Gehl 5625DX Skid Steer Troubleshooting

The Gehl 5625 DX skid steer loader driveline system components: a 152 cu.in (2.5L) Perkins 204.25 vertical 4-cylinder liquid-cooled diesel engine with a rated power of 56 hp (42 kW), and 1-speed hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 21 gal/min (79.5 l/min). The system relief pressure is 3000 psi (207 bar). The Gehl 5625DX is equipped with a radial-lift loader boom, 80HE roller chains, and 12x16.5 or 31-15.5x15 tires. The skid steer loader has a maximum lift height of 119" (3025 mm) to hinge pin and dump height of 94" (2390 mm). The rated operating capacity is 1700 lbs (770 kg), and tipping load is 3400 lbs (1540 kg).

Engine Troubleshooting

Engine starts up hard or will not start

There is air in the fuel system - Bleed the system.
Fuel filter plugged - Replace filter element.
Defective or clogged injection nozzle - If necessary, replace with a new nozzle.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve out of adjustment - Correct valve clearance.
Fuel injection pump is not working correctly - Repair or change injection pump.

Diesel starts but then stops

Clogged air cleaner - Clean or replace air cleaner element.
Clogged fuel filter - Change or clean the filter element.
Fuel injection pump is leaking - Repair any leaks.
Clogged or defective injectors - Replace fuel injectors.
Fuel injection pump damage - Replace or rebuild injection pump.

Engine stops running suddenly

Engine not warmed up - Warm up the engine.
Fuel filter plugging - Install new filter element.
There is air in the fuel system - Bleed the system.
Damaged or dirty injection nozzles - If necessary, replace with a new nozzle.
Timing of fuel injection pump is incorrect - Set it up as required.

Engine shuts off while idling

Low idle speed setting is not correct - Adjustment required.
Faulty fuel injection pump - Repair or replace injection pump.
Dirty or defective injectors - Test and replace fuel injectors if necessary.
Valve out of adjustment - Correct valve clearance.

Lack of engine power

Dirty air filter - Change or service air filter element.
Fuel injection nozzles are faulty or clogged - Replace injection nozzles.
Improper fuel injection pressure - Adjust pressure to proper level.
Valve clearance is out of adjustment - Adjustment procedure required.
Incorrect low idle setting - Adjustment required.
Restricted fuel hoses or lines - Fuel lines and hoses need to be cleaned.
Worn cylinder head gasket - Change cylinder head gasket.
Leaking or defective piston rings - Piston rings replacement required.

Engine overheating

Insufficient coolant fluid - The cooling system needs to be refilled and checked for faults.
Engine oil insufficient - Fill up the oil to required level.
Clogged radiator core or damaged radiator cap - Clean radiator or change cap.
Fan belt is loose or defective - If necessary, replace the belt.
Engine is overloaded - Load reducing required.

Low oil pressure

Low crankcase oil level - Fill up the engine oil.
Oil filter element clogged - Clean or replace engine oil filter element.
Oil grade or viscosity is wrong - Use correct viscosity oil.
Crankshaft bearing has incorrect oil clearance - Bearing replacement required.
Defective oil pump - Repair or change.

Abnormal engine knocking or noise

Engine oil level low - Check oil level and add oil as required.
Low coolant temperature - Warm up the engine to required temperature.
Incorrect adjustment of fuel injection pump timing - Adjust according to specifications.
Too low idle RPM - Adjust low idle speed.
Dirty or defective injectors - Test and replace fuel injectors if necessary.
Connecting rod is worn or misaligned - Connecting rod needs to be replaced or aligned.
Worn or broken pistons - Install new pistons.

Drive System Troubleshooting

Drive system doesn't operate in one direction or either direction

Low hydraulic fluid level - Check and refill the hydraulic fluid.
Drive chain is worn - Inspect drive chain and replace faulty parts.
Input drive shaft is not working properly - Change or repair.
Relief valve worn or defective - Repair or install a new relief valve.
Plugged hydraulic filter or suction line - Check, clean, or change if necessary.
Foot or hand controls are damaged - Repair or replace.
Drive pump or motor is damaged - Check and repair if required.

Lack of power

Plugged hydraulic oil filter - Replace hydraulic filter.
Relief valve is damaged or open - Replace or close relief valve.
Worn or defective transmission parts - Check and replace faulty components.
Input drive shaft is damaged - Repair or replace drive shaft.
Air leaks in hydraulic system - Bleed air from hydraulic system.

Overheated drive system

Low hydraulic fluid level - Fill up the hydraulic fluid.
Hydraulic fluid filter is dirty - Change hydraulic filter.
Relief valve worn or defective - Repair or replace relief valve.
Hydraulic motor or drive pump is worn - Inspect and replace as necessary.
Dirty oil cooler - Clean the cooling fins.
Transmission overloading - Load should be reduced.

Drive system makes excessive noise

Incorrect oil viscosity - Use oil of proper viscosity.
Air trapped in hydraulic system - Air bleeding is required.
Damaged drive pump or hydraulic motor - Repair or change faulty component.
Mechanical components of drive system are defective or worn - Inspect drive system and replace faulty parts.

Hydraulics Troubleshooting

Hydraulic system overheated

Hydraulic pressure is incorrect - Correct adjustment is required.
Main relief valve is defective or unadjusted - Set up or change the relief valve.
Dirty hydraulic oil - Fill up with fresh hydraulic oil.
Not enough hydraulic oil in the system - Fill up the hydraulic oil.
Faulty hydraulic oil pump - Install new pump or repair it.

Lift arm does not lower or raise

Lift controls failure - Inspect and repair if necessary.
Hydraulic pump failure - Install new pump or repair it.
Defective hydraulic control valve - Change or repair hydraulic valve.
Hydraulic cylinder malfunction - Repair or install a new lift cylinder.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.

Bucket does not tilt

Bucket controls failure - Repair or change.
Hydraulic pump is broken - Repair or change pump if required.
Defective hydraulic control valve - Repair or change hydraulic valve.
Faulty hydraulic bucket cylinder - Repair or change cylinder.
Insufficient hydraulic fluid - Add fluid as required.

Bucket or lift arm runs slowly

Hydraulic pump is faulty - Check pump capacity and change if necessary.
Leaking hydraulic cylinder - Cylinder seals need to be replaced.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.
Hydraulic control valve is unadjusted or worn - Repair or set correctly.
Low hydraulic pressure - Adjust pressure as required.

Lift arm or bucket is moving jerkily

Hydraulic system is leaking air - Bleed air from system.
Hydraulic oil filter element is dirty - Change or clean oil filter.
Hydraulic oil is contaminated - Fill up with fresh hydraulic oil.
Scored cylinder tube or rod - Replace defective component.

Hydraulic pump is noisy

Hydraulic leakage or low oil level - Repair hydraulic leaks or add oil as required.
Hydraulic filter is clogged - Change or clean oil filter.
Clogged suction line - Need to service the suction line.
Pump is sucking air - Remove air from hydraulics.
Pump components are worn out - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery does not charge

Electrical wire connections are loose or corroded - Tighten or service connections.
Defective electrical terminal connectors - Terminal connectors need to be changed.
Worn-out battery - Replace the battery.
Belt is damaged or loose - Belt needs to be adjusted or replaced.

Starter motor turns slow

Battery capacity is low - Recharge the battery.
Battery discharges quickly - Service charging system or replace battery.
Bad battery terminals or disconnected wiring - Check wiring and clean or replace terminals.

Starter motor won't turn

Battery is drained or defective - Need to charge or replace the battery.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Low battery output voltage - Battery is drained, recharge it.
Starter motor failure - Change or repair starter.