Gehl CTL60 Operator'S Manual Download Page 93

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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 0

C, add coolant (antifreeze). Follow the

coolant manufacturer’s instructions to determine the mixture ratio.

Expendables

Replace expendables such as filters and elements periodically, referring to the table below.

Item

Part name

Part No.

Replacement interval

Return filter

Cartridge

181607

After first 50 hrs.
Every 500 hrs.

Fuel filter

Cartridge

Every 500 hrs.

Engine oil filter

Cartridge

After first 50 hrs.
Every 250 hrs.

Air cleaner

Outer Element

Every 1000 hrs.

Line filter

Element

180324

CTL60
182130
CTL70
182134
CTL80
182088

CTL60
182131
CTL70
182136
CTL80
425-34635

CTL60
182132
CTL70
182137
CTL80
181879

Inner Element

Every 1000 hrs.

CTL60
182133
CTL70
182138
CTL80
181881

CTL70
Feed pump filter

Repair kit

Every 500 hrs.

182135

Summary of Contents for CTL60

Page 1: ...CTL60 CTL70 CTL80 Compact Track Loader OPERATOR S MANUAL...

Page 2: ...achine can cause injury or death Read and understand this manual before performing any operation inspection or maintenance on this machine Always store this manual near at hand preferably on the machi...

Page 3: ...sed to alert against operators and maintenance personnel about situations which can result in possible damage to the machine and its components It is impossible to foresee every possible circumstance...

Page 4: ...7A002 1 T7A0012 Manual storage A compartment for storing this manual is provided at the position shown on the diagram below 1 Insert the starter key and turn it counterclockwise to unlock the cover 1...

Page 5: ...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...

Page 6: ...4...

Page 7: ...5 CONTENTS Introduction 2 Machine Description 3 Safety 7 Controls 35 Operation 57 Transport 83 Maintenance 87 Troubleshooting 133 Specifications 147 Options 157 Index 161...

Page 8: ...6...

Page 9: ...eneral Precautions 8 Preparing Precautions 12 Starting Precautions 14 Operating Precautions 16 Stopping Precautions 23 Transporting Precautions 24 Maintenance Precautions 25 Safety Signs Decals 32 SAF...

Page 10: ...ch on controls or in moving parts Do not wear oily or fuel stained clothing that can catch fire Wear a hard hat safety shoes safety glasses filter mask heavy gloves ear protection and other protective...

Page 11: ...bricks small concrete blocks and hand encountered in operations such as highway maintenance landscaping and other construction site services Use a signal person and flagman Know and use the hand sign...

Page 12: ...r other flammable material are not stored on the machine Handle all solvents and dry chemicals according to procedures identified on manufacturers containers Work in a well ventilated area Never use f...

Page 13: ...grid The lift arms move close to the ROPS therefore do not stand or lean on the machine Using optional products Consult with a Gehl dealer before installing optional attachments Do not use attachment...

Page 14: ...off the working area and prohibit entry to unauthorized persons When working in water or crossing shallow streams or creeks check the depth of the water the solidity of the ground and the speed of the...

Page 15: ...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 should become trapped inside the...

Page 16: ...he 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...

Page 17: ...d follow the shutdown procedure and report the malfunction Warm up the engine and hydraulics Observe all gauges or warning instruments for proper operation Listen for unusual noises Test engine speed...

Page 18: ...om 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...

Page 19: ...ile traveling Doing so will cause sudden braking and is dangerous Before backing up visually check for safety to the rear Backing up without checking could result in contact with a worker or obstacle...

Page 20: ...uce the engine r p m speed and set the stroke of the left control lever to half or less before going down Going down a slope too fast will lead to loss of control Sudden stopping on a sloped road may...

Page 21: ...stopping or changing directions abruptly Remember that the road shoulder fences etc may be buried in the snow and not visible Lower the bucket when parked on unsure ground conditions Do not carry the...

Page 22: ...safety precautions have been taken Electrocution and death can result from arcing touching or even being close to a machine that is in contact with or near an electrical source Maintain the maximum p...

