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Home / Wheel Loaders / Doosan Wheel Loaders / Doosan DL200-7

Doosan DL200-7 Troubleshooting

The Doosan DL200-7 wheel loader driveline system components: Perkins 1204J 4-cylinder turbocharged aftercooled diesel engine with a rated power of 143 hp (106 kW), and hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 40.9 gal/min (155 l/min). The system relief pressure is 3840 psi (265 bar). The Doosan DL200-7 is equipped with a power steering system, hydraulic dual multi-disc brakes, and 20.5R25 tires. The wheel loader has a maximum lift height to hinge pin of 146.2" (3715 mm) and boom breakout force of 21990 lbs (9995 kg). The rated operating capacity is 9825 lbs (4465 kg), and tipping load is 19650 lbs (8930 kg).

Engine Troubleshooting

Engine difficult to start or won't start
Air trapped in fuel system - Bleed air.
Fuel filter element is clogged - Clean the filter element.
Defective or clogged injection nozzle - Inspect nozzles and replace if necessary.
Dirt or water in fuel system - Drain water or flush dirt from the system.
The valve clearance is not adjusted - Adjustment procedure required.
Defective fuel injection pump - Repair or replace injection pump.

Diesel starts but then stops
Clogged air cleaner - Service or replace air cleaner.
Fuel filter plugged - Replace the filter element.
Fuel injection pump has loose connections - Tighten the connections.
Defective or clogged fuel injectors - Replace fuel injectors.
Fuel injection pump is faulty - Change or repair the pump.

Engine stops running suddenly
Engine is not preheated - Warm up the engine.
Fuel filter is plugged - Service or replace the filter.
Air in fuel system - Bleed fuel system.
Clogged or defective injection nozzles - Inspect nozzles and replace if necessary.
Fuel injection pump timing is wrong - Adjust according to specifications.

Engine stalls at low idle speed
Low idle speed setting is not correct - Adjust as required.
Damaged fuel injection pump - Rebuild or replace pump.
Defective fuel injectors - Replace or clean fuel injectors.
The valve clearance is not adjusted - Correct valve clearance needs to be set.

Diesel engine is losing power
Clogged air cleaner - Clean or replace air cleaner element.
Clogged injection nozzle - Service or change injection nozzles.
Fuel injection pressure is incorrect - Adjust pressure to proper level.
The valve clearance is not adjusted - Adjust valve clearance.
Incorrect low idle speed adjustment - Adjust as required.
Clogged fuel lines or hoses - Service fuel hoses and lines.
Cylinder-head gasket is broken - Install a new gasket.
Piston rings are worn or damaged - Install new piston rings.

Engine overheats
Not enough coolant - Fill radiator to proper level and check components for faults.
Insufficient engine oil - Fill up the oil to required level.
Faulty radiator cap or dirty radiator fins - Change cap or clean radiator.
Fan belt slipping or worn - Belt replacement is recommended.
Engine overloaded - Load reducing is recommended.

Oil pressure too low
Low oil level - Check and refill the oil.
Clogged oil filter element - Replace or clean engine oil filter element.
Oil grade or viscosity is wrong - Use oil of correct viscosity.
Excessive oil clearance of crankshaft bearing - Bearing replacement required.
Worn oil pump - Check and replace if necessary.

Engine noise or knocking
Engine oil level is insufficient - Fill the crankcase with engine oil.
Coolant temperature is low - Normalize the temperature by warming up the engine.
Fuel injection pump timing is not adjusted - Set up as recommended.
Incorrectly set low idle speed - Correct low idle adjustment.
Clogged or defective injectors - Change or clean fuel injectors.
Connecting rod failure or misalignment - Align or replace connecting rod.
Pistons are scored or worn - Replace the pistons.

Transmission Troubleshooting

Low transmission oil pressure
Transmission fluid level is low - Check and refill the transmission fluid.
Transmission fluid filter element clogging (if equipped) - Clean or change transmission fluid filter.
Relief valve malfunction - Install a new valve.

Transmission is excessively noisy
Insufficient transmission oil - Need to add transmission oil.
Transmission oil is contaminated - Transmission oil change required.
Gears are damaged or backlash is incorrect - Install new gears and adjust backlash properly.
Bearings are broken or worn - Change the bearings.
Shift forks are worn or bent - Shift forks need to be changed.
Shaft splines are worn or damaged - Replace the shaft.

Difficulty shifting gears
Rusty or worn gear shift linkage - Install a new gear shift linkage.
Worn or damaged gear shift forks - Replace the shift forks.
Worn parts of the gear shifting mechanism - Change worn parts.
Worn or unadjusted clutch - Replace or adjust clutch.

Transmission fluid leaking
Transmission oil level is high - Correct the oil volume.
Broken seals or gaskets - Install new seal or gaskets.

Hydraulics Troubleshooting

Hydraulic system has overheating
Incorrect hydraulic pressure setting - Hydraulic pressure must be set correctly.
Main relief valve failure or improper setting - Replace or set up the relief valve.
Dirty hydraulic oil - Fill up with fresh hydraulic oil.
Lack of hydraulic oil - Add oil to the hydraulic system.
Hydraulic pump is worn - Repair or change pump if required.

Lift arm won't raise or lower
Lift controls are defective - Replace or repair.
Hydraulic pump is broken - Replace or repair pump if necessary.
Hydraulic control valve malfunction - Repair or replace the valve.
Damaged hydraulic cylinder - Change or repair lift cylinder.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.

Bucket is not working
Faulty bucket tilt controls - Check and repair as required.
Defective hydraulic pump - Change or repair hydraulic pump if required.
Hydraulic control valve is defective - Repair or replace hydraulic valve.
Faulty hydraulic bucket cylinder - Replace or repair cylinder.
Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.

Slow bucket or lift arm operation
Worn hydraulic oil pump - Check pump performance and change it if necessary.
Leaking hydraulic cylinder - Correct leakage by changing the seals.
Hydraulic oil is insufficient - Fill the system to proper hydraulic oil level.
Hydraulic control valve is unadjusted or worn - Adjust correctly or repair.
Hydraulic system loosing pressure - Correct setting is required.

Lift arm or bucket is moving jerkily
Hydraulic system is leaking air - Air bleeding is required.
Hydraulic oil filter element is dirty - Clean or change the filter.
Dirty hydraulic fluid - Hydraulic fluid change required.
Cylinder rod or tube is scuffed - Replace damaged component.

Excessive hydraulic pump noise
Not enough oil or hydraulic system leaking - Refill hydraulic oil or repair leaks in system.
Clogged hydraulic filter - Clean or install new filter.
Suction line is dirty - Service the suction line.
Pump sucks air - Bleed air from hydraulics.
Worn pump parts - Change or rebuild pump.

Electrical Troubleshooting

Battery does not charge
Loose or corroded wire connections - Tighten or service cable connections.
Defective battery terminal clamps - Terminal clamps should be changed.
Worn-out battery - Replace the battery.
Loose or worn belt - Replace belt or adjust belt tension.

Starter cranks slow
Battery power is low - Battery needs to be recharged.
Battery runs out quickly - Service charging system or replace battery.
Bad battery terminals or disconnected wiring - Check wire connections and change or service terminals.

Starter motor won't turn
Battery is low or faulty - Recharge or change battery.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Battery capacity is low - Battery is drained, recharge it.
Starter motor is damaged - Repair or replace starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders