the fuel.
produced from the Engine is overheating If the Engine Overheats
engine (combustion or Refer to page 135.
mechanical noise) Damage in muffler Replace the muffler.
(Request at a sales or
service outlet.)
143
TROUBLESHOOTING
To Lower the Lift Arms
Procedure M 1
T8J003
T8J002
144
TROUBLESHOOTING
Towing
1 2
1 T9A007
145
146
SPECIFICATIONS
Main Specifications ................................. 148
Machine Dimensions ............................... 152
Operating Range ...................................... 154
147
SPECIFICATIONS
Main Specifications
CTL60
MASS
PERFORMANCE
148
SPECIFICATIONS
Main Specifications
CTL70
MASS
PERFORMANCE
149
SPECIFICATIONS
Main Specifications
CTL80
MASS
PERFORMANCE
150
MEMO
151
SPECIFICATIONS
Machine Dimensions
H
J
M
E
C G
B F
T7K0011
152
SPECIFICATIONS
Machine Dimensions
Units: mm (inches)
CTL60 CTL70 CTL80
Standard Bucket
Rubber Crawlers
A 3430 (135.1) 3710 (146.0) 3985 (156.9)
B 2740 (107.8) 2950 (116.1) 3135 (123.5)
C 1390 (54.7) 1495 (58.9) 1595 (62.9)
D 2130 (83.9) 2170 (85.4) 2215 (87.2)
E 310 (12.1) 325 (12.8) 345 (13.5)
F 1580 (62.2) 1770 (69.7) 1860 (73.2)
G 320 (12.6) 450 (17.7)
H 1430 (56.3) 1500 (59.1) 1570 (61.8)
J 980 (38.6)
K 1675 (66.0) 1880 (74.0) 1960 (77.2)
L 510 (20.0) 535 (21.1) 580 (22.8)
M 30
153
SPECIFICATIONS
Operating Range
F G
A B C
T7K0021
154
SPECIFICATIONS
Operating Range
Units: mm (inches)
CTL60 CTL70 CTL80
Standard Bucket
Rubber Crawlers
A 3905 (153.8) 4080 (160.7) 4245 (167.2)
B 3030 (119.3) 3120 (122.9) 3205 (126.1)
C 2370 (93.4) 2405 (94.8) 2430 (95.7)
D 730 (28.8) 875 (34.4) 985 (38.8)
E 2080 (82.0) 2295 (90.4) 2435 (95.8)
F 1375 (54.1) 1500 (59.1) 1560 (61.4)
G 1590 (62.7) 1670 (65.7) 1755 (69.1)
H 30 31
155
156
OPTIONS
General Precautions ................................ 158
157
OPTIONS
General Precautions
Precautions on Safety
WARNING
Heed the following when removing or installing an attachment or option:
Consult with a Gehl dealer before installing optional attachments.
Do not use attachments that have not been approved by Gehl or a Gehl dealer.
Doing so may compromise safety or adversely affect the machines operation or
service life.
Gehl will not be held responsible for any injuries, accidents or damage to products
caused by the use of a non-approved attachment.
Choose a flat, hard surface to perform the operations. Also make sure there is enough
light and good ventilation.
Clean the area, remove any articles that may get in the way or be dangerous, and
remove any spilt oil or grease.
When removing or installing the hoe attachment, place it in a stable position so that
it does not tip over.
Due to the risk of loads falling and/or hitting people, do not allow unauthorized
personnel in the work area.
Use the crane to carry heavy objects (25 kg (55 lb.) or greater).
When removing heavy parts, be sure to prop them up before removing them. When
lifting them with a crane, be careful to balance them properly.
Operating with loads suspended with the crane is dangerous. Place loads on a
stand and check for safety.
When attaching the attachments, failure to follow proper procedures could result in
serious damage. Consult with a Gehl dealer beforehand.
158
OPTIONS
General Precautions
WARNING
Long attachments reduce machine stability. When traveling down steep slopes or
turning on slopes, the machine may loose its balance and tip over.
The following operations are particularly dangerous. Do not perform them.
