Gehl CTL55 User manual

CTL55
CTL65
CTL75
CTL85
Compact
Track Loader
OPERATOR’S MANUAL
Revision E
09/10

SAFETY ALERT SYMBOL
This symbol means Attention! Be Alert! Your Safety Is Involved.
The message that follows this symbol contains important safety
information. Read and understand the message to avoid personal
injury or death.
� It is the owner’s or employer’s responsibility to fully instruct each operator in the
proper and safe operation of all equipment. All persons using this machine should
thoroughly familiarize themselves with the following sections.
� All operators must be instructed on the proper functions of the loader before running
the machine.
� Learn and practice correct use of the machine controls in a safe, clear area before
operating this machine on a job site.
Improper operation, inspection and maintenance of this machine
can cause injury or death.
Read and understand this manual before performing any operation,
inspection or maintenance on this machine.
� Always store this manual where it is ready available, preferably on the machine itself. If it is
lost or damaged, immediately order a new one from your Gehl dealer.
When transferring ownership of this machine, be sure to provide this manual to the new
owner.
� Gehl Company supplies machines complying with the local regulations and standards. If
your machine has been purchased in another country or from a person or company of
another country, it may not have the safety devices or meet the safety standards required
for use in your country. If you have any question about whether your machine complies with
the regulations and standards of your country, contact a Gehl dealer.
� Please note that the contents and diagrams included in this manual may not match your
machine exactly.
CAUTION

1
IMPORTANT: The word “IMPORTANT” is used to alert operators and maintenance
personnel about situations that can result in possible damage to the machine and its
components.
It is impossible to foresee every possible circumstance that might involve a potential hazard.
The warnings in this manual or on the machine can not cover all possible contingencies. You
must exercise all due care and follow normal safety procedures when operating the machine
to ensure that no damage occurs to the machine, its operators or other persons.
 EXPLANATION OF GRAPHICAL SYMBOLS
Following is an explanation of symbols used in this manual.
, X ......... prohibition
/ ....... Lock
/ ...... Unlock
It is your responsibility to observe all pertinent laws and regulations and to follow the
manufacturer’s instructions on machine operation, inspection and maintenance.
Virtually all accidents occur as the result of a failure to observe basic safety rules and
precautions. An accident can often be avoided by recognizing potentially hazardous situations
beforehand. Read and understand all of the safety messages, which explain how to prevent
these accidents from occurring. Do not operate the machine until you are sure that you have
gained a proper understanding of its operation, inspection and maintenance.
 SlGNAL WORDS
Safety messages appearing in this manual and on machine decals are identified by the words
“DANGER”, “WARNING” and “CAUTION”. These signal words mean the following:
The word “DANGER”
indicates an imminently
hazardous situation,
which, if not avoided,
can result in serious
injury or death.
The word “WARNING”
indicates a potentially
hazardous situation,
which, if not avoided,
could result in serious
injury or death.
The word “CAUTlON”
indicates a potentially
hazardous situation,
which, if not avoided,
may result in injury.
CAUTION WARNING DANGER

2
INTRODUCTION
T7A002
for Cab
T9A002
1
Foreword
This manual describes operation, inspection and maintenance of the machine, as well as
safety instructions to be heeded during these operations.
If you have any questions about the machine, please contact a Gehl dealer.
 Serial numbers
Check the serial numbers of the machine
and the engine and write them in the spaces
provided below.
Machine number :
Engine number :
 Manual storage
A compartment for storing this manual
is provided at the position shown in the
diagram below.
1. Insert the starter key and turn it
counterclockwise to unlock the cover (1).
2. Open the cover (1).
3. After using the manual, place it in the
plastic pouch and store it in the manual
storage.
Type A
Type B
1
T7A0012

3
MACHINE DESCRIPTION
 Front, rear, Ieft and right
This manual refers the front, rear, left and
right of the machine as seen when sitting in
the operator’s seat with the bucket visible to
the front.
 Designated operations
Use this machine primarily for the following
operations:
 Carrying
 Leveling
 Loading
 Features
 Hydrostatic drive system
 Roll Over / Falling Object Protective Structure (ROPS/FOPS), tilt-up ROPS
 Low engine noise and exhaust emissions
 Two-way auxiliary hydraulics
 Pilot-operated joystick controls

 Break-in period
When the machine is new, follow the instructions below when operating the machine for the
first 100 hours (as indicated on the hourmeter).
Using a new machine roughly without breaking it in will lead to quicker deterioration of machine
performance and may shorten the machine’s service life.
 Warm up the engine and hydraulic oil sufficiently.
 Avoid heavy loads and rapid operations. Operate with a load of about 80% of the maximum
load.
 Do not start up, accelerate, change directions, or stop abruptly unless necessary.
RIGHTLEFT
REAR
FRONT
T7A004E

