Gehl CTL85 Track Loader Troubleshooting

The Gehl CTL85 compact track loader is powered by 230 cu.in (3.8L) Kubota V3800 DI-T-E3B 4-cylinder direct injection turbocharged diesel engine with a rated power of 91.6 hp (68.3 kW) at 2600 rpm. The Gehl CTL85 is equipped with a 2-speed hydrostatic transmission, planetary final drives, rubber tracks, and wet multi disc brakes. The hydraulic system has a pump with fluid flow rate of 23.4 gpm (88.6 lpm). The hydraulic pressure is 2990 psi (206 bar). The track loader has a rated operating capacity of 2470 lbs (1120 kg) and tipping load of 7055 lbs (3200 kg). The lift height is 126.1 inches (3205 mm) to hinge pin, and dump height is 95.7 inches (2430 mm).

Engine Troubleshooting

Engine hard to start or will not start

Air in fuel tank - Bleed fuel tank.
Fuel filter plugging - Replace the filter element.
Fuel injection nozzles are faulty or clogged - Service or change injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Excessive valve clearance - Adjust valve clearance.
Fuel injection pump failure - Repair or change injection pump.

Diesel starts but stalls suddenly

Dirty air filter - Replace or clean air filter element.
Fuel filter plugged - Clean or change the filter.
Fuel injection pump is leaking - Repair any leaks.
Defective or clogged fuel injectors - Replace fuel injectors.
Fuel injection pump is damaged - Rebuild or change fuel pump.

Engine stops suddenly during operation

Engine is not warmed up to the required temperature - Warm up the engine.
Fuel filter plugging - Service or replace the filter.
Air in the fuel lines - Bleed the fuel lines.
Clogged or defective injection nozzles - Inspect nozzles and replace if necessary.
Fuel injection pump timing is not adjusted - Set up as recommended.

Engine stops at low idle speed

Low idle speed setting is not correct - Adjust low idle speed.
Defective fuel injection pump - Change or repair the pump.
Damaged or clogged injectors - Change or clean fuel injectors.
The valve clearance is incorrect - Adjust valve clearance.

Diesel power loss

Air filter is clogged - Clean or change.
Clogged injection nozzle - Change fuel injection nozzles.
Fuel injection pressure is wrong - Check the fuel injection pressure and adjust if necessary.
Valve clearance is wrong - Adjust valve clearance.
Incorrect low idle speed adjustment - Adjust low idling as recommended.
Clogged fuel lines or hoses - Fuel lines and hoses need to be cleaned.
Worn cylinder head gasket - Replace cylinder head gasket.
Piston rings are worn or defective - Replace piston rings.

Engine overheating

Low coolant level - Add coolant fluid and inspect the cooling system for leaks.
Low engine oil level - Fill up the oil to required level.
Dirty radiator fins or faulty radiator cap - Clean radiator or install new cap.
Damaged or worn fan belt - The fan belt needs to be replaced.
Engine overload - Reduce load on the engine.

Oil pressure is insufficient

Low crankcase oil level - Check and refill the oil.
Dirty oil filter - Clean or change engine oil filter.
Incorrect engine oil Use correct viscosity oil.
Crankshaft bearing oil clearance is incorrect - Bearing replacement required.
Oil pump is worn or damaged - Replace as required.

Engine noise or knocking

Lack of engine oil - Check and refill engine oil.
Engine is not preheated - Warm up engine as required.
Timing of fuel injection pump is incorrect - Adjust fuel injection pump as required.
Too low idle RPM - Adjustment required.
Dirty or defective injectors - Clean or replace fuel injectors.
Connecting rod is worn or not aligned - Connecting rod needs to be replaced or aligned.
Pistons are worn or scored - Have pistons replaced.

Drive System Troubleshooting

Drive system does not work in either direction

Hydraulic fluid is insufficient - Check and refill the hydraulic fluid.
Undercarriage tracks are damaged or blocked - Correct blockage or repair tracks.
Defective relief valve - Repair or replace relief valve.
Plugged hydraulic filter or suction line - Change hydraulic filter or service suction line.
Faulty foot or hand controls - Check and repair as required.
Drive motor or pump failure - Replace or repair faulty component.

