Gehl CTL55 CTL65 CTL75 CTL85 Compact Track Loader Operator’s Manual 917299 – PDF DOWNLOAD

Gehl CTL55 CTL65 CTL75 CTL85 Compact Track Loader Operator’s Manual 917299 – PDF DOWNLOAD

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Gehl CTL55 CTL65 CTL75 CTL85 Compact Track Loader Operator’s Manual 917299 – PDF DOWNLOAD

Language : English
Pages : 202
Downloadable : Yes
File Type : PDF
Size: 5.52 MB

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DESCRIPTION:

Gehl CTL55 CTL65 CTL75 CTL85 Compact Track Loader Operator’s Manual 917299 – PDF DOWNLOAD

INTRODUCTION:
Foreword:

• This manual describes operation, inspection and maintenance of the machine, as well as
  safety instructions to be heeded during these operations.
• If you have any questions about the machine, please contact a Gehl dealer.

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

TABLE OF CONTENTS:

Gehl CTL55 CTL65 CTL75 CTL85 Compact Track Loader Operator’s Manual 917299 – PDF DOWNLOAD

Cover…………………………………………………………………………. 1
SAFETY ALERT SYMBOL…………………………………………………………….. 2
EXPLANATION OF GRAPHICAL SYMBOLS……………………………………………… 3
SlGNAL WORDS……………………………………………………………….. 3
INTRODUCTION…………………………………………………………………… 4
Foreword…………………………………………………………………… 4
Manual storage……………………………………………………………… 4
Serial numbers……………………………………………………………… 4
MACHINE DESCRIPTION…………………………………………………………….. 5
Front, rear, Ieft and right………………………………………………….. 5
Designated operations……………………………………………………….. 5
Features…………………………………………………………………… 5
Break-in period…………………………………………………………….. 5
CONTENTS………………………………………………………………………. 7
SAFETY………………………………………………………………………… 9
General Precautions…………………………………………………………. 10
Observe all safety rules…………………………………………………. 10
Wear appropriate clothing and personal protective equipment………………….. 10
Operating temperature range………………………………………………. 10
Provide a fire extinguisher and first aid kit………………………………. 10
Never remove safety equipment…………………………………………….. 11
Crush Hazard FOPS Limitations…………………………………………….. 11
Use a signal person and flagman…………………………………………… 11
Be sure to raise the safety bar before leaving the operator’s seat……………. 11
Avoid fire and explosion hazards………………………………………….. 12
Fire prevention…………………………………………………………. 12
Exhaust fumes from the engine can kill…………………………………….. 15
Handling asbestos dust…………………………………………………… 15
Be careful not to get crushed or cut………………………………………. 16
Using optional products………………………………………………….. 16
Product usage…………………………………………………………… 16
Never modify the machine…………………………………………………. 16
Preparing Precautions……………………………………………………….. 17
Know the working area……………………………………………………. 17
Check the strength of the bridge………………………………………….. 17
Always keep the machine clean…………………………………………….. 17
Perform inspection and maintenance daily…………………………………… 18
Emergency Exit………………………………………………………….. 18
Starting Precautions………………………………………………………… 19
Maintain three-point contact when mounting and dismounting…………………… 19
Clear the area of other persons before starting the machine………………….. 19
Start the engine from the operator’s seat………………………………….. 19
Starting with jumper cables………………………………………………. 20
After starting the engine………………………………………………… 20
In cold weather…………………………………………………………. 20
Operating Precautions……………………………………………………….. 21
Ensure good visibility…………………………………………………… 21
Do not permit riders on the machine……………………………………….. 21
Operate the machine only from the operator’s seat…………………………… 21
Check for safety in the surrounding area before starting…………………….. 21
Keep your body inside the operator’s cab…………………………………… 21
Cautions on traveling and turning…………………………………………. 22
Cautions on traveling on slopes…………………………………………… 23
Use caution when floating the lift arms……………………………………. 23
Do not drive into materials at high speeds…………………………………. 24
Operate on snow or ice with extra caution………………………………….. 24
Do not carry the bucket over the heads of people……………………………. 24
Caution against falling unstable loads…………………………………….. 24
Do not suddenly stop or lower the working equipment…………………………. 25
Avoid overloading and off-center loads…………………………………….. 25
