Gehl CTL55 Operator'S Manual Download

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MAINTENANCE

144

Every 1000 Hours

Replacing the Hydraulic Oil and
Cleaning the Suction Strainer

WARNING

�

Stop the engine and allow the

machine to cool before performing
maintenance.
• The engine, hydraulic lines and many

other  parts  of  the  machine  are  hot
directly  after  the  engine  is  stopped.
Touching  these  parts  will  cause
burns.

• The hydraulic ﬂuid is also hot and

under high pressure.

Be careful when loosening caps and

plugs. Working on the machine under
these conditions could result in burns
or injuries due to hot oil spraying
out.

�

Oil may spray out if caps or ﬁlters are

removed or pipes disconnected before
releasing the pressure in the hydraulic
system.
• When removing plugs or screws or

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

1. Open the rear door.
2. Drain the coolant.
Refer to page 142, “Cleaning the Engine

Cooling System.”

3. Place a pan for catching the waste oil

under the drain plug (7).

4. Loosen the drain plug (7) and drain the

hydraulic oil.

5. Remove the bolts (a) and open the radiator

/ oil cooler (b).

6. Disconnect the hoses that are connected

to the radiator / oil cooler (b).

7. Temporarily suspend the radiator / oil

cooler (b).

Summary of Contents for CTL55

Page 1: ...CTL55 CTL65 CTL75 CTL85 Compact Track Loader OPERATOR S MANUAL Revision E 09 10...

Page 2: ...f this machine can cause injury or death Readandunderstandthismanualbeforeperforminganyoperation inspection or maintenance on this machine Always store this manual where it is ready available preferab...

Page 3: ...n 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 situation...

Page 4: ...r 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...

Page 5: ...ust 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 rst 100 hours as in...

Page 6: ...4...

Page 7: ...5 CONTENTS Introduction 2 Machine Description 3 Safety 7 Controls 39 Operation 69 Transport 95 Maintenance 101 Troubleshooting 155 Speci cations 169 Options 179 Index 193...

Page 8: ...6...

Page 9: ...eneral Precautions 8 Preparing Precautions 15 Starting Precautions 17 Operating Precautions 19 Stopping Precautions 26 Transporting Precautions 27 Maintenance Precautions 28 Safety Signs Decals 35 SAF...

Page 10: ...mask when using grinders hammers or compressed air because metal fragments or other objects can y and cause serious injury Use hearing protection when operating the machine Loud prolonged noise can c...

Page 11: ...sinvolvedinsiteclearing 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 fa...

Page 12: ...uids and materials in a safe reproof 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...

Page 13: ...or defective parts be found repairs must be made immediately Engine exhaust leaks can cause res Do not operate the machine until the exhaust leak is repaired 10 During daily operation of the machine...

Page 14: ...he 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 re Do not aim the nozzle at the ames In order to put o...

Page 15: ...estos 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 mate...

Page 16: ...nal 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 Gehlwillnotberesponsibleforanyinju...

Page 17: ...off the working area and prohibit entry to unauthorized persons Whenworkinginwaterorcrossingshallow streams or creeks check the depth of the water the rmness of the ground and the speed of the curren...

Page 18: ...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 re...

Page 19: ...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 w...

Page 20: ...nd 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 spee...

Page 21: ...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 ma...

Page 22: ...witch 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 o...

Page 23: ...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 slope...

Page 24: ...g 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 t...

Page 25: ...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...

Page 26: ...s 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 safel...

Page 27: ...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...

Page 28: ...at 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...

Page 29: ...load binders Transport the machine safely Know and follow the safety rules vehicle code and traf c laws when transporting the machine Consider the length width height and weight of the truck with the...

Page 30: ...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 t...

Page 31: ...c control components sensors connectors or the operator s compartment Stop the engine before performing maintenance Avoid lubrication or mechanical adjustmentswiththemachineinmotionor with the engine...

Page 32: ...ported Disconnecting or loosening any hydraulic line hose tting or component or a parts failure can cause the lift arms to drop Service the lift arm stop if damaged or if parts are missing Using a dam...

Page 33: ...use fuel for cleaning purposes Usethecorrectfuelgradefortheoperating season Handling of hoses Fuel oil and hydraulic uid leaks can cause a re Do not twist bend or hit the hoses Never use twisted bent...

Page 34: ...be removed within a few hours by a doctor familiar with this type of injury Release all pressure before working on the hydraulic system Oilmaysprayoutifcapsor ltersareremoved or pipes disconnected be...

