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Gehl 5640 Troubleshooting

The Gehl 5640 skid steer loader driveline system components: a 190 cu.in (3.1 L) Deutz BF4M2011 4-cylinder direct injection turbocharged liquid-cooled diesel engine with a rated power of 82 hp (61 kW), and one-speed or two-speed hydrostatic transmission. The hydraulic system has a pump with rated capacity of 23 gal/min (87.1 l/min). The system pressure is 3000 psi (207 bar). The Gehl 5640 is equipped with 100 roller drive chains and 12x16.5-10 or 14x17.5-12 tires. The skid steer loader has a lift height of 123" (3125 mm) to hinge pin and dump height of 93.5" (2375 mm). The rated operating capacity is 2000 lbs (907 kg), and tipping load is 4000 lbs (1815 kg).

Engine Troubleshooting

Engine starts up hard or doesn't start
Air in fuel system - Bleed fuel system.
Dirty fuel filter - Service or replace the filter.
Faulty or dirty injection nozzles - Service or change injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Excessive valve clearance - Have it adjusted.
Fuel injection pump malfunction - Rebuild or install a new injection pump.

Diesel starts but immediately shuts off
Dirty air cleaner - Clean or change cleaner.
Fuel filter element is dirty - Change the filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Damaged or clogged injectors - Test and replace fuel injectors if necessary.
Faulty fuel injection pump - Replace injection pump or repair it.

Engine shuts off while running
Engine not warmed up - Warm up to required temperature.
Fuel filter is plugged - Change filter element.
Air in fuel system - Bleed fuel system.
Damaged or dirty injection nozzles - Test injection nozzles and change if necessary.
Improper setting of fuel injection pump timing - Adjust the pump as required.

Engine stalls when idling
Incorrectly adjusted low idle speed - Need to adjust idle speed.
Fuel injection pump is broken - Replace injection pump or repair it.
Defective fuel injectors - Change or clean fuel injectors.
Improper valve clearance - Adjustment procedure required.

Low engine power
Air cleaner is dirty - Clean or replace air cleaner element.
Fuel injection nozzles fault - Replace injection nozzles.
Incorrect fuel injection pressure - Adjust to correct pressure.
Excessive valve clearance - Correct valve clearance.
Low idle speed setting is not correct - Need to adjust idle speed.
Clogged fuel hoses or lines - Clean fuel system hoses and lines.
Cylinder head gasket is damaged - Cylinder-head gasket replacement required.
Piston rings are defective or leaking - Replace piston rings.

Engine overheating
Low coolant level - Add coolant fluid to cooling system and also check it for leaks.
Engine oil insufficient - Add oil to the engine crankcase.
Dirty radiator core or faulty radiator cap - Clean radiator or change cap.
Fan belt slipping or worn - Change as required.
Engine overload - Reduce engine load.

Insufficient oil pressure
Low oil level - Check oil level and add oil as required.
Dirty oil filter - Change or clean engine oil filter element.
Oil grade or viscosity is wrong - Use proper viscosity oil.
Incorrect oil clearance in crankshaft bearing - Bearings need to be reinstalled.
Oil pump malfunction - Check and replace if necessary.

Abnormal engine knocking or noise
Engine oil level is insufficient - Fill the crankcase with engine oil.
Engine is not warmed up to the required temperature - Warm up the engine.
Improper fuel injection timing - Adjust as recommended.
Improperly adjusted low idle speed - Correct low idle adjustment.
Clogged or defective injectors - Change or clean fuel injectors.
Misaligned or defective connecting rod - Connecting rod must be aligned or replaced.
Pistons are worn or scored - Have pistons replaced.

Drive System Troubleshooting

Drive system сan't work in either direction
Insufficient hydraulic oil - Check and refill the hydraulic oil.
Damaged drive chain - Inspect drive chain and replace defective parts.
Input drive shaft malfunctioning - Repair or install a new drive shaft.
Stuck relief valve - Repair or replace relief valve.
Dirty hydraulic filter or suction line - Change hydraulic filter or service suction line.
Foot or hand controls are faulty - Check and repair as required.
Drive motor or pump is defective - Replace or repair faulty component.

