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Doosan DL200-3 Troubleshooting

The Doosan DL200-3 wheel loader is powered by 359 cu.in (5.9L) Doosan DL06K 6-cylinder turbocharged diesel engine with a rated power of 160 hp (119 kW) at 2100 rpm. The Doosan DL200-3 is equipped with a 4x3 power shift transmission, power steering system, hydraulic dual multi-disc brakes, and 20.5R25 standard tires. The hydraulic system has a pump with fluid flow rate of 42.2 gpm (160 lpm). The hydraulic pressure is 3625 psi (250 bar). The wheel loader has a rated operating capacity of 8535 lbs (3880 kg) and tipping load of 17070 lbs (7760 kg). The maximum lift height is 152" (3860 mm) to hinge pin, and bucket breakout force is 22165 lbs (10075 kg).

Engine Troubleshooting

Engine difficult to start or will not start
Air in fuel tank - Bleed fuel tank.
Fuel filter plugged - Clean or change the filter.
Fuel injection nozzles are dirty or defective - Clean or change injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Incorrect valve clearance - Check and adjust as required.
Fuel injection pump damage - Repair or change injection pump.

Diesel starts but then stops
Air filter is clogged - Install new air filter element.
Fuel filter element is clogged - Clean or change the filter.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Clogged or defective injectors - Inspect fuel injectors and change as required.
Fuel injection pump malfunctioning - Rebuild or change fuel pump.

Engine shuts off while running
Engine is not warmed up to required temperature - Normalize the temperature by warming up the engine.
Fuel filter element is dirty - Change filter element.
Air in the fuel system - Air bleeding.
Faulty fuel injection nozzles - Install a new kit of correctly balanced nozzles.
Fuel injection pump timing is wrong - Adjust the pump as required.

Engine stalls while idle
Wrong adjustment of low idle speed - Correct low idle adjustment.
Fuel injection pump is broken - Change or repair the pump.
Clogged or defective injectors - Change or clean fuel injectors.
Incorrect valve clearance - Adjust valve clearance.

Diesel power loss
Clogged air cleaner - Install new air cleaner element.
Fuel injection nozzles fault - Inspect nozzles and replace if necessary.
Incorrect fuel injection pressure - Adjust pressure to proper level.
Valve clearance is out of adjustment - Have it adjusted.
Incorrect low idle setting - Adjust as required.
Fuel hoses or lines clogging - Clean fuel system hoses and lines.
Cylinder head gasket is defective - Change cylinder head gasket.
Piston rings are defective or leaking - Replace the piston rings as required.

Engine overheats
Not enough coolant - Fill the cooling system and check components for leaks or other faults.
Low engine oil level - Need to add engine oil.
Radiator core is clogged or radiator cap is leaking - Clean radiator or install new cap.
Fan belt is worn or faulty - Change as required.
Engine is overloaded - Load reducing is recommended.

Low oil pressure
Insufficient engine oil - Need to add oil.
Oil filter element clogging - Change or clean engine oil filter element.
Incorrect engine oil Use oil of correct viscosity.
Crankshaft bearing has incorrect oil clearance - Install new bearings.
Defective oil pump - Inspect and change as required.

Abnormal engine noise or knocking
Engine oil level is low - Checking oil level and add if necessary.
Engine is not warmed up to required temperature - Warm up the engine.
Improper setting of fuel injection pump timing - Adjust fuel injection pump as required.
Improperly adjusted low idle speed - Normalize low idle speed.
Clogged or defective injectors - Replace fuel injectors.
Connecting rod misalignment or failure - Align or replace connecting rod.
Worn or broken pistons - Pistons replacement required.

Hydrostatic Transmission Troubleshooting

HST transmission makes excessive noise
Fluid is contaminated or fluid level is insufficient - Fill to required level or change the fluid.
Speed control pedal linkage is bent or not adjusted - Change or adjust linkage.
Defective relief valve - Change relief valve.
Transmission overload - The load should be reduced.
Worn or defective transmission components - After disassembling and inspection, change defective components.

Loss of power
Transmission fluid level is low - Need to add transmission fluid.
Relief valve failure - Replace the valve.
Worn or out of adjustment speed control linkage - Replace or adjust linkage.

Hot transmission oil
Low fluid level - Check and refill the transmission fluid.
Dirty transmission oil filter element - Service or replace the transmission oil filter.
Defective or plugged cooling components - Inspect all cooling components and replace or clean if necessary.
Excessive transmission load - Reduce transmission load.

Transmission oil leaking
Broken seals or gaskets - Gaskets or seal replacement required.
High internal transmission housing pressure - Check hydrostatic transmission components for defect or damage and change if necessary.
Clogged oil drain line - Clean or replace drain line.

Hydraulics Troubleshooting

Hydraulic system is overheated
Hydraulic pressure incorrectly adjusted - Correct setting is required.
Defective or misadjusted main relief valve - Adjust relief valve or change if required.
Hydraulic oil is dirty - Hydraulic oil change required.
Hydraulic fluid level is low - Fill the hydraulic system with oil.
Hydraulic pump is worn - Repair or install new hydraulic pump.

Boom cannot be lowered or raised
Damaged lift controls - Replace or repair.
Hydraulic pump failure - Repair or install new hydraulic pump.
Faulty hydraulic control valve - Change or repair hydraulic valve.
Hydraulic cylinder is broken - Repair or replace hydraulic cylinder.
Hydraulic fluid level low - Add fluid as required.

Bucket won't move
Bucket controls are faulty - Change or repair.
Damaged hydraulic oil pump - Replace or repair pump if necessary.
Damaged hydraulic control valve - Replace or repair the valve.
Defective bucket cylinder - Repair or change cylinder.
Hydraulic oil level low - Check and refill the hydraulic oil.

Slow boom or bucket operation
Hydraulic pump is defective - Check hydraulic pump flow and replace pump if necessary.
Leaking hydraulic cylinder - Cylinder seals need to be replaced.
Hydraulic fluid is insufficient - Checking hydraulic fluid level and add if necessary.
Hydraulic control valve is not set properly or defective - Set correctly or repair.
Low hydraulic pressure - Set pressure correctly.

Bucket or boom is jerky
Air in the hydraulic system - Bleed hydraulic system.
Dirty hydraulic oil filter element - Replace or clean the filter.
Hydraulic fluid is dirty - Change hydraulic fluid.
Scored cylinder tube or rod - Change damaged component.

Excessive hydraulic pump noise
Hydraulic leakage or low oil level - Refill hydraulic oil or repair leaks in system.
Plugged hydraulic filter - Clean or replace the filter.
Clogged suction line - Service the suction line.
Pump is sucking air - Bleed air.
Damaged pump components - Rebuild or install new pump.

Electrical Troubleshooting

Battery does not charge
Corroded or loose cable connections - Clean or tighten connections.
Battery terminal connectors are defective - Terminal connectors should be replaced.
Dead cell in battery - Battery replacement required.
Belt is loose or defective - Adjust belt tension or change the belt.

Starter motor cranks slow
Low battery power - Charge the battery.
Battery will not hold charge - Service charging system or replace battery.
Battery terminals are corroded or wires are disconnected - Check wire connections and change or service terminals.

Starter is not cranking
Battery is discharged or worn - Charge or replace the battery.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Low battery output voltage - Charge the battery.
Starter motor failure - Starter should be changed.