Keep a safe distance from electrical power lines……………………………. 25
Watch out for hazardous working conditions…………………………………. 26
Travel in narrow or congested places………………………………………. 26
Precautions when passing through tunnels or near high walls………………….. 26
Do not drive on soft ground………………………………………………. 26
Loaders are NOT designed for lifting loads…………………………………. 27
Danger of flying objects…………………………………………………. 27
Cautions on towing………………………………………………………. 27
Stopping Precautions………………………………………………………… 28
Park safely…………………………………………………………….. 28
Transporting Precautions…………………………………………………….. 29
Load and unload the machine safely………………………………………… 29
Transport the machine safely……………………………………………… 29
Hoisting the machine safely………………………………………………. 29
Maintenance Precautions……………………………………………………… 30
Attach a “DO NOT OPERATE” tag…………………………………………….. 30
Use the correct tools……………………………………………………. 30
Replace important safety parts periodically………………………………… 30
Anti-explosive lighting………………………………………………….. 30
Do not allow unauthorized personnel in the work area………………………… 30
Prepare the work area……………………………………………………. 31
Always clean the machine…………………………………………………. 31
Stop the engine before performing maintenance………………………………. 31
Stay clear of moving parts……………………………………………….. 31
Securely block the machine or any component that may fall……………………. 32
Securely block the raised lift arms……………………………………….. 32
Secure the rear door when opened………………………………………….. 32
Cautions on tilting up the ROPS…………………………………………… 32
Place heavy objects in a stable position…………………………………… 32
Use caution when fueling…………………………………………………. 33
Handling of hoses……………………………………………………….. 33
Be careful with hot and pressurized components……………………………… 33
Be careful with hot cooling systems……………………………………….. 34
Be careful with fluids under pressure……………………………………… 34
Release all pressure before working on the hydraulic system………………….. 34
Be careful with grease under pressure……………………………………… 34
Never disassemble the track adjuster………………………………………. 35
Disconnect the battery…………………………………………………… 35
Avoid battery hazards……………………………………………………. 35
Have a Gehl technician repair weld cracks or other damage……………………. 36
Safety signs……………………………………………………………. 36
Vibrations to which the operator is subjected………………………………. 36
Checks after maintenance…………………………………………………. 36
Disposing of wastes……………………………………………………… 36
Handling of poisonous chemicals…………………………………………… 36
Safety Signs (Decals)……………………………………………………….. 37
CONTROLS………………………………………………………………………. 41
Names of Components…………………………………………………………. 42
Doors and Covers……………………………………………………………. 44
Ignition Key……………………………………………………………. 44
Cab Door < CTL55 >………………………………………………………. 44
Side Window < CTL55 >……………………………………………………. 45
Engine Hood…………………………………………………………….. 46
Rear Door………………………………………………………………. 46
Emergency Exit………………………………………………………….. 47
Lift Arm Stop…………………………………………………………… 48
Fuel Filler Cap…………………………………………………………. 49
Seat and Seat Belt………………………………………………………….. 50
Seat < CTL55 >………………………………………………………….. 50
Seat Belt < CTL55 >……………………………………………………… 51
Seat < CTL65 / CTL75 / CTL85 >……………………………………………. 52
Seat Belt < CTL65 / CTL75 / CTL85 >……………………………………….. 53
Instrument Panel……………………………………………………………. 54
Warning Lamps…………………………………………………………… 54
Indicators……………………………………………………………… 55
Meters…………………………………………………………………. 55
Engine Fault Warning Lamp < CTL55 / CTL65 / CTL75 >…………………………. 55
Switches…………………………………………………………………… 56
Ignition Switch…………………………………………………………. 56
Horn Button…………………………………………………………….. 56
Float Button……………………………………………………………. 56
Auxiliary Hydraulic Switches……………………………………………… 58
Travel Speed Button……………………………………………………… 60
Light Switches………………………………………………………….. 60
Wiper Switches (Option)………………………………………………….. 60
Levers and Pedals T7B015 U1B014 B A…………………………………………… 61
Safety Bar……………………………………………………………… 61
Throttle Lever………………………………………………………….. 61
Throttle Pedal………………………………………………………….. 61
Right Control Lever……………………………………………………… 62
Left Control Lever………………………………………………………. 62
Accessories………………………………………………………………… 63
Interior Light (Option)………………………………………………….. 63