Page 35: ...n working with batteries Batteries generate ammable and explosive gases Keep arcs sparks ames and lighted tobacco away Usea ashlighttocheckbatteryelectrolyte level Stop the engine and shut off electri...

Page 36: ...Keep all safety signs clean and legible Replace all missing illegible or damaged safety and warning signs Vibrations to which the operator is subjected According to the results of the tests carried ou...

Page 37: ...or the personal safety of the operator and co workers Please take this manual walk around the machine and note the content and location of these safety signs Review these signs and the operating instr...

Page 38: ...SAFETY 36 Safety Signs Decals...

Page 39: ...37 SAFETY Safety Signs Decals...

Page 40: ...SAFETY 38 Safety Signs Decals...

Page 41: ...39 Names of Components 40 Doors and Covers 42 Seat and Seat Belt 48 Instrument Panel 52 Switches 54 Levers and Pedals 59 Accessories 61 CONTROLS...

Page 42: ...S 4 Safety bar 5 Front light 6 Lift arm stop 7 Left control lever 8 Auxiliary hydraulic lines 9 Lift arm 10 Bucket cylinder 11 Bucket 12 Fuel ller cap 13 Arm cylinder 14 Travel motor 15 Rubber track 1...

Page 43: ...ay 6 Front wiper switch option 7 Rear wiper switch option 8 Safety bar 9 Seat 10 Auxiliary hydraulic buttons 11 Instrument panel 12 Float button 13 Horn button 14 Right control lever 15 Ignition switc...

Page 44: ...grasp the handle securely and move the door slowly Opening the door suddenly could result in it hitting your head or your hands or feet could get caught Preparation before Opening and Closing the Cab...

Page 45: ...43 CONTROLS Doors and Covers Side Window CTL55 1 Grasp the catch 8 unlock it and open the side window 2 To close the side window close it until a click is heard 8 T9C010...

Page 46: ...al position 2 Close the rear door 2 and press it until a click is heard at the front Doors and Covers Engine Hood WARNING Before opening the engine hood be sure to stop the engine If your hands or too...

Page 47: ...to remove the rear window In case of emergency Kick out the rear window Note that the glass may break Be careful not to be injured In case of need 1 Pull off ring A and remove the tip of the rubber we...

Page 48: ...or attachment 2 Lower the lift arms to the ground and stop the engine 3 Align the hook 4 on the tip of the locking pin 1 with the locking pin 4 Support the lift arm stop 2 by hand and pull out the loc...

Page 49: ...rt the locking pin 1 through lift arm stop and bracket 8 To prevent the locking pin 1 from falling off set the hook 4 at a right angle to the locking pin Fuel Filler Cap WARNING Do not smoke or permit...

Page 50: ...k will be locked in that position Adjustment range 15 deg B Fore and aft adjustment 1 Pull on lever 2 and slide the seat rearward or forward to bring it to the optimum position for operating the machi...

Page 51: ...into the seat 2 Pull on adjuster A in the manner shown in the diagram to adjust the seat belt to the desired length 3 Make sure that the belt is not twisted and then insert the tongue plate B into th...

Page 52: ...slide the seat rearward or forward to bring it to the optimum position for operating the machine 2 Releasethelever 2 atthedesiredposition and the seat will be locked there Adjustment range 15 steps 1...

Page 53: ...aise your torso and sit back rmly into the seat 2 Pull the seat belt to the desired length 3 Make sure that the belt is not twisted and then insert the tongue plate A into the buckle B of the seat bel...

Page 54: ...coolant temperature rises abnormally while the engine is running 3 Battery Charge Warning Lamp This lamp ashes and an alarm is sounded if a problem arises in the charging system while the engine is r...

Page 55: ...e operation The red range indicates overheating 10 Fuel Gauge This gauge indicates the amount of fuel in the tank Be sure to top off the tank before running out of fuel C4B013 C4B014 L3B019 L3B020 L3B...

Page 56: ...oat button and move the right control lever forward once To turn off the detent mode move the right control lever rearward When in the Float mode the bucket can follow the contour of the ground witho...

Page 57: ...counterclockwise and remove it 2 To install the female connector or the cap 1 align the notches and turn it clockwise to tighten 14P connector M HDB34 18 14PN 059 Total max working current 20A Max wor...

Page 58: ...xiliary Hydraulics Slider Switch Proportional control Proportional control allows for slow to fast movement of auxiliary functions Example If you move the slider switch half way the auxiliary function...

Page 59: ...mps go out Refer to page 63 High Flow Hydraulic System O OFF I ON Detent Mode Switch D This switch changes the function of auxiliary hydraulic button A Normally auxiliary hydraulic owisonwhilebutton A...