Page 23: ...nches 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 a speed at which the machine can be...

Page 24: ...abruptly to the wire rope Use safety gloves when handling the wire rope Make sure there is an operator on the machine being towed as well as on the machine that is towing Never tow on slopes Do not le...

Page 25: ...etc so that the machine can easily be seen even at night to avoid collision with other vehicles Before leaving the machine do the following 1 Lower the bucket to the ground 2 Set the safety bar in the...

Page 26: ...h can become slippery Clean the tracks Block the transport vehicle so it can not move Use a signal person when loading and unloading the machine and travel slowly in first gear low speed Never change...

Page 27: ...uel hoses periodically Fuel hoses become weaker over time even if they appear to be in good shape Replace important safety parts whenever an irregularity is found even if it is before the normal time...

Page 28: ...nnectors or the operator s compartment Stop the engine before performing maintenance Avoid lubrication or mechanical adjustments with the machine in motion or with the engine running while stationary...

Page 29: ...Disconnecting or loosening any hydraulic line hose fitting or component or a parts failure can cause the lift arms to drop Service the lift arm stop if damaged or if parts are missing Using a damaged...

Page 30: ...se fuel for cleaning purposes Use the correct fuel grade for the operating season Handling of hoses Fuel oil or hydraulic fluid leaks can cause a fire Do not twist bend or hit the hoses Never use twis...

Page 31: ...ust be removed within a few hours by a doctor familiar with this type of injury Release all pressure before working on the hydraulic system Oil may spurt out if caps or filters are removed or pipes di...

Page 32: ...Use a flashlight to check battery electrolyte level Stop the engine and shut off electrical equipment while inspecting or handling the battery Do not short circuit the battery posts with metal items A...

Page 33: ...w idle to maximum speed and check that no oil or air is leaking from serviced parts Move the controls and check that the machine is operating properly Safety signs Keep all safety signs clean and legi...

Page 34: ...ou 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...

Page 35: ...not operate the machine unless the seat belt is properly fastened around you 1 2 3 4 Read operator s manual Know location and function of controls Keep safety devices working Keep screens and windows...

Page 36: ...PEDAL IS IN NEUTRAL BEFORE STARTING ENGINE SEE OPERATOR S MANUAL 5 4 3 1 2 Death can occur if lift arm stop is not properly utilized DANGER WARNING ALWAYS keep legs arms and body out from between lift...

Page 37: ...35 Names of Components 36 Doors and Covers 38 Seat and Seat Belt 42 Instrument Panel 44 Switches 46 Levers and Pedals 50 Accessories 52 CONTROLS...

Page 38: ...Safety bar 5 Front light 6 Lift arm stop 7 Left control lever 8 Auxiliary hydraulic lines 9 Lift arm 10 Bucket cylinder 11 Bucket 12 Fuel filler cap 13 Arm cylinder 14 Travel motor 15 Crawler belt 16...

Page 39: ...option 7 Front wiper switch option 8 Rear wiper switch option 9 Safety bar 10 Seat 11 Auxiliary pedal If equipped 12 Instrument panel 13 Float switch 14 Horn switch 15 Right control lever 16 Starter...

Page 40: ...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 Opening 1 Insert the starter key and turn it counterclockwise to...

Page 41: ...r 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 Emergency Exit If you should become trapped inside the cab r...

Page 42: ...e on level ground and remove the bucket 2 Lower the lift arms to the ground and stop the engine 3 Remove the rear R pin 4 from the locking pin 1 4 Support the lift arm stop 2 by hand and pull out the...

Page 43: ...turn it clockwise 2 Turn the key clockwise to lock the fuel cap then remove the key Disengagement 1 Remove the rear R pin 4 from the locking pin 1 2 Pull out the locking pin 1 from the lift arm stop 2...

Page 44: ...lide the seat backward or forward to bring it to the optimum position for operating the machine 2 Release the lever 2 at the desired position and the seat will be locked there Adjustmentstroke 15steps...

Page 45: ...rso and sit back firmly into the seat 2 Pull the seat belt to the desired length 3 Make sure that the belt is not twisted and then insert the tongue plate A into the buckle B of the seat belt until yo...

