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Home / Wheel Loaders / Doosan Wheel Loaders / Doosan DL250-3

Doosan DL250-3 Troubleshooting

The Doosan DL250-3 wheel loader driveline system components: Doosan DL06K six-cylinder direct injection turbocharged diesel engine with a rated power of 172 hp (128 kW), and powershift transmission with 4 forward and 3 reverse gears. The hydraulic system has a piston pump with a rated capacity of 55.4 gal/min (210 l/min). The Doosan DL250-3 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 153.5" (3900 mm) and bucket breakout force of 27125 lbs (12330 kg). The rated operating capacity is 10340 lbs (4700 kg), and tipping load is 20680 lbs (9400 kg).

Engine Troubleshooting

Engine starts hard or won't start
Air in fuel system - Bleed fuel system.
Fuel filter element is clogged - Service the filter.
Dirty or faulty injection nozzles - Replace injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Improper valve clearance - Check and adjust.
Fuel injection pump is damaged - Rebuild or install a new injection pump.

Engine starts but stops suddenly
Air filter is plugged - Replace or clean air filter element.
Clogged fuel filter - Replace filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Fuel injectors are dirty or defective - Replace or clean fuel injectors.
Damaged fuel injection pump - Replace or repair injection pump.

Engine shuts off while running
Low coolant temperature - Warm up the engine.
Dirty fuel filter - Clean or replace the filter.
Air in fuel tank - Bleed fuel tank.
Dirty or damaged injection nozzles - Install a new kit of correctly balanced nozzles.
Fuel injection pump timing is wrong - Set it up as required.

Engine stalls at idle
Incorrectly set low idle speed - Need to adjust idle speed.
Fuel injection pump is broken - Replace injection pump or repair it.
Defective fuel injectors - Replace fuel injectors.
Valve clearance is not correct - Adjust valve clearance according to specifications.

Diesel power loss
Air cleaner is dirty - Clean or change cleaner.
Clogged or defective injection nozzles - Clean or change injection nozzles.
Incorrect fuel injection pressure - Correct the pressure settings.
Valve clearance is wrong - Adjust valve clearance according to specifications.
Low idle speed setting is not correct - Need to adjust idle speed.
Fuel hoses or lines clogging - Service fuel lines and hoses.
Cylinder-head gasket is broken - Install a new gasket.
Leaking or damaged piston rings - Piston rings replacement required.

Engine overheating
Lack of coolant in cooling system - Add coolant fluid to cooling system and also check it for leaks.
Engine oil level low - Fill up the engine oil.
Clogged radiator fins or leaking radiator cap - Clean radiator or change cap.
Loose or defective fan belt - If necessary, replace the belt.
Engine overloaded - Load reducing is recommended.

Oil pressure is low
Engine oil insufficient - Fill the crankcase with oil.
Clogged oil filter - Clean or change engine oil filter.
Wrong oil viscosity - Drain and refill with oil of correct grade and viscosity.
Main bearing oil clearance is excessive - Bearing replacement required.
Defective oil pump - Check and replace if necessary.

Engine knocks or noises
Engine oil level is low - Check oil level and add oil as required.
Low coolant temperature - Normalize the temperature by warming up the engine.
Fuel injection pump timing is not adjusted - Adjust the pump as required.
Incorrectly set low idle speed - Adjustment required.
Fuel injectors are faulty or clogged - Clean or replace fuel injectors.
Connecting rod is not aligned or worn - Need to replace or align the connecting rod.
Pistons are worn or scored - Replace the pistons as required.

Transmission Troubleshooting

Transmission oil pressure is low
Insufficient transmission fluid - Check and refill the transmission fluid.
Clogged transmission fluid filter (if equipped) - Service or change transmission fluid filter.
Defective relief valve - Replace the valve.

Excessive transmission noise
Low oil level - Add oil to the transmission housing.
Transmission fluid contamination - Change the fluid.
Gears are damaged or backlash is incorrect - Adjust backlash properly or replace the gears.
Bearings are cracked or worn - Faulty bearings should be changed.
Shift forks are bent or worn out - Replace defective shift forks.
Worn or damaged shaft splines - Replace defective shaft.

Gear hard to shift
Stuck or worn gear shift linkage - Install new shift linkage.
Shift forks are worn or bent - Shift forks need to be changed.
Worn out parts of the gearshift mechanism - Replace worn parts.
Unadjusted or worn clutch - Change or adjust clutch.

Transmission fluid leakage
High transmission oil level - Correct the oil level.
Seals or gaskets are worn - Change defective seal or gaskets.

Hydraulics Troubleshooting

Hydraulic system overheated
Hydraulic pressure incorrectly adjusted - Adjust it correctly.
Defective or misadjusted main relief valve - Set up or change the relief valve.
Hydraulic oil is dirty - Fill up with fresh hydraulic oil.
Hydraulic oil level is insufficient - Fill up the hydraulic oil.
Defective hydraulic pump - Install new pump or repair it.

Boom does not raise or lower
Faulty lift controls - Check and repair as required.
Hydraulic pump is broken - Replace or repair pump if necessary.
Damaged hydraulic control valve - Repair or change the valve.
Hydraulic cylinder not working - Replace or repair boom cylinder.
Hydraulic fluid is insufficient - Add fluid as required.

Bucket does not tilt
Bucket controls failure - Repair or change.
Hydraulic pump not working - Repair or replace pump if necessary.
Hydraulic control valve failure - Install a new valve or repair it.
Bucket cylinder failure - Replace or repair cylinder.
Hydraulic oil level low - Check and refill the hydraulic oil.

Bucket or lift arm moves slowly
Worn hydraulic oil pump - Flow-rate pump and change pump if necessary.
Hydraulic cylinder leaking - Cylinder seals need to be replaced.
Low hydraulic fluid level - Fill up the hydraulic fluid.
Damaged or incorrect adjusted hydraulic control valve - Repair or adjust correctly.
Hydraulic system loosing pressure - Adjust pressure correctly.

Jerky operation of the bucket or boom
Air trapped in hydraulic system - Air bleeding is required.
Dirty hydraulic oil filter element - Replace or clean the filter.
Hydraulic fluid is dirty - Hydraulic fluid change required.
Scored cylinder tube or rod - Replace failed component.

Hydraulic pump is excessively noisy
Lack of oil or hydraulic leakage - Top up hydraulic oil or remedy leakage in system.
Clogged hydraulic filter - Clean or replace the filter.
Plugged suction line - Need to service the suction line.
Pump sucks air - Air bleeding is required.
Faulty pump parts - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery won’t charge
Electrical cable connections are loose or corroded - Tighten or service connections.
Battery terminal connectors are defective - Change terminal connectors.
Battery is defective - Battery replacement required.
Loose or damaged belt - Install a new belt or adjust belt tension.

Starter turns slow
Low battery power - Charge the battery.
Battery runs out quickly - Service charging system or change battery.
Disconnected wiring or bad battery terminals - Check cables and clean or change terminals.

Starter motor won't turn
Battery is drained or worn - Need to charge or replace the battery.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Battery power is low - Charge the battery.
Starter motor is defective - Change or repair starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders