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Home / Wheel Loaders / Doosan Wheel Loaders / Doosan DL220-7

Doosan DL220-7 Troubleshooting

The Doosan DL220-7 wheel loader is powered by Doosan DL06 vertical in-line six-cylinder turbocharged diesel engine with a rated power of 160 hp (119 kW) at 2100 rpm. The Doosan DL220-7 is equipped with a powershift 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 40.9 gpm (155 lpm). The hydraulic pressure is 3625 psi (250 bar). The wheel loader has a rated operating capacity of 10045 lbs (4565 kg) and tipping load of 20090 lbs (9130 kg). The max lift height is 151.8 inches (3855 mm) to hinge pin, and boom breakout force is 20415 lbs (9280 kg).

Engine Troubleshooting

Engine starts hard or will not start
Air in fuel system - Bleed fuel system.
Fuel filter element clogging - Service or replace the filter.
Burnt or clogged injection nozzle - Check and replace nozzles if required.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve out of adjustment - Adjust valve clearance according to specifications.
Fuel injection pump malfunctioning - Replace or repair injection pump.

Engine starts and immediately shuts off
Plugged air filter - Replace or clean air filter element.
Fuel filter element is clogged - Clean or replace the filter.
Fuel injection pump is leaking - Repair any leaks.
Damaged or clogged injectors - Change or clean fuel injectors.
Fuel injection pump is not operating properly - Rebuild or replace pump.

Diesel shuts off while driving
Engine is not preheated - Warm up the engine.
Fuel filter plugging - Service or replace the filter.
Air in fuel tank - Bleed fuel tank.
Fuel injection nozzles fault - Replace injection nozzles.
Improper fuel injection timing - Adjust fuel injection pump as required.

Engine stalls at idle
Low idle speed adjustment is incorrect - Adjust as required.
Fuel injection pump malfunctioning - Change or repair the pump.
Damaged or clogged injectors - Replace fuel injectors.
Valve clearance is wrong - Need to adjust valve clearance.

Low engine power
Plugged air cleaner - Service or replace air cleaner.
Defective or clogged injection nozzle - Check injection nozzles and replace if required.
Improper fuel injection pressure - Adjust pressure to proper level.
Improper valve clearance - Adjustment procedure required.
Incorrectly adjusted low idle speed - Test and adjust.
Dirt in the fuel lines or hoses - Clean fuel hoses and lines.
Cylinder-head gasket is leaking - Replace the gasket as required.
Piston rings are worn or damaged - Replace piston rings.

Engine is overheated
Engine coolant is insufficient - Add coolant and check the components of cooling system.
Low engine oil level - Checking oil level and add if necessary.
Clogged radiator core or damaged radiator cap - Change cap or clean radiator.
Fan belt is broken or worn - Install new fan belt.
Engine overload - Reduce engine load.

Low oil pressure
Lack of oil - Check and refill the oil.
Oil filter clogged - Clean or replace engine oil filter element.
Incorrect engine oil Use oil of proper viscosity.
Incorrect oil clearance in crankshaft bearing - Replace bearings.
Oil pump failure - Repair or replace.

Engine knocking or noise
Engine oil insufficient - Checking oil level and add if necessary.
Coolant temperature is low - Warm up the engine.
Improper fuel injection timing - Adjust according to specifications.
Too low idle RPM - Adjust low idle speed.
Dirty or defective injectors - Inspect fuel injectors and change as required.
Connecting rod is not aligned or defective - Need to align or replace the connecting rod.
Pistons are scored or worn - Replace the pistons as required.

Transmission Troubleshooting

Insufficient transmission oil pressure
Low oil level - Check transmission oil level and add oil as required.
Transmission fluid filter element clogging (if equipped) - Clean or change transmission fluid filter.
Defective relief valve - Change relief valve.

Transmission is making noise
Transmission oil insufficient - Fill the transmission housing to proper oil level.
Transmission oil is contaminated - Change the oil.
Improper backlash or worn gears - Replace defective gears or set backlash properly.
Bearings are damaged or worn - Change the bearings.
Worn or bent shift forks - Change defective shift forks.
Damaged or worn shaft splines - Install a new shaft.

Gear shift is hard
Worn or rusty gear shift linkage - Install new shift linkage.
Shift forks are bent or worn out - Shift forks need to be replaced.
Worn parts of the gear shifting mechanism - Change worn parts.
Worn or improperly adjusted clutch - Clutch needs to be adjusted or changed.

Transmission fluid leaking
Transmission oil level is exceeded - Correct the oil volume.
Seals or gaskets are worn - Change defective gaskets or seal.

Hydraulics Troubleshooting

Hydraulic system overheating
Incorrect hydraulic pressure setting - Hydraulic pressure must be set correctly.
Main relief valve is damaged or adjusted improperly - Replace or set up the relief valve.
Hydraulic fluid is dirty - Hydraulic fluid change required.
Not enough hydraulic oil in the system - Add oil to the hydraulic system.
Hydraulic pump is faulty - Replace or repair pump if necessary.

Boom cannot be lowered or raised
Lift controls malfunction - Repair or replace.
Hydraulic pump failure - Install new pump or repair it.
Hydraulic control valve failure - Install a new hydraulic valve or repair it.
Hydraulic cylinder is faulty - Change or repair lift cylinder.
Low hydraulic oil level - Check and refill the hydraulic oil.

Bucket is not working
Faulty bucket tilt controls - Check and repair as required.
Damaged hydraulic oil pump - Change or repair hydraulic pump if required.
Hydraulic control valve malfunction - Repair or change hydraulic valve.
Bucket cylinder is faulty - Repair or install a new cylinder.
Hydraulic fluid is insufficient - Checking hydraulic fluid level and add if necessary.

Bucket or lift arm moves slowly
Hydraulic pump is defective - Check pump flow and change pump if necessary.
Hydraulic cylinder oil leakage - Install new cylinder seals.
Hydraulic oil level low - Need to add oil.
Defective or not adjusted hydraulic control valve - Repair or set properly.
Low hydraulic pressure - Correct adjustment is required.

Lift arm or bucket is moving jerkily
Air in the hydraulic system - Need to bleed air.
Hydraulic oil filter element is dirty - Service or replace the hydraulic filter.
Contaminated hydraulic oil - The oil must be changed.
Scratched cylinder rod or tube - Replace failed component.

Hydraulic pump makes excessive noise
Hydraulic system leaking or not enough oil - Remedy hydraulic leakage or refill oil as necessary.
Hydraulic filter clogging - Clean or replace the filter.
Plugged suction line - Need to clean the suction line.
Air in hydraulic pump - Remove air from hydraulics.
Pump parts are worn out - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery cannot be charged
Loose or corroded electrical wiring connections - Tighten or service cable connections.
Faulty electrical terminal connectors - Terminal connectors need to be changed.
Faulty cell in battery - Change the battery.
Belt is loose or defective - Adjust belt tension or replace belt.

Starter cranks slow
Low battery capacity - Low battery charging, charge as required.
Battery is draining quickly - Service charging system or replace battery.
Bad terminals or disconnected battery cables - Check wiring connections and replace or clean terminals.

Starter motor is not working
Battery is drained or worn - Recharge or change battery.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Battery power is low - Battery needs to be recharged.
Starter motor is damaged - Starter should be changed.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders