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Gehl 5635SXT Troubleshooting

The Gehl 5635 SXT skid steer loader is powered by 178 cu.in (2.9L) Deutz BF4M1011F four-cylinder turbocharged diesel engine with a rated power of 75 hp (56 kW) at 2500 rpm. The Gehl 5635 SXT is equipped with a single-speed or two-speed hydrostatic 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 max lift height is 122.7" (3120 mm) to hinge pin, and dump height is 93.7" (2380 mm).

Engine Troubleshooting

Engine hard to start or won't start
Air in fuel system - Bleed fuel system.
Dirty fuel filter - Install new filter element.
Burnt or clogged injection nozzle - Install a new kit of correctly balanced nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
The valve clearance is incorrect - Have it adjusted.
Fuel injection pump is broken - Rebuild or change fuel pump.

Diesel starts but then stops
Air filter is clogged - Clean or replace element.
Clogged fuel filter - Clean or change the filter.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Defective or clogged fuel injectors - Replace or clean fuel injectors.
Defective fuel injection pump - Replace injection pump or repair it.

Diesel shuts off while driving
Low coolant temperature - Warm up the engine.
Dirty fuel filter - Change the filter element.
Air trapped in fuel system - Bleed air.
Clogged injection nozzle - Replace injection nozzles.
Timing of fuel injection pump is incorrect - Check the fuel injection pump timing adjustment.

Engine stalls at idle
Low idle speed setting is incorrect - Adjust as required.
Fuel injection pump is damaged - Replace or rebuild injection pump.
Dirty or defective injectors - Change or clean fuel injectors.
Valve clearance is out of adjustment - Adjust to proper valve clearance.

Loss of engine power
Air cleaner is clogged - Clean or replace air cleaner element.
Defective injection nozzle - Install a new kit of correctly balanced nozzles.
Incorrect fuel injection pressure - Adjust to proper pressure.
Incorrect valve clearance - Adjust valve clearance according to specifications.
Low idle speed setting is not correct - Correct the settings.
Fuel lines or hoses are clogged - Clean fuel hoses and lines.
Cylinder head gasket defective - Replace the gasket as required.
Leaking or defective piston rings - Piston rings replacement required.

Engine overheating
Insufficient coolant - Add coolant and check the components of cooling system.
Not enough engine oil - Need to add engine oil.
Radiator fins are dirty or radiator cap is defective - Install new cap or clean radiator.
Loose or defective fan belt - Belt replacement is recommended.
Engine is under excessive load - Load reducing is recommended.

Insufficient oil pressure
Lack of oil - Fill crankcase to proper oil level.
Dirty oil filter - Clean or change engine oil filter.
Different type of engine oil - Use oil of proper viscosity.
Excessive crankshaft bearing oil clearance - Bearings need to be reinstalled.
Oil pump is worn or damaged - Repair or change.

Abnormal engine noise or knocking
Low engine oil level - Fill up the oil to required level.
Low coolant temperature - Warm up the engine.
Timing of fuel injection pump is incorrect - Set it up as required.
Too low idle RPM - Adjust low idling as recommended.
Dirty or defective injectors - Replace or clean fuel injectors.
Connecting rod is not aligned or defective - Connecting rod needs to be aligned or changed.
Worn or scored pistons - Have pistons replaced.

Drive System Troubleshooting

Drive system won't operate in either direction
Hydraulic fluid level low - Fill the system to proper hydraulic fluid level.
Drive chain is damaged - Inspect drive chain and replace defective parts.
Defective input drive shaft - Replace drive shaft.
Relief valve failure - Rebuild or install a new relief valve.
Clogged suction line or hydraulic filter - Service suction line or change hydraulic filter.
Defective or worn foot or hand controls - Repair or replace.
Worn drive motor or pump - Repair or change faulty component.

Lack of power
Clogged hydraulic oil filter - Change hydraulic filter.
Worn or open relief valve - Close or replace relief valve.
Transmission parts are faulty or damaged - Inspect and change faulty parts.
Damaged input drive shaft - Replace or service the drive shaft.
Hydraulic system is leaking air - Air bleeding is required.

Drive system overheats
Insufficient hydraulic oil - Check and refill the hydraulic oil.
Hydraulic fluid filter is dirty - Change or service hydraulic filter.
Relief valve failure - Relief valve need to be replaced or repair.
Drive pump or hydraulic motor malfunction - Repair or change faulty component.
Hydraulic oil cooler is dirty - Clean cooling fins as required.
Drive system overloaded continuously - Reduce drive system load.

Excessive noise
Oil viscosity is incorrect - Drain and refill with correct oil.
Air in hydraulic system - Need to bleed air.
Drive pump or hydraulic motor is damaged - Repair or change faulty component.
Mechanical components of drive system are damaged or worn - Check the components for defect or damage and change if necessary.

Hydraulics Troubleshooting

Hydraulic system overheats
Hydraulic pressure is not adjusted correctly - Correct adjustment is required.
Faulty or improperly adjusted main relief valve - Adjust the valve or replace if necessary.
Hydraulic oil contamination - The oil must be changed.
Hydraulic oil level is insufficient - Fill up the hydraulic oil.
Hydraulic pump is faulty - Repair or replace pump if necessary.

Lift arm cannot be raised or lowered
Lift controls are defective - Check and repair as required.
Hydraulic pump not working - Change or repair hydraulic pump if required.
Hydraulic control valve malfunction - Install a new valve or repair it.
Damaged hydraulic cylinder - Replace or repair boom cylinder.
Insufficient hydraulic fluid - Add fluid as required.

Bucket does not function
Damaged bucket controls - Replace or repair.
Defective hydraulic pump - Change or repair hydraulic pump if required.
Hydraulic control valve is faulty - Repair or replace the valve.
Bucket cylinder failure - Install a new cylinder or repair it.
Low hydraulic fluid level - Add fluid as required.

Boom or bucket runs slowly
Defective hydraulic pump - Check pump flow and change pump if necessary.
Leaking hydraulic cylinder - Correct leakage by changing the seals.
Hydraulic fluid level low - Checking hydraulic fluid level and add if necessary.
Damaged or incorrect adjusted hydraulic control valve - Set correctly or repair.
Low hydraulic pressure - Adjust pressure correctly.

Bucket or boom is jerky
Air leaks in hydraulic system - Bleed air from hydraulic system.
Hydraulic oil filter is clogged - Clean or install new filter.
Hydraulic fluid is dirty - Change hydraulic fluid.
Cylinder rod or tube is scuffed - Replace defective component.

Hydraulic pump makes excessive noise
Hydraulic leaks or low oil level - Top up hydraulic oil or remedy leakage in system.
Hydraulic filter is dirty - Change or clean oil filter.
Dirty suction line - Suction line must be serviced.
Pump is sucking air - Bleed air.
Damaged pump parts - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery will not charge
Electrical cable connections are corroded or loose - Tighten or clean electrical wiring connections.
Defective battery terminal connectors - Terminal connectors should be replaced.
Dead cell in battery - Battery change required.
Loose or defective belt - Adjust belt tension or change the belt.

Starter turns slow
Low battery capacity - Battery needs to be recharged.
Battery won’t hold charge - Service charging system or replace battery.
Disconnected cables or faulty battery terminals - Check battery wires and service or replace terminals.

Starter is not cranking
Battery is drained or defective - Change or recharge battery.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery output - Battery is drained, recharge it.
Starter motor failing - Repair or install a new starter.