Gehl CTL75 Track Loader Troubleshooting

The Gehl CTL75 compact track loader is powered by 202.5 cu.in (3.3L) Yanmar 4TNV98T-ZNTBL 4-cylinder direct injection turbocharged diesel engine with a rated power of 83 hp (61.9 kW) at 2500 rpm. The Gehl CTL75 is equipped with a two-speed hydrostatic transmission, wet multi disc brakes, planetary final drives, and rubber tracks. The hydraulic system has a pump with fluid flow rate of 19.8 gpm (74.9 lpm). The hydraulic pressure is 2990 psi (206 bar). The track loader has a rated operating capacity of 2083 lbs (945 kg) and tipping load of 5952 lbs (2700 kg). The boom breakout force is 7400 lbs (3364 kg), and bucket breakout force is 7425 lbs (3375 kg).

Engine Troubleshooting

Engine starts up hard or doesn't start

Air trapped in fuel system - Bleed air.
Fuel filter plugging - Change filter element.
Fuel injection nozzles are clogged or faulty - Clean or replace injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve clearance is wrong - Have it adjusted.
Fuel injection pump malfunctioning - Replace injection pump or repair it.

Diesel starts but stalls immediately

Air cleaner is clogged - Clean or change cleaner.
Fuel filter element clogging - Change filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Dirty or defective injectors - Clean fuel injectors or change it.
Fuel injection pump damage - Replacement or repair required.

Engine stalls during operation

Engine is not preheated - Warm up engine as required.
Fuel filter element is clogged - Change filter element.
Air in fuel system - Bleed fuel system.
Clogged injection nozzle - Install a new kit of correctly balanced nozzles.
Wrong setting of fuel injection pump timing - Adjust fuel injection pump as required.

Engine stops when idling

Low idle speed adjustment is incorrect - Correct low idle settings.
Fuel injection pump malfunctioning - Replacement or repair required.
Clogged or defective injectors - Clean or replace fuel injectors.
Valve out of adjustment - Adjustment procedure required.

Engine power is too low

Plugged air filter - Install new air filter element.
Fuel injection nozzles fault - Check and replace nozzles if required.
Fuel injection pressure is incorrect - Adjust to correct pressure.
Incorrect valve clearance - Correct valve clearance needs to be set.
Incorrectly set low idle speed - Correct the settings.
Clogged fuel hoses or lines - Clean fuel system hoses and lines.
Cylinder-head gasket is broken - Replace the gasket as required.
Leaking or defective piston rings - Replace piston rings.

Engine is overheated

Coolant level is low - Add coolant fluid and inspect the cooling system for leaks.
Engine oil insufficient - Checking oil level and add if necessary.
Radiator core is dirty or radiator cap is damaged - Change cap or clean radiator.
Loose or defective fan belt - If necessary, replace the belt.
Diesel engine is overloaded - Load reducing is recommended.

Low oil pressure

Insufficient engine oil - Check oil level and add oil as required.
Clogged oil filter element - Service or replace engine oil filter.
Incorrect engine oil Use the specified type of engine oil.
Excessive main bearing oil clearance - Replace bearings.
Defective oil pump - Replace as required.

Engine noises or knocks

Engine oil insufficient - Fill up the oil to required level.
Engine not warmed up - Warm up the engine as required.
Improper fuel injection timing - Adjust as recommended.
Incorrectly adjusted low idle speed - Need to adjust idle speed.
Fuel injectors are dirty or defective - Clean fuel injectors or change it.
Misaligned or defective connecting rod - Replace or align connecting rod.
Pistons are worn or broken - Install new pistons.

Drive System Troubleshooting

Drive system doesn't work in either direction

Low hydraulic fluid level - Fill the system to proper hydraulic fluid level.
Defective or blocked track mechanism - Repair or correct blockage.
Relief valve defective or worn - Repair or install a new relief valve.
Clogged suction line or hydraulic filter - Change hydraulic filter or service suction line.
Foot or hand controls are damaged - Check and repair as required.
Drive motor or pump is worn - Check and repair if required.