4

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

6

7
General Precautions .........................................8
Preparing Precautions ...................................15
Starting Precautions .......................................17
Operating Precautions ................................... 19
Stopping Precautions .....................................26
Transporting Precautions ..............................27
Maintenance Precautions ..............................28
Safety Signs (Decals) ......................................35
SAFETY

SAFETY
8
General Precautions
Observe all safety rules
 Operation, inspection and maintenance
of this machine must be performed only
by trained and qualified persons.
 All rules, regulations, precautions and
safety procedures must be understood
and followed when performing operation,
inspection and maintenance of this
machine.
 Do not perform any operation, inspection
and maintenance of this machine when
under the adverse influence of alcohol,
drugs, medication, fatigue, or insufficient
sleep.
Wear appropriate clothing and
personal protective equipment
 Do not wear loose clothing or any
accessory that can catch on controls or in
moving parts.
 Do not wear oily or fuel-stained clothing
that can catch fire.
 Wear a hard hat, safety shoes, safety
glasses, filter mask, heavy gloves, ear
protection and other protective equipment
as required by job conditions. Wear
required appropriate equipment such as
safety glasses and filter mask when using
grinders, hammers or compressed air,
because metal fragments or other objects
can fly and cause serious injury.
 Use hearing protection when operating
the machine. Loud prolonged noise can
cause hearing impairment, even the total
loss of hearing.
Operating temperature range
To maintain the performance of machine and
to prevent it from early wear, observe the
following operating conditions.
 Do not operate the machine if the ambient
temperature is higher than +45°C (+113°F)
or lower than –15°C (+5°F).
 If operated at an ambient temperature of
higher than +45°C (+113°F), the engine
may overheat and cause the engine oil to
degrade.
 If operated at an ambient temperature of
lower than –15°C (+5°F), the parts made of
rubber such as gaskets may get hardened
to cause an early wear or damage to the
machine.
 If the machine is to be used outside the
ambient temperature range described
above, consult your sales or a service
dealer.
Provide a fire extinguisher and
first aid kit
 Know where a fire extinguisher and first
aid kit are located and understand how to
use them.
 Know how to contact emergency
assistance and first aid help.

9
SAFETY
General Precautions
Never remove safety equipment
 Make sure all protective guards, canopies,
doors, etc., are in place and secure. Repair
or replace damaged components before
operating the machine.
 Know how to use the safety bar, seat belt
and other safety equipment and use them
properly.
 Never remove any safety equipment
except for service. Keep all safety
equipment in good operating condition.
Crush Hazard
FOPS Limitations
Various classes and sizes of off-road equipment
operate in a wide variety of applications and
environmental conditions.
With the intention of providing operators with
reasonable protection from falling objects,
two levels of FOPS (Falling-Object Protective
Structure) acceptance criteria have been
developed based on end use:
 Level 1 ...protection from falling bricks,
small concrete blocks and hand
encountered in operations such as
highway maintenance, landscaping
and other construction site services.
 Level 2 ...protection from falling trees or rocks
for machines involved in site clearing,
overhead demolition or forestry.
This machine is equipped with a Level 1 FOPS as
standard equippment. DO NOT use this machine
in an application that may involve the hazards of
falling trees or rocks. If Level 2 FOPS protection
is required in your application, contact your dealer
or the manufacturer concerning the possible
availability of such protection.
T7A005
Use a signal person and flagman
Know and use the hand signals required for
particular jobs and make sure who has the
responsibility for signaling.
 All personnel must fully understand all the
signals.
 The operator shall respond to signals only
from the appointed signal person, but
shall obey a stop signal at any time from
anyone.
 The signal person must stand in a clearly
visible location when giving signals.
Be sure to raise the safety bar
before leaving the operator’s seat
 Before leaving the operator’s seat:
• Lower the lift arms to the ground or
engage the lift arm stop.
• Stop the engine.
• Raise the safety bar to engage the lock.
• Remove the key and take it with you.
 If any controls are touched accidentally
when the safety bar is lowered, the
machine will move suddenly, and cause
serious injury or death.