Traveling down slopes Traveling across slopes Turning on slope
with the attachment lifted
When heavy attachments are installed, the overrun (the distance from where the
operation to stop traveling is performed until traveling stops completely) increases
and mistakes in judgment may result in the attachment hitting surrounding objects.
Allow for plenty of room between the attachment and obstacles.
In addition, the natural drop (the gradual dropping of the attachment under its own
weight when it is stopped in midair) also increases when heavy attachments are
installed.
159
160
INDEX
161
INDEX
A~D
B D
Be careful not to get crushed or cut ........................... 11 Daily Inspection .......................................................... 58
Be careful with fluids under pressure ......................... 29 Daily Inspection (Every 10 Hours) ........................... 102
Be careful with grease under pressure ...................... 29 Danger of flying objects ............................................. 22
Be careful with hot and pressurized components ........... 28 Disconnect the battery ............................................... 30
Be careful with hot cooling systems ........................... 29 Disposing of wastes ................................................... 31
Before Starting Operation .......................................... 60 Do not allow unauthorized personnel in the work
Before Starting the Engine ......................................... 61 area ........................................................................ 25
Bleeding the Air from the Fuel System ..................... 137 Do not carry the bucket over the heads of people ........... 19
Do not drive into materials at high speed ................... 19
Do not enter soft ground ............................................ 21
C
Do not permit riders on the machine .......................... 16
Caution against the falling of an unstable load .......... 19 Do not suddenly stop or lower the working
Cautions ..................................................................... 81 equipment .............................................................. 20
Cautions after Completing Operations ....................... 79 Doors and Covers ...................................................... 38
Cautions on Maintenance .......................................... 88 Draining the Fuel Tank ............................................. 113
162
INDEX
E~I
163
INDEX
I~P
K
N
Keep a safe distance from electrical power lines ........ 20
Keep your body inside the operators cab ................. 16 Names of Components .............................................. 36
Know the working area .............................................. 12 Never modify the machine ......................................... 11
Never remove safety equipment .................................. 9
L
O
Left Control Lever ...................................................... 51
Lever Pattern ............................................................. 62 Observe all safety rules ............................................... 8
Levers and Pedals ..................................................... 50 Operate on snow or ice with extra care ..................... 19
Lift Arm Stop .............................................................. 40 Operate the machine only from the operators seat ........ 16
Light Switches ............................................................ 49 Operating Precautions ............................................... 16
Load and unload the machine safely ......................... 24 Operating Procedures ................................................ 70
Loaders are NOT designed for lifting loads ............... 22 Operating Range ...................................................... 154
Loading and Unloading .............................................. 84 Operating the Auxiliary Hydraulics ............................. 69
Long-term Storage ................................................... 130 Operating the Left Control Lever ................................ 65
Lubricating the Levers .............................................. 128 Operating the Right Control Lever ............................. 68
Lubricating the Working Equipment ......................... 106 Operation ................................................................... 59
Operations Possible with this Machine ...................... 76
Options ..................................................................... 157
M Other Symptoms ...................................................... 142
Machine Description .................................................... 3
Machine Dimensions ................................................ 152
P
Machine Operation ..................................................... 62
Main Specifications .................................................. 148 Park safely ................................................................. 23
Maintain three point contact when mounting and Parking ....................................................................... 78
dismounting ........................................................... 14 Parking the Machine .................................................. 78
164
INDEX
P~T
165
INDEX
T~W
166
GEHL CONSTRUCTION
WARRANTY
Genuine Gehl parts and labor costs required to repair or replace equipment at
the selling dealers business location.
1. Transportation to selling dealers business location or, at the option of the Original
Retail Purchaser, the cost of a service call.
2. Used equipment.
3. Components covered by their own non-Gehl warranties, such as tires, trade
accessories and engines.
4. Normal maintenance service and expendable, high wear items.
5. Repairs or adjustments caused by: improper use; failure to follow recommended
maintenance procedures; use of unauthorized attachments; accident or other
casualty.
6. Liability for incidental or consequential damages of any type, including, but not
limited to lost profits or expenses of acquiring replacement equipment.
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer and birth defects or other reproductive harm.
Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm. Wash hands after handling battery.
Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 U.S.A.
www.gehl.com