Gehl CTL60 User manual

CTL60
CTL70
CTL80
Compact
Track Loader
OPERATOR’S MANUAL

SAFETY ALERT SYMBOL
This symbol means Attention! Be Alert! Your Safety Is Involved.
Themessagethatfollowsthesymbolcontainsimportantinformation
about safety.
Readandunderstand the message to avoidpersonalinjuryordeath.
■It is the owner or employer’s responsibility to fully instruct each operator in the
proper and safe operation of all equipment. All persons using this machine should
thoroughly familiarize themselves with the following sections.
■Alloperatorsmustbe instructed on the proper functions of theloaderbeforerunning
the machine.
■Learn and practice correct use of the machine controls in a safe, clear area before
operating this machine on a job site.
Improper operation, inspection and maintenance of this machine
can cause injury or death.
Read and understand this manual before performing any
operation, inspection or maintenance on this machine.
■Always store this manual 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
countryof export.If yourmachine hasbeen purchasedin anothercountry orfrom aperson
or company of another country, it may not have the safety devices or safety standards
requiredforuseinyourcountry.Shouldyouhaveanyquestionaboutwhetheryourmachine
complies with the regulations and standards of your country, contact a Gehl dealer.
■Please note that the contents and diagrams included in this manual may not match your
machine exactly.
CAUTION

1
It is your responsibility to observe all pertinent laws and regulations and to follow the
manufacturer’s instructions on machine operation, inspection and maintenance.
Virtually all accidents occur as the result of a failure to observe basic safety rules and
precautions.Anaccidentcanoftenbeavoidedbyrecognizing potentially hazardoussituations
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:
IMPORTANT: The word “IMPORTANT” is used 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 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.
■EXPLANATION OF GRAPHICAL SYMBOLS
Following is an explanation of symbols used in this manual.
, X......... prohibition
/ ....... Lock
/ ...... Unlock
The word “DANGER”
indicates an imminently
hazardous situation
which, if not avoided,
can result in serious
injury or death.
The word “WARNING”
indicates a potentially
hazardous situation
which, if not avoided,
could result in serious
injury or death.
The word “CAUTlON”
indicates a potentially
hazardous situation
which, if not avoided,
may result in minor or
moderate injury.
CAUTIONWARNINGDANGER

2
Foreword
Thismanualdescribesoperation,inspection
and maintenance of the machine, as well as
safetyinstructionstobeheededduringthese
operations.
Ifyouhaveanyquestionsaboutthemachine,
pleasecontactaGehlsalesorserviceoutlet.
INTRODUCTION
T7A002
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).
2. Open the cover (1).
3. After using the manual, place it in the
plastic pouch and store it back in the
manual storage.
■Serial numbers
Checktheserialnumbersofthemachineand
the engine and write them in the spaces
provided below.
Machine number :
Engine number :

3
MACHINE DESCRIPTION
■Front, rear, Ieft and right
This manual refers the front, rear, left and
right of the machine as seen when sitting in
the operator’s seat with the bucket visible to
the front.
■Designated operations
Use this machine primarily for the following
operations:
¡Carrying
¡Leveling
¡Loading
RIGHTLEFT
REAR
FRONT
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).
Usinganewmachineroughlywithoutbreakingitinwillleadtoquickerdeteriorationofmachine
performance and may shorten the machine’s service life.
¡Warm up the engine and hydraulic oil sufficiently.
¡Avoid heavy loads and rapid operations. Operate with a load of about 80% the maximum
load.
¡Do not start up, accelerate, change directions, or stop abruptly unless necessary.

4

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

6

7
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
SAFETY

8
SAFETY
Observe all safety rules
¡Operation,inspectionandmaintenanceof
this machine must be performed only by
a trained and qualified person.
¡All rules, regulations, precautions and
safety procedures must be understood
and followed when performing operation,
inspection and maintenance of this
machine.
¡Do not perform any operation, inspection
and maintenance of this machine when
under the adverse influence of alcohol,
drugs, medication, fatigue, or insufficient
sleep.
Wear appropriate clothing and
personal protective equipment
¡Do not wear loose clothing or any
accessorythat cancatch oncontrols orin
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
protectionandotherprotectiveequipment
as required by job conditions. Wear
required appropriate equipment such as
safetyglassesandfilter mask whenusing
grinders, hammers or compressed air, as
metal fragments or other objects can fly
and cause serious injury.
General Precautions
¡Usehearingprotectionwhenoperatingthe
machine.Loudprolongednoisecancause
hearing impairments, even the total loss
of hearing.
Provide a fire extinguisher and
first aid kit
¡Know where a fire extinguisher and first
aid kit are located and understand how to
use them.
¡Know how to contact emergency
assistance and first aid help.

