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Gehl 5240E Troubleshooting

The Gehl 5240E skid steer loader driveline system components: Yanmar 4TNV98 4-cylinder diesel engine with a rated power of 68 hp (51 kW) or Deutz TD2009 4-cylinder diesel engine with a rated power of 62 hp (47 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 Gehl 5240E is equipped with a radial-lift boom, 80K drive chains, and 10x16.5 or 12x16.5 tires. The skid steer loader has a maximum lift height of 120.7" (3065 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 hard or will not start
There is air in the fuel system - Bleed the system.
Fuel filter element is dirty - Clean the filter or install new filter element.
Faulty or dirty injection nozzles - Service or change 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 - Repair or install a new fuel pump.

Engine starts but stops suddenly
Dirty air cleaner - Clean or change.
Dirty fuel filter - Clean or change the filter.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Clogged or defective injectors - Clean or replace fuel injectors.
Damaged fuel injection pump - Rebuild or change fuel pump.

Diesel shuts off while driving
Engine is not preheated - Normalize the temperature by warming up the engine.
Fuel filter plugging - Change filter element.
There is air in the fuel system - Bleed the system.
Fuel injection nozzles are damaged - Change fuel injection nozzles.
Fuel injection pump timing is not adjusted - Use the correct fuel injection pump timing adjustment.

Engine stalls while idle
Low idle speed adjustment is incorrect - Adjust low idle speed.
Fuel injection pump is broken - Replace or rebuild injection pump.
Clogged or defective injectors - Clean or replace fuel injectors.
Incorrect valve clearance - Adjust valve clearance.

Diesel engine loses power
Dirty air cleaner - Install new air cleaner element.
Dirty or faulty injection nozzles - Test injection nozzles and change if necessary.
Uneven fuel injection pressure - Adjust pressure to proper level.
The valve clearance is not adjusted - Check and adjust.
Low idle speed set incorrectly - Normalize low idle speed.
Fuel hoses or lines are dirty - Fuel lines and hoses need to be cleaned.
Worn cylinder head gasket - Install a new gasket.
Piston rings are worn or damaged - Piston rings replacement required.

Engine overheats
Not enough coolant - Top up coolant fluid and check system for leaks.
Engine oil level is low - Fill up the oil to required level.
Clogged radiator core or leaking radiator cap - Clean radiator or change cap.
Excessive wear of the fan belt - The fan belt needs to be replaced.
Diesel engine overloaded - Reduce load on the engine.

Oil pressure is low
Engine oil insufficient - Add oil as required.
Oil filter clogging - Change or clean engine oil filter element.
Incorrect oil viscosity - Use correct viscosity oil.
Excessive main bearing oil clearance - Change bearings.
Oil pump is worn or damaged - Replace as required.

Engine noise or knocking
Engine oil insufficient - Check oil level and add oil as required.
Engine is not fully warmed up - Warm up engine as required.
Timing of fuel injection pump is incorrect - Set the fuel pump timing correctly.
Incorrectly set low idle speed - Need to adjust idle speed.
Damaged or clogged injectors - Clean or replace fuel injectors.
Connecting rod misalignment or failure - Align or replace connecting rod.
Worn or scored pistons - Replace the pistons as required.

Drive System Troubleshooting

Machine will not move in either direction or one direction
Hydraulic oil level is low - Need to add oil.
Drive chain is damaged - Check drive chain and change defective parts.
Relief valve malfunction - Repair or replace.
Clogged suction line or hydraulic filter - Clean suction line or replace hydraulic filter.
Hand or foot controls malfunction - Check and repair as required.
Worn drive motor or pump - Inspect and replace as necessary.

Reduced power
Hydraulic oil filter is clogged - Change hydraulic filter.
Worn or open relief valve - Replace or close relief valve.
Transmission parts are damaged or faulty - Check and change faulty components.
Damaged input drive shaft - Repair or replace faulty drive shaft.
There is air in the hydraulic system - Need to bleed air.

Overheated drive system
Low hydraulic fluid level - Fill up the hydraulic fluid.
Plugged hydraulic fluid filter - Change or service hydraulic filter.
Defective relief valve - Repair or change.
Drive pump or hydraulic motor malfunction - Inspect and replace as necessary.
Hydraulic oil cooler is plugged - Cooling fins need to be cleaned.
Transmission overloading - Reduce drive system load.

Drive system is excessively noisy
Incorrect oil viscosity - Use correct oil viscosity.
Air trapped in hydraulic system - Bleed air from system.
Hydraulic motor or drive pump is worn - Repair or change faulty component.
Defective or worn mechanical parts of drive system - Check the parts for worn or defect and replace if required.

Hydraulics Troubleshooting

Hydraulic system overheats
Hydraulic pressure is not correct - Adjust it correctly.
Main relief valve improper adjustment or failure - Adjust the valve or replace if necessary.
Hydraulic oil is contaminated - Fill up with fresh hydraulic oil.
Lack of hydraulic fluid - Need to add fluid.
Defective hydraulic pump - Repair or install new hydraulic pump.

Lift arm does not lower or raise
Lift controls malfunction - Check and repair as required.
Hydraulic pump malfunction - Change or repair hydraulic pump if required.
Faulty hydraulic control valve - Replace or repair the valve.
Defective hydraulic cylinder - Install a new boom cylinder or repair it.
Insufficient hydraulic fluid - Fill up the hydraulic fluid.

Bucket does not function
Defective bucket controls - Inspect and repair if necessary.
Hydraulic pump malfunction - Install new pump or repair it.
Hydraulic control valve failure - Change or repair hydraulic valve.
Bucket cylinder malfunction - Repair or install a new cylinder.
Low hydraulic oil level - Need to add oil.

Bucket or lift arm moves slowly
Hydraulic pump is defective - Flow-rate pump and change pump if necessary.
Hydraulic cylinder oil leakage - Replace cylinder piston seals.
Hydraulic oil level low - Fill the system to proper hydraulic oil level.
Faulty or incorrect setting hydraulic control valve - Set properly or repair.
Hydraulic pressure loss - Adjust pressure as required.

Bucket or boom is jerky
Air leaks in hydraulic system - Need to bleed air.
Hydraulic oil filter element is clogged - Replace or clean the filter.
Hydraulic fluid contamination - Change hydraulic fluid.
Scored cylinder tube or rod - Change failed component.

Hydraulic pump is excessively noisy
Not enough oil or hydraulic system leaking - Repair hydraulic leaks or add oil as required.
Plugged hydraulic filter - Clean or install new filter.
Plugged suction line - Clean suction line as required.
Pump is sucking air - Remove air from hydraulics.
Damaged pump components - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery will not charge
Electrical wire connections are loose or corroded - Tighten or service connections.
Electrical terminal connectors are faulty - Terminal connectors should be replaced.
Bad cell in battery - Change the battery.
Defective or loose belt - Change belt or adjust belt tension.

Starter cranks slow
Battery capacity is low - Charge the battery.
Battery does not hold charge - Service charging system or install new battery.
Battery cables are disconnected or terminals are faulty - Check cables and clean or change terminals.

Starter is not working
Battery is low or faulty - Replace or charge as required.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Low battery output - Battery needs to be recharged.
Starter motor is damaged - Starter needs to be changed.