Auxiliary Hydraulic Lines………………………………………………… 64
High-flow Hydraulic System (If Equipped)…………………………………… 65
OPERATION……………………………………………………………………… 71
Before Starting Operation……………………………………………………. 72
Mounting and Dismounting…………………………………………………. 72
Walk-Around Inspection…………………………………………………… 72
Daily Inspection………………………………………………………… 72
Starting and Stopping the Engine……………………………………………… 73
Before Starting the Engine……………………………………………….. 73
Starting the Engine……………………………………………………… 74
Warming Up the Engine……………………………………………………. 75
Stopping the Engine……………………………………………………… 75
Machine Operation…………………………………………………………… 76
Lever Pattern…………………………………………………………… 76
Warming Up the Hydraulics………………………………………………… 77
Inspection After Warm-up…………………………………………………. 78
Operating the Left Control Lever………………………………………….. 79
Operating the Right Control Lever…………………………………………. 82
Operating the Auxiliary Hydraulics………………………………………… 83
Operating Procedures………………………………………………………… 84
Prohibited Operations……………………………………………………. 84
Cautions on Operating……………………………………………………. 86
Cautions on Traveling on Slopes…………………………………………… 88
Operations Possible with this Machine……………………………………… 90
Parking the Machine…………………………………………………………. 92
Parking………………………………………………………………… 92
Inspection and Checks After Stopping the Engine…………………………….. 92
Operating in Cold Weather……………………………………………………. 93
Preparing for Cold Weather……………………………………………….. 93
Cautions after Completing Operations………………………………………. 93
After Cold Weather is Over……………………………………………….. 93
Using Rubber Tracks…………………………………………………………. 94
Prohibited Actions………………………………………………………. 94
Precautions…………………………………………………………….. 95
TRANSPORT……………………………………………………………………… 97
Hoisting the Machine………………………………………………………… 98
Loading and Unloading………………………………………………………..100
Securing the Machine…………………………………………………………101
Cautions on Transporting……………………………………………………..102
MAINTENANCE…………………………………………………………………….103
General…………………………………………………………………….104
Maintenance Description…………………………………………………..104
Cautions on Maintenance…………………………………………………..104
Service Data………………………………………………………………..106
Lubricant and Fuel Chart………………………………………………….106
Expendables……………………………………………………………..108
Tools…………………………………………………………………..109
Tightening Torques……………………………………………………….110
Important Parts……………………………………………………………..111
Maintenance Chart……………………………………………………………112
Maintenance Log……………………………………………………………..114
Walk-Around Inspection……………………………………………………….116
Inspecting by Opening the Engine Hood and Rear Door………………………….116
Inspecting by Walking Around the Machine……………………………………117
Inspecting While Sitting in the Operator’s Seat……………………………..117
Daily Inspection (Every 10 Hours)……………………………………………..118
Inspecting and Replenishing the Coolan……………………………………..118
Inspecting and Replenishing the Engine Oil………………………………….119
Inspecting the Water Separator…………………………………………….119
Inspecting the Fuel Level…………………………………………………120
Inspecting the Hydraulic Oil Level and Replenishing………………………….121
Lubricating the Working Equipment………………………………………….122
After First 50 Hours (New Machines Only)……………………………………….124
Replacing the Hydraulic Oil Return Filter…………………………………..124
Replacing the Engine Oil and Oil Filter…………………………………….125
Inspecting and Adjusting the Fan Belt………………………………………127
Replacing the Pilot Line Filter……………………………………………128
Every 50 Hours………………………………………………………………130
Inspecting and Adjusting the Track Tension………………………………….130
Inspecting the Battery Fluid Level and Replenishing………………………….132
Draining the Fuel Tank……………………………………………………134
Inspecting the Bucket Stoppers (bolts / nuts)……………………………….135
Every 100 Hours……………………………………………………………..136
Cleaning the Water Separator………………………………………………136
After First 250 Hours (New Machines Only)………………………………………137
Replacing the Travel Motor Gear Oil………………………………………..137
Every 250 Hours……………………………………………………………..138
Replacing the Air Cleaner Elements…………………………………………138
Cleaning the Radiator Fins and Oil Cooler Fins………………………………139
Replacing the Engine Oil and Oil Filter…………………………………….139
Inspecting and Adjusting the Fan Belt………………………………………139
