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Gehl 4525 Troubleshooting

The Gehl 4525 skid steer loader is powered by 79 cubic inches (1.3L) Ford VSG-413 vertical in-line four-cylinder gasoline engine with a rated power of 42 hp (31.3 kW) at 3000 rpm. The Gehl 4525 is equipped with a radial-lift loader boom, single-speed hydrostatic transmission, 80H drive chains, and 10.0x16.5 or 12.0x16.5 tires. The hydraulic system has a pump with fluid flow rate of 18 gpm (68.2 lpm). The hydraulic pressure is 2750 psi (190 bar). The skid steer loader has a rated operating capacity of 1225 lbs (557 kg) and tipping load of 2450 lbs (1115 kg). The lift height is 114.8 inches (2915 mm) to hinge pin, and dump height is 90.9 inches (2310 mm).

Engine Troubleshooting

Engine hard starting or not starting
No fuel in fuel tank - Add gasoline.
Improper fuel grade - Use correct fuel grade.
Air trapped in fuel system - Bleed air.
Spark plug wiring connection is damaged - Check spark plug wiring connection, repair or change.
Spark plug is defective - Spark plug need to be replaced.
Defective ignition system - Check ignition and replace faulty components.
Dirty fuel filter - Change fuel filter.
Dirt in the fuel lines - Fuel lines need to be cleaned.
Clogged or damaged fuel pump - Inspect fuel pump and change as required.
Carburetor components worn out - Repair or replace parts.
Low engine compression - Inspect cylinder block and change defective components.

Unstable engine running
Ignition system problems - Check ignition and replace faulty components.
Clogged air filter - Service or replace air filter.
Defective spark plug - Change spark plug as required.
Dirty or damaged fuel pump - Clean or install new fuel pump.
Valve clearance is incorrect - Adjustment procedure required.
Wrong ignition timing - Set the ignition timing properly.
Incorrectly adjusted low idle speed - Adjust idle speed.

Engine starts but then shuts off
Defective spark plug - Change spark plug.
Clogged or faulty carburetor - Service or replace carburetor.
Defective ignition coil - Install a new ignition coil.
Valve springs are bad or broken - Valve springs need to be changed.
Valves sticking - Valves must be cleaned.

Engine overheated
Insufficient engine oil - Check and refill engine oil.
Excessive engine load - Load reducing is recommended.
Carburetor fuel mixture is too lean - Adjust carburetor correctly.
Improper ignition timing - Adjust ignition timing as required.
Incorrect valve setting - Valves needs to be adjusted properly.
Dirty radiator core or defective radiator cap - Install new cap or clean radiator.
Low engine coolant - Refill to the correct level and inspect system for leaks.
Defective thermostat - Change thermostat.
Defective water pump - Water pump need to be replaced.

Engine noises or knocks
Stale gasoline - Use correct fuel.
Engine overloaded - Load reducing required.
Engine oil level is low - Add oil to the engine crankcase.
Low idle speed set incorrectly - Adjust idling as required.
Dirty or defective fuel pump - Inspect fuel pump and change as required.
Crankshaft or main bearings are worn out - Worn parts replacement required.
Valve clearance is not correct - Need to adjust valve clearance.
Cylinder bore or piston rings are worn - Replace faulty parts.

Engine power is too low
Carburetor is improperly adjusted or clogged - Adjust the carburetor correctly or clean it.
Clogged air filter - Change or service air filter.
Dirty or defective fuel pump - Check fuel pump and replace if necessary.
Ignition failure - Test ignition and replace failed parts.
Cylinder head gasket is blown - Replace the head gasket.
Valves are burned or stuck - Service or replace valves.
Worn cylinder block parts - Change defective parts.
Oil filter is dirty - Service or change oil filter.

Excessive fuel consumption
Air filter element is plugged - Clean or replace air filter.
Incorrect adjustment of carburetor main jet - Adjust the carburetor main jet correctly.
Spark plug is faulty or loose - Re-tighten or replace spark plug.
Wrong ignition timing - Set the ignition timing correctly.
Stuck, burned, or worn valves - Replace or service valves.
Worn sleeve, piston, or rings - Replace defective parts as required.
Improper valve clearance - Need to adjust valve clearance.
Bad compression - Check and change damaged parts.

Engine using too much oil
Gaskets or seals may be damaged - Defective components must be replaced.
Valve guides or stems are damaged - Valves need to be changed.
Piston rings are stuck or worn - Replace piston rings.
Cylinder liner or piston is worn - Check liner and piston, install new components as required.

Engine backfires
Carburetor fuel mixture is too lean - Adjust carburetor properly.
Dirty fuel lines - Clean fuel lines.
Bad ignition timing - Set the ignition timing properly.
Incorrect valve setting - Valves needs to be adjusted properly.
Plugged air filter - Change or clean air filter.

Drive System Troubleshooting

Drive system сan't work in either direction
Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.
Worn drive chain - Check drive chain and change faulty parts.
Input drive shaft is defective - Replace drive shaft.
Relief valver is broken - Change or repair relief valve.
Plugged suction line or hydraulic filter - Service suction line or change hydraulic filter.
Damaged or worn hand or foot controls - Repair or replace.
Defective drive pump or motor - Change or repair faulty component.

Low power
Hydraulic oil filter is dirty - Check, clean, or change as necessary.
Relief valve is damaged or open - Replace or close relief valve.
Transmission components are damaged or faulty - Check and replace defective components.
Stuck input drive shaft - Replace or service the drive shaft.
Air in the hydraulic system - Bleed air from system.

Drive system overheating
Hydraulic oil is insufficient - Fill the system to proper hydraulic oil level.
Hydraulic fluid filter is dirty - Change hydraulic filter.
Worn or damaged relief valve - Relief valve need to be replaced or repair.
Hydraulic motor or drive pump failure - Inspect and change as required.
Plugged hydraulic oil cooler - Cooling fins need to be cleaned.
Drive system overload - Reduce the load.

Excessive noise
Oil viscosity is too heavy - Use the specified type of oil.
Air trapped in hydraulic system - Bleed hydraulic system.
Hydraulic motor or drive pump is defective - Repair or change faulty component.
Mechanical parts of drive system are damaged or worn - Check drive system and change faulty parts.

Hydraulics Troubleshooting

Hydraulic system overheating
Hydraulic pressure incorrectly adjusted - Adjust pressure as required.
Unadjusted or defective main relief valve - Adjust relief valve or change if required.
Hydraulic oil is dirty - Fill up with fresh hydraulic oil.
Lack of hydraulic oil - Fill the hydraulic system with oil.
Faulty hydraulic oil pump - Repair or change pump if required.

Boom won't lower or raise
Lift controls malfunction - Repair or replace.
Damaged hydraulic oil pump - Repair or install new hydraulic pump.
Damaged hydraulic control valve - Install a new hydraulic valve or repair it.
Damaged hydraulic cylinder - Repair or replace hydraulic cylinder.
Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.

Bucket does not function
Bucket tilt controls are damaged - Inspect and repair if necessary.
Hydraulic pump malfunction - Repair or install new hydraulic pump.
Hydraulic control valve is faulty - Repair or change hydraulic valve.
Damaged bucket cylinder - Repair or replace cylinder.
Low hydraulic oil level - Check and refill the hydraulic oil.

Bucket or lift arm moves slowly
Defective hydraulic pump - Check hydraulic pump flow and replace pump if necessary.
Oil leaks from hydraulic cylinder - Correct leakage by changing the seals.
Low hydraulic oil level - Checking hydraulic oil level and add if necessary.
Hydraulic control valve is defective or set improper - Set properly or repair.
Hydraulic pressure has dropped - Correct setting is required.

Jerky operation of the bucket or boom
Air leaks in hydraulic system - Bleed air from system.
Hydraulic oil filter element is dirty - Change or clean oil filter.
Contaminated hydraulic fluid - Hydraulic fluid change required.
Cylinder tube or rod scoring - Replace worn component.

Hydraulic pump is excessively noisy
Hydraulic leakage or lack of oil - Refill hydraulic oil or repair leaks in system.
Hydraulic filter is dirty - Clean or change the filter.
Clogged suction line - Need to service the suction line.
Air in hydraulic pump - Bleed air.
Damaged pump components - Rebuild or install new pump.

Electrical Troubleshooting

Battery does not charge
Corroded or loose wire connections - Service or tighten cable connections.
Battery terminal connectors are defective - Install new terminal connectors.
Battery failing - Use a new battery.
Belt is loose or defective - Belt needs to be adjusted or changed.

Starter turns slow
Battery voltage is low - Recharge the battery.
Battery won’t hold charge - Service battery or change it.
Disconnected battery cables or bad terminals - Check cables and clean or change terminals.

Starter will not crank
Battery is drained or defective - Need to charge or replace the battery.
Wiring is incorrectly connected or disconnected - Inspect wiring and connect correctly.
Battery power is low - Recharge the battery.
Damaged starter motor - Repair or install a new starter.