Page 60: ...ht switch O Off I Tail lights turn on Wiper Switches Option IMPORTANT If no washer uid is discharged do not operate the washer Doing so may damage the pump IMPORTANT Operating the wiper with no moistu...

Page 61: ...ath Be careful not to touch the control levers and pedal when lowering or raising the safety bar This device is for locking the control levers pedal and selector detent mode and high ow switches When...

Page 62: ...r to page 77 Operating the Left Control Lever Levers and Pedals Right Control Lever WARNING Be sure to check which pattern of lever control arrangement you are operating with before beginning operatio...

Page 63: ...ries Interior Light Option IMPORTANT The battery charge will decrease if the interior light is left on for long periods of time with the engine stopped Turn the light off when leaving the machine O Of...

Page 64: ...elease sleeve slides forward on the female coupler Disconnecting Hold the male coupler Retract the sleeve on the female coupler until the couplers disconnect Releasing Residual Pressure Connecting Pus...

Page 65: ...rain which need to be connected to the small port T 2 Turn on the High Flow switch E green light is ON 3 Press the auxiliary hydraulic switch A or slide the slider switch to the left side A Refer to p...

Page 66: ...64 MEMO...

Page 67: ...65 MEMO...

Page 68: ...66 MEMO...

Page 69: ...67 MEMO...

Page 70: ...68...

Page 71: ...69 Before Starting Operation 70 Starting and Stopping the Engine 71 Machine Operation 74 Operating Procedures 82 Parking the Machine 90 Operating in Cold Weather 91 Using Rubber Tracks 92 OPERATION...

Page 72: ...point contact with the handholds and steps while getting on and off the machine Keep steps and platform clean Never use the control levers as hand holds Walk Around Inspection Perform the walk around...

Page 73: ...ion then perform the following inspection All the warning lamps ash and an alarm is sounded for 2 seconds The instruments also start functioning After 2 seconds only the battery charge warning lamp 3...

Page 74: ...utomatically returns to the ON position 4 Check that the warning lamps are off 5 Return the throttle lever to idle position and warm up the engine Refer to page 73 Warming Up the Engine Starting in Co...

Page 75: ...o idle position and idle the engine for about 5 minutes with no load Stopping the Engine IMPORTANT Do not stop the engine suddenly when operating with heavy loads or at maximum speed Doing so maycause...

Page 76: ...operating with before beginning operations The explanations in this manual are for this pattern Crawler Forward Crawler Reverse Left Spin Turn Right Spin Turn Left Pivot Turn Right Pivot Turn Right Pi...

Page 77: ...122 to 176 F but if operations must be performed at lower temperatures heat up the hydraulic oil to at least 20 C 68 F Normal Warm up 1 Run the engine at medium speed for about 5 minutes with no load...

Page 78: ...if there is a problem 1 Check that the warning lamps and instruments are as follows Are all the warning lamps off Is the water temperature gauge needle within the green range 2 Check that there are no...

Page 79: ...gerous Before backing up visually check for safety to the rear Backing up without checking could result in contact with a worker or obstacle If unavoidable while traveling when operating the working e...

Page 80: ...h to 2nd high speed and press it again to return to 1st speed low speed Pivot Turn Turning to the left To turn forward to the left Tilt the left control lever forward to the left To turn rearward to t...

Page 81: ...the safety bar is lowered the machine will move suddenly and may cause serious injury or death CAUTION Never bring the machine to a sudden stop except in the case of a true emergency Stop as gently as...

Page 82: ...eration after the bucket cylinder has reached fall stroke will result in the lift arms rising or stopping without going lower Be cautious of any unexpected movement of the lift arms Use the right cont...

Page 83: ...direction of the hydraulic oil ow by setting ow selector switch C ON to return the oil in the b port line directly to the hydraulic tank Refer to page 56 Flow Selector Switch When using detent mode sw...

Page 84: ...rking equipment and there is the danger of the machine tipping over Keep the bucket as low as possible during travel Do not travel or attempt to change directions with the bucket raised Travel at a sp...

Page 85: ...he tracks to come off Donotexceedtheloader sratedoperating capacity Do not use buckets or attachments that exceed the loader s operating capacity Do not use the downward force of the bucket to drive p...

Page 86: ...ders and this may damage them Cautions on Operating Cautions on Traveling Travelingoverobstacles rocks stumps etc may subject the machine to strong shocks and result in damage Avoid traveling over obs...