SAFETY
10
General Precautions
Avoid fire and explosion hazards
Keep flames away from fuel, hydraulic fluid,
oil, grease and antifreeze. Fuel is particularly
flammable and dangerous.
 When handling these combustible
materials, keep lit cigarettes, matches,
lighters and other flames or sources of
flames away.
 Do not smoke or permit open flames while
fueling or near fueling operations.
 Never remove the fuel cap or refuel with
the engine running or hot. Never allow fuel
to spill on hot machine components.
 Clean up spilled fuel, oil and other
flammable fluids immediately.
 Check for fuel, oil and hydraulic fluid leaks.
Stop all leaks and clean the machine
before operating.
 Do not cut or weld on pipes or tubes that
contain flammable fluids. Clean thoroughly
with nonflammable solvent before cutting
or welding.
 Remove all trash and debris from the
machine. Make sure that oily rags and
other flammable material are not stored
on the machine.
 Handle all solvents and dry chemicals
according to procedures identified on
manufacturers’ containers. Work in a well-
ventilated area.
 Never use fuel for cleaning purposes.
Always use a nonflammable solvent.
 Store all flammable fluids and materials
in a safe, fireproof and well-ventilated
place.
Fire prevention
When working in a certain environment, it is
impossible to prevent combustible debris
from collecting in the machine. This debris,
in itself, may cause a fire; however, when
mixed with fuel, oil or grease in a hot or
confined place, the danger of fire is greatly
increased.
The following fire prevention guidelines
should be used to supplement the operator’s
fire prevention efforts. In no case should
the guidelines be used, or assumed, as
replacements for diligent operator efforts
at preventing fires. (that include regular
schedule of cleaning and inspecting the
machine as conditions require.)
The following guidelines will help to keep
your equipment up and running efficiently
and keep the risk of fire to a minimum.
1. Maintain a CHARGED fire extinguisher
on or near the machine at all times and
KNOW HOW TO USE IT.
2. Remove debris and blow out dust regularly
from side air intake areas, engine radiator,
hydraulic oil cooler, air conditioning
condenser core to prevent overheating of
the engine and hydraulics and to maintain
efficient operation of the machine.
3. Blow off all accumulated debris near hot
engine exhaust components (turbocharger
and exhaust manifold as well as exhaust
pipes and muffler) at the completion of
each work shift or more frequently when
AU1E001

11
SAFETY
General Precautions
working in severe conditions where
large amounts of combustible debris
are present. Engine exhaust systems
provide numerous small pockets where
flammable debris can gather. Even small
accumulations close to hot exhaust
components can ignite and smolder.
4. Clean out all accumulated debris (twigs,
pine needles, branches, bark, leaves,
saw dust, small wood chips) and any
other combustible materials from inside
the machine belly pans or lower machine
structures as well as from areas in
proximity to the engine, fuel and hydraulic
oil systems no less frequently than at the
completion of each work shift.
5. Inspect the machine regularly for any
signs of diesel fuel or hydraulic system
leakage. Check for worn or damaged fuel
or hydraulic lines before starting up any
equipment.
6. Clean up any grease, diesel fuel, hydraulic
and lubricating oil accumulation and
spillage immediately.
7. Steam clean the engine, and belly pan areas
at least once a month or more frequently
when working in sever conditions where
large amounts of combustible debris are
present.
8. Use only nonflammable solutions for
cleaning the machine and components.
9. Inspect the exhaust system daily for any
signs of leakage. Check for worn, cracked,
broken or damaged pipes or muffler. Also
check for missing or damaged bolts or
clamps. Should any exhaust leaks or
defective parts be found, repairs must
be made immediately. Engine exhaust
leaks can cause fires. Do not operate
the machine until the exhaust leak is
repaired.
10. During daily operation of the machine,
the occurrence of exhaust leaks are
usually accompanied by a change or
increase in engine exhaust noise levels.
These audible warnings cannot be
ignored. Should any exhaust leaks occur
during operation, the machine must be
shut down immediately and not put back
to work until the necessary repairs have
been completed.
11. Before starting repair work, such as
welding, the surrounding area should be
cleaned and a fire extinguisher should be
close by.
12. Do not use the machine on top of or to
push piles of burning timber. A machine
fire will likely result.
What to do to prepare for a machine
fire
 Prevent the fire from happening in the
first place by ensuring that all machine
systems are frequently inspected and
always well maintained.
 Ensure that any hand held fire extinguishers
are charged and in working order. Fire
extinguishers require routine care. Follow
the manufacturer’s instructions for
inspection and maintenance shown on
the label of the fire extinguisher and in the
extinguisher manufacturer’s manual.
 Ensure that you follow all national, state
/ provincial and local regulations dealing
with fire fighting in effect in your specific
geographic region.
 Ensure that all information necessary for
you to immediately contact all sources
of help (local fire department, etc) in the
event of a fire emergency is recorded and
readily available at all times.