Page 46: ...bnormally while the engine is running 3 Coolant Temperature Warning Lamp This lamp flashes and an alarm is sounded if the engine coolant temperature rises abnormally while the engine is running 4 Batt...

Page 47: ...git indicates tenths of hours 6 minutes Set the inspection and maintenance intervals according to the time displayed on the hour meter 10 Water Temperature Gauge This gauge indicates the temperature o...

Page 48: ...When in the Float position the bucket can follow the level of the ground without movement of the control lever Starter Switch IMPORTANT Do not repeatedly switch the key from OFF to ON and ON to OFF ov...

Page 49: ...uipped Proportional control Proportional control allows for slow to fast movement of auxiliary functions Example If you move the slider switch half way the auxiliary function will move at approximatel...

Page 50: ...he built in lamp orange lights when the switch is on Thus there is no need to hold the switch in When this switch is pressed again the function of the auxiliary hydraulic switch returns to normal and...

Page 51: ...ing the wiper forcibly may damage the wiper motor Front wiper switch O Off I Wiper operates PUSH Washer fluid is squirted from the nozzle while pressed and stops when released Rear wiper switch O Off...

Page 52: ...his device is for locking the control levers pedal and selector detent mode and high flow switches When the safety bar is lifted then levers pedal and switches are locked Throttle Lever This controls...

Page 53: ...Lever Pattern Refer to page 65 Operating the Left Control Lever Auxiliary Pedal If equipped Use this pedal to operate the auxiliary hydraulics circuit A Hydraulic oil flows to auxiliary hydraulic lin...

Page 54: ...ement Use the heater with care in warm seasons Coolant circulates in the heater even when the heater switch is turned off When the heater is no longer needed stop coolant circulation as follows IMPORT...

Page 55: ...ward on the female coupler Disconnecting Hold the male coupler Retract the sleeve on the female coupler until the couplers disconnect Releasing the Residual Pressure Connecting Push the quick couplers...

Page 56: ...ower This system can be used only for one way flow attachments Auxiliary hydraulic flow rate and rated pressure Flow Rate CTL80 150L min 39 6 gal min Rated Pressure 20 6 Mpa 2987 psi 1 Connect the att...

Page 57: ...et as an external power supply When using this socket be careful not to exceed 12V 5A To use raise the cap 1 Interior Light Option IMPORTANT The battery capacity will decrease if the interior light is...

Page 58: ...56...

Page 59: ...7 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 OPERATION...

Page 60: ...tact 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 Walk Around Inspection Perform the walk arou...

Page 61: ...ection All the warning lamps flash and an alarm is sounded for 2 seconds The meters also start functioning After 2 seconds only the battery charge warning lamp 4 and engine oil pressure coolant level...

Page 62: ...ically returns to the ON position 4 Check that the warning lamps are off 5 Return the throttle lever and warm up the engine Refer to page 61 Warming Up the Engine Starting in Cold Weather 1 Pull the t...

Page 63: ...d run it for about 5 minutes with no load Stopping the Engine IMPORTANT Do not stop the engine suddenly when operating with heavy loads or at maximum speed Doing so may cause the engine to overheat or...

Page 64: ...ons in this manual are for this pattern N N B A T7D007 Crawler Forward Crawler Reverse Left Spin Turn Right Spin Turn Left Pivot Turn Right Pivot Turn Right Pivot Turn Reverse Left Pivot Turn Reverse...

Page 65: ...76 F but if operations must be performed at lower temperatures heat up the hydraulic oil to at least 20 C 68 F Normal Warm up 1 Run the engine at medium speed for about 5 minutes with no load 2 Set th...

Page 66: ...ere is a problem 1 Check that the warning lamps and meters are as follows Are all the warning lamps off Is the water temperature gauge s needle within the green range 2 Check that there are no irregul...

Page 67: ...acking up visually check for safety to the rear Backing up without checking could result in contact with a worker or obstacle If unavoidable while traveling when operating the working equipment do so...