Low power
Hydraulic oil filter is dirty - Change or service hydraulic filter.
Opened or worn relief valve - Close or change relief valve.
Faulty or damaged transmission components - Check and change faulty components.
Input drive shaft is damaged - Change or repair faulty drive shaft.
Air leaks in hydraulic system - Bleed air from hydraulic system.

Drive system overheats
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.
Hydraulic fluid filter is dirty - Change hydraulic filter.
Stuck relief valve - Repair or replace.
Drive pump or hydraulic motor is damaged - Repair or replace faulty component.
Clogged hydraulic oil cooler - Clean cooling fins as required.
Drive system overload - Reduce drive system load.

Drive system makes excessive noise
Oil viscosity is incorrect - Drain and refill with proper oil.
There is air in the hydraulic system - Bleed air from hydraulic system.
Hydraulic motor or drive pump failure - Check and repair if required.
Mechanical parts of drive system are defective or worn - Inspect drive system and replace faulty components.

Hydraulics Troubleshooting

Hydraulic system has overheating
Hydraulic pressure is incorrect - Correct setting is required.
Main relief valve malfunction or improper adjustment - Replace or set up the relief valve.
Dirty hydraulic oil - Hydraulic oil change required.
Lack of hydraulic fluid - Add fluid to the hydraulic system.
Faulty hydraulic oil pump - Change or repair hydraulic pump if required.

Lift arm cannot be raised or lowered
Damaged lift controls - Check and repair as required.
Hydraulic pump failure - Repair or install new hydraulic pump.
Defective hydraulic control valve - Repair or replace the valve.
Defective hydraulic cylinder - Repair or replace hydraulic cylinder.
Hydraulic oil level low - Check and refill the hydraulic oil.

Bucket fails to tilt
Bucket tilt controls are defective - Inspect and repair if necessary.
Hydraulic pump malfunction - Repair or replace pump if necessary.
Defective hydraulic control valve - Repair or change the valve.
Faulty hydraulic bucket cylinder - Repair or change cylinder.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.

Slow boom or bucket action
Defective hydraulic pump - Check pump flow and install new pump if necessary.
Hydraulic cylinder oil leakage - Replace cylinder piston seals.
Hydraulic oil is insufficient - Check and refill the hydraulic oil.
Hydraulic control valve is faulty or out of adjustment - Set properly or repair.
Hydraulic pressure has dropped - Hydraulic pressure must be set correctly.

Bucket or boom movements are jerky
Air in hydraulic system - Air bleeding is required.
Hydraulic oil filter is dirty - Clean or replace the filter.
Contaminated hydraulic oil - Hydraulic oil change required.
Scored cylinder tube or rod - Change worn component.

Hydraulic pump is excessively noisy
Leaking hydraulic system or insufficient oil level - Remedy hydraulic leakage or refill oil as necessary.
Dirty hydraulic filter - Clean or change the filter.
Suction line clogging - Suction line needs to be cleaned.
Pump is sucking air - Bleed air from hydraulics.
Pump parts are worn out - Change or rebuild pump.

Electrical Troubleshooting

Battery is not charging
Electrical wire connections are corroded or loose - Clean or tighten connections.
Defective battery terminal connectors - Terminal connectors should be replaced.
Battery bad cell - Battery replacement required.
Belt is damaged or loose - Adjust belt tension or install a new belt.

Starter motor cranks slow
Battery capacity is low - Battery is drained, charge it.
Battery is not holding charge - Battery needs service or replacement.
Bad terminals or disconnected battery cables - Check wiring connections and replace or clean terminals.

Starter motor won't turn
Battery is low or faulty - Recharge or replace battery.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Battery capacity is low - Low battery charging, charge as required.
Starter motor failure - Repair or replace starter.