SAFETY
12
General Precautions
What to do if a machine fire occurs
If operating the machine when a fire occurs:
1. Lower all working attachments to the
ground.
2. Shut the engine off.
3. Exit the machine. Call for help. Be
certain to report a fire immediately.
4. At all times ensure your own personal
safety and the safety of anyone that
may be in the area. Approach any fire
with extreme caution. All fires can be
very dangerous and life threatening.
Before deciding to fight the fire, be certain
that:
1. The fire is small and not rapidly
spreading.
2. There is always a clear, safe escape
route.
3. You have received training in the use of
the available fire extinguishing devices
and are confident that you can operate
them effectively.
 Be aware that engine coolant, diesel fuel
or hydraulic hoses could fail during a fire.
If this happens, hot coolant, fuel or oil
could possibly be ignited by the fire.
 If in any doubt about whether or not to
fight the fire – DON’T. Instead stand well
clear of the fire and wait for help to arrive.
 Use the PASS method. This is the most
effective use of a fire extinguisher.
• Pull the pin at the top of the extinguisher
that keeps the handle from being
pressed. Break the plastic seal as the
pin is pulled.
• Aim the nozzle at the base of the fire. Do
not aim the nozzle at the flames. In order
to put out the fire, you must extinguish
the fuel, not the flames. Hose nozzles
are often clipped to the extinguisher
body. Release the hose before taking
aim.
• Squeeze the handle to release the
pressurized extinguishing agent. The
handle can be released at any time to
stop the discharge.
• Sweep from side to side at the base of
the fire until the fire is completely out or
the fire extinguisher is empty
 Only if you can safely do so, open the
access panels to the machine in the area
of the fire.
 Failing all attempts to access the machine
compartment, discharge the extinguisher
through the mesh or any available
openings on the machine.
 Ensure that the machine and all
components have cooled down
sufficiently after a fire so that re-ignition
does not occur.
 Remain in the area until help arrives.
What to do after a machine fire has
occurred
 Before returning the machine to work.
1. Ensure that the cause of the fire is
determined and all appropriate repairs
are completed.
2. Ensure that all extinguishers used
in fighting the fire are replaced or
recharged.
 Notify your equipment dealer and / or
GEHL Manufacturing.

13
SAFETY
Exhaust fumes from the engine
can kill
 Do not operate the engine in an enclosed
area without adequate ventilation.
 If natural ventilation is poor, install
ventilators, fans, exhaust extension pipes
or other artificial venting devices.
Handling asbestos dust
Inhaling asbestos dust has been linked to
lung cancer. When handling materials which
may contain asbestos, take the following
precautions:
 Never use compressed air for cleaning.
 Avoid brushing or grinding of the
materials.
 For clean up, use wet methods or a
vacuum equipped with a high efficiency
particulate air (HEPA) filter.
 Wear an approved respirator if there is
no other way to control the dust. When
working indoors, install a ventilation
system with a macro molecular filter.
General Precautions

SAFETY
14
General Precautions
Be careful not to get crushed or cut
 Your body, hands and feet must not enter
between moving parts, such as between
lift arms and main body, or between lift
arms and bucket. When operating lift arms
and bucket, the gap between the moving
parts will be changing, and getting caught
in between can cause serious injury or
death .
 The lift arms move close to the outside of
the side screens; never stick out arms or
other portions of your body from the side
screens.
 The lift arms move close to the ROPS;
therefore, do not stand or lean on the
machine.
T7A007
T7A008
T8A006
Using optional products
 Consult with a Gehl dealer before installing
optional attachments.
 Do not use attachments that have not
been approved by Gehl. Doing so may
compromise safety or adversely affect the
machine’s operation or service life.
 Gehl will not be responsible for any injuries,
accidents or damage to its products
caused by the use of a non-approved
attachment.
Product usage
Keep in mind that the use of high-output
brush cutter attachments on this unit can
only be used in part-time, lighter-duty brush
clearing applications, with appropriate
cooling system care and in moderate
ambient temperatures. Care with respect to
usage and prevention of track damage must
also be adhered to.
This usage notice also applies to all
other high-performance, high-demand
attachments.
Never modify the machine
Unauthorized modifications to this machine
can cause injury or death. Never make
unauthorized modifications to any part of
this machine.