9
SAFETY
General Precautions
Never remove safety equipment
¡Makesureallprotectiveguards,canopies,
doors,etc.,areinplaceandsecure.Repair
or replace damaged components before
operating the machine.
¡Know how to use the safety bar, seat belt
andothersafetyequipmentand usethem
properly.
¡Never remove any safety equipment
except for service. Keep all safety
equipment in good operating condition.
T7A005
Crush Hazard
FOPS Limitations
Various classes and sizes of off-road
equipment operate in a wide variety of
applications and environmental conditions.
Withtheintentionofprovidingoperators with
reasonable protection from falling objects,
twolevelsofFOPS(Falling-ObjectProtective
Structure) acceptance criteria have been
developed based on end use:
¡Level 1...... protection from falling bricks,
small concrete blocks and
hand encountered in
operations such as highway
maintenance, landscaping
and other construction site
services.
Use a signal person and flagman
Know and use the hand signals required for
particular jobs and make sure who has the
responsibility for signaling.
¡Allpersonnelmustfully understand allthe
signals.
¡Theoperatorshallrespondtosignals only
fromtheappointedsignalperson,butshall
obey a stop signal at any time from
anyone.
¡The signal person must stand in a clearly
visible location when giving signals.
¡Level 2 ......protectionfromfallingtreesor
rocks for machines involved
in site clearing, overhead
demolition or forestry.
This machine is equipped with a Level 1
FOPS as standard equippment. DO NOT
use this machine in an application that may
involve the hazards of falling trees or rocks.
IfLevel2FOPSprotectionisrequiredinyour
application, contact your dealer or the
manufacturer concerning the possible
availability of such protection.

10
SAFETY
General Precautions
Avoid fire and explosion hazards
Keep flames away from fuel, hydraulic fluid,
oil,greaseandantifreeze.Fuelisparticularly
flammable and dangerous.
¡When handling these combustible
materials, keep lit cigarettes, matches,
lighters and other flames or sources of
flames away.
¡Donotsmokeorpermitopenflameswhile
fueling or near fueling operations.
¡Never remove the fuel cap or refuel with
theenginerunningorhot.Neverallowfuel
to spill on hot machine components.
¡Clean up spilled fuel, oil or other
flammable fluids immediately.
¡Check for fuel, oil or hydraulic fluid leaks.
Stop all leaks and clean the machine
before operating.
¡Do not cut or weld on pipes or tubes that
containflammablefluids.Cleanthoroughly
with nonflammable solvent before cutting
or welding.
¡Remove all trash or debris from the
machine.Makesurethatoilyragsorother
flammable material are not stored on the
machine.
¡Handle all solvents and dry chemicals
according to procedures identified on
manufacturers’containers.Workinawell-
ventilated area.
¡Never use fuel for cleaning purposes.
Always use a nonflammable solvent.
¡Store all flammable fluids and materials
in a safe and well-ventilated place.
Exhaust fumes from the engine
can kill
¡Do not operate the engine in an enclosed
area without adequate ventilation.
¡If natural ventilation is poor, install
ventilators,fans,exhaust extension pipes
or other artificial venting devices.
Handling asbestos dust
Inhaling asbestos dust has been linked to
lungcancer.Whenhandlingmaterials which
may contain asbestos, take the following
precautions:
¡Never use compressed air for cleaning.
¡Avoidbrushingorgrindingofthematerials.
¡For clean up, use wet methods or a
vacuum equipped with a high efficiency
particulate air (HEPA) filter.
¡Wear anapproved respiratorifthere isno
other way to control the dust. When
working indoors, install a ventilation
system with a macro molecular filter.

11
SAFETY
General Precautions
Be careful not to get crushed or cut
¡Your body, hands or feet must not enter
between moving parts such as between
lift arms and main body, or between lift
armsandbucket.Whenoperatingliftarms
and bucket, the gap between the moving
parts will be changing and getting caught
in between can cause serious injury or
death .
¡The lift arms move close to the outside of
the grid; never stick out arms or other
portions of your body from the grid.
¡The lift arms move close to the ROPS;
therefore, do not stand or lean on the
machine.
Using optional products
¡ConsultwithaGehldealerbeforeinstalling
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 machine’s operation
or service life.
¡Gehl will not be held responsible for any
injuries, accidents or damage to its
products caused by the use of a non-
approved attachment.
Never modify the machine
Unauthorized modifications to this machine
can cause injury or death. Never make
unauthorizedmodificationstoanypartofthis
machine.
T7A007
T7A008
T8A006

