Gehl CTL60 Track Loader Troubleshooting

The Gehl CTL60 compact track loader is powered by 202.5 cu.in (3.3L) Yanmar 4TNV98 vertical in-line 4-cylinder liquid-cooled diesel engine with a rated power of 67 hp (49.3 kW) at 2500 rpm. The Gehl CTL60 is equipped with a two-speed hydro transmission, radial-lift loader boom, undercarriage with four steel rollers, and 12.6" (320 mm) rubber tracks. The hydraulic system has a pump with fluid flow rate of 18 gpm (68.2 lpm). The hydraulic pressure is 3000 psi (207 bar). The track loader has a rated operating capacity of 1620 lbs (735 kg) and tipping load of 4630 lbs (2100 kg). The lift height is 119.3" (3030 mm) to hinge pin, and dump height is 93.4" (2370 mm).

Engine Troubleshooting

Engine difficult to start or will not start

Air in fuel tank - Bleed fuel tank.
Clogged fuel filter - Change filter element.
Defective or clogged injection nozzle - Service or change injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Excessive valve clearance - Adjust valve clearance.
Fuel injection pump is not operating properly - Replacement or repair required.

Engine starts and stalls suddenly

Dirty air filter - Change or service air filter element.
Clogged fuel filter - Replace filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Fuel injectors are dirty or defective - Inspect fuel injectors and change as required.
Damaged fuel injection pump - Change pump or rebuild it.

Engine stops running suddenly

Low coolant temperature - Warm up the engine to required temperature.
Fuel filter element is clogged - Change filter element.
Air in fuel system - Bleed fuel system.
Damaged or dirty injection nozzles - Check and replace nozzles if required.
Timing of fuel injection pump is incorrect - Adjust as recommended.

Engine stalls while idle

Wrong adjustment of low idle speed - Correct the settings.
Fuel injection pump is broken - Replace injection pump or repair it.
Clogged or defective injectors - Replace fuel injectors.
Valve out of adjustment - Adjust to proper valve clearance.

Engine power loss

Dirty air filter - Service or replace the air filter.
Dirty or faulty injection nozzles - Change fuel injection nozzles.
Uneven fuel injection pressure - Adjust to correct pressure.
Valve clearance is wrong - Adjustment procedure required.
Incorrect low idle speed adjustment - Adjust the low idle speed.
Dirt in the fuel hoses or lines - Fuel hoses and lines must be clean.
Cylinder head gasket is defective - Replace cylinder head gasket.
Leaking or defective piston rings - Piston rings replacement required.

Engine is overheated

Coolant level is low - Add coolant fluid to cooling system and also check it for leaks.
Low engine oil level - Add oil to the engine crankcase.
Clogged radiator fins or damaged radiator cap - Change cap or clean radiator.
Fan belt is worn or faulty - Install new fan belt.
Engine is overloaded - Reduce engine load.

Oil pressure is low

Insufficient engine oil - Fill crankcase to proper oil level.
Dirty oil filter - Change or clean engine oil filter element.
Incorrect oil viscosity - Use the specified type of engine oil.
Excessive oil clearance of crankshaft bearing - Replace bearings.
Oil pump is worn or damaged - Install a new pump.

Engine knocks or noises

Not enough engine oil - Fill the crankcase with engine oil.
Low coolant temperature - Warm up the engine.
Timing of fuel injection pump is incorrect - Set the fuel pump timing correctly.
Wrong adjustment of low idle speed - Adjust low idling as recommended.
Defective fuel injectors - Replace fuel injectors.
Misaligned or defective connecting rod - Need to replace or align the connecting rod.
Broken or worn pistons - Pistons need to be replaced.

Drive System Troubleshooting

Machine does not move forward or backward

Insufficient hydraulic oil - Need to add oil.
Track mechanism is blocked or damaged - Correct blockage or repair tracks.
Relief valve malfunction - Rebuild or install a new relief valve.
Suction line or hydraulic filter is clogged - Clean suction line or replace hydraulic filter.
Worn or damaged foot or hand controls - Repair or change.
Drive motor or pump failure - Replace or repair faulty component.