Page 68: ...h speed and press it again to return to 1st speed low speed Pivot Turn Turning to the left aTo turn forward to the left Tilt the left control lever forward to the left eTo turn backward to the left Ti...

Page 69: ...y 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 1 S...

Page 70: ...eached the stroke end will result in the arm rising or stopping without going lower Be cautious of any unexpected movement of the arm Use the right control lever to operate the lift arms and bucket Re...

Page 71: ...ge the direction of the hydraulic oil flow by setting Flow selector switch C ON to return the oil in the b port line directly to the hydraulic tank Refer to page 47 Flow Selector Switch When using a d...

Page 72: ...quipment and there is the danger of the machine tipping over Keep the bucket as low as possible during travel Do not travel or attempt to change directions with the bucket raised Travel at a speed whi...

Page 73: ...r to fall off extreme wear etc Do not exceed the loader s rated operation capacity Do not use buckets or attachments which exceed the loader s operation capacity Do not use the downward force of the b...

Page 74: ...nders and this may damage them Cautions on Operating Cautions on Traveling Traveling over obstacles rocks stumps etc may subject the body to strong shocks and result in damage Avoid traveling over obs...

Page 75: ...e machine get 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 body When greasing places used under water for long periods o...

Page 76: ...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 When going up or down slopes having a gradient of 15 degrees or more tr...

Page 77: ...e 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 if equipped while traveling on s...

Page 78: ...the bucket is filled with the material Next tilt the bucket backward and scoop up the material Grading Tilt the front edge of the bucket down at an angle which is appropriate for the ground hardness t...

Page 79: ...and is extremely dangerous Do not drive the loader forward with the lift arms in Float position Lower the bucket onto the ground then put the lift arms in a Float position Tilt the bucket forward to s...

Page 80: ...d by the lift arm stop Before leaving the machine do the following 1 Set the control levers and pedal to the neutral position 2 Return the throttle lever and idle the engine at low speed 3 Lower the b...

Page 81: ...he machine as well as the lower body from freezing Remove any dirt or water from the body In particular water droplets on the hydraulic cylinder rod surfaces could freeze and if dirt enters into the s...

Page 82: ...rocks may cause the crawlers 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 Do not let fuel oil salt or chemical solvents...

Page 83: ...e crawler belts tend to slip Use rubber crawler belts at temperatures between 25 C to 55 C 14 F to 131 F When storing the rubber crawlers for long periods of time 3 months or more do so indoors in a p...

Page 84: ...82 OPERATION Handling Rubber Crawlers Do not change directions when the crawler belts are slack as shown in the diagram T7E008...

Page 85: ...83 Loading and Unloading 84 Securing the Machine 85 Cautions on Transporting 86 TRANSPORT...

Page 86: ...truck s parking brake and place 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...

Page 87: ...Posture 1 Lower the bucket 2 Stop the engine and remove the starter key 3 Set the safety bar securely to the locked position 4 Set stoppers in front and behind the crawlers 5 Put a chain or wire rope...

Page 88: ...sporting 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 whe...

Page 89: ...ction 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 50...

Page 90: ...this manual Have inspection and maintenance procedures not prescribed in this manual performed by a Gehl sales or service outlet Always keep the machine clean Always keep the machine clean and wash i...

Page 91: ...ght leaving 1 or 2 threads at the tip free Disposing of wastes Collect spent fluids from the machine in containers Disposing of wastes irresponsibly damages the environment Dispose of oil fuel cooling...

Page 92: ...I No 2 Every 1000 hrs Every 1000 hrs Daily or every 10 hrs When required After first 500 hrs Every 1000 hrs As required SAE 90 Use a clean Quality fuel for good performance and optimum engine life To...

Page 93: ...ables such as filters and elements periodically referring to the table below Item Part name Part No Replacement interval Return filter Cartridge 181607 After first 50 hrs Every 500 hrs Fuel filter Car...

