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Gehl CTL55 Troubleshooting

The Gehl CTL55 compact track loader driveline system components: a 121.7 cu.in (2L) Yanmar 4TNV84T-ZKTBL 4-cylinder direct injection turbocharged diesel engine with a rated power of 51.2 hp (38.2 kW), and 2-speed hydrostatic transmission. The hydraulic system has a pump with a rated flow of 15.1 gpm (57.2 lpm). The system pressure is 2990 psi (206 bar). The Gehl CTL55 is equipped with planetary final drives, rubber tracks, and wet multi disc brakes. The loader has a boom breakout force of 5040 lbs (2290 kg) and bucket breakout force of 4820 lbs (2190 kg). The rated operating capacity is 1245 lbs (565 kg), and tipping load is 3558 lbs (1780 kg).

Engine Troubleshooting

Engine starts up hard or won't start
Air trapped in fuel system - Bleed air.
Fuel filter plugged - Change filter element.
Faulty or dirty injection nozzles - Clean or change injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve out of adjustment - Adjust valve clearance.
Fuel injection pump is broken - Rebuild or change fuel pump.

Engine starts but immediately stalls
Clogged air filter - Change or service air filter element.
Fuel filter element is dirty - Replace the filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Dirty or defective injectors - Inspect fuel injectors and change as required.
Fuel injection pump malfunction - Change pump or rebuild it.

Engine stops running suddenly
Low coolant temperature - Warm up to required temperature.
Fuel filter element is dirty - Replace the filter element.
Air in the fuel pipes - Bleed the fuel pipes.
Damaged or dirty injection nozzles - Test injection nozzles and change if necessary.
Fuel injection pump timing is wrong - Set the fuel pump timing correctly.

Engine stops while idle
Too low idle RPM - Test and adjust.
Fuel injection pump is damaged - Rebuild or install a new injection pump.
Fuel injectors are faulty or clogged - Replace fuel injectors.
Valve clearance is not correct - Check and adjust as required.

Diesel power loss
Air filter is dirty - Clean or change filter.
Fuel injection nozzles are faulty or clogged - Inspect nozzles and replace if necessary.
Fuel injection pressure is wrong - Correct the pressure settings.
Improper valve clearance - Adjustment procedure required.
Low idle speed set incorrectly - Correct low idle settings.
Dirty fuel lines or hoses - Service fuel lines and hoses.
Cylinder head gasket defective - Gasket should be replaced.
Defective or worn piston rings - Piston rings replacement required.

Engine is overheated
Insufficient coolant - Fill the cooling system and check components for leaks or other faults.
Low engine oil level - Fill up the engine oil.
Radiator fins are clogged or radiator cap is faulty - Clean radiator or replace cap.
Damaged or worn fan belt - Belt replacement is recommended.
Diesel engine is overloaded - Load reducing is recommended.

Low oil pressure
Engine oil level low - Check oil level and add oil as required.
Oil filter clogged - Replace or clean engine oil filter element.
Oil grade or viscosity is wrong - Drain crankcase and refill with correct oil.
Crankshaft bearing oil clearance is excessive - Change bearings.
Worn oil pump - Repair or change.

Abnormal engine noise or knocking
Lack of engine oil - Check and refill engine oil.
Engine is cold - Warm up the engine.
Improper fuel injection timing - Adjust fuel injection pump as required.
Wrong adjustment of low idle speed - Adjust low idling as recommended.
Fuel injectors are faulty or clogged - Inspect fuel injectors and change as required.
Misaligned or faulty connecting rod - Need to align or replace the connecting rod.
Broken or worn pistons - Pistons need to be replaced.

Drive System Troubleshooting

Drive system won't work in one direction or either direction
Hydraulic fluid level low - Add fluid as required.
Undercarriage tracks are jammed or defective - Repair or remedy jamming.
Relief valve is worn or damaged - Repair or install a new relief valve.
Hydraulic filter or suction line is clogged - Check, clean, or change if necessary.
Defective hand or foot controls - Inspect and repair if necessary.
Defective drive pump or motor - Inspect and change as required.

