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Gehl 5635SX Troubleshooting

The Gehl 5635 SX skid steer loader is powered by 178 cu.in (2.9L) Deutz F4M1011F 4-cycle 4-cylinder direct injection diesel engine with a rated power of 56 hp (41.8 kW) at 2500 rpm. The Gehl 5635SX is equipped with one-speed or two-speed transmission, radial-lift loader boom, 100H roller chains, and 12x16.5 or 33-15.5x16.5 tires. The hydraulic system has a pump with fluid flow rate of 23 gpm (87.1 lpm). The hydraulic pressure is 3000 psi (207 bar). The skid steer loader has a rated operating capacity of 1900 lbs (862 kg) and tipping load of 3800 lbs (1724 kg). The lift height is 122.7 inches (3120 mm) to hinge pin, and dump height is 93.7 inches (2380 mm).

Engine Troubleshooting

Engine difficult to start or will not start
Air in fuel system - Bleed fuel system.
Fuel filter element is clogged - Change filter element.
Fuel injection nozzles are damaged - Clean or replace injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
The valve clearance is incorrect - Adjust valve clearance.
Faulty fuel injection pump - Change or repair the pump.

Diesel starts and then shuts off
Plugged air filter - Clean or change.
Fuel filter plugged - Clean or change the filter.
Fuel injection pump has loose connections - Tighten the connections.
Damaged or clogged injectors - Inspect fuel injectors and change as required.
Fuel injection pump is not working correctly - Install a new pump or rebuild.

Engine shuts off while running
Low coolant temperature - Warm up the engine.
Fuel filter element is dirty - Clean or replace the filter.
Air in fuel tank - Bleed fuel tank.
Defective or clogged injection nozzle - Check injection nozzles and replace if required.
Wrong setting of fuel injection pump timing - Adjust as recommended.

Engine stalls when idling
Low idle speed adjustment is incorrect - Correct low idle settings.
Defective fuel injection pump - Replace or repair injection pump.
Damaged or clogged injectors - Inspect fuel injectors and change as required.
Improper valve clearance - Adjust valve clearance.

Engine loses power
Plugged air cleaner - Clean or replace element.
Defective injection nozzle - Service or change injection nozzles.
Uneven fuel injection pressure - Check the fuel injection pressure and adjust if necessary.
Excessive valve clearance - Need to adjust valve clearance.
Incorrectly set low idle speed - Correct low idle adjustment.
Clogged fuel lines or hoses - Service fuel lines and hoses.
Leaking cylinder head gasket - Cylinder-head gasket replacement required.
Piston rings are defective or leaking - Install new piston rings.

Engine is overheated
Low engine coolant - Refill to the correct level and inspect system for leaks.
Engine oil level is insufficient - Fill up the engine oil.
Radiator fins are clogged or radiator cap is faulty - Clean radiator or install new cap.
Damaged or worn fan belt - The fan belt needs to be replaced.
Engine overload - Reduce engine load.

Insufficient oil pressure
Not enough oil in the engine - Need to add oil.
Oil filter clogged - Change or clean engine oil filter element.
Improper type of engine oil - Fill up with the correct oil viscosity.
Excessive main bearing oil clearance - Bearing needs to be changed.
Oil pump failure - Replace as required.

Abnormal engine noise or knocking
Insufficient engine oil - Need to add engine oil.
Coolant temperature is low - Warm up the engine.
Improper setting of fuel injection pump timing - Adjust as recommended.
Low idle speed adjustment is incorrect - Correct the settings.
Fuel injector fault - Clean fuel injectors or change it.
Misaligned or defective connecting rod - Alignment procedure or replacement is required.
Piston wear or scoring - Pistons replacement required.

Drive System Troubleshooting

Machine does not move forward or backward
Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.
Drive chain is damaged - Inspect drive chain and replace faulty components.
Worn input drive shaft - Repair or replace drive shaft.
Relief valve is defective - Repair or replace.
Hydraulic filter or suction line is dirty - Clean suction line or change hydraulic filter.
Foot or hand controls are faulty - Change or repair.
Drive motor or pump is worn - Change or repair faulty component.