Page 87: ...e submerged Allowable water depth In water only use the machine up to a depth at which the water comes up to the bottom of the chassis When greasing places used under water for long periods of time ap...

Page 88: ...set the position of the left control lever tohalforlessbeforegoingdown Going down a slope too fast will lead to loss of control When going up or down slopes having a gradient of 15 degrees or more tra...

Page 89: ...f the engine stops when traveling down a slope set the control levers and pedal to the neutral position stop the machine and re start the engine Do not open the front door while traveling on slopes if...

Page 90: ...h the material Next tilt the bucket rearward and scoop up the material Grading Tilt the front edge of the bucket down at an angle that is appropriate for the ground hardness then drive the loader forw...

Page 91: ...t drive the loader forward with the lift arms in Float position Lower the bucket onto the ground then put the lift arms in Float position Tilt the bucket forward to stand it on its cutting edge then l...

Page 92: ...ft arm stop Before leaving the machine do the following 1 Set the control levers and pedal to the neutral position 2 Return the throttle lever to idle position and idle the engine at low speed 3 Lower...

Page 93: ...g stuck on the machine as well as the lower chassis from freezing Remove any dirt or water from the chassis In particular water droplets on the hydraulic cylinder rod surfaces could freeze and if dirt...

Page 94: ...ocks may cause the tracks to slip off or be damaged due to rocks getting stuck in them Do not use on the seashore The salt may corrode the metal cores of the tracks Donotletfuel oil saltorchemicalsolv...

Page 95: ...as the tracks tend to slip Use rubber tracks only at temperatures between 25 C to 55 C 14 F to 131 F When storing the rubber tracks for long periods of time 3 months or more do so indoors in a place n...

Page 96: ...OPERATION 94 Using Rubber Tracks Do not change directions when the tracks are slack as shown in the diagram T7E008...

Page 97: ...95 Hoisting the Machine 96 Loading and Unloading 98 Securing the Machine 99 Cautions on Transporting 100 TRANSPORT...

Page 98: ...en hoisting Do not move the machine over the heads of the persons IMPORTANT This hoisting method applles to machines with standard speci cations The center of gravity differs according to the attachme...

Page 99: ...3 1675 65 9 B 930 36 7 1005 39 6 C 1525 60 1590 62 6 D 950 37 4 960 37 8 E 575 22 6 635 25 F 585 23 1 440 17 3 G 425 16 7 600 23 6 CTL75 CTL85 A 1660 65 3 1705 67 1 B 940 37 1 950 37 4 C 1720 67 7 189...

Page 100: ...d place chocks stoppers against its tires 2 Fasten the ramps securely to the truck bed so that they will not come off Set the ramps to an angle of 15 or less 3 Move the machine up or down the ramps wi...

Page 101: ...Position 1 Lower the bucket 2 Stop the engine and remove the ignition key 3 Set the safety bar securely to the locked position 4 Set stoppers in front and behind the tracks 5 Put a chain or wire rope...

Page 102: ...d follow the safety rules vehicle code and traf c 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 ro...

Page 103: ...spection Every 10 Hours 116 After First 50 Hours New Machines Only 122 Every 50 Hours 128 Every 100 Hours 134 After First 250 Hours New Machines Only 135 Every 250 Hours 136 Every 500 Hours 138 Every...

Page 104: ...al Have inspection and maintenance procedures not prescribed in this manual performed by a Gehl dealer Always keep the machine clean Always keep the machine clean and wash it before performing inspect...

Page 105: ...eaving 1 or 2 threads at the tip free Disposing of wastes Collect waste uids from the machine in containers Disposing of wastes irresponsibly damages the environment Dispose of oil fuel cooling water...

Page 106: ...gher After rst 50 hrs Every 250 hrs Hydraulic tank Engine cooling system Travel reduction gear Working equipment Cooling water water coolant Gear oil API GL 4 Lithium based grease EP 2 NLGI No 2 Every...

Page 107: ...erformance and optimum engine life To prevent fuel ow problems in cold weather use diesel fuel with a pour point of at least 12 C 10 F below the lowest expected ambient temperature Minimum cetane numb...

Page 108: ...rs Engine oil lter Cartridge After rst 50 hrs Every 250 hrs Air cleaner Outer Element Every 250 hrs or when the air cleaner warning lamp lights Do not clean Pilot line lter Element 180324 CTL55 195566...