Machine won't drive straight or drives jerkily
Track mechanism is defective or jammed - Fix jamming or repair tracks.
Tracks are faulty or sagging - Adjust track sag with tensioning or replace tracks.
Track frame is blocked with debris, dirt, or foreign objects - Remove foreign objects and clean track frame.

Low power
Hydraulic oil filter is clogged - Replace or service hydraulic filter.
Worn or open relief valve - Replace or close relief valve.
Faulty or worn transmission components - Inspect and replace defective parts.
Input drive shaft is damaged - Service or change faulty drive shaft.
There is air in the hydraulic system - Need to bleed air.

Drive system is overheated
Low hydraulic oil level - Check and refill the hydraulic oil.
Hydraulic fluid filter is clogged - Change or service hydraulic filter.
Worn or damaged relief valve - Service or change relief valve.
Worn hydraulic motor or drive pump - Change or repair faulty component.
Plugged hydraulic oil cooler - Clean the cooling fins.
Overloaded drive system - Reduce loading.

Drive system is excessively noisy
Wrong oil viscosity - Use correct oil viscosity.
Air in hydraulic system - Bleed air from system.
Damaged drive pump or hydraulic motor - Inspect and change as required.
Worn or defective mechanical parts of drive system - Check drive system and change faulty parts.

Hydraulics Troubleshooting

Hydraulic system overheats
Incorrect hydraulic pressure setting - Adjust it correctly.
Main relief valve improper adjustment or failure - Adjust or replace the relief valve.
Contaminated hydraulic oil - The oil must be changed.
Lack of hydraulic fluid - Check and refill the hydraulic fluid.
Hydraulic pump is faulty - Replace or repair pump if necessary.

Lift arm can't drop or lift
Lift controls are faulty - Repair or replace.
Damaged hydraulic oil pump - Install new pump or repair it.
Damaged hydraulic control valve - Replace or repair the valve.
Faulty hydraulic cylinder - Repair or install a new lift cylinder.
Hydraulic oil is insufficient - Check and refill the hydraulic oil.

Bucket is not working
Bucket controls are faulty - Replace or repair.
Hydraulic pump malfunction - Change or repair hydraulic pump if required.
Damaged hydraulic control valve - Repair or replace hydraulic valve.
Hydraulic bucket cylinder is defective - Repair or replace cylinder.
Hydraulic fluid level low - Fill up the hydraulic fluid.

Bucket or lift arm is moving slowly
Faulty hydraulic oil pump - Flow-rate pump and change pump if necessary.
Leaking hydraulic cylinder - Correct leakage by changing the seals.
Insufficient hydraulic oil - Check and refill the hydraulic oil.
Faulty or incorrect setting hydraulic control valve - Adjust correctly or repair.
Low hydraulic pressure - Adjust it correctly.

Lift arm or bucket jerks when working
Air trapped in hydraulic system - Need to bleed air.
Dirty hydraulic oil filter element - Clean or install new filter.
Hydraulic fluid is dirty - Change hydraulic fluid.
Cylinder tube or rod scoring - Change defective component.

Hydraulic pump is noisy
Hydraulic leakage or low oil level - Top up hydraulic oil or remedy leakage in system.
Hydraulic filter is clogged - Clean or change the filter.
Suction line clogging - Clean suction line as required.
Air in hydraulic pump - Bleed air from hydraulics.
Damaged pump parts - Rebuild or install new pump.

Electrical Troubleshooting

Battery cannot be charged
Electrical cable connections are corroded or loose - Service or tighten cable connections.
Faulty electrical terminal connectors - Change terminal connectors.
Dead cell in battery - Install a new battery.
Belt is loose or defective - Adjust belt tension or change the belt.

Starter cranks slow
Low battery voltage - Battery is drained, charge it.
Battery runs out quickly - Service charging system or change battery.
Bad terminals or disconnected battery cables - Check battery wires and service or replace terminals.

Starter will not crank
Battery is discharged or worn - Charge or change the battery.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Low battery capacity - Charge the battery.
Defective starter motor - Starter needs to be changed.