Gehl CTL65 Track Loader Troubleshooting

The Gehl CTL65 compact track loader driveline system components: a 202.5 cu.in (3.3L) Yanmar 4TNV98-ZNTBL 4-cycle 4-cylinder liquid-cooled naturally aspirated diesel engine with a rated power of 67.1 hp (50.1 kW), and hydrostatic two-speed transmission. The hydraulic system has a pump with a rated flow of 18.4 gpm (69.7 lpm). The system pressure is 2990 psi (206 bar). The Gehl CTL65 is equipped with wet multi disc brakes, planetary final drives, and rubber tracks. The loader has a lift height of 119.3" (3030 mm) to hinge pin and dump height of 93.4" (2370 mm). The rated operating capacity is 1620 lbs (735 kg), and tipping load is 4630 lbs (2100 kg).

Engine Troubleshooting

Diesel engine hard to start or doesn't start

Air in the fuel pipes - Bleed the fuel pipes.
Dirty fuel filter - Clean or replace the filter.
Dirty or faulty injection nozzles - Test injection nozzles and change if necessary.
Dirt or water in fuel system - Drain water or flush dirt from the system.
The valve clearance is incorrect - Check and adjust as required.
Faulty fuel injection pump - Change or repair the pump.

Engine stalls after starting

Plugged air cleaner - Service or replace air cleaner.
Fuel filter element is clogged - Change the filter element.
Fuel injection pump has loose connections - Tighten the connections.
Fuel injectors are faulty or clogged - Replace fuel injectors.
Faulty fuel injection pump - Rebuild or install a new injection pump.

Engine stops unexpectedly during operation

Engine has not warmed up to recommended temperature - Warm up the engine.
Clogged fuel filter - Change filter element.
Air in fuel tank - Bleed fuel tank.
Clogged or burnt injection nozzle - Inspect nozzles and replace if necessary.
Improper setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.

Engine shuts off while idling

Low idle speed setting is incorrect - Normalize low idle speed.
Damaged fuel injection pump - Repair or change injection pump.
Damaged or clogged injectors - Replace or clean fuel injectors.
Valve clearance is wrong - Adjustment procedure required.

Engine power is insufficient

Dirty air cleaner - Clean or replace air cleaner element.
Dirty or faulty injection nozzles - Test injection nozzles and change if necessary.
Insufficient fuel injection pressure - Correct the pressure settings.
Improper valve clearance - Have it adjusted.
Low idle speed setting is not correct - Correct the settings.
Fuel hoses or lines are dirty - Fuel hoses and lines must be clean.
Cylinder-head gasket is leaking - Replace cylinder head gasket.
Piston rings are broken or leaking - Install new piston rings.

Engine overheated

Engine has a lack of coolant - Top up coolant fluid and check system for leaks.
Engine oil level is insufficient - Fill the crankcase with engine oil.
Faulty radiator cap or dirty radiator fins - Clean radiator or change cap.
Loose or damaged fan belt - Install new fan belt.
Engine is under excessive load - Reduce engine load.

Oil pressure too low

Oil level is low - Checking oil level and add if necessary.
Oil filter clogging - Change or service engine oil filter.
Incorrect oil viscosity - Drain and refill with oil of correct grade and viscosity.
Excessive crankshaft bearing oil clearance - Bearings need to be reinstalled.
Oil pump malfunction - Inspect and change as required.

Engine knocks or noises

Engine oil level low - Check oil level and add oil as required.
Engine is not preheated - Warm up engine as required.
Wrong setting of fuel injection pump timing - Set the fuel pump timing correctly.
Low idle speed set incorrectly - Adjustment required.
Defective fuel injectors - Change or clean fuel injectors.
Faulty or misaligned connecting rod - Align or change connecting rod.
Scored or worn pistons - Have pistons replaced.

Drive System Troubleshooting

Machine will not move forward or backward

Insufficient hydraulic fluid - Fill up the hydraulic fluid.
Blocked or defective track mechanism - Remove blockage or repair tracks.
Worn or damaged relief valve - Service or change relief valve.
Hydraulic filter or suction line is dirty - Replace hydraulic filter or clean suction line.
Faulty hand or foot controls - Change or repair.
Worn drive motor or pump - Replace or repair faulty component.

