Gehl CTL80 Track Loader Troubleshooting

The Gehl CTL80 compact track loader driveline system components: a 269 cu.in (4.4L) Yanmar 4TNV106T 4-cylinder turbocharged diesel engine with a rated power of 86 hp (64 kW), and 2-speed hydrostatic transmission. The hydraulic system has a pump with a rated flow of 23.4 gpm (88.7 lpm). The system pressure is 3000 psi (207 bar). The Gehl CTL80 is equipped with a radial-lift loader boom, undercarriage with four steel rollers, and 17.7" (450 mm) rubber tracks. The loader has a maximum lift height of 126.1" (3205 mm) to hinge pin and dump height of 95.7" (2430 mm). The rated operating capacity is 2470 lbs (1120 kg), and tipping load is 7056 lbs (3200 kg).

Engine Troubleshooting

Engine starts up hard or doesn't start

Air trapped in fuel system - Bleed air.
Dirty fuel filter - Filter maintenance required.
Fuel injection nozzles are damaged or dirty - Change fuel injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve out of adjustment - Adjust valve clearance according to specifications.
Fuel injection pump failure - Rebuild or change fuel pump.

Engine starts but stalls suddenly

Clogged air filter - Clean or replace element.
Fuel filter plugging - Clean or replace the filter.
Fuel injection pump has loose connections - Tighten the connections.
Damaged or clogged injectors - Change or clean fuel injectors.
Defective fuel injection pump - Change pump or rebuild it.

Engine shuts off while running

Coolant temperature is low - Warm up the engine.
Fuel filter element clogging - Clean or change the filter.
Air trapped in fuel system - Bleed air.
Dirty or faulty injection nozzles - Clean or replace injection nozzles.
Incorrect adjustment of fuel injection pump timing - Set it up as required.

Engine stalls at idle

Wrong adjustment of low idle speed - Test and adjust.
Fuel injection pump is faulty - Change pump or rebuild it.
Fuel injector fault - Clean or replace fuel injectors.
Improper valve clearance - Check and adjust.

Diesel engine is losing power

Plugged air filter - Change or service air filter element.
Dirty or faulty injection nozzles - If necessary, replace with a new nozzle.
Incorrect fuel injection pressure - Adjust pressure to proper level.
The valve clearance is incorrect - Check and adjust.
Incorrectly adjusted low idle speed - Correct the settings.
Fuel lines or hoses are dirty - Service fuel hoses and lines.
Cylinder-head gasket is broken - Replace cylinder head gasket.
Worn or broken piston rings - Change piston rings.

Engine overheats

Low coolant level - The cooling system needs to be refilled and checked for faults.
Engine oil level is low - Fill up the engine oil.
Radiator core is dirty or radiator cap is damaged - Replace cap or clean radiator.
Excessive wear of the fan belt - Change the fan belt.
Engine overload - Load reducing is recommended.

Oil pressure is low

Low crankcase oil level - Fill crankcase to proper oil level.
Plugged engine oil filter - Clean or replace engine oil filter element.
Wrong oil viscosity - Use oil of proper viscosity.
Incorrect oil clearance in main bearing - Bearing replacement required.
Oil pump failure - Inspect and change as required.

Engine noises or knocks

Engine oil insufficient - Check and refill engine oil.
Engine is not preheated - Warm up the engine.
Improper setting of fuel injection pump timing - Set up as recommended.
Incorrectly set low idle speed - Test and adjust.
Fuel injector fault - Change or clean fuel injectors.
Connecting rod is defective or not aligned - Connecting rod must be aligned or replaced.
Broken or worn pistons - Have pistons replaced.

Drive System Troubleshooting

Drive system сan't work in either direction

Low hydraulic oil level - Fill the system to proper hydraulic oil level.
Defective or blocked track mechanism - Repair or correct blockage.
Faulty relief valve - Repair or replace relief valve.
Hydraulic filter or suction line is dirty - Check, clean, or replace if required.
Faulty foot or hand controls - Repair or change.
Worn drive motor or pump - Inspect and replace as necessary.