Page 109: ...rench 14 17 4 Wrench 19 22 5 Wrench 24 27 6 Wrench 30 7 Wrench 41 8 Screwdriver 9 L type wrench 19 10 Adjustable wrench 250 mm 11 Pliers 200 mm 12 Hammer 3 4 13 Allen wrench 5 mm 14 Allen wrench 6 mm...

Page 110: ...bolts alternately top bottom left then right or in 2 or 3 times so that they are tightened uniformly Thread Coarse Fine Head width b Size a X Pitch Torque General Connection Points mm mm N m ft lb 10...

Page 111: ...hem 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...

Page 112: ...117 Inspecting the water separator 117 Inspecting the fuel level 118 Inspecting the hydraulic oil level and replenishing 119 Lubricating the working equipment 120 After First 50 Hours New Machines Onl...

Page 113: ...lts nuts 140 Every 1000 Hours Cleaning the engine cooling system 142 Replacing the hydraulic oil and cleaning the suction strainer 144 Inspecting and adjusting the engine valve clearance 146 Retighten...

Page 114: ...MAINTENANCE 112 Maintenance Log Date Hours Service Procedure...

Page 115: ...113 MAINTENANCE Maintenance Log Date Hours Service Procedure...

Page 116: ...fore starting the engine look around the machine and lower chassis clean any combustible materials off high temperature parts of the engine and inspect for irregularities such as oil leakage water lea...

Page 117: ...or oil leakage from the travel motor 10 Check the ROPS cab and guard for damage and loose nuts and bolts Check the rearview mirrors for dirt damage and angle adjustment 11 Check the decals for dirt an...

Page 118: ...gs when the coolant is hot Stop the engine let the engine and radiator cool and loosen the radiator cap or drain plugs slowly Inspection 1 Open the rear door 2 Inspect the quantity of coolant in the r...

Page 119: ...the oil supply cap 2 4 Start the engine run it at low idle for about 3 minutes then stop it 5 After about 10 minutes inspect the oil level Inspecting the Water Separator WARNING Stop the engine and a...

Page 120: ...ecting the Fuel Level WARNING Do not smoke or permit open ames while fueling or near fueling operations Stop the engine in a well ventilated place when adding fuel Clean up spilled fuel immediately Do...

Page 121: ...l in the hydraulic oil level inspection position shown in the diagram Hydraulic oil level inspection position 1 Start the engine and run it at low speed 2 Fully retract the lift arms and bucket cylind...

Page 122: ...Hours Lubricating the Working Equipment 1 Set the machine to the lubrication position shown in the diagram above ground the bucket then stop the engine 2 Use the grease gun to lubricate the grease tti...

Page 123: ...121 MEMO...

Page 124: ...se conditions could result in burns or injuries due to hot oil spraying out Oil may spray out if caps or lters are removed or pipes disconnected before releasing the pressure in the hydraulic system W...

Page 125: ...these conditions could result in burns 1 Open the engine hood 2 Tilt up the ROPS Refer to page 151 Tilting Up the ROPS 3 Remove the oil supply cap 2 4 Place a pan under the under cover 3 5 Loosen the...

Page 126: ...lter by hand 13 Tighten one more turn after the lter packing comes in contact with the surface 14 Supply oil up to the upper limit H of the dipstick 1 Problems could arise if the oil level is either...

Page 127: ...r pulley 3 and check the tension about 98N or 22 lbs The slack A should be about 7 to 10 mm 0 28 to 0 4 in 4 Inspect the fan belt 4 and replace it if there are cuts or cracks the belt is worn and touc...

Page 128: ...e pressure in the hydraulic system When removing plugs or screws or disconnecting hoses stand to the side and loosen slowly to gradually release the internal pressure before removing 1 Tilt up the ROP...

Page 129: ...127 MEMO...

Page 130: ...en the grease discharge valve slowly Do not put your face arms legs or body in front of the grease discharge valve If no grease is expelled when the grease discharge valve is loosened there is a probl...

Page 131: ...valve 1 3 Check the track tension Decreasing the tension 1 Remove the cover 2 Use the wrench to slowly loosen the grease discharge valve 1 and drain the grease If the grease does not drain easily mov...

Page 132: ...hen the uid level is below the lower level Doing so will hasten the deterioration of the internal portions of the battery and shorten the battery life and can also cause rupturing or an explosion Batt...

Page 133: ...to swell and the plate appears distorted Level too low B The uid does not reach up to the bottom edgeofthesleeve 3 sotheplateappears laminar not distorted 4 Also check the terminals for looseness and...

Page 134: ...r cap 2 2 Place a pan under the drain plug 3 3 Remove the cover 4 4 Remove the drain plug 3 and drain the water and sediment from the bottom of the tank 5 Tighten the drain plug 3 6 While watching the...

