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Home / Wheel Loaders / Doosan Wheel Loaders / Doosan DL250-5

Doosan DL250-5 Troubleshooting

The Doosan DL250-5 wheel loader is powered by 359 cu.in (5.9L) Doosan DL06 six-cylinder turbocharged diesel engine with a rated power of 172 hp (128 kW) at 2100 rpm. The Doosan DL250-5 is equipped with a 4x3 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 3840 psi (265 bar). The wheel loader has a rated operating capacity of 10595 lbs (4805 kg) and tipping load of 21190 lbs (9610 kg). The maximum lift height is 152" (3860 mm) to hinge pin, and breakout force is 23830 lbs (10810 kg).

Engine Troubleshooting

Engine hard to start or will not start
Air in the fuel system - Air bleeding.
Dirty fuel filter - Clean or change the filter.
Dirty or damaged injection nozzles - If necessary, replace with a new nozzle.
Dirt or water in fuel system - Drain water or flush dirt from the system.
The valve clearance is not adjusted - Adjust valve clearance.
Fuel injection pump is defective - Repair or install new pump.

Diesel starts but immediately shuts off
Plugged air cleaner - Clean or change.
Fuel filter element is clogged - Install new filter element.
Fuel injection pump is leaking - Repair any leaks.
Fuel injectors are faulty or clogged - Change or clean fuel injectors.
Fuel injection pump malfunction - Rebuild or install a new injection pump.

Engine stops suddenly during operation
Engine not warmed up - Warm up to required temperature.
Fuel filter element is dirty - Replace filter element.
Air in the fuel lines - Bleed the fuel lines.
Faulty fuel injection nozzles - Service or change injection nozzles.
Improper fuel injection timing - Set the fuel pump timing correctly.

Engine stalls at low idle speed
Incorrect low idle setting - Adjust low idling as recommended.
Fuel injection pump malfunction - Rebuild or install a new injection pump.
Damaged or clogged injectors - Clean or replace fuel injectors.
The valve clearance is not adjusted - Check and adjust.

Engine power is too low
Air filter is dirty - Service or replace the air filter.
Clogged or burnt injection nozzle - Change fuel injection nozzles.
Fuel injection pressure is incorrect - Test fuel injection pressure and adjust it correctly.
Incorrect valve clearance - Adjust valve clearance.
Low idle speed setting is incorrect - Correct low idle settings.
Dirt in the fuel lines or hoses - Fuel lines and hoses need to be cleaned.
Cylinder head gasket defective - Replace cylinder head gasket.
Piston rings are defective or leaking - Install new piston rings.

Engine overheats
Low coolant level - The cooling system needs to be refilled and checked for faults.
Engine oil level is insufficient - Fill up the oil to required level.
Radiator core is dirty or radiator cap is damaged - Clean radiator or replace cap.
Damaged or worn fan belt - Fan belt must be replaced.
Diesel engine overloaded - Reduce load on the engine.

Insufficient oil pressure
Oil level is low - Fill crankcase to proper oil level.
Dirty oil filter - Service or replace engine oil filter.
Different type of engine oil - Fill up with the correct oil viscosity.
Excessive main bearing oil clearance - Replace bearings.
Oil pump failure - Repair or replace.

Engine knocking sound or abnormal noise
Not enough engine oil - Need to add engine oil.
Engine is not preheated - Warm up the engine.
Incorrect adjustment of fuel injection pump timing - Set up as recommended.
Incorrect low idle setting - Correct low idle settings.
Defective fuel injectors - Test and replace fuel injectors if necessary.
Connecting rod is misaligned or worn - Need to change or align the connecting rod.
Scored or worn pistons - Have pistons replaced.

Transmission Troubleshooting

Insufficient transmission fluid pressure
Insufficient transmission oil - Check and refill the transmission oil.
Clogged transmission oil filter element (if fitted) - Clean or change transmission oil filter.
Relief valve is stuck - Change relief valve.

Transmission noises
Low fluid level - Add fluid to the transmission housing.
Transmission oil contamination - Transmission oil change required.
Worn gears or incorrect backlash - Install new gears and adjust backlash properly.
Bearings are damaged or worn - Replace faulty bearings.
Worn or damaged gear shift forks - Shift forks need to be replaced.
Shaft splines are stuck or worn out - Shaft need to be replaced.

Gear shift is hard
Gear shift linkage is corroded or worn - Lubricate or replace the shift linkage.
Damaged or worn gear shift forks - Install new shift forks.
Gearshift mechanism is damaged - Replace or repair the mechanism.
Malfunction or incorrect clutch adjustment - Adjust clutch or change if necessary.

External oil leaks
Transmission oil level is exceeded - Correct the oil volume.
Damaged seals or gaskets - Install new components.

Hydraulics Troubleshooting

Hydraulic system overheats
Hydraulic pressure incorrectly adjusted - Hydraulic pressure must be set correctly.
Misadjusted or defective main relief valve - Adjust or replace the relief valve.
Hydraulic fluid is contaminated - Hydraulic fluid change required.
Not enough hydraulic fluid in the system - Add fluid to the hydraulic system.
Hydraulic pump is defective - Repair or replace pump if necessary.

Boom can't lift or drop
Damaged lift controls - Repair or change.
Damaged hydraulic oil pump - Repair or replace pump if necessary.
Hydraulic control valve failure - Repair or replace hydraulic valve.
Faulty hydraulic cylinder - Install a new boom cylinder or repair it.
Insufficient hydraulic oil - Need to add oil.

Bucket fails to tilt
Bucket tilt controls are defective - Replace or repair.
Damaged hydraulic oil pump - Install new pump or repair it.
Hydraulic control valve is defective - Install a new hydraulic valve or repair it.
Faulty hydraulic bucket cylinder - Repair or change cylinder.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.

Bucket or lift arm runs slowly
Faulty hydraulic oil pump - Check pump performance and change it if necessary.
Hydraulic cylinder oil leakage - Correct leakage by changing the seals.
Insufficient hydraulic oil - Check and refill the hydraulic oil.
Hydraulic control valve is not set properly or defective - Adjust correctly or repair.
Hydraulic pressure has dropped - Correct adjustment is required.

Bucket or boom is jerky
Air in the hydraulic system - Bleed air from hydraulic system.
Hydraulic oil filter is dirty - Clean or install new filter.
Hydraulic oil is dirty - The oil must be changed.
Cylinder rod or tube is scuffed - Replace damaged component.

Hydraulic pump is noisy
Hydraulic leakage or lack of oil - Refill hydraulic oil or repair leaks in system.
Hydraulic filter is clogged - Clean or install new filter.
Suction line is dirty - Suction line must be serviced.
Pump is sucking air - Need to bleed air.
Worn pump components - Replace or rebuild the pump.

Electrical Troubleshooting

Battery cannot be charged
Corroded or loose wire connections - Tighten or clean connections.
Defective battery terminal clamps - Replace terminal clamps.
Battery failing - Battery change required.
Loose or defective belt - Belt needs to be adjusted or changed.

Starter motor turns slow
Battery power is low - Battery needs to be recharged.
Battery discharges quickly - Service charging system or install new battery.
Faulty battery terminals or disconnected cables - Check cables and service or change terminals.

Starter will not work
Battery is low or faulty - Recharge or change battery.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Battery voltage is low - Battery needs to be recharged.
Starter motor is damaged - Starter needs to be changed.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders