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Gehl R220 Troubleshooting

The Gehl R220 skid steer loader is powered by 202.5 cu.in (3.3L) Yanmar 4TNV98CT vertical in-line 4-cylinder turbocharged diesel engine with a rated power of 72 hp (53.7 kW) at 2500 rpm. The Gehl R220 is equipped with 1-speed or 2-speed hydrostatic transmission, radial-lift loader boom, 100H roller chains, and 12x16.5 tires. The hydraulic system has a pump with fluid flow rate of 23.5 gpm (89.6 lpm). The hydraulic pressure is 3300 psi (228 bar). The skid steer loader has a rated operating capacity of 2200 lbs (1000 kg) and tipping load of 4400 lbs (2000 kg). The max lift height is 123 inches (3125 mm) to hinge pin, and dump height is 94 inches (2390 mm).

Engine Troubleshooting

Diesel hard to start or doesn't start
Air in fuel tank - Bleed fuel tank.
Clogged fuel filter - Service the filter.
Faulty or dirty injection nozzles - Clean or replace injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is wrong - Check and adjust as required.
Fuel injection pump is not operating properly - Replace or rebuild injection pump.

Engine starts and then shuts off
Clogged air filter - Change or service air filter element.
Dirty fuel filter - Replace filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Fuel injectors are dirty or defective - Inspect fuel injectors and change as required.
Fuel injection pump failure - Repair or replace injection pump.

Engine stalls while running
Coolant temperature is low - Warm up the engine.
Fuel filter is plugged - Service or replace the filter.
Air in fuel tank - Bleed fuel tank.
Dirty or faulty injection nozzles - Inspect nozzles and replace if necessary.
Wrong setting of fuel injection pump timing - Set it up as required.

Engine stalls when idle
Improperly adjusted low idle speed - Adjustment required.
Fuel injection pump is faulty - Repair or change injection pump.
Dirty or defective injectors - Inspect fuel injectors and change as required.
Valve out of adjustment - Check and adjust as required.

Loss of engine power
Plugged air cleaner - Clean or change cleaner.
Fuel injection nozzles fault - Test injection nozzles and change if necessary.
Fuel injection pressure is wrong - Correct the pressure settings.
Incorrect valve clearance - Adjust valve clearance.
Low idle speed setting is incorrect - Test and adjust.
Fuel lines or hoses are clogged - Service fuel hoses and lines.
Cylinder head gasket is damaged - Replace cylinder head gasket.
Piston rings are worn or damaged - Replace the piston rings as required.

Engine overheating
Coolant level is low - Refill to the correct level and inspect system for leaks.
Engine oil level low - Checking oil level and add if necessary.
Radiator core is clogged or radiator cap is leaking - Clean radiator or change cap.
Loose or defective fan belt - If necessary, replace the belt.
Engine is under excessive load - Load reducing is recommended.

Oil pressure too low
Not enough oil in the engine - Check and refill the oil.
Clogged oil filter - Service or change engine oil filter element.
Wrong oil viscosity - Use correct viscosity oil.
Incorrect oil clearance in main bearing - Change bearings.
Worn oil pump - Install a new pump.

Engine knocking sound or abnormal noise
Engine oil level is insufficient - Check and refill engine oil.
Engine not warmed up - Warm up engine as required.
Wrong setting of fuel injection pump timing - Adjust fuel injection pump as required.
Low idle speed set incorrectly - Normalize low idle speed.
Clogged or defective injectors - Test and replace fuel injectors if necessary.
Connecting rod is not aligned or defective - Align or replace connecting rod.
Scored or worn pistons - Replace the pistons as required.

Drive System Troubleshooting

Drive system won't work in one direction or either direction
Insufficient hydraulic fluid - Check and refill the hydraulic fluid.
Drive chain fault - Inspect drive chain and replace faulty components.
Input drive shaft is worn - Replace drive shaft.
Relief valve failure - Change or repair relief valve.
Dirty hydraulic filter or suction line - Service suction line or replace hydraulic filter.
Defective or worn foot or hand controls - Repair or change.
Drive pump or motor is damaged - Inspect and replace as necessary.

