Gehl Extend Reach Running Issue

[MikePhua]

Background of Gehl and Its Extend Reach Loaders
Gehl, founded in 1859 in West Bend, Wisconsin, has a long history in agricultural and construction machinery. Originally known for its forage harvesters and farm equipment, the company later diversified into compact construction equipment such as skid steer loaders, telescopic handlers, and compact excavators. By the 1980s and 1990s, Gehl had become widely recognized for its skid steer loaders, including models with extend reach capabilities that allowed operators to lift and place loads further than standard designs. This innovation provided advantages on job sites requiring additional reach for loading trucks, stacking pallets, or handling materials in confined areas. The extend reach series was particularly popular with contractors who valued maneuverability combined with greater lifting height and forward reach.
Common Running Issues in Extend Reach Models
Like many machines that rely heavily on hydraulics and fuel systems, Gehl extend reach loaders can develop intermittent performance problems. One frequently reported issue is hesitation or stalling during operation, particularly under load. This may present as the machine starting fine but losing power once hydraulic demand increases, or even shutting down unexpectedly. Operators often describe these symptoms as "running rough," "bogging down," or "dying under pressure."
Typical problem areas include:

• Fuel delivery systems, especially clogged filters or weak lift pumps.
  
• Air restrictions in the intake system.
  
• Faulty injectors or injection pumps leading to inconsistent fuel spray.
  
• Electrical sensors or wiring that interrupt fuel solenoid operation.
  
• Hydraulic system loading issues that place excessive demand on the engine.
  

Troubleshooting Fuel System Problems
Fuel issues are among the most common culprits. A clogged fuel filter can starve the engine, leading to erratic running. Replacing filters is an inexpensive first step, and operators often note immediate improvement. However, if the machine continues to struggle, attention should shift to the lift pump. A weak or failing lift pump cannot supply enough fuel to the injection system, especially when the loader is working at full power. Installing a fuel pressure gauge can help verify whether the pump maintains the recommended pressure range, often between 4 to 7 psi for small diesel loaders.
Another overlooked issue is air ingress into the fuel lines. Even a small crack in a hose or loose clamp can allow air bubbles, which disrupt the fuel flow and cause surging or stalling. Bleeding the system and tightening connections is an important preventive step.
Hydraulic Load and Engine Performance
The interaction between the hydraulic system and the diesel engine is critical. On extend reach models, the longer boom and additional hydraulic cylinders place greater demand on the pump, which in turn requires more power from the engine. If the hydraulic pump begins to seize or has internal wear, it can create drag that overloads the engine, mimicking fuel starvation. Testing hydraulic pressure and flow helps confirm whether the system is functioning within specification.
In some cases, the machine may run normally until an operator attempts to lift a heavy load, at which point the engine bogs down. This scenario suggests that while the engine itself is functional, hydraulic resistance is excessive. Rebuilding or replacing the main hydraulic pump may be required in such cases.
Electrical and Sensor-Related Issues
Modern Gehl models incorporate electrical solenoids and sensors to manage fuel cutoff, throttle response, and safety interlocks. A failing solenoid may intermittently cut fuel supply, producing symptoms similar to clogged filters. Likewise, corroded wiring or faulty relays can prevent consistent current flow, especially in older machines exposed to moisture and dust. Technicians often recommend cleaning all major electrical connectors and testing relays with a multimeter before replacing more expensive components.
Historical Cases and Lessons Learned
A notable example occurred in the early 2000s, when several contractors in the Midwest reported recurring shutdowns in Gehl extend reach loaders during peak summer construction. Investigation revealed that under high ambient temperatures, older fuel hoses softened and collapsed under suction, restricting flow to the engine. Once hoses were replaced with reinforced lines, the issue disappeared. This story illustrates how sometimes a seemingly complex engine problem can be traced back to a simple maintenance oversight.
Preventive Maintenance Practices
To reduce the likelihood of running issues, operators and fleet managers are advised to:

• Replace fuel filters every 250 hours or sooner if working in dusty conditions.
  
• Inspect and replace fuel hoses every 1,000 hours or five years, whichever comes first.
  
• Regularly bleed air from the fuel system after filter changes.
  
• Check lift pump pressure with a gauge during routine servicing.
  
• Monitor hydraulic pump pressures to ensure they stay within factory specifications.
  
• Clean electrical connectors annually and apply dielectric grease to prevent corrosion.
  

Conclusion
Gehl extend reach loaders are valued for their combination of reach, lift capacity, and compact size, making them indispensable on construction sites, farms, and warehouses. However, their reliability depends heavily on proper fuel and hydraulic system performance. Most running issues can be traced to fuel starvation, hydraulic overload, or electrical interruptions. With consistent preventive maintenance and timely troubleshooting, operators can extend machine life well beyond 5,000 hours of service, ensuring that these versatile machines continue to contribute effectively to demanding work environments.