Machine will not move straight or moves jerkily

Track mechanism is defective or jammed - Repair or fix jamming.
Tracks are worn or loose - Replace tracks or adjust track tension.
Foreign objects, debris, or dirt jammed in track frame - Clean undercarriage track frame.

Reduced power

Hydraulic oil filter is plugged - Check, clean, or replace as required.
Relief valve is open or defective - Close or replace relief valve.
Worn or faulty transmission components - Inspect and replace defective parts.
Input drive shaft malfunction - Replace or service the drive shaft.
Hydraulic system is leaking air - Need to bleed air.

Drive system is overheated

Hydraulic fluid level low - Check and refill the hydraulic fluid.
Hydraulic fluid filter is dirty - Replace or service hydraulic filter.
Worn or defective relief valve - Repair or change.
Defective drive pump or hydraulic motor - Replace or repair faulty component.
Hydraulic oil cooler is plugged - Clean the cooling fins.
Drive system overload - Reduce drive system load.

Drive system is noisy

Wrong oil viscosity - Drain and refill with correct oil.
Hydraulic system is leaking air - Bleed hydraulic system.
Hydraulic motor or drive pump failure - Inspect and replace as necessary.
Worn or damaged mechanical parts of drive system - Check parts for worn or defect and replace if required.

Hydraulics Troubleshooting

Hydraulic system has overheating

Hydraulic pressure incorrectly adjusted - Correct setting is required.
Main relief valve is damaged or adjusted improperly - Adjust or change relief valve.
Dirty hydraulic oil - The oil must be changed.
Hydraulic oil level is insufficient - Fill up the hydraulic oil.
Hydraulic pump is faulty - Repair or change pump if required.

Lift arm does not lower or raise

Lift controls are faulty - Repair or change.
Damaged hydraulic oil pump - Repair or replace pump if necessary.
Hydraulic control valve is defective - Repair or change the valve.
Hydraulic cylinder malfunction - Replace or repair boom cylinder.
Insufficient hydraulic oil - Need to add oil.

Bucket does not function

Faulty bucket tilt controls - Replace or repair.
Hydraulic pump is broken - Replace or repair pump if necessary.
Hydraulic control valve malfunction - Change or repair hydraulic valve.
Bucket cylinder malfunction - Repair or change cylinder.
Low hydraulic fluid level - Add fluid as required.

Boom or bucket is working slowly

Hydraulic pump is defective - Test the pump flow rate and change pump if required.
Hydraulic cylinder leaking - Cylinder seals need to be replaced.
Insufficient hydraulic fluid - Add fluid as required.
Faulty or incorrect setting hydraulic control valve - Adjust properly or repair.
Hydraulic pressure has dropped - Correct setting is required.

Bucket or boom is working jerkily

There is air in the hydraulic system - Air bleeding is required.
Hydraulic oil filter element clogging - Change or clean oil filter.
Contaminated hydraulic fluid - The fluid must be changed.
Cylinder tube or rod is scored - Change worn component.

Excessive hydraulic pump noise

Hydraulic leaks or lack of oil - Correct hydraulic leaks or top up oil as needed.
Hydraulic filter is clogged - Service or replace hydraulic filter.
Clogged suction line - Need to clean the suction line.
Air in hydraulic pump - Remove air from hydraulics.
Pump components are faulty - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery won’t charge

Electrical wire connections are loose or corroded - Tighten or clean electrical wiring connections.
Battery terminal clamps are faulty - Replace terminal clamps.
Dead cell in battery - Use a new battery.
Loose or defective belt - Replace belt or adjust belt tension.

Starter turns slowly

Low battery output voltage - Battery is drained, recharge it.
Battery drains quickly - Battery needs service or replacement.
Bad battery terminals or disconnected wiring - Connect wiring correctly or install new terminals.

Starter is not working

Battery is discharged or worn - Charge or change the battery.
Disconnected or improperly connected wiring harness - Inspect battery wiring harness and connect as required.
Low battery output - Battery is drained, charge it.
Starter motor failing - Replace or repair starter.