Page 135: ...lowermost position 1 Park the machine on rm level ground and remove the bucket 2 Retract the bucket cylinders and lift arm cylinders to the minimum length 3 Inspect the adjusting bolts 1 and lock nut...

Page 136: ...e 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 Tight...

Page 137: ...e travel motor reduction gears case may cause oil or the plug to y out Loosen the plug slowly to release the pressure IMPORTANT If the percentage of the travel time within the total operating time is...

Page 138: ...not dust could be drawn into the cylinder damaging the engine IMPORTANT Besuretolocktheaircleaner after completing the maintenance 1 Open the engine hood 2 Push down the lever 6 to tilt up the air cl...

Page 139: ...ater cover the electrical system to prevent water from getting in IMPORTANT When operating the machine in very dusty places inspection and maintenance should be performed every day 1 Open the rear doo...

Page 140: ...CTL65 CTL 75 1 Open the engine hood CTL85 1 Tilt up the ROPS 2 Place a pan under the lter 1 3 Using a lter wrench turn the lter 1 counterclockwise and remove it 4 Clean the surface of installation of...

Page 141: ...ic Oil Return Filter Refer to page 122 Replacing the Hydraulic Oil Return Filter Replacing the Pilot Line Filter Refer to page 126 Replacing the Pilot Line Filter Replacing the Travel Motor Gear Oil R...

Page 142: ...ound for work Work as a 2 person team and stay in communication with each other One person must sit at the operator s seat and stop the engine whenever necessary and must take care not to touch the le...

Page 143: ...he engine extend the bucket cylinders to the maximum length and then stop the engine 10 Adjust each plate 9 right left and the stopper bolt 8 so that they evenly contact each other 11 Start the engine...

Page 144: ...tand at the back of the machine while the engine is running Do not remove the radiator cap or drain plugs when the coolant is hot Stop the engine let the engine and radiator cool and loosen the radiat...

Page 145: ...is 13 Close the radiator cap 3 14 Warmuptheengine Usetheinstruments to check that there are no irregularities in the cooling system at this time 15 Raise the coolant temperature to at least 90 C 195 F...

Page 146: ...injuries due to hot oil spraying out Oil may spray out if caps or lters are removed or pipes disconnected before releasing the pressure in the hydraulic system When removing plugs or screws or discon...

Page 147: ...ange 9 20 Tighten the drain plug 7 21 Replenish hydraulic oil up to the middle of the sight gauge 2 through the port for plug 1 22 Tighten the plug 1 23 Follow the procedure Bleeding the air below to...

Page 148: ...it performed by a Gehl dealer Retightening the Engine Cylinder Head Bolts This operation requires experience Have it performed by a Gehl dealer Cylinders 1 Start the engine and run it at low idle for...

Page 149: ...n requires experience Have it performed by a Gehl dealer Inspecting and Cleaning the EGR Valve Lead Valve and Cooler This operation requires experience Have it performed by a Gehl dealer MAINTENANCE L...

Page 150: ...ck levers 2 are in the unlocked position 2 While sitting in the operator s seat with the safety bar down start the engine and tilt the quick hitch 3 forward 3 Move the machine slowly forward and raise...

Page 151: ...achment and investigate the cause Removal 1 Raise the bucket 1 or attachment 25 to 50 mm 1 to 2 in off the ground 2 Stop the engine raise the safety bar and release the seat belt 3 Pull both attachmen...

Page 152: ...ount section of the boot 1 and turn it upwards 2 Wipe off the old grease 3 Apply grease to points A and B 4 Re install the boot 1 Inspecting and Replenishing the Windshield Washer Fluid Use a windshie...

Page 153: ...und and stop the engine 2 Set the safety bar to the lock position 3 Remove a R pin and remove the stopper pin B 4 Remove the lock bolts A 5 Slowly raise the ROPS 6 Insert the stopper pin B into the bo...

Page 154: ...ug Replace if the height of the lugs A is 5 mm 0 2 in or less 2 Steel cord Replace if the steel cord is exposed over 2 or more links Replace if half or more of the steel cords on one side are cut 3 Me...

Page 155: ...7 Apply rust prevention oil to the hydraulic cylinder rods 8 Disconnect the cable from the battery s negative terminal and cover the battery to prevent freezing During storage WARNING Donotoperatethee...

Page 156: ...154...