12
SAFETY
Preparing Precautions
Know the working area
Before starting operation, know the working
area to ensure safety.
¡Check the topography and ground
condition of the working area, or the
structure of the building when working
indoors, and take the necessary safety
measures in dangerous spots.
¡Note and avoid all hazards and
obstructionssuchasditches,underground
lines,trees,cliffs,overheadelectricalwires
or areas where there is danger of a slide.
¡Check with the local utilities for the
locations of buried gas and water pipes
andburiedpowercables.Determinejointly
what specific precautions must be taken
to insure safety.
¡When working on roads, be sure to take
intoaccountthesafetyof pedestriansand
vehicles.
•Use a flagman and/or signals.
•Fence off the working area and prohibit
entry to unauthorized persons.
¡Whenworkinginwaterorcrossingshallow
streams or creeks, check the depth of the
water, the solidity of the ground, and the
speed of the current beforehand. Make
sure the water is not deeper than the
allowable depth.
Refer to the section titled “Cautions on
Use in Water” for further instructions.
Check the strength of the bridge
When travelling over a bridge or other
structure, check the permissible load. If the
strength is insufficient, reinforce it.
Always keep the machine clean
¡Clean windows, mirrors and lights to
ensure good visibility.
¡Wipe off any oil, grease, mud, snow or
ice, to prevent accidents due to slipping.
¡Remove all loose objects stored in the
machine and all objects which do not
belong in or on the machine and its
equipment.
¡Remove any dirt, oil or grease from the
engine area, to prevent fires.
¡Cleantheareaaroundtheoperator’sseat,
removing any potential obstacles.
T7A009
T7A025

13
SAFETY
Preparing Precautions
Perform inspection and
maintenance daily
Failure to notice or repair machine
irregularities or damage can lead to
accidents.
¡Before operating, perform the prescribed
inspectionsandmakerepairsimmediately
should any irregularities be found.
¡Ifafailurethat causeslossofcontrolsuch
as steering, service brakes or engine
occurs, stop the machine motion as
quickly as possible, follow the shutdown
procedure, and keep machine securely
parked until the malfunction is corrected.
Emergency Exit
Ifyoushouldbecometrappedinsidethecab,
remove the rear window to get out.
There are two ways to remove the rear
window.
In case of emergency
1. Kick off the rear window. Note that the
glass may break. Be careful not to get
injured.
In case of need
1. Pull off ring (A) and remove the tip of the
rubber wedge.
2. Grasp the tip, pull, and remove the entire
rubber wedge.
3. Pull inside knob (B).
E X IT
T8B001
AB

14
SAFETY
Starting Precautions
Maintain three point contact
when mounting and dismounting
¡Do not jump on or off the machine. Never
attempt to mount or dismount a moving
machine.
¡Whenmountinganddismountingthecab,
first open the door fully to the locked
position and check that it does not move.
(For machines with cab)
¡Always face the access system and
maintain a three point contact with the
recommended handrails and steps while
gettingonandoffthemachine.Keepsteps
and platform clean.
¡Never use the control levers as hand
holds.
¡Donot gounder theraisedlift armsif they
are not sufficiently supported.
Lower the lift arms to the ground before
mounting or dismounting the cab.
Clear the area of other persons
before starting the machine
Donot start theengineuntil you aresureit is
safe. Before starting, check or perform the
following.
¡Walk around the machine and warn all
personnel who may be servicing the
machine or are in the machine path. Do
notstartuntilallpersonnelareclearlyaway
from the machine.
¡Check for any “DO NOT OPERATE” tags
orsimilarwarningnoticesonthecabdoor,
controls or starter switch.
¡Sound horn to alert everyone around the
machine.
Start the engine from the
operator’s seat
¡Adjust, secure and latch the operator’s
seat.
¡Fasten the seat belt.
¡Check that the parking device is applied
and place all controls in the neutral
position.
¡Check that the safety bar is in the lock
position.
¡Clear the area of all persons.
¡Start and operate the engine from the
operator’s seat only.
¡Never attempt to start the engine by
shorting across the starter terminals.

15
SAFETY
Starting Precautions
Starting with jumper cables
Usejumpercablesonlyintherecommended
manner. Improper use of jumper cables can
result in battery explosion or unexpected
machine motion.
Refer to the section titled “If the Battery
Goes Dead” for proper instructions.
After starting the engine
After starting the engine, perform the
following operations and checks in a safe
place with no persons or obstacles in the
area. If any malfunctions are found, follow
the shutdown procedure and report the
malfunction.
¡Warm up the engine and hydraulics.
¡Observe all gauges or warning
instruments for proper operation.
¡Listen for unusual noises.
¡Test engine speed control.
¡Operate each control to insure proper
operation.
In cold weather
¡Be careful of slippery conditions on
freezing ground, steps and hand holds.
¡In severe cold weather, do not touch any
metal parts of the machine with exposed
flesh,as fleshcanfreeze tothe metal and
Cause injury.
¡Do not use ether or starting fluids on this
engine. These starting aids can cause
explosion and serious injury or death.
¡Warm up the engine and hydraulic fluid
before operating.

