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Gehl 2500 Troubleshooting

The Gehl HL2500 skid steer loader driveline system components: a 60 cubic inches (0.98L) Onan NHC/MS 4-cycle 2-cylinder horizontally opposed air-cooled gasoline engine with a rated power of 22.5 hp (16.7 kW), and one-speed hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 7.25 gal/min (27.5 l/min). The system pressure is 2000 psi (138 bar). The Gehl HL2500 is equipped with a radial-lift boom, 60K drive chains, and 7.00x13 tires. The skid steer loader has a max lift height of 91" (2310 mm) to hinge pin and dump height of 98" (2490 mm). The rated operating capacity is 800 lbs (363 kg), and tipping load is 1600 lbs (725 kg).

Engine Troubleshooting

Engine hard starting or not starting
Gas tank is empty - Fill fuel up.
Wrong fuel grade - Use correct gasoline grade.
Air in the fuel pipes - Bleed the fuel pipes.
Disconnected or loose spark plug wire - Inspect spark plug wiring connection, change or repair.
Spark plug is faulty - Change spark plug.
Clogged fuel filter - Install new filter.
Safety contact for brake pedal defective - Install new part.
Carburetor is not working properly - Inspect and adjust.
Engine has bad compression - Check cylinder block and change wear parts.
Worn or unadjusted choke cable - Adjust properly or change the cable.

Rough engine running
Air intake grill is clogged - Clean and wash as required.
Defective ignition system - Inspect ignition system and change failed components.
Choke cable is stuck or faulty - Service or change the cable.
Plugged air filter - Replace or service air filter.
Dirty or damaged fuel pump - Test fuel pump and change if necessary.

Engine starts and immediately shuts off
Spark plug is damaged - Install new spark plug.
Dirty or faulty carburetor - Clean or change carburetor.
Ignition coil is not working - Install a new ignition coil.
Valve springs are loose or broken - Install new valve springs.
Valves are stuck - Valves need to be cleaned.

Engine is overheated
Insufficient engine oil - Check oil level and add oil as required.
Excessive engine load - Load reducing is recommended.
Cooling fins are plugged - Need to wash or clean.
Too lean fuel mixture in carburetor - Use proper settings.
Wrong ignition timing - Ignition timing needs to be set properly.
Valve setting is improper - Set the valves properly.

Engine noises or knocks
Low octane gasoline - Change gasoline.
Engine is overloaded - Load reducing required.
Insufficient engine oil - Add oil to the engine crankcase.
Incorrect low idle setting - Adjustment required.
Dirty or damaged fuel pump - Test fuel pump and replace if necessary.
Worn main bearings or crankshaft - Change or repair worn components.
Valve clearance is incorrect - Check and adjust.
Piston rings or cylinder bore are damaged - Change faulty components.

Loss of engine power
Carburetor is incorrectly adjusted or clogged - Clean or properly adjust carburetor.
Air filter is blocked - Replace or clean air filter.
Fuel pump is faulty or clogged - Service or change fuel pump.
Ignition system malfunction - Inspect ignition system and change faulty parts.
Cylinder head gasket is worn - Cylinder-head gasket replacement required.
Stuck or burned valves - Change or service valves.
Worn or damaged push rod - Push rod needs to be changed.
Cylinder block components are damaged - Replace defective components.
Clogged oil filter (if equipped) - Change or clean oil filter.

Engine using too much gasoline
Choke did not open fully - Change or adjust choke cable.
Improper carburetor main jet adjustment - Adjust the carburetor main jet properly.
Spark plug is defective or loose - Re-tighten or replace spark plug.
Valves are stuck, worn, or burned - Service or replace valves.
Sleeve, piston, or rings are damaged - Change faulty components.
Excessive valve clearance - Adjustment procedure required.

Engine using too much oil
Gaskets or seals can be faulty - Change worn parts according to specifications.
Valve stems or guides are damaged - Change the valves.
Stuck or worn piston rings - Replace piston rings.
Cylinder liner or piston is scored - Check piston and liner, replace as required.
Clogged breather hose or pipe - Replace or clean.