Reduced power
Dirty hydraulic oil filter - Change or service hydraulic filter.
Opened or defective relief valve - Close or replace relief valve.
Faulty or damaged transmission components - Check and change faulty components.
Worn input drive shaft - Repair or replace faulty drive shaft.
Air in the hydraulic system - Bleed air from system.

Drive system overheats
Hydraulic oil is insufficient - Check and refill the hydraulic oil.
Dirty hydraulic fluid filter - Change or clean hydraulic filter.
Defective relief valve - Repair or install a new relief valve.
Hydraulic motor or drive pump is defective - Inspect and change as required.
Plugged hydraulic oil cooler - Cooling fins need to be cleaned.
Drive system overloaded continuously - Reduce drive system load.

Drive system is noisy
Oil viscosity is too heavy - Use oil of correct viscosity.
Hydraulic system is leaking air - Need to bleed air.
Hydraulic motor or drive pump is defective - Inspect and replace as necessary.
Mechanical components of drive system are worn or damaged - Inspect the parts for worn or defect and repair as needed.

Hydraulics Troubleshooting

Hydraulic system has overheating
Incorrect hydraulic pressure setting - Adjust pressure as required.
Main relief valve is damaged or adjusted improperly - Replace or set up the relief valve.
Hydraulic fluid contamination - The fluid must be changed.
Hydraulic fluid level is low - Fill the hydraulic system with oil.
Hydraulic pump is defective - Repair or change pump if required.

Boom won't lower or raise
Faulty lift controls - Check and repair as required.
Hydraulic pump malfunction - Repair or install new hydraulic pump.
Hydraulic control valve is faulty - Install a new hydraulic valve or repair it.
Broken hydraulic cylinder - Repair or change hydraulic cylinder.
Hydraulic fluid level low - Add fluid as required.

Bucket can't tilt
Bucket tilt controls are damaged - Replace or repair.
Defective hydraulic pump - Repair or install new hydraulic pump.
Damaged hydraulic control valve - Repair or replace the valve.
Hydraulic bucket cylinder not working - Change or repair cylinder.
Insufficient hydraulic oil - Check and refill the hydraulic oil.

Bucket or lift arm functions slowly
Faulty hydraulic oil pump - Check pump flow and change pump if necessary.
Hydraulic cylinder oil leakage - Install new cylinder seals.
Low hydraulic oil level - Check and refill the hydraulic oil.
Faulty or incorrect setting hydraulic control valve - Repair or adjust properly.
Hydraulic pressure has dropped - Set pressure correctly.

Lift arm or bucket is working jerkily
Air leaks in hydraulic system - Need to bleed air.
Hydraulic oil filter is clogged - Clean or replace the filter.
Contaminated hydraulic fluid - The fluid must be changed.
Cylinder rod or tube is scuffed - Change damaged component.

Hydraulic pump makes excessive noise
Not enough oil or hydraulic system leaking - Refill hydraulic oil or repair leaks in system.
Dirty hydraulic filter - Service or replace hydraulic filter.
Suction line is dirty - Need to clean the suction line.
Air trapped in hydraulic pump - Bleed air.
Worn pump parts - Replace or rebuild the pump.

Electrical Troubleshooting

Battery cannot be charged
Loose or corroded cable connections - Clean or tighten connections.
Battery terminal clamps are defective - Terminal clamps need to be replaced.
Defective battery - Install a new battery.
Belt is worn or loose - Adjust belt tension or change the belt.

Starter motor cranks slow
Low battery voltage - Low battery charging, charge as required.
Battery will not hold charge - Battery needs service or replacement.
Faulty battery terminals or disconnected cables - Check wire connections and change or service terminals.

Starter is not working
Battery is discharged or defective - Replace or charge as required.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery output - Low battery charging, charge as required.
Damaged starter motor - Repair or replace starter.