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Gehl 4640E Troubleshooting

The Gehl 4640E skid steer loader driveline system components: a 142.1 cu.in (2.3L) Deutz BF3M2011 3-cylinder direct injection turbocharged diesel engine with a rated power of 60 hp (44.7 kW), and 1-speed or 2-speed hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 19 gal/min (72 l/min). The system relief pressure is 3000 psi (207 bar). The Gehl 4640E is equipped with 80 roller drive chains and 10x16.5-8 or 12x16.5-10 tires. The skid steer loader has a lift height of 115.5" (2935 mm) to hinge pin and dump height of 89.5" (2275 mm). The rated operating capacity is 1650 lbs (748 kg), and tipping load is 3300 lbs (1495 kg).

Engine Troubleshooting

Engine starts hard or won't start
There is air in the fuel system - Bleed the system.
Fuel filter plugged - Service the filter.
Fuel injection nozzles are faulty or clogged - Replace injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Incorrect valve clearance - Adjust to proper valve clearance.
Fuel injection pump malfunction - Repair or change injection pump.

Diesel starts but stalls immediately
Air cleaner is clogged - Clean or replace air cleaner element.
Fuel filter element is clogged - Change filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Defective or clogged fuel injectors - Clean fuel injectors or change it.
Defective fuel injection pump - Install a new fuel pump or repair.

Engine stalls during operation
Engine is not warmed up to the required temperature - Warm up the engine as required.
Fuel filter element clogging - Clean the filter or install new filter element.
Air in the fuel lines - Bleed the fuel lines.
Clogged injection nozzle - Check injection nozzles and replace if required.
Improper setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.

Engine stalls while idling
Low idle speed setting is incorrect - Test and adjust.
Fuel injection pump is not operating properly - Replacement or repair required.
Fuel injectors are faulty or clogged - Clean fuel injectors or change it.
Improper valve clearance - Need to adjust valve clearance.

Engine loses power
Air filter is dirty - Install new air filter element.
Dirty or faulty injection nozzles - Check injection nozzles and replace if required.
Fuel injection pressure is wrong - Adjust to correct pressure.
Valve clearance is wrong - Adjustment procedure required.
Incorrect low idle speed adjustment - Correct low idle adjustment.
Dirty fuel lines or hoses - Service fuel lines and hoses.
Cylinder head gasket is defective - Install a new gasket.
Damaged or leaking piston rings - Replace the piston rings as required.

Engine overheating
Engine coolant is insufficient - Fill the cooling system and check components for leaks or other faults.
Lack of engine oil - Fill the crankcase with engine oil.
Radiator core is clogged or radiator cap is leaking - Install new cap or clean radiator.
Loose or damaged fan belt - Belt change is required.
Engine is under excessive load - Reduce load on the engine.

Insufficient oil pressure
Oil level is low - Need to add oil.
Plugged engine oil filter - Clean or replace engine oil filter element.
Different type of engine oil - Use correct viscosity oil.
Excessive oil clearance of crankshaft bearing - Change bearings.
Worn oil pump - Inspect and change as required.

Engine noise or knocking
Lack of engine oil - Fill the crankcase with engine oil.
Low coolant temperature - Warm up the engine.
Wrong setting of fuel injection pump timing - Set the fuel pump timing correctly.
Incorrectly set low idle speed - Adjust low idle speed.
Fuel injectors are faulty or clogged - Change or clean fuel injectors.
Connecting rod is defective or not aligned - Need to align or replace the connecting rod.
Worn or scored pistons - Have pistons replaced.

Drive System Troubleshooting

Drive system will not operate in either direction
Low hydraulic fluid level - Fill the system to proper hydraulic fluid level.
Drive chain is worn - Inspect drive chain and replace faulty components.
Worn input drive shaft - Drive shaft need to be replaced or repair.
Relief valve is worn or damaged - Change or repair relief valve.
Suction line or hydraulic filter is clogged - Replace hydraulic filter or clean suction line.
Defective hand or foot controls - Inspect and repair if necessary.
Drive pump or motor malfunction - Repair or replace faulty component.

