Gehl 5635DXT Skid Steer Troubleshooting

The Gehl 5635 DXT skid steer loader driveline system components: a 178 cu.in (2.9L) Deutz BF4M1011F 4-cylinder turbo diesel engine with a rated power of 75 hp (56 kW), and 1-speed or 2-speed hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 23 gal/min (87.1 l/min). The system relief pressure is 3000 psi (207 bar). The Gehl 5635DXT is equipped with a radial-lift loader boom, 100H roller chains, and 12x16.5 or 33-15.5x16.5 tires. The skid steer has a maximum lift height of 122.7" (3120 mm) to hinge pin and dump height of 93.7" (2380 mm). The rated operating capacity is 1900 lbs (862 kg), and tipping load is 3800 lbs (1724 kg).

Engine Troubleshooting

Engine starts hard or won't start

Air trapped in fuel system - Bleed air.
Dirty fuel filter - Clean or change the filter.
Clogged or defective injection nozzles - Inspect nozzles and replace if necessary.
Water or dirt in fuel system - Drain, flush, and service the system.
Improper valve clearance - Adjust valve clearance according to specifications.
Fuel injection pump failure - Repair or install a new fuel pump.

Engine starts and then shuts off

Dirty air cleaner - Install new air cleaner element.
Dirty fuel filter - Change the filter element.
Fuel injection pump is leaking - Repair any leaks.
Fuel injectors are dirty or defective - Replace or clean fuel injectors.
Fuel injection pump failure - Repair or replace injection pump.

Engine stops unexpectedly during operation

Engine not warmed up - Normalize the temperature by warming up the engine.
Fuel filter plugging - Change filter element.
Air in the fuel lines - Bleed the fuel lines.
Clogged or defective injection nozzles - Service or change injection nozzles.
Improper fuel injection timing - Adjust according to specifications.

Engine stalls at low idle speed

Low idle speed set incorrectly - Correct the settings.
Fuel injection pump is not working correctly - Repair or install a new fuel pump.
Fuel injectors are dirty or defective - Clean fuel injectors or change it.
Valve clearance is out of adjustment - Adjust to proper valve clearance.

Engine lacks power

Plugged air cleaner - Clean or replace element.
Fuel injection nozzles are faulty or clogged - Inspect nozzles and replace if necessary.
Insufficient fuel injection pressure - Adjust pressure to proper level.
Valve out of adjustment - Adjust valve clearance.
Improperly adjusted low idle speed - Adjustment required.
Dirty fuel lines or hoses - Service fuel hoses and lines.
Cylinder head gasket is worn - Install new cylinder head gasket.
Piston rings are leaking or defective - Install new piston rings.

Engine overheating

Low coolant level - Add coolant and check the components of cooling system.
Insufficient engine oil - Add oil to the engine crankcase.
Defective radiator cap or clogged radiator fins - Change cap or clean radiator.
Broken or loose fan belt - Install new fan belt.
Engine overloaded - Reduce load on the engine.

Oil pressure too low

Low oil level - Check oil level and add oil as required.
Engine oil filter is plugged - Change or service engine oil filter.
Oil grade or viscosity is incorrect - Fill up with the proper oil viscosity.
Excessive oil clearance of crankshaft bearing - Change bearings.
Oil pump failure - Install a new pump.

Engine knocking sound or abnormal noise

Insufficient engine oil - Fill up the engine oil.
Engine is not warmed up to required temperature - Warm up the engine.
Fuel injection pump timing is wrong - Adjust as recommended.
Incorrectly adjusted low idle speed - Normalize low idle speed.
Damaged or clogged injectors - Test and replace fuel injectors if necessary.
Connecting rod is misaligned or defective - Connecting rod needs to be aligned or changed.
Scored or worn pistons - Install new pistons.