Page 94: ...panner 24 27 6 Spanner 30 7 Spanner 41 8 Screwdriver 9 L type wrench 19 10 Monkey wrench 250mm 11 Pliers 200mm 12 Hammer 3 4 13 Hex wrench 5mm 14 Hex wrench 6mm 15 Hex wrench 8mm 16 Hex wrench 10mm 17...

Page 95: ...uts and 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 f...

Page 96: ...ts 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 a...

Page 97: ...95 MEMO...

Page 98: ...level 104 Inspecting the hydraulic oil level and replenishing 105 Lubricating the working equipment 106 After First 50 Hours New Machines Only Replacing the hydraulic oil return filter 107 Replacing t...

Page 99: ...119 Every 1000 Hours Cleaning the engine cooling system 120 Replacing the air cleaner elements 121 Replacing the hydraulic oil and cleaning the suction strainer 122 Replacing the travel motor gear oi...

Page 100: ...98 MAINTENANCE Maintenance Log Date Hours Service Procedure...

Page 101: ...99 MAINTENANCE Maintenance Log Date Hours Service Procedure...

Page 102: ...ind 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...

Page 103: ...the crawler track roller idler and sprocket for damage wear and loose bolts 9 Check for oil leakage from the travel motor 10 Check the ROPS and guard for damage and loose nuts and bolts 11 Check the...

Page 104: ...adiator cap or drain plugs when the coolant is hot Stop the engine let the engine and radiator cool and loosen the radiator cap or drain plugs slowly Inspection 1 Open the rear door 2 Inspect the quan...

Page 105: ...h 3 Tighten the oil supply cap 2 4 Start the engine run it at low idle for about 3 minutes then stop it 5 After about 20 minutes inspect the oil level Inspecting the Water Separator WARNING Stop the e...

Page 106: ...n a well ventilated place when adding fuel Clean up spilled fuel immediately Do not fill the fuel tank to capacity Allow room for expansion Tighten the fuel filler cap securely 1 Check the fuel level...

Page 107: ...e hydraulic oil level inspection posture shown in the diagram Hydraulic oil level inspection posture 1 Start the engine and run it at low speed 2 Fully retract the lift arms and bucket cylinders and g...

Page 108: ...Hours Lubricating the Working Equipment 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 nipp...

Page 109: ...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 removin...

Page 110: ...A install connector B and drain the oil The oil comes out when the screw is tightened 7 Remove connector B and install cap A IMPORTANT Check the spent oil If it contains large amounts of metal powder...

Page 111: ...ter the engine is stopped Touching these parts will cause burns Inspection 1 Open the rear door 2 Remove the bolts a and open the radiator b 3 Press at the center of the fan pulley 2 and alternator pu...

Page 112: ...es Only Replacing the Line Filter WARNING Stop the engine and allow the machine to cool down before performing maintenance Oil may spurt out if caps or filters are removed or pipes disconnected before...

Page 113: ...sened there is a problem Contact your nearest service outlet for repairs DO NOT disassemble as this is very dangerous Inspection 1 Lower the lift arm and tilt the bucket forward to raise the front of...

Page 114: ...s eyes flush immediately with clean water and get prompt medical attention If acid is accidentally swallowed drink large quantities of water or milk and call a physician immediately If acid contacts s...

Page 115: ...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 116: ...mmediately 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 scratche...

Page 117: ...ANCE Every 250 Hours Replacing the Engine Oil and Oil Filter Refer to page 108 Replacing the Engine Oil and Oil Filter Inspecting and Adjusting the Fan Belt Refer to page 109 Inspecting andAdjusting t...

Page 118: ...ies The pressure in the travel motor reduction gears case may cause oil or the plug to fly out Loosen the plug slowly to release the pressure IMPORTANT If the percentage of the traveling time within t...

Page 119: ...e rear door 2 Blow compressed air on the radiator and oil cooler fins to remove mud and dirt stuck on them Do not use steam or water instead of compressed air Replacing the Fuel Filter WARNING Do not...

Page 120: ...NG 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 spil...

Page 121: ...9 MAINTENANCE Every 500 Hours Replacing the Hydraulic Oil Return Filter Refer to page 107 Replacing the Hydraulic Oil Return Filter Replacing the Line Filter Refer to page 110 Replacing the Line Filte...

Page 122: ...stand at the back of the machine while the engine is running Do not remove the radiator cap or drain plugs when the coolant is hot Stop the engine let the engine and radiator cool and loosen the radia...

Page 123: ...gine and allow the machine to cool down before performing maintenance The engine muffler radiator and many other parts of the machine are hot directly after the engine is stopped Touching these parts...

Page 124: ...rs 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...

Page 125: ...the temperature of the oil has dropped Refer to page 105 Inspecting the Hydraulic Oil Level and Replenishing Bleeding the air IMPORTANT Afterreplacingthehydraulic oil bleed the air from the hydraulic...

Page 126: ...e This operation requires experience Have it performed by a Gehl sales or service outlet Retightening the Engine Cylinder Head Bolts This operation requires experience Have it performed by a Gehl sale...

Page 127: ...Engine Fuel Injection Timing This operation requires experience Have it performed by a Gehl sales or service outlet Inspecting the Engine Fuel Injection Valve This operation requires experience Have...

Page 128: ...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 attachment 3 forward 3 Move the machine slowly forward and rai...

Page 129: ...attachment 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 attach...

Page 130: ...the boot 1 back as it was Auxiliary pedal 1 Remove the lower mount section of the boot 1 and turn it upwards 2 Wipe off the old grease 3 Supply grease to points A and B 4 Set the boot 1 back as it was...

Page 131: ...d 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 body...

Page 132: ...annot be adjusted 1 Lug Replace if the height of A is 5 mm 0 2 in or below 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...

Page 133: ...If natural ventilation is poor install ventilators fans exhaust extension pipes or other artificial venting devices 1 To prevent rusting operate the machine once a month so that the oil is fully circu...

Page 134: ...erform cranking 1 Insert the key into the starter switch 2 Turn the key to the START position and hold it there The engine will begin turning 3 Continue cranking the engine for about 5 seconds checkin...

Page 135: ...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 T...

Page 136: ...during high speed travel The control valve produces noise if excessive force is applied to the working equipment and when the stroke end is reached At times of combined operation of bucket and arm lo...

Page 137: ...ine slows down and the power decreases Steam comes from the engine room Procedure 1 Park the machine in a safe place 2 Inspect whether the engine oil pressure coolant level warning lamp is flashing or...

Page 138: ...ne IMPORTANT Use jumper cables and clips of a size suited to the battery s capacity Do not used damaged or corroded jumper cables and clips IMPORTANT The rescue vehicle s battery must have the same ca...

Page 139: ...m vehicle s terminal Recharging Have a Gehl sales or service outlet recharge batteries that have gone dead Bleeding the Air from the Fuel System 1 Add fuel 2 Turn the starter key to the ON position an...

Page 140: ...the OFF position and stop the engine 2 Open the fuse box cover 1 3 Inspect for any blown fuses 4 If a fuse is blown replace it with a spare fuse of the same capacity T7J002 1 E4J007 Normal Blown Fuse...

Page 141: ...ht be blown open Open the rear door and inspect If the fusible link is blown please contact your dealer Supplement A fusible link is a large piece of fuse wiring which is mounted in a circuit which ca...

Page 142: ...temperature warning lamp flashes simultaneously For the procedures refer to the respective warning lamps below Inspect the engine oil level or coolant level If the lamp is flashing even though the lev...

Page 143: ...filter is clogged Stop the engine and replace the filter Continuing to operate the machine while the lamp is lit could damage the line filter and hydraulic equipment Replace the filter immediately sh...

Page 144: ...on left and right control levers Insufficient grease on pedal Safety bar is raised Fuse is blown Insufficient hydraulic oil level Hydraulic oil is not heated Air cleaner is clogged Hydraulic oil is n...

Page 145: ...system Water in fuel system Crawlers are too loose Excessive engine oil Insufficient fuel Air cleaner is clogged Low quality fuel is being used Engine is overheating Damage in muffler Replenish to the...

