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Gehl R165 Troubleshooting

The Gehl R165 skid steer loader is powered by 201.5 cu.in (3.3L) Yanmar 4TNV98C-NMS2 4-cylinder vertical in-line direct injection liquid-cooled diesel engine with a rated power of 68.4 hp (51.1 kW). The Gehl R165 is equipped with a radial-lift boom, single or two speed hydrostatic transmission, 80K drive chains, and 10x16.5 HD standard tires. The hydraulic system has a pump with fluid flow rate of 18.9 gpm (71.4 lpm). The hydraulic pressure is 3000 psi (207 bar). The skid steer loader has a rated operating capacity of 1650 lbs (748 kg) and tipping load of 3275 lbs (1486 kg). The lift height is 119" (3025 mm) to hinge pin, and dump height is 93.7" (2380 mm).

Engine Troubleshooting

Engine starts hard or doesn't start
Air in fuel system - Bleed fuel system.
Fuel filter plugging - Clean the filter element.
Fuel injection nozzles are damaged or dirty - If necessary, replace with a new nozzle.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Incorrect valve clearance - Correct valve clearance needs to be set.
Faulty fuel injection pump - Rebuild or replace pump.

Diesel starts and stalls immediately
Dirty air filter - Clean or change.
Clogged fuel filter - Clean or change the filter.
Fuel injection pump has loose connections - Tighten the connections.
Fuel injectors are faulty or clogged - Clean fuel injectors or change it.
Fuel injection pump damage - Install a new fuel pump or repair.

Engine stalls while running
Engine is not fully warmed up - Warm up engine as required.
Fuel filter element is dirty - Install new filter element.
There is air in the fuel system - Bleed the system.
Fuel injection nozzles are damaged or dirty - Change fuel injection nozzles.
Fuel injection pump timing is not adjusted - Check the fuel injection pump timing adjustment.

Engine stops at low idle speed
Too low idle RPM - Need to adjust idle speed.
Fuel injection pump malfunctioning - Replacement or repair required.
Dirty or defective injectors - Replace fuel injectors.
Valve clearance is not correct - Adjust valve clearance according to specifications.

Engine lacks power
Air filter is plugged - Clean or change.
Fuel injection nozzles are faulty or clogged - Change fuel injection nozzles.
Improper fuel injection pressure - Check the fuel injection pressure and adjust if necessary.
Valve clearance is out of adjustment - Adjust valve clearance.
Low idle speed set incorrectly - Adjust as required.
Fuel hoses or lines clogging - Clean fuel system lines and hoses.
Cylinder head gasket is blown - Replace the gasket as required.
Piston rings are broken or leaking - Piston rings need to be replaced.

Engine overheating
Lack of engine coolant - Fill the cooling system and check components for leaks or other faults.
Engine oil level is insufficient - Check and refill engine oil.
Radiator core is clogged or radiator cap is leaking - Clean radiator or replace cap.
Broken or loose fan belt - Install new fan belt.
Engine overload - Reduce engine load.

Oil pressure is insufficient
Insufficient engine oil - Add oil as required.
Clogged oil filter - Clean or replace engine oil filter element.
Oil grade or viscosity is incorrect - Use correct viscosity oil.
Crankshaft bearing has incorrect oil clearance - Change bearings.
Oil pump is defective - Remove and inspect oil pump.

Engine knocks or noises
Lack of engine oil - Need to add engine oil.
Engine is not fully warmed up - Warm up to required temperature.
Fuel injection pump timing is not adjusted - Check the fuel injection pump timing adjustment.
Incorrect low idle speed adjustment - Adjust the low idle speed.
Clogged or defective injectors - Clean or replace fuel injectors.
Connecting rod is misaligned or worn - Align or change connecting rod.
Pistons are broken or worn - Install new pistons.

