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Gehl 3635 Troubleshooting

The Gehl 3635 skid steer loader is powered by 100.2 cu.in (1.6L) Yanmar 3TNV88 three-cylinder direct injection liquid-cooled diesel engine with a rated power of 36.7 hp (27.4 kW) at 3000 rpm. The Gehl 3635 is equipped with a radial-lift loader boom, single-speed hydrostatic transmission, 80K drive chains, and 27x8.5x15 or 27x10.5x15 tires. The hydraulic system has a pump with fluid flow rate of 14.5 gpm (55 lpm). The hydraulic pressure is 2750 psi (190 bar). The skid steer loader has a rated operating capacity of 1050 lbs (476 kg) and tipping load of 2100 lbs (953 kg). The lift height is 108" (2745 mm) to hinge pin, and dump height is 84.5" (2145 mm).

Engine Troubleshooting

Engine difficult to start or will not start
Air in the fuel system - Air bleeding.
Fuel filter element is dirty - Install new filter element.
Fuel injection nozzles are damaged - If necessary, replace with a new nozzle.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Excessive valve clearance - Adjustment procedure required.
Fuel injection pump is faulty - Replace or repair injection pump.

Engine starts but stops suddenly
Air cleaner is dirty - Clean or change.
Clogged fuel filter - Change filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Damaged or clogged injectors - Change or clean fuel injectors.
Fuel injection pump is broken - Repair or change injection pump.

Engine stops suddenly during operation
Engine is not fully warmed up - Normalize the temperature by warming up the engine.
Fuel filter element is dirty - Change filter element.
Air in the fuel system - Air bleeding.
Faulty or dirty injection nozzles - Replace injection nozzles.
Improper fuel injection timing - Set it up as required.

Engine stops when idling
Too low idle RPM - Correct low idle adjustment.
Fuel injection pump malfunction - Replace injection pump or repair it.
Damaged or clogged injectors - Inspect fuel injectors and change as required.
Valve clearance is wrong - Adjust to proper valve clearance.

Diesel engine is losing power
Plugged air filter - Replace or clean air filter element.
Dirty or damaged injection nozzles - Install a new kit of correctly balanced nozzles.
Fuel injection pressure is wrong - Check the fuel injection pressure and adjust if necessary.
Valve clearance is wrong - Adjust valve clearance according to specifications.
Too low idle RPM - Correct the settings.
Dirty fuel lines or hoses - Clean fuel hoses and lines.
Cylinder-head gasket is broken - Replace cylinder head gasket.
Worn or broken piston rings - Replace piston rings.

Engine overheated
Low engine coolant - The cooling system needs to be refilled and checked for faults.
Not enough engine oil - Add oil to the engine crankcase.
Clogged radiator fins or leaking radiator cap - Change cap or clean radiator.
Excessive wear of the fan belt - Change as required.
Diesel engine overloaded - Load reducing required.

Low oil pressure
Low crankcase oil level - Add oil to the engine crankcase.
Oil filter element is dirty - Clean or replace engine oil filter element.
Oil grade or viscosity is incorrect - Use oil of proper viscosity.
Excessive main bearing oil clearance - Install new bearings.
Oil pump is worn or damaged - Repair or change.

Engine knocks or noises
Low engine oil level - Checking oil level and add if necessary.
Engine is not preheated - Warm up to required temperature.
Timing of fuel injection pump is incorrect - Adjust fuel injection pump as required.
Incorrect low idle speed adjustment - Need to adjust idle speed.
Fuel injector fault - Test and replace fuel injectors if necessary.
Connecting rod is defective or not aligned - Alignment procedure or replacement is required.
Broken or worn pistons - Have pistons replaced.

Drive System Troubleshooting

Machine will not move forward or backward
Hydraulic fluid level low - Check and refill the hydraulic fluid.
Drive chain is damaged - Inspect drive chain and replace defective parts.
Relief valve is worn or damaged - Change or repair relief valve.
Suction line or hydraulic filter is dirty - Replace hydraulic filter or clean suction line.
Foot or hand controls are faulty - Repair or change.
Worn drive motor or pump - Check and repair if required.

Power is too low
Dirty hydraulic oil filter - Replace or clean hydraulic filter.
Opened or defective relief valve - Close or replace relief valve.
Transmission components are faulty or damaged - Check and replace defective components.
Input drive shaft is stuck - Change or repair faulty drive shaft.
Air leaks in hydraulic system - Bleed hydraulic system.

Drive system keeps overheating
Hydraulic fluid level low - Fill up the hydraulic fluid.
Hydraulic fluid filter is dirty - Replace hydraulic filter.
Worn or defective relief valve - Repair or install a new relief valve.
Drive pump or hydraulic motor malfunction - Inspect and change as required.
Dirty oil cooler - Cooling fins need to be cleaned.
Overloaded drive system - Reduce the load.

Drive system is noisy
Oil viscosity is too heavy - Use oil of correct viscosity.
Air leaks in hydraulic system - Bleed hydraulic system.
Defective drive pump or hydraulic motor - Check and repair if required.
Worn or damaged mechanical parts of drive system - Inspect the components for worn or defect and repair as required.

Hydraulics Troubleshooting

Hydraulic system overheats
Hydraulic pressure is not correct - Hydraulic pressure must be set correctly.
Unadjusted or defective main relief valve - Set up or change the relief valve.
Hydraulic oil is dirty - Change hydraulic oil.
Lack of hydraulic oil - Fill up the hydraulic oil.
Faulty hydraulic oil pump - Repair or install new hydraulic pump.

Lift arm won't raise or lower
Lift controls are defective - Replace or repair.
Hydraulic pump not working - Install new pump or repair it.
Damaged hydraulic control valve - Install a new valve or repair it.
Damaged hydraulic cylinder - Repair or install a new lift cylinder.
Insufficient hydraulic oil - Check and refill the hydraulic oil.

Bucket tilt does not work
Bucket controls failure - Inspect and repair if necessary.
Hydraulic pump is broken - Install new pump or repair it.
Damaged hydraulic control valve - Repair or replace the valve.
Defective bucket cylinder - Replace or repair cylinder.
Hydraulic oil is insufficient - Fill the system to proper hydraulic oil level.

Boom or bucket moves slowly
Hydraulic pump is faulty - Check pump performance and change it if necessary.
Hydraulic cylinder oil leakage - Change cylinder piston seals.
Hydraulic fluid is insufficient - Fill the system to proper hydraulic fluid level.
Hydraulic control valve is not set properly or defective - Repair or adjust correctly.
Hydraulic pressure loss - Adjust pressure correctly.

Lift arm or bucket is jerky
Air in the hydraulic system - Bleed air from hydraulic system.
Plugged hydraulic oil filter - Clean or change the filter.
Hydraulic oil is dirty - Fill up with fresh hydraulic oil.
Scratched cylinder rod or tube - Replace worn component.

Hydraulic pump is excessively noisy
Leaking hydraulic system or insufficient oil level - Repair hydraulic leaks or add oil as required.
Dirty hydraulic filter - Service or change hydraulic filter.
Dirty suction line - Service the suction line.
Pump is sucking air - Bleed air.
Faulty pump components - Replace or rebuild the pump.

Electrical Troubleshooting

Battery won’t charge
Electrical cable connections are corroded or loose - Clean or tighten wiring connections.
Battery terminal clamps are defective - Terminal clamps should be changed.
Faulty cell in battery - Use a new battery.
Worn or loose belt - Replace belt or adjust belt tension.

Starter turns slow
Low battery voltage - Low battery charging, charge as required.
Battery won’t hold charge - Battery needs to be serviced or replaced.
Wires are disconnected or battery terminals are corroded - Check wiring connections and replace or clean terminals.

Starter doesn't crank
Battery is discharged or worn - Charge or change the battery.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Low battery output - Battery is drained, charge it.
Damaged starter motor - Repair or change starter.