Cleaning the Condenser < CTL55 Option >…………………………………….139
Inspecting and Adjusting the Air Conditioner Belt < CTL55 Option >…………….139
Every 500 Hours……………………………………………………………..140
Replacing the Fuel Filter…………………………………………………140
Replacing the Hydraulic Oil Return Filter…………………………………..141
Replacing the Pilot Line Filter……………………………………………141
Replacing the Travel Motor Gear Oil………………………………………..141
Adjusting or Replacing the Bucket Stoppers (bolts / nuts)…………………….142
Every 1000 Hours…………………………………………………………….144
Cleaning the Engine Cooling System…………………………………………144
Replacing the Hydraulic Oil and Cleaning the Suction Strainer…………………146
Inspecting and Adjusting the Engine Valve Clearance………………………….148
Retightening the Engine Cylinder Head Bolts…………………………………148
Every 1500 Hours…………………………………………………………….148
Inspecting and Cleaning the Engine Fuel Injectors……………………………148
Inspecting the Crankcase Breather System……………………………………148
Every 2000 Hours…………………………………………………………….149
Lapping the Engine Valve Seats…………………………………………….149
Every 3000 Hours…………………………………………………………….149
Inspecting the Turbocharger (Blower wash as necessary) <CTL55 / CTL75 / CTL85>….149
Inspecting and Cleaning the EGR Valve, Lead Valve and Cooler………………….149
When Required……………………………………………………………….150
Replacing the Bucket or Attachment…………………………………………150
Lubricating the Levers……………………………………………………152
Inspecting and Replenishing the Windshield Washer Fluid………………………152
Tilting Up the ROPS………………………………………………………153
Inspecting the Rubber Tracks………………………………………………154
Long-term Storage……………………………………………………………155
TROUBLESHOOTING…………………………………………………………………157
Symptoms that Are Not Malfunctions…………………………………………….158
If the Engine Overheats………………………………………………………159
If the Battery Goes Dead……………………………………………………..160
After the Fuel Runs Out………………………………………………………161
Bleeding the Air from the Fuel System………………………………………161
If a Fuse Blows……………………………………………………………..162
Inspecting and Replacing Fuses…………………………………………….162
Inspecting the Fusible Link……………………………………………….163
If a Warning Lamp Flashes…………………………………………………….164
Other Symptoms………………………………………………………………166
To Lower the Lift Arms……………………………………………………….168
Towing……………………………………………………………………..169
SPECIFICATIONS………………………………………………………………….171
Main Specifications………………………………………………………….172
Machine Dimensions…………………………………………………………..176
Operating Range……………………………………………………………..178
OPTIONS………………………………………………………………………..181
General Precautions………………………………………………………….182
Precautions on Safety…………………………………………………….182
Precautions on Installing Attachments………………………………………182
Precautions on Operating Attachments……………………………………….183
Air Conditioner < CTL55 >…………………………………………………….184
CAUTIONS ON USE………………………………………………………….184
Ventilate periodically……………………………………………………184
Always maintain good visibility……………………………………………184
Do not overcool………………………………………………………….184
Do not turn the air conditioner on until the engine is started………………..184
Let hot air out first…………………………………………………….184
Caution on refrigerant (gas)………………………………………………184
NAMES OF COMPONENTS………………………………………………………185
Air Conditioner Switch……………………………………………………186
Temperature Control Dial………………………………………………….186
Fan Switch………………………………………………………………186
Outlets…………………………………………………………………187
OPERATION……………………………………………………………….187
Heating and Dehumidifying (in cold weather or when the humidity is high)……….187
Cooling…………………………………………………………………187
Defogging the Windows…………………………………………………….188
INSPECTION AND MAINTENANCE………………………………………………..189
Cleaning the Condenser……………………………………………………189
Inspecting and Adjusting the Air Conditioner Belt……………………………189
Cleaning the Filter………………………………………………………190
Inspecting the Refrigerant (gas) Level……………………………………..190
Off-Season Inspection…………………………………………………….191
Condition of the refrigerant………………………………………………192
INDEX………………………………………………………………………….195
A ~ D………………………………………………………………………196
D ~ I………………………………………………………………………197
I ~ M………………………………………………………………………198
N ~ S………………………………………………………………………199
S ~ W………………………………………………………………………200
GEHL COMPANY WARRANTY……………………………………………………………201
California Proposition 65 Warning…………………………………………………202