Reduced power
Clogged hydraulic oil filter - Change hydraulic filter.
Relief valve is opened or defective - Close or replace relief valve.
Transmission parts are faulty or damaged - Inspect and replace defective parts.
Input drive shaft malfunction - Repair or replace faulty drive shaft.
Hydraulic system is leaking air - Need to bleed air.

Drive system overheating
Hydraulic fluid is insufficient - Add fluid as required.
Clogged hydraulic fluid filter - Change or service hydraulic filter.
Faulty relief valve - Repair or install a new relief valve.
Drive pump or hydraulic motor malfunction - Inspect and replace as necessary.
Plugged hydraulic oil cooler - Cooling fins should be cleaned.
Transmission overloading - Load needs to be reduced.

Drive system is excessively noisy
Incorrect oil viscosity - Drain and refill with correct oil.
There is air in the hydraulic system - Bleed air from system.
Drive pump or hydraulic motor is damaged - Repair or replace faulty component.
Defective or worn mechanical parts of drive system - Check drive system and change faulty components.

Hydraulics Troubleshooting

Hydraulic system overheated
Hydraulic pressure incorrectly adjusted - Set pressure correctly.
Main relief valve is faulty or misadjusted - Adjust or replace the relief valve.
Hydraulic oil is contaminated - Hydraulic oil change required.
Hydraulic oil level is low - Fill up the hydraulic oil.
Worn hydraulic oil pump - Repair or change pump if required.

Boom fails to lift or drop
Lift controls failure - Repair or change.
Hydraulic pump is broken - Change or repair hydraulic pump if required.
Hydraulic control valve failure - Repair or replace the valve.
Hydraulic cylinder failure - Repair or replace hydraulic cylinder.
Low hydraulic fluid level - Add fluid as required.

Bucket can't tilt
Faulty bucket tilt controls - Inspect and repair if necessary.
Hydraulic pump not working - Repair or change pump if required.
Hydraulic control valve is faulty - Repair or replace the valve.
Faulty hydraulic bucket cylinder - Repair or change cylinder.
Low hydraulic fluid level - Fill the system to proper hydraulic fluid level.

Boom or bucket moves slowly
Hydraulic pump is worn - Check the pump capacity and replace pump if required.
Leaking hydraulic cylinder - Change cylinder piston seals.
Low hydraulic fluid level - Fill the system to proper hydraulic fluid level.
Hydraulic control valve is faulty or out of adjustment - Repair or adjust properly.
Low hydraulic pressure - Hydraulic pressure must be set correctly.

Jerky operation of the bucket or boom
Hydraulic system is leaking air - Bleed air from system.
Hydraulic oil filter is clogged - Service or replace the hydraulic filter.
Hydraulic fluid is contaminated - Hydraulic fluid change required.
Cylinder tube or rod is scored - Replace defective component.

Hydraulic pump makes excessive noise
Leaking hydraulic system or insufficient oil level - Refill hydraulic oil or repair leaks in system.
Hydraulic filter clogging - Replace or clean the filter.
Suction line clogging - Clean suction line as required.
Air in hydraulic pump - Bleed air from hydraulics.
Faulty pump components - Change or rebuild pump.

Electrical Troubleshooting

Battery won’t charge
Corroded or loose wire connections - Tighten or clean electrical wiring connections.
Battery terminal clamps are faulty - Terminal clamps need to be replaced.
Battery dead cell - Replace the battery.
Belt is worn or loose - Need to adjust belt tension or replace belt.

Starter turns slowly
Battery voltage is low - Battery needs to be recharged.
Battery does not hold charge - Service battery or replace it.
Corroded battery terminals or disconnected wires - Check wire connections and change or service terminals.

Starter motor is not working
Battery is drained or defective - Replace or charge as required.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Low battery output - Charge the battery.
Starter motor failure - Starter needs to be replaced.