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Gehl R135 Troubleshooting

The Gehl R135 skid steer loader is powered by 133.6 cu.in (2.2L) Yanmar 4TNV88C-KMS vertical 4-cylinder direct injection water-cooled diesel engine with a rated power of 44.5 hp (33 kW). The Gehl R135 is equipped with a radial-lift boom, single-speed hydrostatic transmission, 80H drive chains, and 10x16.5 HD standard tires. The hydraulic system has a pump with fluid flow rate of 17 gpm (64.4 lpm). The hydraulic pressure is 3000 psi (207 bar). The skid steer loader has a rated operating capacity of 1350 lbs (612 kg) and tipping load of 2700 lbs (1225 kg). The lift height is 109.6 inches (2785 mm) to hinge pin, and dump height is 82.6 inches (2100 mm).

Engine Troubleshooting

Engine hard to start or won't start
Air in fuel system - Bleed fuel system.
Clogged fuel filter - Change filter element.
Defective or clogged injection nozzle - Inspect nozzles and replace if necessary.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is not correct - Correct valve clearance.
Fuel injection pump malfunctioning - Repair or replace injection pump.

Diesel starts and stalls immediately
Clogged air filter - Install new air filter element.
Fuel filter element is dirty - Change the filter element.
Fuel injection pump is leaking - Repair any leaks.
Defective or clogged fuel injectors - Replace or clean fuel injectors.
Fuel injection pump is damaged - Repair or install a new fuel pump.

Engine stops unexpectedly during operation
Engine has not warmed up to the recommended temperature - Warm up to required temperature.
Dirty fuel filter - Change filter element.
Air in the fuel system - Air bleeding.
Dirty or damaged injection nozzles - Check and replace nozzles if required.
Improper fuel injection timing - Set the fuel pump timing correctly.

Engine stops while idle
Incorrectly set low idle speed - Correct low idle settings.
Fuel injection pump is not working correctly - Rebuild or install a new injection pump.
Fuel injectors are dirty or defective - Change or clean fuel injectors.
Improper valve clearance - Adjust valve clearance.

Engine power loss
Dirty air filter - Change or service air filter element.
Faulty fuel injection nozzles - Inspect nozzles and replace if necessary.
Insufficient fuel injection pressure - Test fuel injection pressure and adjust it correctly.
Valve clearance is wrong - Adjust to proper valve clearance.
Low idle speed adjustment is incorrect - Normalize low idle speed.
Dirt in the fuel hoses or lines - Fuel hoses and lines must be clean.
Blown cylinder head gasket - Gasket should be replaced.
Defective or worn piston rings - Piston rings replacement required.

Engine overheats
Lack of engine coolant - The cooling system needs to be refilled and checked for faults.
Insufficient engine oil - Fill up the oil to required level.
Radiator fins are clogged or radiator cap is faulty - Replace cap or clean radiator.
Damaged or worn fan belt - Belt replacement is recommended.
Engine overload - Reduce engine load.

Oil pressure too low
Engine oil insufficient - Check and refill the oil.
Oil filter clogging - Replace or service engine oil filter.
Oil grade or viscosity is incorrect - Use proper viscosity oil.
Excessive oil clearance of crankshaft bearing - Install new bearings.
Oil pump malfunction - Remove and inspect oil pump.

Engine noise or knocking
Engine oil level is low - Need to add engine oil.
Engine is not preheated - Engine is not warmed up to the required temperature.
Incorrect adjustment of fuel injection pump timing - Set up as recommended.
Incorrectly adjusted low idle speed - Adjustment required.
Defective fuel injectors - Change or clean fuel injectors.
Connecting rod is not aligned or worn - Connecting rod must be aligned or replaced.
Pistons are worn or scored - Replace the pistons.

