Gehl 3825SX Skid Steer Troubleshooting

The Gehl 3825SX skid steer loader is powered by 81.5 cu.in (1.3L) Kubota V1305 4-cylinder naturally aspirated water-cooled diesel engine with a rated power of 29.3 hp (22 kW) at 2800 rpm. The Gehl 3825 SX is equipped with 1-speed hydrostatic transmission, radial-lift loader boom, 60HE roller chains, and 10.5x15 or 27-8.5x15 tires. The hydraulic system has a pump with fluid flow rate of 10 gpm (38 lpm). The hydraulic pressure is 3000 psi (207 bar). The skid steer loader has a rated operating capacity of 1000 lbs (455 kg) and tipping load of 2000 lbs (910 kg). The lift height is 107.5 inches (2730 mm) to hinge pin, and dump height is 86.3 inches (2190 mm).

Engine Troubleshooting

Engine hard to start or doesn't start

Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter plugged - Filter maintenance required.
Burnt or clogged injection nozzle - Inspect nozzles and replace if necessary.
Water in the fuel system - Change fuel and repair fuel system.
The valve clearance is incorrect - Have it adjusted.
Fuel injection pump damage - Replacement or repair required.

Diesel starts but stalls suddenly

Plugged air filter - Clean or change filter.
Fuel filter plugged - Change or clean the filter element.
Fuel injection pump is leaking - Repair any leaks.
Clogged or defective injectors - Clean or replace fuel injectors.
Fuel injection pump is defective - Change pump or rebuild it.

Engine stops running suddenly

Engine is cold - Warm up engine as required.
Fuel filter is plugged - Install new filter element.
Air trapped in fuel system - Bleed air.
Faulty or dirty injection nozzles - Clean or replace injection nozzles.
Improper fuel injection timing - Adjust according to specifications.

Engine stalls while idling

Wrong adjustment of low idle speed - Correct low idle settings.
Defective fuel injection pump - Replace injection pump or repair it.
Clogged or defective injectors - Replace fuel injectors.
Excessive valve clearance - Correct valve clearance.

Engine power is too low

Plugged air filter - Service or replace the air filter.
Clogged or burnt injection nozzle - Service or change injection nozzles.
Fuel injection pressure is wrong - Adjust pressure to proper level.
Valve clearance is out of adjustment - Adjust valve clearance.
Low idle speed adjustment is incorrect - Correct low idle settings.
Fuel lines or hoses clogging - Clean fuel system lines and hoses.
Cylinder-head gasket is leaking - Replace cylinder head gasket.
Leaking or damaged piston rings - Change piston rings.

Engine overheating

Insufficient coolant - Fill radiator to proper level and check components for faults.
Insufficient engine oil - Check and refill engine oil.
Defective radiator cap or clogged radiator fins - Replace cap or clean radiator.
Fan belt is worn or faulty - Change the fan belt.
Engine is under excessive load - Reduce engine load.

Oil pressure is low

Oil level is low - Checking oil level and add if necessary.
Clogged oil filter element - Change or clean engine oil filter element.
Incorrect engine oil Drain crankcase and refill with correct oil.
Incorrect crankshaft bearing oil clearance - Bearing replacement required.
Worn oil pump - Check and replace if necessary.

Engine noise or knocking

Not enough engine oil - Fill up the oil to required level.
Engine not warmed up - Warm up engine as required.
Timing of fuel injection pump is incorrect - Adjust according to specifications.
Incorrect low idle speed adjustment - Normalize low idle speed.
Fuel injectors are dirty or defective - Inspect fuel injectors and change as required.
Connecting rod is worn or not aligned - Connecting rod needs to be aligned or changed.
Scored or worn pistons - Pistons replacement required.