Lack of power
Hydraulic oil filter is plugged - Change or service hydraulic filter.
Relief valve is opened or defective - Close or change relief valve.
Faulty or damaged transmission components - Check and replace faulty components.
Input drive shaft is stuck - Repair or replace drive shaft.
Air in hydraulic system - Bleed hydraulic system.

Drive system is overheated
Low hydraulic oil level - Need to add oil.
Plugged hydraulic fluid filter - Check, clean, or change as necessary.
Relief valve is defective - Service or change relief valve.
Worn hydraulic motor or drive pump - Change or repair faulty component.
Hydraulic oil cooler is plugged - Clean the cooling fins.
Transmission overloading - Load needs to be reduced.

Drive system is excessively noisy
Incorrect oil viscosity - Use oil of proper viscosity.
Air trapped in hydraulic system - Bleed air from system.
Worn hydraulic motor or drive pump - Inspect and replace as necessary.
Mechanical parts of drive system are damaged or worn - Inspect the components and repair as required.

Hydraulics Troubleshooting

Hydraulic system overheating
Hydraulic pressure is not adjusted correctly - Set pressure correctly.
Main relief valve is defective or unadjusted - Adjust or change relief valve.
Contaminated hydraulic oil - Change hydraulic oil.
Not enough hydraulic oil in the system - Check oil level and add hydraulic oil as required.
Worn hydraulic oil pump - Install new pump or repair it.

Boom cannot be lowered or raised
Lift controls are faulty - Change or repair.
Hydraulic pump not working - Repair or change pump if required.
Hydraulic control valve is defective - Change or repair hydraulic valve.
Hydraulic cylinder is faulty - Install a new boom cylinder or repair it.
Insufficient hydraulic fluid - Add fluid as required.

Bucket won't move
Bucket controls failure - Repair or change.
Hydraulic pump is broken - Change or repair hydraulic pump if required.
Hydraulic control valve is defective - Install a new valve or repair it.
Bucket cylinder malfunction - Install a new cylinder or repair it.
Hydraulic fluid level low - Fill up the hydraulic fluid.

Boom or bucket is moving slowly
Hydraulic pump is worn - Check pump flow and install new pump if necessary.
Hydraulic cylinder leaking - Change cylinder piston seals.
Low hydraulic fluid level - Fill up the hydraulic fluid.
Damaged or incorrect adjusted hydraulic control valve - Adjust correctly or repair.
Hydraulic pressure is low - Adjust it correctly.

Jerky operation of the bucket or boom
Air trapped in hydraulic system - Air bleeding is required.
Dirty hydraulic oil filter element - Clean or install new filter.
Contaminated hydraulic fluid - Change hydraulic fluid.
Scored cylinder tube or rod - Replace failed component.

Hydraulic pump is noisy
Hydraulic system leaking or not enough oil - Refill hydraulic oil or repair leaks in system.
Clogged hydraulic filter - Clean or replace the filter.
Clogged suction line - Need to clean the suction line.
Air enters the pump - Bleed air from hydraulics.
Faulty pump parts - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery won’t charge
Corroded or loose cable connections - Clean or tighten wiring connections.
Defective electrical terminal connectors - Change terminal connectors.
Battery dead cell - Replace the battery.
Belt is defective or loose - Belt needs to be adjusted or changed.

Starter turns slowly
Low battery power - Low battery charging, charge as required.
Battery drains quickly - Service battery or replace it.
Corroded battery terminals or disconnected wires - Check wire connections and change or service terminals.

Starter does not work
Battery is low or faulty - Charge or change the battery.
Disconnected or improperly connected wiring harness - Inspect battery wiring harness and connect as required.
Battery voltage is low - Battery needs to be recharged.
Faulty starter motor - Repair or install a new starter.