Page 157: ...Malfunctions 156 If the Engine Overheats 157 If the Battery Goes Dead 158 After the Fuel Runs Out 159 If a Fuse Blows 160 If a Warning Lamp Flashes 162 Other Symptoms 164 To Lower the Lift Arms 166 T...

Page 158: ...ces noise if excessive force is applied to the working equipment and when the stroke end is reached At times of combined operation of bucket and lift arm lowering continuation of the combined operatio...

Page 159: ...Steam comes from the engine compartment Procedure 1 Park the machine in a safe place 2 Inspect whether the coolant temperature warning lamp is ashing or if there is steam coming out when the engine ho...

Page 160: ...ne IMPORTANT Usejumpercablesandclips of a size suited to the battery s capacity Donotuseddamagedorcorrodedjumper cables and clips IMPORTANT The rescue vehicle s battery must have the same capacity as...

Page 161: ...batteries Bleeding the Air from the Fuel System IMPORTANT NEVER use the starter motor to crank the engine in order to prime the fuel system This may cause the starter motor to overheat and damage the...

Page 162: ...own CTL55 CTL65 CTL75 Protected circuit Capacity Protected circuit 15A Front light 30A Lever lock Radio ACC 10A Instrument cluster 10A Immobilizer ACC 5A Controller service tool 10A Feed pump Sensor 1...

Page 163: ...pe fusible links 1 might be blown Open the rear door and inspect If the fusible link is blown please contact your dealer Note A fusible link is a large piece of fuse wiring that is mounted in a circui...

Page 164: ...er to page 117 Inspecting and Replenishing the Engine Oil This indicates the coolant temperature has risen irregularly and the engine is overheating Refer to page 157 If the Engine Overheats This indi...

Page 165: ...ngine and replace the lter Replace the lter immediately if the lamp ashes Refer to page 126 Replacing the Pilot Line Filter IMPORTANT Continuing to operate the machine while the lamp is lit could dama...

Page 166: ...type Stones or foreign objects are stuck Stones or foreign objects are stuck Fuse is blown Safety bar is raised Fuse is blown Insuf cient hydraulic oil Add grease Refer to page 150 Lower the safety ba...

Page 167: ...ter in fuel system Crawlers are too loose Excessive engine oil Insuf cient fuel Air cleaner is clogged Low quality fuel is being used Engine is overheating Damage in muf er Add fuel Refer to page 118...

Page 168: ...arms lowers slowly Do not turn the screw more than the speci ed amount CTL55 CTL65 CTL75 CTL85 1 Tilt up the ROPS 2 Put mark M on the plug of the port relief valve 1 and set screw 2 3 Grippingthesets...

Page 169: ...d below to tow light weight objects or the machine itself if it is stuck in the mud and not able to get out on its own IMPORTANT Do not tow a machine if its engine does not start or if the machine doe...

Page 170: ...168...

Page 171: ...169 Main Speci cations 170 Machine Dimensions 174 Operating Range 176 SPECIFICATIONS...

Page 172: ...racks 32 1 4 65 32 8 4 75 Sound power level LWA 103 Sound pressure level LpA 81 Manufacturer and model Yanmar 4TNV84T ZKTBL Rated output kW min 1 hp rpm 38 2 2800 51 2 2800 Displacement mI cu in 1995...

Page 173: ...racks 35 7 5 18 Sound power level LWA 103 Sound pressure level LpA 85 Manufacturer and model Yanmar 4TNV98 ZNTBL Rated output kW min 1 hp rpm 50 1 2500 67 1 2500 Displacement mI cu in 3319 203 Starter...

Page 174: ...6 7 21 Rubber tracks 28 9 4 2 28 8 4 18 Sound power level LWA 104 Sound pressure level LpA 85 Manufacturer and model Yanmar 4TNV98T ZNTBL Rated output kW min 1 hp rpm 61 9 2500 83 2500 Displacement m...

Page 175: ...58 Sound power level LWA 105 Sound pressure level LpA 85 Manufacturer and model KUBOTA V3800DI T E3B TLTU 1 Rated output kW min 1 hp rpm 68 3 2600 91 6 2600 Displacement mI cu in 3769 230 Starter V k...

Page 176: ...SPECIFICATIONS 174 Machine Dimensions...

Page 177: ...1390 54 7 2130 83 9 310 12 1 1580 62 2 320 12 6 1430 56 3 980 38 6 1675 66 0 510 20 0 30 Standard Bucket Rubber Tracks CTL65 CTL85 CTL75 3740 147 2 2980 117 3 1495 58 9 2270 89 4 325 12 8 1770 69 7 4...