Drive System Troubleshooting

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

Insufficient hydraulic fluid - Add fluid as required.
Damaged drive chain - Inspect drive chain and replace defective parts.
Damaged input drive shaft - Repair or install a new drive shaft.
Worn or damaged relief valve - Repair or replace.
Hydraulic filter or suction line is dirty - Replace hydraulic filter or clean suction line.
Worn or defective hand or foot controls - Change or repair.
Damaged drive pump or motor - Repair or replace faulty component.

Loss of power

Hydraulic oil filter is dirty - Replace hydraulic filter.
Relief valve is open or worn - Close or replace relief valve.
Transmission components are damaged or faulty - Check and change defective components.
Defective input drive shaft - Replace drive shaft.
Hydraulic system is leaking air - Bleed hydraulic system.

Drive system overheats

Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.
Hydraulic fluid filter is dirty - Check, clean, or change as necessary.
Stuck relief valve - Repair or replace.
Drive pump or hydraulic motor is damaged - Replace or repair faulty component.
Hydraulic oil cooler is plugged - Clean cooling fins as required.
Overloaded drive system - Load should be reduced.

Excessive noise

Incorrect oil viscosity - Use oil of proper viscosity.
Air leaks in hydraulic system - Bleed air from system.
Drive pump or hydraulic motor malfunction - Replace or repair faulty component.
Mechanical parts of drive system are worn or damaged - Inspect the components for defect or damage and repair as needed.

Hydraulics Troubleshooting

Hydraulic system is overheated

Hydraulic pressure is not correct - Correct adjustment is required.
Unadjusted or defective main relief valve - Adjust relief valve or change if required.
Hydraulic oil contamination - Fill up with fresh hydraulic oil.
Not enough hydraulic fluid in the system - Fill the hydraulic system with oil.
Worn hydraulic oil pump - Replace or repair pump if necessary.

Boom can't lift or drop

Defective lift controls - Check and repair as required.
Damaged hydraulic oil pump - Replace or repair pump if necessary.
Faulty hydraulic control valve - Install a new valve or repair it.
Hydraulic cylinder is broken - Replace or repair boom cylinder.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.

Bucket does not tilt

Bucket tilt controls are defective - Repair or change.
Damaged hydraulic oil pump - Repair or install new hydraulic pump.
Hydraulic control valve is defective - Change or repair hydraulic valve.
Defective bucket cylinder - Repair or change cylinder.
Low hydraulic oil level - Checking hydraulic oil level and add if necessary.

Boom or bucket moves slowly

Worn hydraulic oil pump - Check the pump performance and replace it if required.
Hydraulic cylinder oil leakage - Change cylinder piston seals.
Low hydraulic oil level - Check and refill the hydraulic oil.
Defective or not adjusted hydraulic control valve - Adjust properly or repair.
Low hydraulic pressure - Set pressure correctly.

Bucket or boom is jerky

Air in hydraulic system - Bleed hydraulic system.
Hydraulic oil filter element clogging - Service or replace the hydraulic filter.
Hydraulic oil is dirty - The oil must be changed.
Cylinder tube or rod is scored - Replace worn component.

Excessive hydraulic pump noise

Not enough oil or hydraulic system leaking - Top up hydraulic oil or remedy leakage in system.
Hydraulic filter clogging - Clean or replace the filter.
Clogged suction line - Clean suction line as required.
Pump is sucking air - Remove air from hydraulics.
Worn pump parts - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery won’t charge

Electrical wire connections are loose or corroded - Clean or tighten connections.
Battery terminal connectors are defective - Change terminal connectors.
Worn-out battery - Change the battery.
Belt is damaged or loose - Need to adjust belt tension or replace belt.

Starter motor cranks slow

Battery voltage is low - Battery needs to be recharged.
Battery runs out quickly - Service charging system or change battery.
Faulty battery terminals or disconnected cables - Check wiring and clean or replace terminals.

Starter doesn't crank

Battery is drained or worn - Change or recharge battery.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery output voltage - Charge the battery.
Damaged starter motor - Repair or replace starter.