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Gehl 5640E Troubleshooting

The Gehl 5640E skid steer loader is powered by 190 cu.in (3.1L) Deutz BF4M2011 4-cycle direct injection turbocharged liquid-cooled diesel engine with a rated power of 82 hp (61 kW) at 2500 rpm. The Gehl 5640E is equipped with a single-speed or two-speed transmission, 100 roller drive chains, and 12x16.5-10 or 14x17.5-12 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 2200 lbs (1000 kg) and tipping load of 4400 lbs (2000 kg). The lift height is 123 inches (3125 mm) to hinge pin, and dump height is 93.5 inches (2375 mm).

Engine Troubleshooting

Diesel engine hard to start or doesn't start
Air in the fuel system - Air bleeding.
Fuel filter element clogging - Install new filter element.
Dirty or faulty injection nozzles - Change fuel injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
The valve clearance is incorrect - Adjustment procedure required.
Fuel injection pump is defective - Repair or install a new fuel pump.

Engine starts but then stalls
Dirty air cleaner - Clean or replace air cleaner element.
Fuel filter plugged - Change the filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Fuel injectors are dirty or defective - Test and replace fuel injectors if necessary.
Fuel injection pump is faulty - Replace or rebuild injection pump.

Diesel shuts off while driving
Engine is not preheated - Normalize the temperature by warming up the engine.
Clogged fuel filter - Change the filter element.
Air in fuel system - Bleed fuel system.
Dirty or damaged injection nozzles - If necessary, replace with a new nozzle.
Fuel injection pump timing is not adjusted - Adjust fuel injection pump as required.

Engine stops at idle
Incorrectly set low idle speed - Adjust as required.
Fuel injection pump is faulty - Replace or rebuild injection pump.
Clogged or defective injectors - Replace fuel injectors.
Incorrect valve clearance - Have it adjusted.

Low engine power
Air cleaner is clogged - Clean or change.
Defective or clogged injection nozzle - Clean or change injection nozzles.
Incorrect fuel injection pressure - Adjust pressure to proper level.
Valve clearance is not correct - Adjust valve clearance according to specifications.
Wrong adjustment of low idle speed - Adjust as required.
Fuel lines or hoses clogging - Service fuel hoses and lines.
Cylinder head gasket is worn - Replace the gasket as required.
Defective or worn piston rings - Piston rings replacement required.

Engine overheated
Low engine coolant - Add coolant fluid to cooling system and also check it for leaks.
Low engine oil level - Fill up the engine oil.
Clogged radiator core or leaking radiator cap - Clean radiator or replace cap.
Loose or damaged fan belt - Fan belt must be replaced.
Diesel engine overloaded - Load reducing required.

Oil pressure too low
Oil level is low - Fill crankcase to proper oil level.
Oil filter is clogged - Replace or service engine oil filter.
Different type of engine oil - Use oil of correct viscosity.
Main bearing oil clearance is excessive - Change bearings.
Oil pump failure - Remove and inspect oil pump.

Abnormal engine noise or knocking
Engine oil level is low - Fill up the engine oil.
Engine is cold - Warm up to required temperature.
Fuel injection pump timing is wrong - Set up as recommended.
Incorrect low idle speed adjustment - Adjustment required.
Fuel injectors are dirty or defective - Replace or clean fuel injectors.
Connecting rod is defective or misaligned - Align or change connecting rod.
Pistons are worn or broken - Pistons need to be replaced.

Drive System Troubleshooting

Drive system does not work in either direction
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.
Drive chain malfunction - Inspect drive chain and replace defective components.
Faulty input drive shaft - Replace drive shaft.
Worn or defective relief valve - Repair or change.
Plugged suction line or hydraulic filter - Change hydraulic filter or service suction line.
Foot or hand controls are defective - Repair or change.
Drive pump or motor malfunction - Inspect and replace as necessary.

Low power
Clogged hydraulic oil filter - Change or clean hydraulic filter.
Faulty or opened relief valve - Replace or close relief valve.
Transmission components are faulty or damaged - Check and change defective components.
Worn input drive shaft - Faulty drive shaft need to be replaced or repair.
Air in hydraulic system - Need to bleed air.

Overheated drive system
Hydraulic oil is insufficient - Fill the system to proper hydraulic oil level.
Plugged hydraulic fluid filter - Change or service hydraulic filter.
Relief valve is worn or damaged - Repair or change.
Damaged drive pump or hydraulic motor - Check and repair if required.
Hydraulic oil cooler is plugged - Cooling fins should be cleaned.
Drive system is overloaded - Load needs to be reduced.

Drive system is excessively noisy
Incorrect oil viscosity - Use oil of correct viscosity.
Hydraulic system is leaking air - Air bleeding is required.
Hydraulic motor or drive pump failure - Replace or repair faulty component.
Worn or damaged mechanical components of drive system - Inspect the parts and repair as required.

Hydraulics Troubleshooting

Hydraulic system overheating
Hydraulic pressure is not correct - Correct adjustment is required.
Main relief valve failure or improper setting - Replace or set up the relief valve.
Contaminated hydraulic oil - Change hydraulic oil.
Lack of hydraulic fluid - Add fluid to the hydraulic system.
Defective hydraulic pump - Repair or install new hydraulic pump.

Lift arm cannot be raised or lowered
Faulty lift controls - Inspect and repair if necessary.
Hydraulic pump malfunction - Repair or change pump if required.
Damaged hydraulic control valve - Install a new hydraulic valve or repair it.
Faulty hydraulic cylinder - Repair or change hydraulic cylinder.
Hydraulic fluid is insufficient - Checking hydraulic fluid level and add if necessary.

Bucket is not working
Bucket tilt controls malfunction - Repair or change.
Hydraulic pump failure - Repair or change pump if required.
Defective hydraulic control valve - Replace or repair the valve.
Hydraulic bucket cylinder is broken - Repair or replace cylinder.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.

Slow bucket or lift arm operation
Hydraulic pump is worn - Flow-rate hydraulic pump and replace pump if necessary.
Leaking hydraulic cylinder - Cylinder seals need to be replaced.
Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.
Worn or unadjusted hydraulic control valve - Adjust correctly or repair.
Low hydraulic pressure - Set pressure correctly.

Jerky operation of the bucket or boom
There is air in the hydraulic system - Need to bleed air.
Hydraulic oil filter clogging - Service or replace the hydraulic filter.
Dirty hydraulic oil - Change hydraulic oil.
Cylinder rod or tube is scratched - Replace defective component.

Excessive hydraulic pump noise
Low oil level or hydraulic leaks - Add hydraulic oil or correct system leaks.
Hydraulic filter is dirty - Service or change hydraulic filter.
Suction line is dirty - Clean suction line as required.
Pump sucks air - Remove air from hydraulics.
Faulty pump parts - Rebuild or install new pump.

Electrical Troubleshooting

Battery does not charge
Corroded or loose wire connections - Tighten or clean electrical wiring connections.
Faulty battery terminal clamps - Install new terminal clamps.
Worn-out battery - Change the battery.
Defective or loose belt - Adjust belt tension or change the belt.

Starter cranks slow
Low battery output voltage - Low battery charging, charge as required.
Battery will not hold charge - Service or replace the battery.
Disconnected battery cables or bad terminals - Connect wires properly or change terminals.

Starter is not working
Battery is discharged or worn - Battery needs to be recharged or replaced.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Low battery output voltage - Battery needs to be recharged.
Starter motor is faulty - Replace or repair starter.