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Gehl 4240E Troubleshooting

The Gehl 4240E skid steer loader is powered by 133.6 cu.in (2.19L) Yanmar 4TNV88-BKMS 4-cycle 4-cylinder direct injection naturally aspirated liquid-cooled diesel engine with a rated power of 46 hp (34 kW) at 2600 rpm. The Gehl 4240E is equipped with a radial-lift loader boom, single-speed hydrostatic transmission, 80K drive chains, and 10x16.5 HD standard tires. The hydraulic system has a pump with fluid flow rate of 16.5 gpm (62 lpm). 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 110 inches (2795 mm) to hinge pin, and dump height is 86.4 inches (2195 mm).

Engine Troubleshooting

Engine difficult to start or won't start
Air in fuel tank - Bleed fuel tank.
Fuel filter element is dirty - Clean the filter or install new filter element.
Fuel injection nozzles are dirty or defective - Change fuel injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
The valve clearance is incorrect - Adjust valve clearance.
Fuel injection pump damage - Replace or rebuild injection pump.

Engine starts and immediately shuts off
Air filter is plugged - Service or replace the air filter.
Clogged fuel filter - Change filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Fuel injectors are dirty or defective - Change or clean fuel injectors.
Defective fuel injection pump - Install a new pump or rebuild.

Engine stalls while running
Engine is not warmed up to the required temperature - Engine is not warmed up to the required temperature.
Fuel filter plugging - Clean or replace the filter.
Air in fuel tank - Bleed fuel tank.
Fuel injection nozzles are faulty or clogged - Check and replace nozzles if required.
Timing of fuel injection pump is incorrect - Adjust as recommended.

Engine stops at idle
Incorrect low idle setting - Adjust low idling as recommended.
Fuel injection pump is broken - Replace or rebuild injection pump.
Fuel injectors are dirty or defective - Inspect fuel injectors and change as required.
Valve clearance is wrong - Adjust valve clearance according to specifications.

Lack of engine power
Plugged air filter - Replace or clean air filter element.
Fuel injection nozzles are faulty or clogged - Install a new kit of correctly balanced nozzles.
Fuel injection pressure is incorrect - Test fuel injection pressure and adjust it correctly.
Valve clearance is not correct - Need to adjust valve clearance.
Low idle speed setting is incorrect - Adjust the low idle speed.
Fuel lines or hoses are clogged - Clean fuel system hoses and lines.
Cylinder head gasket is blown - Replace cylinder head gasket.
Piston rings are broken or leaking - Install new piston rings.

Engine is overheated
Low coolant level - Add coolant and check the components of cooling system.
Engine oil level low - Add oil to the engine crankcase.
Dirty radiator fins or faulty radiator cap - Install new cap or clean radiator.
Excessive wear of the fan belt - Change as required.
Diesel engine overloaded - Reduce engine load.

Oil pressure too low
Oil level is low - Check and refill the oil.
Clogged oil filter element - Clean or change engine oil filter.
Incorrect engine oil Use proper viscosity oil.
Incorrect crankshaft bearing oil clearance - Change bearings.
Defective oil pump - Repair or replace.

Abnormal engine noise or knocking
Engine oil insufficient - Need to add engine oil.
Coolant temperature is low - Warm up the engine.
Fuel injection pump timing is wrong - Use the correct fuel injection pump timing adjustment.
Incorrect low idle setting - Adjustment required.
Fuel injector fault - Replace or clean fuel injectors.
Connecting rod is defective or not aligned - Connecting rod needs to be replaced or aligned.
Pistons are worn or scored - Replace the pistons.

Drive System Troubleshooting

Drive system doesn't function in one direction or either direction
Low hydraulic fluid level - Add fluid as required.
Drive chain malfunction - Inspect drive chain and replace faulty components.
Relief valve worn or defective - Service or change relief valve.
Dirty hydraulic filter or suction line - Clean suction line or change hydraulic filter.
Faulty hand or foot controls - Repair or change.
Drive pump or motor malfunction - Inspect and change as required.

Low power
Plugged hydraulic oil filter - Check, clean, or replace as required.
Relief valve is damaged or open - Replace or close relief valve.
Transmission components are faulty or damaged - Inspect and replace defective parts.
Input drive shaft malfunction - Faulty drive shaft need to be replaced or repair.
Air in the hydraulic system - Bleed air from hydraulic system.

Drive system overheating
Insufficient hydraulic oil - Check and refill the hydraulic oil.
Hydraulic fluid filter is clogged - Check, clean, or change as necessary.
Relief valve failure - Relief valve need to be replaced or repair.
Drive pump or hydraulic motor malfunction - Repair or replace faulty component.
Clogged hydraulic oil cooler - Cooling fins should be cleaned.
Drive system overloaded continuously - Reduce loading.

Drive system is noisy
Improper oil viscosity - Drain and refill with correct oil.
Hydraulic system is leaking air - Bleed air from system.
Defective drive pump or hydraulic motor - Inspect and replace as necessary.
Mechanical components of drive system are damaged or worn - Check drive system and change faulty components.

Hydraulics Troubleshooting

Hydraulic system overheated
Hydraulic pressure incorrectly adjusted - Correct setting is required.
Main relief valve malfunction or improper adjustment - Adjust relief valve or change if required.
Hydraulic oil is dirty - Change hydraulic oil.
Hydraulic fluid level is low - Need to add fluid.
Hydraulic pump is faulty - Repair or install new hydraulic pump.

Lift arm does not lower or raise
Lift controls malfunction - Repair or change.
Hydraulic pump not working - Replace or repair pump if necessary.
Hydraulic control valve is defective - Change or repair hydraulic valve.
Hydraulic cylinder is broken - Replace or repair boom cylinder.
Insufficient hydraulic fluid - Fill up the hydraulic fluid.

Bucket does not tilt
Defective bucket controls - Inspect and repair if necessary.
Hydraulic pump failure - Repair or change pump if required.
Hydraulic control valve malfunction - Repair or change the valve.
Damaged bucket cylinder - Repair or replace cylinder.
Insufficient hydraulic fluid - Add fluid as required.

Slow boom or bucket operation
Faulty hydraulic oil pump - Check the pump performance and replace it if required.
Leaking hydraulic cylinder - Change cylinder piston seals.
Hydraulic oil level low - Check and refill the hydraulic oil.
Hydraulic control valve is faulty or out of adjustment - Repair or set properly.
Hydraulic pressure is low - Correct setting is required.

Lift arm or bucket is working jerkily
Hydraulic system is leaking air - Bleed air from system.
Plugged hydraulic oil filter - Change or clean oil filter.
Hydraulic oil contamination - Hydraulic oil change required.
Cylinder rod or tube is scratched - Replace damaged component.

Hydraulic pump is excessively noisy
Insufficient oil level or leaking hydraulic system - Top up hydraulic oil or remedy leakage in system.
Hydraulic filter clogging - Clean or change the filter.
Clogged suction line - Suction line must be serviced.
Air enters the pump - Remove air from hydraulics.
Faulty pump components - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery does not charge
Wiring connections are corroded or loose - Service or tighten connections.
Defective battery terminal clamps - Terminal clamps need to be replaced.
Battery is defective - Battery change required.
Defective or loose belt - Change belt or adjust belt tension.

Starter turning slow
Low battery voltage - Recharge the battery.
Battery drains quickly - Service or replace the battery.
Battery terminals are corroded or wires are disconnected - Connect wiring properly or install new terminals.

Starter doesn't crank
Battery is low or faulty - Replace or charge as required.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery capacity - Charge the battery.
Starter motor is faulty - Replace or repair starter.