Page 178: ...SPECIFICATIONS 176 Operating Range T7K0021 F H C A D B G E...

Page 179: ...61 4 1755 69 1 31 3905 153 8 3030 119 3 2370 93 4 730 28 8 2080 82 0 1375 54 1 1590 62 7 30 Standard Bucket Rubber Tracks CTL65 CTL85 CTL75 4080 160 7 3120 122 9 2405 94 8 875 34 4 2295 90 4 1500 59 1...

Page 180: ...178...

Page 181: ...179 General Precautions 180 Air Conditioner CTL55 182 OPTIONS...

Page 182: ...removing or installing a backhoe attachment place it in a stable position so that it does not tip over Due to the risk of loads falling and or hitting people do not allow unauthorized personnel in the...

Page 183: ...distance from where the control movement to stop traveling is performed until traveling stops completely increases and mistakes in judgment may result in the attachment hitting surrounding objects Al...

Page 184: ...of the windows If this happens either turn off the air conditioner or turn the temperature control dial clockwise to increase the inside temperature Mist may blow out of the air outlets This is not a...

Page 185: ...drier 4 Foot outlets 5 Rear outlets 6 Control panel 7 Compressor 8 Air conditioner unit 9 Inner lter 10 Outer lter Control Pannel 11 Air conditioner switch 12 Temperature control dial 13 Fan switch Ai...

Page 186: ...leakage of refrigerant gas from the compressor s seal operate the air conditioner at least once a week regardless of the season Note The air conditioner will not function if the temperature in the cab...

Page 187: ...esired positions Cooling CAUTION Excessive cooling can be harmful to your health It is best to keep the air inside the cab only about 5 to 6 C 9 to 11 F cooler than the outside air If the loader has b...

Page 188: ...ncreases and fog may form on the outside of the windows If this happens either turn the air conditioner OFF or turn the temperature control dial clockwise WARM After starting the engine turn the air c...

Page 189: ...conditioner s cooling capacity If the belt is slack it will slip and vibrate shortening its service life and reducing the air conditioner s cooling capacity The belt should also not be too tight Adju...

Page 190: ...Cleaning CAUTION Wear safety glasses when using compressed air 1 Blow dry compressed air 138 kPa 20 psi or less directly on the lter from the inside moving up and down along the creases Be sure to kee...

Page 191: ...ge 190 Condition of the refrigerant CAUTION The high pressure pipe becomes hot 80 to 120 C 176 to 248 F so be careful not to burn yourself when inspecting the refrigerant level 4 Open the radiator Ref...

Page 192: ...High pressure pipe 1 hot 80 to 120 C 176 to 248 F low pressure pipe 2 cold 8 to 15 C 46 to 59 F Clear difference in temperature between the pipes No irregularities Flow of bubbles can be seen constan...

Page 193: ...191 MEMO...

Page 194: ...192...

Page 195: ...193 INDEX...

Page 196: ...ing Operation 70 Before Starting the Engine 71 Bleeding the Air from the Fuel System 159 C Cab Door CTL55 42 Caution against falling unstable loads 22 Caution on refrigerant gas 182 Cautions after Com...

Page 197: ...13 Expendables 106 F Fan Switch 184 Fire prevention 10 Float Button 54 Fuel Filler Cap 47 G General 102 General Precautions 8 General Precautions 180 H Handling asbestos dust 13 Handling of hoses 31 H...

Page 198: ...55 CTL75 CTL85 147 Inspecting the Water Separator 117 Inspecting While Sitting in the Operator s Seat 115 Inspection After Warm up 76 Inspection and Checks After Stopping the Engine 90 Instrument Pane...

Page 199: ...ng Attachments 181 Precautions on Safety 180 Precautions when passing through tunnels or near high walls 24 Prepare the work area 29 Preparing for Cold Weather 91 Preparing Precautions 15 Product usag...

Page 200: ...Not Malfunctions 156 T Temperature Control Dial 184 Throttle Lever 59 Throttle Pedal 59 Tightening Torques 108 Tilting Up the ROPS 151 To Lower the Lift Arms 166 Tools 107 Towing 167 TRANSPORT 95 Tra...

Page 201: ...TO APPLY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW GEHL WARRANTY DOES NOT INCLUDE 1 Transportation to selling deale...

Page 202: ...ause cancer and birth defects or other reproductive harm Wash hands after handling battery WARNING THIS OPERATOR S MANUAL IS PROVIDED FOR OPERATOR USE DO NOT REMOVE FROM THIS MACHINE Do not start oper...

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Gehl CTL55, Operator'S Manual

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