16
SAFETY
Operating Precautions
Ensure good visibility
¡When working in dark places, turn on the
machine’s working lights and headlights
and/or provide extra stationary lighting if
necessary.
¡When visibility is poor due to severe
weather(fog,snoworrain),stopoperating
the machine and wait until conditions
improves.
Do not permit riders on the
machine
¡Donot allowanyone toride onany partof
the machine at any time while traveling.
¡Do not allow anyone to be on any part of
the machine while operating.
Operate the machine only from
the operator’s seat
Operate all the controls only from the
operator’s seat. Failure to do so can cause
serious injury or death.
Check for safety in the
surrounding area before starting
¡Understand the machine limitations.
¡Useasignalpersonwhereclearancesare
close or your vision is obstructed.
¡Never allow anyone to enter the turning
radius and machine path.
¡Signalyourintentiontomovebysounding
the horn.
¡There are blind spots to the rear of the
machine.
If necessary, before backing up to check
that the area is safe and clear.
Keep your body inside the
operator’s cab
Keep your body inside the operator’s cab
while operating the loader. Never work with
yourarms,feetorlegsbeyondtheoperator’s
compartment.
T7A010
T7A011

17
SAFETY
Operating Precautions
Cautions on traveling and turning
¡Travelingandturningshouldbeperformed
withthebucketcylinderfullyretractedand
the bucket at a height of approximately
30 cm (12 in.) from the ground.
¡Avoid sudden stops, start or turns.
¡Donotraisethesafety bar whiletraveling.
Thisisdangerous,sinceraisingthesafety
bar will cause the parking brake of the
traveling motor to operate and apply the
brake abruptly.
¡Do not switch off the starter switch while
traveling. Doing so will cause sudden
braking and is dangerous.
¡Before backing up, visually check for
safety to the rear. Backing up without
checking could result in contact with a
worker or obstacle.
¡If unavoidable while traveling, when
operating the working equipment, do so
with care.
¡When traveling, try not to cross over
obstacles.Whencrossingoversomething
cannot be avoided, maintain the bucket
close above the ground and travel slowly.
Alsonotethatthemachinemust not cross
over an obstacle with the machine body
on an extreme slant (of 15 degrees or
more).
¡When traveling on rough terrain or when
carrying a load, lower the load and travel
slowly.
T7A012E
30 cm
(12 in.)
T7A013

18
SAFETY
Operating Precautions
Cautions on traveling on slopes
Work should not be performed on a slope
sincethebalanceof the machinecanbelost
when operating the working equipment and
there is the danger of the machine tipping
over.
When traveling on a slope, be cautious of
tipping over or sliding sideways.
Whentraveling on a slope, have the heavier
endofthemachine(front or back,whichever
is heavier) pointing up the slope.
¡When going up or down slopes having a
gradient of 15 degrees or more, travel up
and down slope with the heavy end of the
machine pointed uphill.
¡When traveling on a slope, lower the
bucket to a height of 20 to 30 cm from the
ground and at the time of an emergency,
lower the bucket to the ground and stop
the machine.
¡Travelatslowspeedonslopes.Especially
when going down slopes, reduce the
engine (r.p.m.) speed and set the stroke
oftheleftcontrollevertohalforlessbefore
going down. Going down a slope too fast
will lead to loss of control.
¡Sudden stopping on a sloped road may
leadtolossofbalanceofthe machine and
it could tip over.
¡Travelingacrossan inclinedsurfaceatan
angle or traveling straight across an
inclined surface could result in slipping
sideways or tipping over. Travel straight
up and down the slope.
¡Whentravelingovergrassorfallenleaves,
wet iron plate or frozen surfaces, the
machine might unexpectedly slide
sidewaysevenwhenona slight slope.Do
notallowthemachineto become oriented
across the slope.
Use caution when floating the lift
arms
¡Make sure the bucket is lowered on the
ground before floating the lift arms.
Floatingthe liftarms whiletheyare raised
will cause the bucket to fall and is
extremely dangerous.
¡Do not drive the loader forward with the
lift arms in Float position.
T7A014E
With bucket full

T7A015E
With bucket empty
T7A016
T8A0051