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Gehl 4840E Troubleshooting

The Gehl 4840E skid steer loader driveline system components: a 190 cu.in (3.1L) Deutz F4M2011 4-cycle 4-cylinder direct injection liquid-cooled diesel engine with a rated power of 61.2 hp (45 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 4840E 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 1900 lbs (862 kg), and tipping load is 3800 lbs (1724 kg).

Engine Troubleshooting

Engine starts up hard or won't start
Air in the fuel lines - Bleed the fuel lines.
Fuel filter element clogging - Replace filter element.
Dirty or faulty injection nozzles - If necessary, replace with a new nozzle.
Water or dirt in fuel system - Drain, flush, and service the system.
Incorrect valve clearance - Need to adjust valve clearance.
Fuel injection pump is not operating properly - Replace or rebuild injection pump.

Engine starts but stops suddenly
Air filter is clogged - Clean or change.
Clogged fuel filter - Install new filter element.
Fuel injection pump has loose connections - Tighten the connections.
Dirty or defective injectors - Test and replace fuel injectors if necessary.
Fuel injection pump malfunction - Rebuild or install a new injection pump.

Engine stops unexpectedly during operation
Low coolant temperature - Normalize the temperature by warming up the engine.
Fuel filter is plugged - Change the filter element.
There is air in the fuel system - Bleed the system.
Faulty fuel injection nozzles - Service or change injection nozzles.
Fuel injection pump timing is not adjusted - Set up as recommended.

Engine stalls at idle
Incorrect low idle speed adjustment - Correct the settings.
Fuel injection pump damage - Repair or replace injection pump.
Dirty or defective injectors - Change or clean fuel injectors.
The valve clearance is not adjusted - Adjust valve clearance according to specifications.

Diesel engine is losing power
Air cleaner is clogged - Clean or replace element.
Fuel injection nozzles are clogged or faulty - Clean or change injection nozzles.
Fuel injection pressure is wrong - Check the fuel injection pressure and adjust if necessary.
The valve clearance is not adjusted - Correct valve clearance needs to be set.
Improperly adjusted low idle speed - Correct the settings.
Dirty fuel hoses or lines - Clean fuel lines and hoses.
Cylinder head gasket is defective - Gasket should be replaced.
Worn or broken piston rings - Piston rings replacement required.

Engine is overheated
Low engine coolant - Add coolant fluid and inspect the cooling system for leaks.
Not enough engine oil - Fill up the oil to required level.
Dirty radiator fins or faulty radiator cap - Change cap or clean radiator.
Broken or loose fan belt - Fan belt must be replaced.
Diesel engine overloaded - Load reducing required.

Oil pressure too low
Insufficient engine oil - Need to add oil.
Oil filter element is dirty - Clean or change engine oil filter.
Incorrect engine oil Use oil of proper viscosity.
Main bearing oil clearance is excessive - Change bearings.
Oil pump is worn or damaged - Repair or replace.

Abnormal engine knocking or noise
Insufficient engine oil - Fill up the oil to required level.
Low coolant temperature - Warm up engine as required.
Improper fuel injection timing - Adjust according to specifications.
Wrong adjustment of low idle speed - Need to adjust idle speed.
Fuel injector fault - Clean or replace fuel injectors.
Connecting rod is misaligned or worn - Replace or align connecting rod.
Broken or worn pistons - Install new pistons.

Drive System Troubleshooting

Drive system won't work in one direction or either direction
Low hydraulic fluid level - Add fluid as required.
Drive chain is worn - Check drive chain and change defective components.
Input drive shaft malfunction - Rebuild or change.
Relief valve is stuck - Service or change relief valve.
Clogged hydraulic filter or suction line - Clean suction line or change hydraulic filter.
Defective or worn foot or hand controls - Change or repair.
Drive motor or pump is worn - Replace or repair faulty component.

Power is too low
Hydraulic oil filter is plugged - Replace or service hydraulic filter.
Open or faulty relief valve - Close or change relief valve.
Transmission parts are faulty or damaged - Inspect and replace faulty parts.
Input drive shaft is defective - Rebuild or change the shaft.
Hydraulic system is leaking air - Bleed air from system.

Overheated drive system
Low hydraulic fluid level - Add fluid as required.
Hydraulic fluid filter is plugged - Check, clean, or replace as required.
Defective or worn relief valve - Change or repair relief valve.
Worn hydraulic motor or drive pump - Repair or replace faulty component.
Oil cooler is clogged - Cooling fins should be cleaned.
Drive system overloaded continuously - Load needs to be reduced.

Drive system is excessively noisy
Oil viscosity is wrong - Use the specified type of oil.
Air in hydraulic system - Air bleeding is required.
Defective drive pump or hydraulic motor - Repair or change faulty component.
Defective or worn mechanical components of drive system - Check the components and replace if necessary.

Hydraulics Troubleshooting

Hydraulic system is overheated
Hydraulic pressure is not adjusted correctly - Hydraulic pressure must be set correctly.
Misadjusted or defective main relief valve - Adjust or change relief valve.
Hydraulic oil is dirty - Fill up with fresh hydraulic oil.
Not enough hydraulic fluid in the system - Check and refill the hydraulic fluid.
Defective hydraulic pump - Repair or replace pump if necessary.

Lift arm can't drop or lift
Lift controls are defective - Replace or repair.
Hydraulic pump not working - Repair or change pump if required.
Hydraulic control valve is faulty - Replace or repair the valve.
Hydraulic cylinder is broken - Repair or install a new lift cylinder.
Insufficient hydraulic oil - Need to add oil.

Bucket does not tilt
Faulty bucket tilt controls - Change or repair.
Damaged hydraulic oil pump - Change or repair hydraulic pump if required.
Hydraulic control valve malfunction - Repair or replace the valve.
Bucket cylinder failure - Replace or repair cylinder.
Hydraulic fluid level low - Fill the system to proper hydraulic fluid level.

Slow bucket or lift arm operation
Worn hydraulic oil pump - Test the pump performance and change pump if required.
Leaking hydraulic cylinder - Repair leak by replacing the seals.
Insufficient hydraulic fluid - Checking hydraulic fluid level and add if necessary.
Hydraulic control valve is not set properly or defective - Repair or set properly.
Hydraulic pressure is low - Correct setting is required.

Bucket or boom jerks when working
Air in the hydraulic system - Need to bleed air.
Hydraulic oil filter element is dirty - Clean or change the filter.
Hydraulic oil contamination - Fill up with fresh hydraulic oil.
Cylinder tube or rod scoring - Replace failed component.

Hydraulic pump is excessively noisy
Low oil level or hydraulic leaks - Refill hydraulic oil or repair leaks in system.
Hydraulic filter clogging - Clean or change the filter.
Suction line is clogged - Need to clean the suction line.
Air enters the pump - Air bleeding is required.
Faulty pump components - Rebuild or install new pump.

Electrical Troubleshooting

Battery does not charge
Electrical cable connections are loose or corroded - Service or tighten connections.
Battery terminal connectors are faulty - Install new terminal connectors.
Battery is defective - Install a new battery.
Belt is worn or loose - Adjust belt tension or replace belt.

Starter turns slow
Low battery output voltage - Recharge the battery.
Battery is draining quickly - Service battery or replace it.
Disconnected wiring or bad battery terminals - Connect cables properly or replace terminals.

Starter is not cranking
Battery is discharged or defective - Battery needs to be recharged or replaced.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Low battery capacity - Battery is drained, recharge it.
Defective starter motor - Repair or change starter.