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Gehl 3825 Troubleshooting

The Gehl 3825 skid steer loader driveline system components: a 81.5 cu.in (1.3L) Kubota V1305 four-cylinder indirect injection diesel engine with a rated power of 29.3 hp (22 kW), and single-speed hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 10 gal/min (38 l/min). The system relief pressure is 3000 psi (207 bar). The Gehl 3825 is equipped with a radial-lift loader boom, 60HE roller chains, and 10.5x15 or 27-8.5x15 tires. The skid steer loader has a maximum lift height of 107.5" (2730 mm) to hinge pin and dump height of 86.3" (2190 mm). The rated operating capacity is 1000 lbs (455 kg), and tipping load is 2000 lbs (910 kg).

Engine Troubleshooting

Diesel hard to start or doesn't start
Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter element is dirty - Service the filter.
Clogged or burnt injection nozzle - Check and replace nozzles if required.
Water or dirt in fuel system - Drain, flush, and service the system.
Excessive valve clearance - Adjust to proper valve clearance.
Fuel injection pump malfunction - Repair or replace injection pump.

Diesel starts but immediately stops
Air filter is plugged - Clean or replace element.
Fuel filter element clogging - Change filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Damaged or clogged injectors - Clean or replace fuel injectors.
Faulty fuel injection pump - Repair or install new pump.

Engine shuts off suddenly while running
Low coolant temperature - Warm up the engine.
Fuel filter element is clogged - Replace the filter element.
Air in the fuel lines - Bleed the fuel lines.
Dirty or faulty injection nozzles - Clean or change injection nozzles.
Improper fuel injection timing - Adjust according to specifications.

Engine stops when idling
Improperly adjusted low idle speed - Adjust the low idle speed.
Fuel injection pump is faulty - Repair or install new pump.
Damaged or clogged injectors - Clean fuel injectors or change it.
Valve clearance is out of adjustment - Have it adjusted.

Engine power is insufficient
Air filter is plugged - Clean or change filter.
Dirty or damaged injection nozzles - Inspect nozzles and replace if necessary.
Insufficient fuel injection pressure - Adjust to correct pressure.
Valve out of adjustment - Check and adjust as required.
Incorrect low idle setting - Correct low idle settings.
Fuel lines or hoses clogging - Clean fuel system lines and hoses.
Defective cylinder head gasket - Change cylinder head gasket.
Leaking or defective piston rings - Piston rings replacement required.

Engine overheating
Insufficient coolant - Add coolant fluid to cooling system and also check it for leaks.
Low engine oil level - Fill up the engine oil.
Dirty radiator fins or defective radiator cap - Clean radiator or replace cap.
Loose or defective fan belt - If necessary, replace the belt.
Diesel engine is overloaded - Load reducing is recommended.

Low oil pressure
Lack of oil - Fill crankcase to proper oil level.
Plugged engine oil filter - Clean or change engine oil filter.
Oil grade or viscosity is wrong - Fill up with the proper oil viscosity.
Excessive crankshaft bearing oil clearance - Bearing needs to be changed.
Oil pump malfunction - Replace as required.

Engine noises or knocks
Not enough engine oil - Need to add engine oil.
Low coolant temperature - Warm up the engine to required temperature.
Fuel injection pump timing is not adjusted - Set it up as required.
Low idle speed set incorrectly - Correct low idle adjustment.
Fuel injector fault - Clean or replace fuel injectors.
Connecting rod is not aligned or worn - Need to align or replace the connecting rod.
Pistons are scored or worn - Install new pistons.

Drive System Troubleshooting

Machine is not moving in one direction or either direction
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.
Worn drive chain - Inspect drive chain and replace defective components.
Input drive shaft failure - Repair or replace.
Defective relief valve - Service or change relief valve.
Plugged suction line or hydraulic filter - Check, clean, or replace if required.
Faulty foot or hand controls - Inspect and repair if necessary.
Drive motor or pump is worn - Repair or replace faulty component.

Low power
Plugged hydraulic oil filter - Replace or clean hydraulic filter.
Relief valve is defective or open - Close or change relief valve.
Worn or faulty transmission components - Check and change faulty components.
Input drive shaft is worn - Replace drive shaft.
Air in hydraulic system - Bleed air from system.

Drive system overheating
Hydraulic oil level is low - Need to add oil.
Plugged hydraulic fluid filter - Change or service hydraulic filter.
Relief valve is worn or damaged - Repair or replace relief valve.
Worn hydraulic motor or drive pump - Repair or change faulty component.
Hydraulic oil cooler is plugged - Clean the cooling fins.
Drive system overloaded continuously - Load needs to be reduced.

Excessive noise
Oil viscosity is wrong - Use correct oil viscosity.
Air in hydraulic system - Bleed air from system.
Hydraulic motor or drive pump failure - Inspect and replace as necessary.
Worn or damaged mechanical parts of drive system - Check the components for worn or defect and replace if necessary.

Hydraulics Troubleshooting

Hydraulic system overheated
Hydraulic pressure is not adjusted correctly - Adjust it correctly.
Faulty or improperly adjusted main relief valve - Set up or change the relief valve.
Hydraulic oil contamination - Change hydraulic oil.
Hydraulic oil level is low - Fill up the hydraulic oil.
Faulty hydraulic oil pump - Repair or install new hydraulic pump.

Lift arm fails to drop or lift
Lift controls malfunction - Replace or repair.
Hydraulic pump not working - Replace or repair pump if necessary.
Faulty hydraulic control valve - Replace or repair the valve.
Damaged hydraulic cylinder - Repair or replace hydraulic cylinder.
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.

Bucket won't move
Bucket controls are faulty - Repair or change.
Defective hydraulic pump - Repair or replace pump if necessary.
Faulty hydraulic control valve - Repair or change hydraulic valve.
Damaged bucket cylinder - Install a new cylinder or repair it.
Hydraulic oil is insufficient - Check and refill the hydraulic oil.

Boom or bucket moves slowly
Defective hydraulic pump - Test the pump performance and change pump if required.
Hydraulic cylinder leaking - Correct leakage by changing the seals.
Insufficient hydraulic fluid - Add fluid as required.
Faulty or incorrect setting hydraulic control valve - Repair or adjust properly.
Hydraulic pressure is low - Correct adjustment is required.

Lift arm or bucket jerks when working
Air in the hydraulic system - Air bleeding is required.
Plugged hydraulic oil filter - Replace or clean the filter.
Dirty hydraulic oil - Fill up with fresh hydraulic oil.
Cylinder tube or rod scoring - Replace worn component.

Excessive hydraulic pump noise
Hydraulic leaks or lack of oil - Remedy hydraulic leakage or refill oil as necessary.
Hydraulic filter is dirty - Service or replace hydraulic filter.
Plugged suction line - Suction line needs to be cleaned.
Air trapped in hydraulic pump - Remove air from hydraulics.
Pump parts are worn out - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery cannot be charged
Loose or corroded wire connections - Service or tighten cable connections.
Battery terminal connectors are defective - Install new terminal connectors.
Dead cell in battery - Use a new battery.
Worn or loose belt - Adjust belt tension or install a new belt.

Starter cranks slow
Low battery output voltage - Charge the battery.
Battery will not hold charge - Service battery or replace it.
Battery cables are disconnected or terminals are faulty - Check wire connections and change or service terminals.

Starter will not crank
Battery is low or faulty - Recharge or replace battery.
Wiring harness is disconnected or improperly connected - Check wiring harness and connect as required.
Battery power is low - Battery is drained, recharge it.
Defective starter motor - Starter should be replaced.