Drive System Troubleshooting

Drive system doesn't function in one direction or either direction

Low hydraulic oil level - Check and refill the hydraulic oil.
Drive chain malfunction - Inspect drive chain and replace faulty parts.
Input drive shaft is not working properly - Replace drive shaft.
Defective relief valve - Service or change relief valve.
Suction line or hydraulic filter is plugged - Change hydraulic filter or service suction line.
Foot or hand controls are faulty - Repair or change.
Drive pump or motor malfunction - Change or repair faulty component.

Low power

Hydraulic oil filter is clogged - Replace hydraulic filter.
Relief valve is damaged or open - Replace or close relief valve.
Faulty or damaged transmission components - Check and change faulty components.
Stuck input drive shaft - Service or change faulty drive shaft.
There is air in the hydraulic system - Air bleeding is required.

Drive system is overheated

Hydraulic oil level is low - Check and refill the hydraulic oil.
Dirty hydraulic fluid filter - Change hydraulic filter.
Relief valve is damaged or worn - Service or change relief valve.
Damaged drive pump or hydraulic motor - Replace or repair faulty component.
Hydraulic oil cooler is plugged - Cooling fins should be cleaned.
Drive system overloaded continuously - Reduce the load.

Drive system is noisy

Wrong oil viscosity - Drain and refill with proper oil.
Air in hydraulic system - Bleed hydraulic system.
Worn hydraulic motor or drive pump - Inspect and replace as necessary.
Mechanical parts of drive system are damaged or worn - Check drive system and change faulty parts.

Hydraulics Troubleshooting

Hydraulic system overheated

Incorrect hydraulic pressure setting - Adjust pressure correctly.
Main relief valve is damaged or adjusted improperly - Adjust or change relief valve.
Dirty hydraulic oil - The oil must be changed.
Lack of hydraulic fluid - Check and refill the hydraulic fluid.
Hydraulic pump is worn - Install new pump or repair it.

Boom won't lower or raise

Damaged lift controls - Change or repair.
Defective hydraulic pump - Replace or repair pump if necessary.
Hydraulic control valve is faulty - Repair or change hydraulic valve.
Hydraulic cylinder not working - Install a new boom cylinder or repair it.
Hydraulic fluid is insufficient - Add fluid as required.

Bucket can't tilt

Bucket controls are faulty - Repair or replace.
Hydraulic pump failure - Replace or repair pump if necessary.
Hydraulic control valve malfunction - Repair or change the valve.
Bucket cylinder malfunction - Repair or install a new cylinder.
Insufficient hydraulic fluid - Add fluid as required.

Slow bucket or lift arm action

Defective hydraulic pump - Test the pump flow rate and install new pump if required.
Hydraulic cylinder leaking - Cylinder seals need to be replaced.
Hydraulic oil is insufficient - Need to add oil.
Hydraulic control valve is unadjusted or worn - Adjust correctly or repair.
Low hydraulic pressure - Adjust it correctly.

Bucket or boom is working jerkily

Hydraulic system is leaking air - Need to bleed air.
Clogged hydraulic oil filter element - Service or change the hydraulic filter.
Hydraulic fluid contamination - Fill up with fresh hydraulic fluid.
Cylinder tube or rod scoring - Replace failed component.

Hydraulic pump is excessively noisy

Low oil level or hydraulic leaks - Remedy hydraulic leakage or refill oil as necessary.
Dirty hydraulic filter - Replace or clean the filter.
Plugged suction line - Need to service the suction line.
Air enters the pump - Need to bleed air.
Pump components are faulty - Change or rebuild pump.

Electrical Troubleshooting

Battery is not charging

Wiring connections are loose or corroded - Tighten or service connections.
Defective electrical terminal connectors - Replace terminal connectors.
Battery is worn - Battery change required.
Belt is defective or loose - Belt needs to be adjusted or replaced.

Starter cranks slowly

Low battery power - Battery is drained, charge it.
Battery does not hold charge - Service or change the battery.
Disconnected wires or corroded battery terminals - Check wire connections and change or service terminals.

Starter motor is not working

Battery is discharged or worn - Recharge or replace battery.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Low battery voltage - Battery needs to be recharged.
Starter motor is faulty - Replace or repair starter.