Drive System Troubleshooting

Machine is not moving forward or backward
Hydraulic fluid is insufficient - Checking hydraulic fluid level and add if necessary.
Drive chain failure - Inspect drive chain and replace faulty components.
Relief valver is broken - Repair or install a new relief valve.
Plugged hydraulic filter or suction line - Change hydraulic filter or service suction line.
Hand or foot controls failure - Repair or replace.
Damaged drive pump or motor - Repair or change faulty component.

Low power
Hydraulic oil filter is plugged - Check, clean, or change as necessary.
Relief valve is open or worn - Close or change relief valve.
Transmission parts are faulty or damaged - Inspect and change defective parts.
Input drive shaft is stuck - Replace drive shaft.
There is air in the hydraulic system - Bleed air from system.

Drive system is overheated
Hydraulic oil is insufficient - Need to add oil.
Hydraulic fluid filter is clogged - Change hydraulic filter.
Relief valve defective or worn - Rebuild or install a new relief valve.
Drive pump or hydraulic motor malfunction - Repair or change faulty component.
Dirty oil cooler - Cooling fins need to be cleaned.
Drive system overload - Reduce drive system load.

Drive system is excessively noisy
Oil viscosity is too heavy - Use correct oil viscosity.
Air trapped in hydraulic system - Need to bleed air.
Defective drive pump or hydraulic motor - Repair or replace faulty component.
Mechanical components of drive system are worn or damaged - Inspect the parts for worn or defect and repair as needed.

Hydraulics Troubleshooting

Hydraulic system overheated
Incorrect hydraulic pressure setting - Correct setting is required.
Defective or misadjusted main relief valve - Adjust or replace the relief valve.
Hydraulic oil is dirty - Change hydraulic oil.
Hydraulic fluid level is low - Fill the hydraulic system with oil.
Faulty hydraulic oil pump - Repair or change pump if required.

Boom fails to lift or drop
Lift controls are faulty - Change or repair.
Damaged hydraulic oil pump - Replace or repair pump if necessary.
Hydraulic control valve is faulty - Repair or change the valve.
Hydraulic cylinder not working - Change or repair lift cylinder.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.

Bucket won't move
Bucket tilt controls malfunction - Repair or change.
Defective hydraulic pump - Replace or repair pump if necessary.
Defective hydraulic control valve - Change or repair hydraulic valve.
Defective bucket cylinder - Repair or install a new cylinder.
Hydraulic fluid is insufficient - Checking hydraulic fluid level and add if necessary.

Boom or bucket moves slowly
Hydraulic pump is defective - Check the pump capacity and replace pump if required.
Leaking hydraulic cylinder - Install new cylinder seals.
Low hydraulic fluid level - Fill the system to proper hydraulic fluid level.
Hydraulic control valve is faulty or out of adjustment - Repair or set properly.
Hydraulic system loosing pressure - Hydraulic pressure must be set correctly.

Lift arm or bucket is moving jerkily
Air trapped in hydraulic system - Bleed hydraulic system.
Hydraulic oil filter clogging - Clean or install new filter.
Hydraulic oil is contaminated - The oil must be changed.
Scratched cylinder rod or tube - Change damaged component.

Hydraulic pump is excessively noisy
Not enough oil or hydraulic system leaking - Top up hydraulic oil or remedy leakage in system.
Hydraulic filter clogging - Clean or change the filter.
Plugged suction line - Need to service the suction line.
Air in hydraulic pump - Remove air from hydraulics.
Pump components are damaged - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery will not charge
Electrical cable connections are loose or corroded - Service or tighten connections.
Electrical terminal connectors are defective - Install new terminal connectors.
Faulty cell in battery - Battery change required.
Worn or loose belt - Change belt or adjust belt tension.

Starter turns slow
Low battery power - Battery is drained, charge it.
Battery discharges quickly - Service battery or change it.
Disconnected wiring or bad battery terminals - Connect wiring correctly or install new terminals.

Starter is not cranking
Battery is discharged or defective - Recharge or replace battery.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Low battery voltage - Recharge the battery.
Starter motor is defective - Change or repair starter.