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Home / Wheel Loaders / Doosan Wheel Loaders / Doosan DL220-5

Doosan DL220-5 Troubleshooting

The Doosan DL220-5 wheel loader driveline system components: Doosan DL06 4-cycle 4-cylinder direct injection turbocharged intercooled diesel engine with a rated power of 160 hp (119 kW), and 4x3 power shift transmission with a torque converter. The hydraulic system has a pump with a rated capacity of 40.9 gal/min (155 l/min). The Doosan DL220-5 is equipped with a power steering system, hydraulic dual multi-disc brakes, and 20.5R25 tires. The wheel loader has a maximum lift height of 152" (3860 mm) and bucket breakout force of 22705 lbs (10300 kg). The rated operating capacity is 9375 (4255 kg), and tipping load is 18750 lbs (8510 kg).

Engine Troubleshooting

Engine starts up hard or doesn't start
Air in fuel tank - Bleed fuel tank.
Fuel filter plugged - Change the filter element.
Fuel injection nozzles are clogged or faulty - Service or change injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Excessive valve clearance - Adjust to proper valve clearance.
Fuel injection pump failure - Replacement or repair required.

Diesel starts but stalls immediately
Dirty air filter - Change or service air filter element.
Fuel filter element is dirty - Change filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Fuel injectors are dirty or defective - Clean or replace fuel injectors.
Fuel injection pump is faulty - Install a new fuel pump or repair.

Engine shuts off suddenly while running
Low coolant temperature - Warm up engine as required.
Fuel filter is plugged - Clean or change the filter.
There is air in the fuel system - Bleed the system.
Faulty or dirty injection nozzles - Change fuel injection nozzles.
Incorrect adjustment of fuel injection pump timing - Adjust as recommended.

Engine stops while idling
Too low idle RPM - Adjustment required.
Fuel injection pump is not operating properly - Replace or rebuild injection pump.
Clogged or defective injectors - Replace or clean fuel injectors.
Valve clearance is out of adjustment - Check and adjust.

Engine power is insufficient
Dirty air filter - Clean or change filter.
Damaged or dirty injection nozzles - Install a new kit of correctly balanced nozzles.
Incorrect fuel injection pressure - Adjust to proper pressure.
The valve clearance is incorrect - Check and adjust.
Wrong adjustment of low idle speed - Adjust low idle speed.
Fuel hoses or lines are dirty - Clean fuel system lines and hoses.
Leaking cylinder head gasket - Gasket should be replaced.
Worn or broken piston rings - Piston rings replacement required.

Engine overheating
Engine has a lack of coolant - Add coolant fluid to cooling system and also check it for leaks.
Engine oil level low - Add oil to the engine crankcase.
Clogged radiator fins or leaking radiator cap - Clean radiator or change cap.
Excessive wear of the fan belt - If necessary, replace the belt.
Engine is under excessive load - Load reducing required.

Oil pressure too low
Low crankcase oil level - Add oil as required.
Oil filter is clogged - Service or change engine oil filter element.
Incorrect oil viscosity - Use oil of correct viscosity.
Incorrect crankshaft bearing oil clearance - Bearing replacement required.
Oil pump is defective - Remove and inspect oil pump.

Abnormal engine noise or knocking
Insufficient engine oil - Need to add engine oil.
Engine is not warmed up to required temperature - Warm up to required temperature.
Timing of fuel injection pump is incorrect - Set the fuel pump timing correctly.
Improperly adjusted low idle speed - Normalize low idle speed.
Defective fuel injectors - Test and replace fuel injectors if necessary.
Misaligned or defective connecting rod - Alignment procedure or replacement is required.
Piston wear or scoring - Pistons replacement required.

Transmission Troubleshooting

Transmission oil pressure is insufficient
Lack of transmission oil supply - Add oil to the transmission housing.
Dirty transmission oil filter element (if equipped) - Clean or change transmission oil filter.
Relief valve is damaged - Replace relief valve.

Transmission makes excessive noise
Transmission fluid level is low - Need to add transmission fluid.
Transmission oil contamination - Fill up with fresh transmission oil.
Gears are damaged or backlash is incorrect - Adjust backlash correctly or replace the gears.
Bearings are broken or worn - Change faulty bearings.
Damaged or worn gear shift forks - Install new shift forks.
Stuck or worn shaft splines - Shaft need to be changed.

Gear hard to shift
Gear shift linkage is worn or rusty - Replace or lubricate the shift linkage.
Worn or damaged gear shift forks - Install new shift forks.
Worn gear shifting mechanism - Repair or change worn components if necessary.
Unadjusted or worn clutch - Clutch replacement or adjustment required.

Transmission fluid leakage
High transmission fluid level - Drain the excess fluid.
Damaged gaskets or seals - Replace worn seal or gaskets.

Hydraulics Troubleshooting

Hydraulic system overheats
Hydraulic pressure incorrectly adjusted - Correct adjustment is required.
Main relief valve malfunction or improper adjustment - Adjust the valve or replace if necessary.
Contaminated hydraulic oil - Fill up with fresh hydraulic oil.
Hydraulic oil level is low - Fill the hydraulic system with oil.
Defective hydraulic pump - Install new pump or repair it.

Lift arm does not lower or raise
Lift controls are damaged - Change or repair.
Hydraulic pump not working - Repair or replace pump if necessary.
Faulty hydraulic control valve - Replace or repair the valve.
Hydraulic cylinder is defective - Repair or change hydraulic cylinder.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.

Bucket does not function
Bucket controls are faulty - Inspect and repair if necessary.
Hydraulic pump not working - Install new pump or repair it.
Faulty hydraulic control valve - Install a new hydraulic valve or repair it.
Bucket cylinder malfunction - Repair or replace cylinder.
Low hydraulic fluid level - Add fluid as required.

Boom or bucket runs slowly
Hydraulic pump is faulty - Check the pump performance and replace it if required.
Hydraulic cylinder leaking - Replace cylinder piston seals.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.
Faulty or incorrect setting hydraulic control valve - Adjust correctly or repair.
Hydraulic system loosing pressure - Adjust pressure as required.

Bucket or boom jerks when working
There is air in the hydraulic system - Bleed hydraulic system.
Plugged hydraulic oil filter - Clean or install new filter.
Contaminated hydraulic fluid - Fill up with fresh hydraulic fluid.
Scored cylinder tube or rod - Change damaged component.

Hydraulic pump is noisy
Hydraulic leakage or low oil level - Refill hydraulic oil or repair leaks in system.
Hydraulic filter is clogged - Service or change hydraulic filter.
Dirty suction line - Suction line needs to be cleaned.
Pump sucks air - Bleed air.
Pump components are damaged - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery is not charging
Loose or corroded cable connections - Service or tighten connections.
Faulty battery terminal connectors - Terminal connectors need to be changed.
Bad cell in battery - Install a new battery.
Belt is defective or loose - Install a new belt or adjust belt tension.

Starter motor turns slow
Battery power is low - Recharge the battery.
Battery does not hold charge - Service or replace the battery.
Disconnected battery cables or bad terminals - Check wiring and clean or replace terminals.

Starter will not work
Battery is low or faulty - Charge or replace the battery.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery capacity - Battery is drained, recharge it.
Defective starter motor - Repair or install a new starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders