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Gehl 3840 Troubleshooting

The Gehl SL 3840 skid steer loader driveline system components: a 100.2 cu.in (1.6L) Yanmar 3TNV88-BKMS 3-cylinder direct injection liquid-cooled diesel engine with a rated power of 35 hp (26 kW), and 1-speed hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 14.5 gal/min (55 l/min). The system relief pressure is 2750 psi (190 bar). The Gehl SL 3840 is equipped with a radial-lift loader boom, 80K drive chains, and 27x8.50x15 standard tires. The skid steer has a max lift height of 108" (2745 mm) to hinge pin and dump height of 84.5" (2145 mm). The rated operating capacity is 1050 lbs (476 kg), and tipping load is 2100 lbs (953 kg).

Engine Troubleshooting

Engine starts up hard or will not start
Air in fuel system - Bleed fuel system.
Fuel filter element clogging - Filter maintenance required.
Fuel injection nozzles are faulty or clogged - Service or change injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve out of adjustment - Adjust valve clearance.
Damaged fuel injection pump - Replace or rebuild injection pump.

Diesel starts and suddenly stops
Clogged air filter - Change or service air filter element.
Fuel filter plugging - Clean or replace the filter.
Fuel injection pump has loose connections - Tighten the connections.
Defective or clogged fuel injectors - Clean or replace fuel injectors.
Defective fuel injection pump - Repair or replace injection pump.

Engine stalls during operation
Low coolant temperature - Warm up to required temperature.
Fuel filter is plugged - Clean the filter or install new filter element.
Air in fuel system - Bleed fuel system.
Fuel injection nozzles fault - Service or change injection nozzles.
Incorrect adjustment of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.

Engine stalls while idling
Low idle speed set incorrectly - Correct the settings.
Fuel injection pump is faulty - Repair or change injection pump.
Dirty or defective injectors - Change or clean fuel injectors.
Valve clearance is out of adjustment - Adjust to proper valve clearance.

Engine loses power
Air filter is dirty - Replace or clean air filter element.
Faulty fuel injection nozzles - Replace injection nozzles.
Incorrect fuel injection pressure - Adjust to correct pressure.
Valve clearance is out of adjustment - Check and adjust.
Incorrect low idle setting - Correct the settings.
Fuel hoses or lines clogging - Service fuel hoses and lines.
Damaged cylinder-head gasket - Replace cylinder head gasket.
Piston rings are leaking or defective - Replace the piston rings as required.

Engine overheating
Engine coolant is insufficient - Add coolant and check the components of cooling system.
Engine oil level is low - Check oil level and add oil as required.
Clogged radiator fins or damaged radiator cap - Change cap or clean radiator.
Fan belt is worn or faulty - The fan belt needs to be replaced.
Engine overloaded - Reduce engine load.

Oil pressure is low
Engine oil insufficient - Fill the crankcase with oil.
Oil filter is clogged - Change or service engine oil filter.
Different type of engine oil - Use oil of proper viscosity.
Incorrect oil clearance in main bearing - Bearing needs to be changed.
Worn oil pump - Inspect and change as required.

Engine noise or knocking
Lack of engine oil - Checking oil level and add if necessary.
Engine is not fully warmed up - Warm up to required temperature.
Improper fuel injection timing - Set it up as required.
Incorrectly adjusted low idle speed - Adjust low idling as recommended.
Damaged or clogged injectors - Clean or replace fuel injectors.
Connecting rod is misaligned or defective - Replace or align connecting rod.
Pistons are broken or worn - Install new pistons.

Drive System Troubleshooting

Machine will not move forward or backward
Low hydraulic fluid level - Check and refill the hydraulic fluid.
Drive chain malfunction - Inspect drive chain and replace defective parts.
Relief valve failure - Rebuild or install a new relief valve.
Hydraulic filter or suction line is clogged - Service suction line or replace hydraulic filter.
Worn or damaged foot or hand controls - Inspect and repair if necessary.
Worn drive motor or pump - Replace or repair faulty component.

Reduced power
Hydraulic oil filter is plugged - Check, clean, or replace as required.
Relief valve is defective or opened - Close or change relief valve.
Transmission parts are faulty or damaged - Inspect and replace defective parts.
Damaged input drive shaft - Replace drive shaft.
Air in the hydraulic system - Bleed air from system.

Drive system is overheated
Insufficient hydraulic oil - Need to add oil.
Plugged hydraulic fluid filter - Check, clean, or replace as required.
Relief valve is worn or damaged - Repair or install a new relief valve.
Defective drive pump or hydraulic motor - Replace or repair faulty component.
Plugged hydraulic oil cooler - Clean the cooling fins.
Drive system overload - Reduce the load.

Drive system makes excessive noise
Oil viscosity is incorrect - Use proper oil viscosity.
Air leaks in hydraulic system - Air bleeding is required.
Drive pump or hydraulic motor malfunction - Repair or change faulty component.
Mechanical parts of drive system are worn or damaged - Check the components for worn or defect and replace if necessary.

Hydraulics Troubleshooting

Hydraulic system is overheated
Hydraulic pressure is incorrect - Correct setting is required.
Main relief valve malfunction or improper adjustment - Adjust or replace the relief valve.
Hydraulic oil is contaminated - Change hydraulic oil.
Lack of hydraulic oil - Fill the hydraulic system with oil.
Worn hydraulic oil pump - Change or repair hydraulic pump if required.

Lift arm does not lower or raise
Lift controls failure - Repair or change.
Hydraulic pump is broken - Repair or replace pump if necessary.
Defective hydraulic control valve - Repair or replace hydraulic valve.
Damaged hydraulic cylinder - Change or repair lift cylinder.
Hydraulic fluid level low - Checking hydraulic fluid level and add if necessary.

Bucket is not working
Damaged bucket controls - Repair or change.
Hydraulic pump is broken - Repair or install new hydraulic pump.
Damaged hydraulic control valve - Repair or change hydraulic valve.
Bucket cylinder malfunction - Replace or repair cylinder.
Insufficient hydraulic fluid - Fill up the hydraulic fluid.

Slow bucket or lift arm action
Faulty hydraulic oil pump - Check pump capacity and change if necessary.
Hydraulic cylinder leaking - Correct leakage by changing the seals.
Insufficient hydraulic oil - Need to add oil.
Damaged or incorrect adjusted hydraulic control valve - Repair or adjust properly.
Low hydraulic pressure - Adjust pressure as required.

Bucket or boom is working jerkily
Air leaks in hydraulic system - Need to bleed air.
Hydraulic oil filter element clogging - Clean or install new filter.
Hydraulic oil contamination - Fill up with fresh hydraulic oil.
Scratched cylinder rod or tube - Change defective component.

Hydraulic pump makes excessive noise
Hydraulic leaks or low oil level - Refill hydraulic oil or repair leaks in system.
Dirty hydraulic filter - Clean or change the filter.
Suction line is clogged - Need to clean the suction line.
Air trapped in hydraulic pump - Bleed air.
Pump parts are faulty - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery will not charge
Electrical wire connections are corroded or loose - Service or tighten cable connections.
Battery terminal connectors are faulty - Install new terminal connectors.
Worn-out battery - Install a new battery.
Belt is loose or defective - Belt needs to be adjusted or changed.

Starter motor turns slow
Low battery power - Charge the battery.
Battery is draining quickly - Service or replace the battery.
Corroded battery terminals or disconnected wires - Check battery wires and service or replace terminals.

Starter is not working
Battery is drained or defective - Change or recharge battery.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Battery capacity is low - Battery is drained, charge it.
Starter motor is damaged - Starter should be replaced.