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Doosan DL200-5 Troubleshooting

The Doosan DL200-5 wheel loader is powered by 268.5 cu.in (4.4L) Perkins 1204F 4-cylinder direct injection turbocharged diesel engine with a rated power of 143 hp (106 kW) at 2200 rpm. The Doosan DL200-5 is equipped with a hydrostatic 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 48.5 gpm (184 lpm). The hydraulic pressure is 3120 psi (215 bar). The wheel loader has a rated operating capacity of 9290 lbs (4223 kg) and tipping load of 18580 lbs (8445 kg). The max lift height is 146.8" (3730 mm) to hinge pin, and breakout force is 22440 lbs (10200 kg).

Engine Troubleshooting

Engine hard to start or won't start
Air in the fuel system - Air bleeding.
Fuel filter plugged - Change filter element.
Dirty or damaged injection nozzles - Replace injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve clearance is not correct - Need to adjust valve clearance.
Faulty fuel injection pump - Rebuild or install a new injection pump.

Diesel starts and then shuts off
Air filter is dirty - Clean or change filter.
Clogged fuel filter - Clean or change the filter.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Fuel injectors are faulty or clogged - Clean or replace fuel injectors.
Fuel injection pump is defective - Rebuild or replace pump.

Engine stalls after running
Engine is not fully warmed up - Warm up engine as required.
Fuel filter element is dirty - Replace the filter element.
There is air in the fuel system - Bleed the system.
Fuel injection nozzles are damaged - Clean or change injection nozzles.
Fuel injection pump timing is not adjusted - Check the fuel injection pump timing adjustment.

Engine stops when idling
Incorrect low idle setting - Correct low idle settings.
Fuel injection pump is damaged - Replace injection pump or repair it.
Damaged or clogged injectors - Clean fuel injectors or change it.
Incorrect valve clearance - Correct valve clearance.

Lack of engine power
Dirty air filter - Change or service air filter element.
Fuel injection nozzles are faulty or clogged - If necessary, replace with a new nozzle.
Fuel injection pressure is wrong - Correct the pressure settings.
Valve clearance is out of adjustment - Have it adjusted.
Low idle speed adjustment is incorrect - Adjustment required.
Restricted fuel lines or hoses - Fuel lines and hoses need to be cleaned.
Cylinder head gasket is damaged - Gasket should be replaced.
Piston rings are damaged or leaking - Piston rings need to be replaced.

Engine is overheated
Insufficient coolant fluid - The cooling system needs to be refilled and checked for faults.
Engine oil insufficient - Fill up the engine oil.
Damaged radiator cap or dirty radiator core - Clean radiator or change cap.
Loose or damaged fan belt - Fan belt must be replaced.
Diesel engine overloaded - Reduce load on the engine.

Low oil pressure
Lack of oil - Check oil level and add oil as required.
Oil filter clogging - Service or replace engine oil filter.
Improper type of engine oil - Use the specified type of engine oil.
Excessive crankshaft bearing oil clearance - Bearing needs to be changed.
Defective oil pump - Install a new pump.

Abnormal engine noise or knocking
Insufficient engine oil - Check and refill engine oil.
Low coolant temperature - Warm up to required temperature.
Timing of fuel injection pump is incorrect - Adjust according to specifications.
Low idle speed setting is incorrect - Correct low idle settings.
Defective fuel injectors - Clean fuel injectors or change it.
Connecting rod is not aligned or worn - Need to replace or align the connecting rod.
Pistons are broken or worn - Replace the pistons.

Hydrostatic Transmission Troubleshooting

Excessive HST transmission noise
Low transmission oil level or contaminated oil - Change transmission oil or top up to proper level.
Worn or unadjusted speed control linkage - Adjust or repair linkage.
Stuck relief valve - Replace valve as required.
Transmission overloaded - Load needs to be reduced.
Damaged or worn components of hydrostatic transmission - Change or repair defective parts.

Low power
Insufficient transmission fluid - Check and refill the transmission fluid.
Relief valve is stuck - Install a new relief valve.
Speed control pedal linkage is damaged or out of adjustment - Adjust or replace linkage.

Transmission fluid over heats
Insufficient transmission fluid - Add fluid to the transmission housing.
Clogged transmission oil filter element - Clean or replace the transmission filter.
Cooling components are defective or plugged - Check all cooling components and change or repair if required.
Transmission is under excessive load - Reduce loading.

Transmission fluid leakage
Damaged seals or gaskets - Install new components.
High internal transmission case pressure - Change defective parts.
Clogged transmission fluid return tube - Clean or replace return tube.

Hydraulics Troubleshooting

Hydraulic system overheating
Hydraulic pressure is not adjusted correctly - Correct adjustment is required.
Main relief valve improper adjustment or failure - Adjust the valve or replace if necessary.
Hydraulic fluid contamination - The fluid must be changed.
Not enough hydraulic fluid in the system - Add fluid to the hydraulic system.
Defective hydraulic pump - Change or repair hydraulic pump if required.

Lift arm fails to drop or lift
Lift controls are damaged - Repair or change.
Defective hydraulic pump - Change or repair hydraulic pump if required.
Hydraulic control valve is faulty - Repair or change hydraulic valve.
Hydraulic cylinder malfunction - Repair or change hydraulic cylinder.
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.

Bucket fails to tilt
Bucket controls failure - Replace or repair.
Hydraulic pump failure - Change or repair hydraulic pump if required.
Hydraulic control valve failure - Repair or change hydraulic valve.
Hydraulic bucket cylinder not working - Repair or install a new cylinder.
Hydraulic oil is insufficient - Need to add oil.

Slow boom or bucket operation
Hydraulic pump is faulty - Check pump capacity and change if necessary.
Oil leaks from hydraulic cylinder - Install new cylinder seals.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.
Damaged or incorrect adjusted hydraulic control valve - Repair or adjust properly.
Hydraulic pressure has dropped - Hydraulic pressure must be set correctly.

Lift arm or bucket is jerky
Air leaks in hydraulic system - Need to bleed air.
Hydraulic oil filter clogging - Service or replace the hydraulic filter.
Hydraulic oil is contaminated - Hydraulic oil change required.
Scratched cylinder rod or tube - Change failed component.

Hydraulic pump is noisy
Low oil level or hydraulic leaks - Add hydraulic oil or correct system leaks.
Hydraulic filter is dirty - Clean or change the filter.
Suction line is dirty - Need to clean the suction line.
Air trapped in hydraulic pump - Air bleeding is required.
Faulty pump parts - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery is not charging
Wiring connections are loose or corroded - Tighten or service connections.
Electrical terminal connectors are defective - Install new terminal connectors.
Battery faulty cell - Replace the battery.
Loose or defective belt - Adjust belt tension or change the belt.

Starter motor cranks slow
Low battery output voltage - Battery needs to be recharged.
Battery discharges quickly - Service battery or replace it.
Terminals are faulty or battery cables are disconnected - Check cable connections and change or clean terminals.

Starter motor is not working
Battery is low or faulty - Replace or charge as required.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Low battery voltage - Battery needs to be recharged.
Starter motor is faulty - Change or repair starter.