Drive System Troubleshooting

Machine is not moving forward or backward
Low hydraulic oil level - Check and refill the hydraulic oil.
Worn drive chain - Check drive chain and change faulty parts.
Relief valve is damaged - Repair or replace relief valve.
Dirty suction line or hydraulic filter - Clean suction line or change hydraulic filter.
Worn or defective hand or foot controls - Repair or change.
Damaged drive pump or motor - Repair or change faulty component.

Low power
Clogged hydraulic oil filter - Replace or clean hydraulic filter.
Opened or worn relief valve - Replace or close relief valve.
Transmission parts are faulty or damaged - Check and change defective components.
Input drive shaft is damaged - Repair or replace drive shaft.
Hydraulic system is leaking air - Air bleeding is required.

Drive system is overheated
Hydraulic oil is insufficient - Need to add oil.
Dirty hydraulic fluid filter - Replace or clean hydraulic filter.
Defective relief valve - Repair or replace relief valve.
Hydraulic motor or drive pump is worn - Inspect and replace as necessary.
Hydraulic oil cooler is dirty - Clean the cooling fins.
Drive system is overloaded - Reduce the load.

Drive system is noisy
Oil viscosity is incorrect - Use proper oil viscosity.
Hydraulic system is leaking air - Bleed air from system.
Hydraulic motor or drive pump is worn - Replace or repair faulty component.
Mechanical parts of drive system are damaged or worn - Check drive system and change faulty parts.

Hydraulics Troubleshooting

Hydraulic system overheated
Hydraulic pressure is incorrect - Correct setting is required.
Unadjusted or defective main relief valve - Adjust the valve or replace if necessary.
Hydraulic fluid is contaminated - The fluid must be changed.
Hydraulic fluid level is low - Need to add fluid.
Faulty hydraulic oil pump - Install new pump or repair it.

Boom won't lower or raise
Damaged lift controls - Check and repair as required.
Hydraulic pump is broken - Repair or install new hydraulic pump.
Hydraulic control valve is faulty - Repair or change hydraulic valve.
Broken hydraulic cylinder - Repair or change hydraulic cylinder.
Hydraulic oil level low - Need to add oil.

Bucket tilt does not work
Bucket controls failure - Inspect and repair if necessary.
Hydraulic pump failure - Install new pump or repair it.
Faulty hydraulic control valve - Install a new hydraulic valve or repair it.
Damaged bucket cylinder - Repair or install a new cylinder.
Low hydraulic oil level - Checking hydraulic oil level and add if necessary.

Slow bucket or lift arm action
Worn hydraulic oil pump - Test the pump flow rate and install new pump if required.
Hydraulic cylinder leaking - Replace cylinder piston seals.
Insufficient hydraulic fluid - Fill the system to proper hydraulic fluid level.
Faulty or incorrect setting hydraulic control valve - Repair or set properly.
Low hydraulic pressure - Adjust pressure correctly.

Bucket or boom is working jerkily
Hydraulic system is leaking air - Air bleeding is required.
Hydraulic oil filter element is clogged - Change or clean oil filter.
Hydraulic fluid contamination - Change hydraulic fluid.
Cylinder tube or rod is scored - Change worn component.

Hydraulic pump is excessively noisy
Hydraulic system leaking or not enough oil - Refill hydraulic oil or repair leaks in system.
Plugged hydraulic filter - Service or change hydraulic filter.
Suction line clogging - Service the suction line.
Air enters the pump - Bleed air from hydraulics.
Worn pump parts - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery won’t charge
Electrical cable connections are corroded or loose - Tighten or service connections.
Battery terminal clamps are defective - Terminal clamps need to be replaced.
Dead cell in battery - Battery change required.
Belt is defective or loose - Install a new belt or adjust belt tension.

Starter cranks slowly
Battery voltage is low - Low battery charging, charge as required.
Battery will not hold charge - Battery needs to be serviced or replaced.
Disconnected wiring or bad battery terminals - Check wiring connections and replace or clean terminals.

Starter will not crank
Battery is drained or defective - Replace or charge as required.
Disconnected or improperly connected wiring harness - Inspect battery wiring harness and connect as required.
Battery power is low - Battery needs to be recharged.
Starter motor is faulty - Starter needs to be replaced.