Machine does not drive straight or drives jerky

Damaged or jammed track mechanism - Remove jamming or repair tracks.
Sagging or faulty tracks - Correct track sag with tensioning or repair tracks.
Debris, dirt, or foreign objects jammed in undercarriage track frame - Clean track frame, remove foreign objects.

Loss of power

Dirty hydraulic oil filter - Check, clean, or replace as required.
Relief valve is damaged or open - Close or change relief valve.
Transmission components are defective or worn - Check and replace faulty components.
Input drive shaft is worn - Rebuild or change the shaft.
Air leaks in hydraulic system - Bleed air from hydraulic system.

Drive system overheating

Insufficient hydraulic fluid - Add fluid as required.
Hydraulic fluid filter is clogged - Check, clean, or change as necessary.
Relief valve failure - Rebuild or install a new relief valve.
Drive pump or hydraulic motor malfunction - Inspect and change as required.
Plugged hydraulic oil cooler - Cooling fins need to be cleaned.
Drive system overload - Reduce the load.

Excessive noise

Oil viscosity is too heavy - Use the specified type of oil.
Hydraulic system is leaking air - Bleed hydraulic system.
Drive pump or hydraulic motor is damaged - Repair or replace faulty component.
Mechanical parts of drive system are defective or worn - Inspect the parts and repair as needed.

Hydraulics Troubleshooting

Hydraulic system has overheating

Hydraulic pressure is not correct - Correct setting is required.
Main relief valve is faulty or misadjusted - Set up or change the relief valve.
Hydraulic oil contamination - Change hydraulic oil.
Not enough hydraulic fluid in the system - Need to add fluid.
Defective hydraulic pump - Repair or replace pump if necessary.

Boom fails to lift or drop

Lift controls malfunction - Change or repair.
Hydraulic pump not working - Repair or replace pump if necessary.
Defective hydraulic control valve - Repair or change hydraulic valve.
Hydraulic cylinder not working - Repair or install a new lift cylinder.
Low hydraulic oil level - Need to add oil.

Bucket fails to tilt

Bucket tilt controls are defective - Inspect and repair if necessary.
Hydraulic pump not working - Replace or repair pump if necessary.
Faulty hydraulic control valve - Change or repair hydraulic valve.
Damaged bucket cylinder - Change or repair cylinder.
Hydraulic fluid is insufficient - Fill the system to proper hydraulic fluid level.

Slow boom or bucket operation

Hydraulic pump is faulty - Check pump capacity and change if necessary.
Hydraulic cylinder oil leakage - Replace cylinder piston seals.
Insufficient hydraulic fluid - Checking hydraulic fluid level and add if necessary.
Damaged or incorrect adjusted hydraulic control valve - Adjust properly or repair.
Hydraulic system loosing pressure - Adjust pressure as required.

Bucket or boom is moving jerkily

Air leaks in hydraulic system - Bleed hydraulic system.
Clogged hydraulic oil filter element - Service or change the hydraulic filter.
Hydraulic fluid is contaminated - Fill up with fresh hydraulic fluid.
Cylinder tube or rod is scored - Change failed component.

Hydraulic pump makes excessive noise

Not enough oil or hydraulic system leaking - Correct hydraulic leaks or top up oil as needed.
Clogged hydraulic filter - Clean or replace the filter.
Plugged suction line - Need to service the suction line.
Pump is sucking air - Need to bleed air.
Pump parts are damaged - Change or rebuild pump.

Electrical Troubleshooting

Battery won’t charge

Wiring connections are corroded or loose - Tighten or clean electrical wiring connections.
Defective battery terminal connectors - Replace terminal connectors.
Bad cell in battery - Change the battery.
Belt is defective or loose - Adjust belt tension or replace belt.

Starter turning slow

Battery voltage is low - Battery is drained, charge it.
Battery is draining quickly - Service or change the battery.
Disconnected wires or corroded battery terminals - Connect wires properly or change terminals.

Starter will not work

Battery is discharged or worn - Charge or replace the battery.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Low battery output voltage - Recharge the battery.
Starter motor failing - Change or repair starter.