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Gehl 4840 Troubleshooting

The Gehl 4840 skid steer loader is powered by 190 cubic inches (3.1 L) Deutz F4M2011 four-cylinder liquid-cooled naturally aspirated diesel engine with a rated power of 61.2 hp (45 kW) at 2500 rpm. The Gehl 4840 is equipped with a single-speed or two-speed transmission, 80 roller drive chains, and 10x16.5-8 or 12x16.5-10 tires. The hydraulic system has a pump with fluid flow rate of 19 gpm (72 lpm). The hydraulic pressure is 3000 psi (207 bar). The skid steer loader has a rated operating capacity of 1700 lbs (770 kg) and tipping load of 3400 lbs (1540 kg). The lift height is 115.5 inches (2935 mm) to hinge pin, and dump height is 89.5 inches (2275 mm).

Engine Troubleshooting

Engine starts up hard or doesn't start
Air in fuel tank - Bleed fuel tank.
Fuel filter element is dirty - Clean the filter or install new filter element.
Clogged or defective injection nozzles - Test injection nozzles and change if necessary.
Water or dirt in fuel system - Drain, flush, and service the system.
The valve clearance is incorrect - Check and adjust as required.
Damaged fuel injection pump - Replacement or repair required.

Engine starts but immediately stalls
Air filter is plugged - Service or replace the air filter.
Dirty fuel filter - Clean or replace the filter.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Fuel injectors are dirty or defective - Inspect fuel injectors and change as required.
Fuel injection pump damage - Replace or rebuild injection pump.

Engine stops suddenly during operation
Engine is cold - Warm up to required temperature.
Fuel filter element is clogged - Change filter element.
Air in the fuel system - Air bleeding.
Dirty or faulty injection nozzles - Install a new kit of correctly balanced nozzles.
Improper fuel injection timing - Set it up as required.

Engine stalls when idle
Low idle speed setting is not correct - Adjustment required.
Fuel injection pump malfunctioning - Rebuild or replace pump.
Defective fuel injectors - Test and replace fuel injectors if necessary.
The valve clearance is not adjusted - Correct valve clearance needs to be set.

Engine power is too low
Dirty air cleaner - Install new air cleaner element.
Damaged or dirty injection nozzles - Change fuel injection nozzles.
Fuel injection pressure is incorrect - Adjust pressure to proper level.
Incorrect valve clearance - Have it adjusted.
Low idle speed setting is incorrect - Adjust low idle speed.
Clogged fuel hoses or lines - Clean fuel hoses and lines.
Leaking cylinder head gasket - Replace cylinder head gasket.
Piston rings are damaged or leaking - Install new piston rings.

Engine overheated
Insufficient coolant - Add coolant fluid and inspect the cooling system for leaks.
Insufficient engine oil - Checking oil level and add if necessary.
Radiator fins are clogged or radiator cap is faulty - Change cap or clean radiator.
Broken or loose fan belt - Belt replacement is recommended.
Engine overloaded - Reduce engine load.

Oil pressure too low
Engine oil level low - Check and refill the oil.
Oil filter element clogged - Change or service engine oil filter.
Incorrect oil viscosity - Drain and refill with oil of correct grade and viscosity.
Crankshaft bearing has excessive oil clearance - Bearings need to be reinstalled.
Oil pump is damaged - Repair or change.

Engine knocks or noises
Low engine oil level - Fill up the oil to required level.
Engine is cold - Normalize the temperature by warming up the engine.
Improper setting of fuel injection pump timing - Adjust according to specifications.
Low idle speed set incorrectly - Correct the settings.
Dirty or defective injectors - Replace or clean fuel injectors.
Misaligned or defective connecting rod - Alignment procedure or replacement is required.
Pistons are broken or worn - Pistons need to be replaced.

Drive System Troubleshooting

Drive system doesn't work in either direction
Insufficient hydraulic oil - Need to add oil.
Drive chain is damaged - Inspect drive chain and replace faulty parts.
Input drive shaft is damaged - Repair or replace.
Relief valver is broken - Rebuild or install a new relief valve.
Dirty hydraulic filter or suction line - Clean suction line or change hydraulic filter.
Defective or worn foot or hand controls - Change or repair.
Drive pump or motor is damaged - Change or repair faulty component.

Loss of power
Dirty hydraulic oil filter - Change hydraulic filter.
Worn or open relief valve - Close or replace relief valve.
Transmission parts are defective or worn - Inspect and change faulty parts.
Input drive shaft malfunction - Repair or install a new drive shaft.
Hydraulic system is leaking air - Air bleeding is required.

Overheated drive system
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.
Dirty hydraulic fluid filter - Replace or clean hydraulic filter.
Defective relief valve - Change or repair relief valve.
Damaged drive pump or hydraulic motor - Replace or repair faulty component.
Plugged hydraulic oil cooler - Clean cooling fins as required.
Overloaded drive system - Reduce the load.

Drive system makes excessive noise
Wrong oil viscosity - Use correct oil viscosity.
Hydraulic system is leaking air - Bleed hydraulic system.
Damaged drive pump or hydraulic motor - Change or repair faulty component.
Worn or defective mechanical parts of drive system - Inspect drive system and replace faulty components.

Hydraulics Troubleshooting

Hydraulic system overheated
Hydraulic pressure is incorrect - Correct adjustment is required.
Main relief valve improper adjustment or failure - Replace or set up the relief valve.
Hydraulic fluid is dirty - The fluid must be changed.
Not enough hydraulic fluid in the system - Need to add fluid.
Defective hydraulic pump - Repair or install new hydraulic pump.

Lift arm fails to drop or lift
Faulty lift controls - Repair or replace.
Hydraulic pump malfunction - Repair or replace pump if necessary.
Faulty hydraulic control valve - Replace or repair the valve.
Broken hydraulic cylinder - Replace or repair boom cylinder.
Insufficient hydraulic oil - Need to add oil.

Bucket tilt does not work
Bucket tilt controls malfunction - Inspect and repair if necessary.
Hydraulic pump failure - Repair or replace pump if necessary.
Defective hydraulic control valve - Repair or change hydraulic valve.
Hydraulic bucket cylinder is defective - Replace or repair cylinder.
Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.

Bucket or lift arm moves slowly
Hydraulic pump is defective - Check pump capacity and change if necessary.
Oil leaks from hydraulic cylinder - Replace cylinder piston seals.
Low hydraulic oil level - Check and refill the hydraulic oil.
Hydraulic control valve is not set properly or defective - Set properly or repair.
Hydraulic pressure has dropped - Hydraulic pressure must be set correctly.

Lift arm or bucket is moving jerkily
There is air in the hydraulic system - Bleed air from system.
Hydraulic oil filter is clogged - Change or clean oil filter.
Dirty hydraulic oil - Hydraulic oil change required.
Scratched cylinder rod or tube - Replace damaged component.

Hydraulic pump makes excessive noise
Hydraulic leakage or low oil level - Top up hydraulic oil or remedy leakage in system.
Hydraulic filter clogging - Service or replace hydraulic filter.
Suction line is dirty - Clean suction line as required.
Pump is sucking air - Bleed air.
Damaged pump parts - Replace or rebuild the pump.

Electrical Troubleshooting

Battery will not charge
Electrical wire connections are corroded or loose - Tighten or service connections.
Battery terminal clamps are faulty - Terminal clamps need to be replaced.
Battery is worn - Change the battery.
Defective or loose belt - Replace belt or adjust belt tension.

Starter motor cranks slow
Battery capacity is low - Battery is drained, recharge it.
Battery will not hold charge - Service charging system or install new battery.
Disconnected cables or faulty battery terminals - Connect wires properly or change terminals.

Starter will not crank
Battery is drained or defective - Change or recharge battery.
Battery wiring is disconnected or improperly connected - Inspect wiring and connect as required.
Low battery capacity - Battery is drained, recharge it.
Starter motor is faulty - Repair or change starter.