Machine will not move straight or moves jerkily

Undercarriage tracks are defective or jammed - Repair or remedy jamming.
Worn or loose tracks - Adjust track tension properly or repair tracks.
Undercarriage track frame is plugged with dirt, debris, or foreign objects - Clean track frame, remove debris and foreign objects.

Loss of power

Hydraulic oil filter is plugged - Replace hydraulic filter.
Relief valve is worn or opened - Replace or close relief valve.
Faulty or damaged transmission components - Inspect and change faulty parts.
Input drive shaft malfunction - Faulty drive shaft need to be replaced or repair.
Air in the hydraulic system - Bleed air from system.

Drive system overheats

Hydraulic fluid is insufficient - Fill the system to proper hydraulic fluid level.
Clogged hydraulic fluid filter - Check, clean, or change as necessary.
Relief valve is damaged - Service or change relief valve.
Worn hydraulic motor or drive pump - Change or repair faulty component.
Hydraulic oil cooler is dirty - Clean the cooling fins.
Transmission overloading - Reduce drive system load.

Excessive noise

Oil viscosity is too heavy - Use oil of proper viscosity.
Air in the hydraulic system - Bleed air from system.
Hydraulic motor or drive pump is defective - Repair or replace faulty component.
Worn or damaged mechanical components of drive system - Check drive system and change faulty parts.

Hydraulics Troubleshooting

Hydraulic system overheats

Incorrect hydraulic pressure setting - Adjust pressure as required.
Main relief valve is damaged or adjusted improperly - Adjust relief valve or change if required.
Hydraulic fluid is dirty - The fluid must be changed.
Lack of hydraulic fluid - Check and refill the hydraulic fluid.
Defective hydraulic pump - Repair or replace pump if necessary.

Boom cannot be lowered or raised

Lift controls are damaged - Repair or change.
Hydraulic pump malfunction - Change or repair hydraulic pump if required.
Hydraulic control valve failure - Repair or replace the valve.
Hydraulic cylinder is defective - Install a new boom cylinder or repair it.
Hydraulic fluid level low - Fill up the hydraulic fluid.

Bucket fails to tilt

Bucket controls are faulty - Check and repair as required.
Hydraulic pump failure - Replace or repair pump if necessary.
Defective hydraulic control valve - Change or repair hydraulic valve.
Damaged bucket cylinder - Repair or replace cylinder.
Low hydraulic fluid level - Add fluid as required.

Slow bucket or lift arm operation

Hydraulic pump is worn - Check pump flow and change pump if necessary.
Leaking hydraulic cylinder - Install new cylinder seals.
Hydraulic oil level low - Check and refill the hydraulic oil.
Hydraulic control valve is unadjusted or worn - Set properly or repair.
Hydraulic system loosing pressure - Hydraulic pressure must be set correctly.

Bucket or boom is jerky

Air trapped in hydraulic system - Bleed air from hydraulic system.
Dirty hydraulic oil filter element - Service or replace the hydraulic filter.
Hydraulic oil is dirty - The oil must be changed.
Cylinder tube or rod is scored - Replace defective component.

Hydraulic pump is excessively noisy

Hydraulic leakage or low oil level - Refill hydraulic oil or repair leaks in system.
Hydraulic filter clogging - Clean or install new filter.
Dirty suction line - Suction line needs to be cleaned.
Air enters the pump - Bleed air.
Worn pump components - Change or rebuild pump.

Electrical Troubleshooting

Battery is not charging

Wiring connections are corroded or loose - Tighten or service connections.
Battery terminal clamps are faulty - Install new terminal clamps.
Battery dead cell - Battery replacement required.
Belt is loose or defective - Adjust belt tension or change the belt.

Starter motor cranks slow

Battery power is low - Charge the battery.
Battery drains quickly - Service or change the battery.
Battery terminals are corroded or wires are disconnected - Check cables and service or change terminals.

Starter doesn't crank

Battery is discharged or defective - Change or recharge battery.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Low battery power - Battery is drained, charge it.
Starter motor failure - Starter needs to be changed.