Troubleshooting Skid Steer Loader Issues: Case Study on the Gehl 5640

[MikePhua]

Skid steer loaders, such as the Gehl 5640, are integral pieces of equipment in construction, landscaping, agriculture, and a range of other industries. They are known for their compact size, versatility, and powerful performance in tight spaces. However, like all machinery, they can experience operational issues that affect productivity. Proper maintenance and troubleshooting are essential for keeping these machines running smoothly. One of the most common problems that owners and operators face is hydraulic issues or malfunctioning control systems. This article will explore how to troubleshoot common issues with a Gehl 5640 skid steer loader and offer practical solutions.
Common Problems with Gehl 5640 Skid Steer Loaders
The Gehl 5640, a popular model in the Gehl skid steer line, is designed to handle various tasks efficiently. However, users have reported a range of problems that can compromise performance. These issues often stem from hydraulic system failures, electrical glitches, or mechanical malfunctions.
1. Hydraulic System Failures
Hydraulic issues are among the most commonly reported problems in skid steer loaders, including the Gehl 5640. The loader’s hydraulic system powers many of its functions, including lifting, tilting, and turning. A malfunctioning hydraulic system can make the machine difficult to operate and lead to expensive repairs.
Symptoms of hydraulic issues:

• Slow or unresponsive lift arms
  
• Weak or no movement when engaging the loader bucket
  
• Overheating or noisy hydraulic pump
  
• Leaks in hydraulic lines or components
  

Causes of hydraulic problems:

• Low fluid levels: Insufficient hydraulic fluid can cause the system to lose power and even damage the pump.
  
• Contaminated fluid: Dirt or debris in the hydraulic system can lead to clogs, inefficient fluid movement, and wear on the pump and valves.
  
• Faulty hydraulic pump or motor: Over time, the hydraulic pump or motor may wear out, causing a reduction in hydraulic pressure or complete failure.
  

Solution:

• Always maintain the recommended hydraulic fluid levels and regularly inspect for leaks.
  
• Replace hydraulic fluid and filters every 500 hours or as recommended by the manufacturer.
  
• Clean or replace hydraulic hoses and fittings as needed to prevent blockages or leaks.
  
• If the hydraulic pump is faulty, it should be replaced or repaired by a qualified technician.
  

2. Engine Problems and Fuel Delivery
Another common issue that operators face is engine-related problems, particularly related to fuel delivery or engine performance. For the Gehl 5640, problems such as engine stalling, loss of power, or difficulty starting may be indicative of an issue with the fuel system or the engine’s electrical components.
Symptoms of engine-related issues:

• Engine stalls or struggles to start
  
• Loss of power during operation
  
• Black smoke from the exhaust
  
• Unusual engine noise or vibration
  

Causes of engine issues:

• Clogged fuel filters: Over time, dirt and debris can clog the fuel filter, reducing the amount of fuel delivered to the engine.
  
• Fuel pump failure: The fuel pump may wear out or become damaged, leading to insufficient fuel flow to the engine.
  
• Faulty fuel injectors: A malfunctioning injector can lead to poor fuel atomization, causing rough engine operation and decreased efficiency.
  

Solution:

• Check and replace the fuel filter regularly to prevent blockages.
  
• Inspect the fuel pump for signs of wear or damage, and replace it if necessary.
  
• Clean or replace fuel injectors that are clogged or malfunctioning.
  
• If the engine continues to struggle, consult a technician to diagnose deeper issues with the ignition or electrical system.
  

3. Electrical System Malfunctions
Electrical issues can also cause problems in Gehl 5640 skid steer loaders. These issues can affect everything from engine starting to the operation of attachments and other electrical components.
Symptoms of electrical problems:

• Difficulty starting the engine
  
• Flashing warning lights or error codes on the display
  
• Non-functioning attachments
  
• Dead battery or intermittent power loss
  

Causes of electrical issues:

• Battery problems: A dead or weak battery can prevent the machine from starting or cause intermittent power loss.
  
• Loose or corroded electrical connections: Over time, electrical connections can become loose or corroded, causing short circuits or power loss.
  
• Faulty alternator: If the alternator is not charging the battery properly, it can lead to electrical failures.
  

Solution:

• Check the battery and terminals for corrosion, cleaning or replacing them if needed.
  
• Inspect and tighten all electrical connections, especially those near the alternator, battery, and starter motor.
  
• Test the alternator to ensure it is charging the battery properly. If it’s faulty, replace it.
  
• If the electrical issues persist, consult a technician for further diagnostics.
  

4. Control System Malfunctions
The control system is responsible for translating the operator’s commands into mechanical actions. A malfunction in the control system can cause erratic or unresponsive movements, making it difficult to operate the loader.
Symptoms of control system issues:

• Unresponsive or jerky bucket movements
  
• Inconsistent speed or direction of the skid steer
  
• Erratic arm or tilt function
  
• Control levers feeling loose or unresponsive
  

Causes of control issues:

• Worn-out control cables or linkages: Over time, control cables and linkages may wear out, leading to poor response from the control levers.
  
• Faulty joystick or control valve: The joystick and valve system may become damaged or clogged, affecting responsiveness.
  
• Electrical issues: Sometimes, electrical faults in the control system can interfere with communication between the operator’s commands and the hydraulic system.
  

Solution:

• Inspect control cables and linkages for wear and replace them if needed.
  
• Clean or replace the control valves and joysticks that are malfunctioning.
  
• Check for any electrical issues in the control system and repair any damaged wiring or connectors.
  

Regular Maintenance Tips to Prevent Issues
While troubleshooting can resolve immediate problems, regular maintenance is the best way to prevent recurring issues with your Gehl 5640 skid steer loader. Here are some key maintenance tips:

• Inspect and change filters regularly: Both air and fuel filters should be checked and replaced every 250 hours or according to the manufacturer’s recommendation.
  
• Check fluid levels: Maintain proper levels of hydraulic fluid, engine oil, and coolant to ensure the machine operates smoothly.
  
• Lubricate moving parts: Grease all moving components to reduce friction and prevent premature wear.
  
• Keep the machine clean: Regularly clean the undercarriage, hydraulic lines, and engine compartment to prevent dirt buildup, which can lead to overheating and wear.
  
• Pre-operation checks: Always perform a walk-around inspection before using the machine, checking for leaks, worn parts, and fluid levels.
  

Conclusion
Skid steer loaders like the Gehl 5640 are designed to be durable and reliable, but like any piece of machinery, they require regular maintenance and troubleshooting to keep them running at their best. Whether you're dealing with hydraulic failures, engine issues, electrical malfunctions, or control problems, identifying the root cause and addressing it early can prevent costly repairs and downtime. By following manufacturer guidelines and performing regular maintenance, operators can ensure their Gehl 5640 continues to deliver reliable performance for years to come.