Page 146: ...owly so that the lift arms lowers slowly Do not turn the screw more than the specified amount 1 Tilt up the ROPS 2 Put mark M on the plug of the port relief valve 1 and set screw 2 3 Gripping the set...

Page 147: ...ine being towed as well as on the machine that is towing Never tow on slopes Do not let anyone near the wire rope while towing Towing the Machine Use the procedure described below to tow light weight...

Page 148: ...146...

Page 149: ...147 Main Specifications 148 Machine Dimensions 152 Operating Range 154 SPECIFICATIONS...

Page 150: ...4 83 Sound power level LWA105 Sound pressure level LpA 88 Manufacturer and model Yanmar 4TNV98 YTBL Rated output kW min 1 hp rpm 49 2 2450 66 9 2450 Displacement mI cu in 3319 202 5 Starter V kW 12 3...

Page 151: ...28 2 4 1 Sound power level LWA 105 Sound pressure level LpA 92 Manufacturer and model ISUZU 4JG1T Rated output kW min 1 hp rpm 60 3 2500 80 9 2500 Displacement mI cu in 3059 186 7 Starter V kW 12 2 2...

Page 152: ...vel LWA106 Sound pressure level LpA 86 Manufacturer and model Yanmar 4TNV106T XTBL Rated output kW min 1 hp rpm 72 0 2200 96 5 2200 Displacement mI cu in 4412 269 2 Starter V kW 12 3 0 Alternator V kW...

Page 153: ...151 MEMO...

Page 154: ...152 SPECIFICATIONS Machine Dimensions T7K0011 L M D J H K C F G A E B...

Page 155: ...77 2 580 22 8 A 3430 135 1 B 2740 107 8 C 1390 54 7 D 2130 83 9 E 310 12 1 F 1580 62 2 G 320 12 6 H 1430 56 3 J 980 38 6 K 1675 66 0 L 510 20 0 M 30 Units mm inches Standard Bucket Rubber Crawlers CTL...

Page 156: ...154 SPECIFICATIONS Operating Range T7K0021 F H C A D B G E...

Page 157: ...ubber Crawlers CTL60 CTL80 A 3905 153 8 B 3030 119 3 C 2370 93 4 D 730 28 8 E 2080 82 0 F 1375 54 1 G 1590 62 7 H 30 4245 167 2 3205 126 1 2430 95 7 985 38 8 2435 95 8 1560 61 4 1755 69 1 4080 160 7 3...

Page 158: ...156...

Page 159: ...157 General Precautions 158 OPTIONS...

Page 160: ...en 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 th...

Page 161: ...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...

Page 162: ...160...

Page 163: ...161 INDEX...

Page 164: ...s after Completing Operations 79 Cautions on Maintenance 88 Cautions on Operating 72 Cautions on tilting up the canopy 27 Cautions on Towing 22 Cautions on Transporting 86 Cautions on traveling and tu...

Page 165: ...136 If the Engine Overheats 135 Important Parts 94 In cold weather 15 Index 161 Indicators 45 Inspecting and Adjusting the Crawler Tension 111 Inspecting and Adjusting the Engine Valve Clearance 124 I...

Page 166: ...t 106 M Machine Description 3 Machine Dimensions 152 Machine Operation 62 Main Specifications 148 Maintain three point contact when mounting and dismounting 14 Maintenance 87 Maintenance Chart 96 Main...

Page 167: ...2 Replacing the Hydraulic Oil Return Filter 107 Replacing the Hydraulic Oil Return Filter 119 Replacing the Line Filter 110 Replacing the Line Filter 119 Replacing the Travel Motor Gear Oil 116 Replac...

Page 168: ...ignal person and flagman 9 Use caution when floating the lift arms 18 Use caution when fueling 28 Use the correct tools 25 Using optional products 11 W Walk Around Inspection 58 Walk Around Inspection...

Page 169: ...TY SERVICE DOES NOT INCLUDE 1 Transportation to selling dealer s business location or at the option of the Original Retail Purchaser the cost of a service call 2 Used equipment 3 Components covered by...

Page 170: ...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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