Drive System Troubleshooting

Drive system does not work in either direction
Hydraulic fluid is insufficient - Check and refill the hydraulic fluid.
Worn drive chain - Inspect drive chain and replace faulty parts.
Relief valver is broken - Relief valve need to be replaced or repair.
Plugged hydraulic filter or suction line - Clean suction line or replace hydraulic filter.
Faulty hand or foot controls - Repair or change.
Drive motor or pump failure - Inspect and replace as necessary.

Reduced power
Hydraulic oil filter is clogged - Change or service hydraulic filter.
Relief valve is defective or open - Change or close relief valve.
Transmission components are damaged or faulty - Check and replace defective components.
Stuck input drive shaft - Replace drive shaft.
Air trapped in hydraulic system - Bleed air from hydraulic system.

Drive system overheating
Insufficient hydraulic fluid - Check and refill the hydraulic fluid.
Dirty hydraulic fluid filter - Check, clean, or replace as required.
Relief valve is stuck - Relief valve need to be replaced or repair.
Damaged drive pump or hydraulic motor - Repair or change faulty component.
Oil cooler is clogged - Cooling fins should be cleaned.
Drive system overloaded continuously - Reduce the load.

Drive system makes excessive noise
Incorrect oil viscosity - Use oil of correct viscosity.
Air trapped in hydraulic system - Air bleeding is required.
Damaged drive pump or hydraulic motor - Repair or replace faulty component.
Worn or damaged mechanical components of drive system - Check the parts for worn or defect and replace if required.

Hydraulics Troubleshooting

Hydraulic system overheats
Hydraulic pressure is not correct - Correct adjustment is required.
Main relief valve is defective or unadjusted - Adjust relief valve or change if required.
Hydraulic oil contamination - Hydraulic oil change required.
Lack of hydraulic oil - Fill up the hydraulic oil.
Hydraulic pump is worn - Replace or repair pump if necessary.

Lift arm does not lower or raise
Damaged lift controls - Change or repair.
Damaged hydraulic oil pump - Replace or repair pump if necessary.
Hydraulic control valve malfunction - Replace or repair the valve.
Hydraulic cylinder malfunction - Repair or change hydraulic cylinder.
Hydraulic fluid level low - Fill up the hydraulic fluid.

Bucket tilt does not work
Bucket controls failure - Repair or replace.
Hydraulic pump malfunction - Repair or install new hydraulic pump.
Hydraulic control valve is faulty - Repair or change the valve.
Bucket cylinder failure - Install a new cylinder or repair it.
Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.

Boom or bucket is moving slowly
Hydraulic pump is defective - Test the pump performance and change pump if required.
Oil leaks from hydraulic cylinder - Correct leakage by changing the seals.
Hydraulic fluid level low - Fill up the hydraulic fluid.
Hydraulic control valve is defective or set improper - Repair or adjust correctly.
Low hydraulic pressure - Correct adjustment is required.

Bucket or boom is jerky
Air in the hydraulic system - Bleed air from hydraulic system.
Plugged hydraulic oil filter - Change or clean oil filter.
Hydraulic fluid is contaminated - Change hydraulic fluid.
Scratched cylinder rod or tube - Replace worn component.

Hydraulic pump is noisy
Hydraulic system leaking or not enough oil - Top up hydraulic oil or remedy leakage in system.
Dirty hydraulic filter - Replace or clean the filter.
Suction line is dirty - Need to service the suction line.
Pump is sucking air - Remove air from hydraulics.
Pump components are damaged - Rebuild or install new pump.

Electrical Troubleshooting

Battery is not charging
Corroded or loose cable connections - Clean or tighten wiring connections.
Battery terminal clamps are defective - Replace terminal clamps.
Defective battery - Use a new battery.
Loose or defective belt - Belt needs to be adjusted or changed.

Starter motor cranks slow
Battery power is low - Recharge the battery.
Battery discharges quickly - Service or replace the battery.
Disconnected cables or faulty battery terminals - Check cable connections and replace or service terminals.

Starter is not working
Battery is low or faulty - Recharge or change battery.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery voltage - Charge the battery.
Starter motor failing - Starter should be replaced.