Machine does not drive straight or drives jerky

Track mechanism is defective or jammed - Remedy jamming or repair tracks.
Tracks are improperly tensioned or faulty - Adjust track tension as required or replace tracks.
Foreign objects, debris, or dirt jammed in track frame - Remove debris or foreign objects and clean track frame.

Reduced power

Dirty hydraulic oil filter - Check, clean, or change as necessary.
Relief valve is damaged or open - Replace or close relief valve.
Transmission parts are faulty or damaged - Check and replace faulty components.
Input drive shaft is damaged - Replace drive shaft.
Hydraulic system is leaking air - Need to bleed air.

Drive system is overheated

Insufficient hydraulic oil - Check and refill the hydraulic oil.
Plugged hydraulic fluid filter - Replace or clean hydraulic filter.
Relief valve malfunction - Repair or replace relief valve.
Drive pump or hydraulic motor is damaged - Replace or repair faulty component.
Dirty oil cooler - Cooling fins need to be cleaned.
Overloaded drive system - Load needs to be reduced.

Drive system makes excessive noise

Improper oil viscosity - Use correct oil viscosity.
Air trapped in hydraulic system - Bleed hydraulic system.
Drive pump or hydraulic motor is damaged - Inspect and replace as necessary.
Worn or defective mechanical components of drive system - Check drive system and change faulty components.

Hydraulics Troubleshooting

Hydraulic system overheated

Incorrect hydraulic pressure setting - Correct setting is required.
Main relief valve improper adjustment or failure - Adjust or change relief valve.
Hydraulic oil is contaminated - The oil must be changed.
Not enough hydraulic oil in the system - Fill the hydraulic system with oil.
Hydraulic pump is faulty - Install new pump or repair it.

Lift arm can't drop or lift

Lift controls are damaged - Inspect and repair if necessary.
Hydraulic pump malfunction - Repair or replace pump if necessary.
Hydraulic control valve failure - Repair or change the valve.
Faulty hydraulic cylinder - Repair or replace hydraulic cylinder.
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.

Bucket fails to tilt

Bucket tilt controls malfunction - Inspect and repair if necessary.
Hydraulic pump malfunction - Replace or repair pump if necessary.
Faulty hydraulic control valve - Repair or change hydraulic valve.
Damaged bucket cylinder - Change or repair cylinder.
Insufficient hydraulic oil - Need to add oil.

Boom or bucket is moving slowly

Worn hydraulic oil pump - Test the pump flow rate and change pump if required.
Oil leaks from hydraulic cylinder - Cylinder seals need to be replaced.
Insufficient hydraulic fluid - Checking hydraulic fluid level and add if necessary.
Defective or not adjusted hydraulic control valve - Repair or adjust correctly.
Low hydraulic pressure - Adjust pressure as required.

Jerky operation of the bucket or boom

Air leaks in hydraulic system - Bleed air from hydraulic system.
Dirty hydraulic oil filter - Clean or install new filter.
Contaminated hydraulic oil - Fill up with fresh hydraulic oil.
Scratched cylinder rod or tube - Change worn component.

Excessive hydraulic pump noise

Hydraulic leakage or lack of oil - Repair hydraulic leaks or add oil as required.
Hydraulic filter is clogged - Clean or replace the filter.
Dirty suction line - Suction line needs to be cleaned.
Air in hydraulic pump - Need to bleed air.
Damaged pump components - Rebuild or install new pump.

Electrical Troubleshooting

Battery will not charge

Corroded or loose wire connections - Service or tighten connections.
Battery terminal clamps are faulty - Terminal clamps should be changed.
Bad cell in battery - Install a new battery.
Loose or worn belt - Replace belt or adjust belt tension.

Starter motor turns slow

Battery power is low - Low battery charging, charge as required.
Battery runs out quickly - Service charging system or install new battery.
Disconnected cables or faulty battery terminals - Check cables and clean or change terminals.

Starter motor won't turn

Battery is discharged or worn - Replace or charge as required.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Battery voltage is low - Battery is drained, charge it.
Starter motor is damaged - Starter needs to be replaced.