15
SAFETY
Preparing Precautions
Know the working area
Before starting operation, know the working
area to ensure safety.
 Check the topography and ground
condition of the working area, or the
structure of the building when working
indoors, and take the necessary safety
measures in dangerous spots.
 Note and avoid all hazards and obstructions
such as ditches, underground lines, trees,
cliffs, overhead electrical wires and areas
where there is danger of a slide.
 Check with the local utilities for the
locations of buried gas and water pipes
and buried power cables. Determine
jointly what specific precautions must be
taken to ensure safety.
 When working on roads, be sure to take
into account the safety of pedestrians and
vehicles.
• Use a flagman and/or signals.
• Fence off the working area and prohibit
entry to unauthorized persons.
 When working in water or crossing shallow
streams or creeks, check the depth of the
water, the firmness of the ground, and the
speed of the current beforehand. Make
sure the water is not deeper than the
allowable depth.
Refer to the section titled “Cautions on
Use in Water” for further instructions.
Check the strength of the bridge
When travelling over a bridge or other
structure, check the permissible load. If the
strength is insufficient, reinforce it.
Always keep the machine clean
 Clean windows, mirrors and lights to
ensure good visibility.
 Wipe off any oil, grease, mud, snow and
ice, to prevent accidents due to slipping.
 Remove all loose objects stored in the
machine and all objects that do not belong
in or on the machine and its equipment.
 Remove any dirt, oil and grease from the
engine area, to prevent fires.
 Clean the area around the operator’s seat,
removing any potential obstacles.
T7A009
T7A025
T3A004

SAFETY
16
Preparing Precautions
Perform inspection and
maintenance daily
Failure to notice and repair machine
malfunctions or damage can lead to
accidents.
 Before operating, perform the prescribed
inspections and make repairs immediately
if any malfunctions are found.
 If a failure that causes loss of control,
such as steering, service brakes or engine
occurs, stop the machine motion as
quickly as possible, follow the shutdown
procedure, and keep machine securely
parked until the malfunction is corrected.
Emergency Exit
If you become trapped inside the cab,
remove the rear window to get out.
There are two ways to remove the rear
window.
In case of emergency
Kick off the rear window. Note that the glass
may break. Be careful not to get injured.
In case of need
1. Pull off ring (A) and remove the tip of the
rubber wedge.
2. Grasp the tip, pull, and remove the entire
rubber wedge.
3. Pull inside knob (B).
E X I T
T8B001
A
B

17
SAFETY
Starting Precautions
Maintain three-point contact
when mounting and dismounting
 Do not jump on or off the machine. Never
attempt to mount or dismount a moving
machine.
 For machines with cab, when mounting
and dismounting the cab, first open the
door fully to the locked position and check
that it does not move.
 Always face the access system and
maintain a three-point contact with the
recommended handrails and steps while
getting on and off the machine. Keep
steps and platform clean.
 Never use the control levers as hand
holds.
 Do not go under the raised lift arms if they
are not sufficiently supported.
 Lower the lift arms to the ground before
mounting or dismounting the cab.
Clear the area of other persons
before starting the machine
Do not start the engine until you are sure it
is safe. Before starting, check or perform the
following.
 Walk around the machine and warn all
personnel who may be servicing the
machine or are in the machine path. Do
not start until all personnel are clearly
away from the machine.
 Check for any “DO NOT OPERATE” tags
or similar warning notices on the cab door,
controls and ignition switch.
 Sound horn to alert everyone around the
machine.
Start the engine from the
operator’s seat
 Adjust, secure and latch the operator’s
seat.
 Fasten the seat belt.
 Check that the parking brake is applied
and place all controls in the neutral
position.
 Check that the safety bar is in the lock
position.
 Clear the area of all persons.
 Start and operate the engine from the
operator’s seat only.
 Never attempt to start the engine by
shorting across the starter terminals.

SAFETY
18
Starting Precautions
Starting with jumper cables
Use jumper cables only in the recommended
manner. Improper use of jumper cables can
result in battery explosion or unexpected
machine motion.
Refer to the section titled “If the Battery Goes
Dead” for proper instructions.
After starting the engine
After starting the engine, perform the
following operations and checks in a safe
place with no persons or obstacles in the
area. If any malfunctions are found, follow
the shutdown procedure and report the
malfunction.
 Warm up the engine and hydraulics.
 Observe all gauges and warning
instruments for proper operation.
 Listen for unusual noises.
 Test engine speed control.
 Operate each control to ensure proper
operation.
In cold weather
 Be careful of slippery conditions on
freezing ground, steps and hand holds.
 In severe cold weather, do not touch any
metal parts of the machine with exposed
flesh, because flesh can freeze to the
metal and cause injury.
 Do not use ether or starting fluids on this
engine. These starting aids can cause
explosion and serious injury or death.
 Warm up the engine and hydraulic fluid
before operating.