Machine is not driving straight or driving is jerky

Jammed or damaged track mechanism - Remedy jamming or repair tracks.
Tracks are sagging or worn - Repair tracks or correct track sag with tension.
Debris, or foreign objects stuck in undercarriage track frame - Clean undercarriage track frame.

Power is too low

Plugged hydraulic oil filter - Replace hydraulic filter.
Opened or worn relief valve - Change or close relief valve.
Worn or defective transmission parts - Inspect and change faulty parts.
Input drive shaft is stuck - Change or repair faulty drive shaft.
There is air in the hydraulic system - Bleed hydraulic system.

Drive system overheating

Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.
Hydraulic fluid filter is dirty - Replace or service hydraulic filter.
Relief valver is broken - Repair or install a new relief valve.
Drive pump or hydraulic motor is damaged - Replace or repair faulty component.
Hydraulic oil cooler is plugged - Clean the cooling fins.
Overloaded drive system - Reduce loading.

Drive system makes excessive noise

Oil viscosity is wrong - Drain and refill with proper oil.
Air leaks in hydraulic system - Need to bleed air.
Hydraulic motor or drive pump is worn - Check and repair if required.
Mechanical parts of drive system are damaged or worn - Inspect the components and repair as needed.

Hydraulics Troubleshooting

Hydraulic system overheating

Hydraulic pressure is incorrect - Adjust pressure correctly.
Misadjusted or defective main relief valve - Adjust or change relief valve.
Contaminated hydraulic fluid - The fluid must be changed.
Hydraulic fluid level is low - Add fluid to the hydraulic system.
Hydraulic pump is defective - Replace or repair pump if necessary.

Boom can't lift or drop

Damaged lift controls - Replace or repair.
Damaged hydraulic oil pump - Replace or repair pump if necessary.
Hydraulic control valve is faulty - Repair or replace the valve.
Hydraulic cylinder is faulty - Install a new boom cylinder or repair it.
Hydraulic oil level low - Fill the system to proper hydraulic oil level.

Bucket is not working

Bucket tilt controls malfunction - Repair or change.
Hydraulic pump failure - Install new pump or repair it.
Hydraulic control valve is faulty - Repair or replace the valve.
Broken bucket cylinder - Repair or replace cylinder.
Insufficient hydraulic fluid - Add fluid as required.

Bucket or lift arm is working slowly

Faulty hydraulic oil pump - Check pump flow and change pump if necessary.
Leaking hydraulic cylinder - Change cylinder piston seals.
Hydraulic fluid level low - Fill up the hydraulic fluid.
Worn or unadjusted hydraulic control valve - Repair or set correctly.
Hydraulic pressure loss - Correct setting is required.

Lift arm or bucket is working jerkily

Air in the hydraulic system - Bleed air from system.
Hydraulic oil filter clogging - Clean or replace the filter.
Dirty hydraulic oil - Hydraulic oil change required.
Cylinder rod or tube is scuffed - Change damaged component.

Hydraulic pump is noisy

Lack of oil or hydraulic leakage - Repair hydraulic leaks or add oil as required.
Hydraulic filter clogging - Replace or clean the filter.
Dirty suction line - Service the suction line.
Pump is sucking air - Bleed air from hydraulics.
Damaged pump components - Rebuild or install new pump.

Electrical Troubleshooting

Battery is not charging

Loose or corroded electrical wiring connections - Tighten or service cable connections.
Defective electrical terminal connectors - Install new terminal connectors.
Battery faulty cell - Install a new battery.
Loose or damaged belt - Adjust belt tension or change the belt.

Starter turns slow

Battery power is low - Recharge the battery.
Battery discharges quickly - Service charging system or replace battery.
Disconnected cables or faulty battery terminals - Check cables and service or change terminals.

Starter motor is not working

Battery is drained or worn - Recharge or change battery.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Battery capacity is low - Battery is drained, recharge it.
Faulty starter motor - Starter should be changed.