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Doosan DL280-5 Troubleshooting
The
Doosan DL280-5 wheel loader is powered by Doosan DL06 vertical in-line
6-cylinder direct injection turbocharged diesel engine with a rated power of 172
hp (128 kW) at 1800 rpm. The Doosan DL280-5 is equipped with a four-speed
powershift transmission, power steering system, hydraulic dual multi-disc
brakes, and 20.5R25 standard tires. The hydraulic system has an axial piston pump with fluid
flow rate of 55.4 gpm (210 lpm). The wheel loader has a rated operating capacity
of 11670 (5305 kg) and tipping load of 23340 lbs (10610 kg). The maximum lift height
is 155.1 inches (3940 mm) to hinge pin, and boom breakout force is 30295 lbs
(13770 kg).
| Engine Troubleshooting |
Engine hard to start or will not start
Air in the fuel pipes - Bleed the fuel pipes.
Dirty fuel filter - Clean or replace the filter.
Clogged or burnt injection nozzle - Check injection nozzles and replace if required.
Water in the fuel system - Change fuel and repair fuel system.
Incorrect valve clearance - Check and adjust.
Defective fuel injection pump - Rebuild or replace pump.
Diesel starts and stalls immediately
Air filter is clogged - Clean or change.
Dirty fuel filter - Clean the filter or install new filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Clogged or defective injectors - Replace fuel injectors.
Fuel injection pump is broken - Replace or rebuild injection pump.
Engine shuts off suddenly during operation
Engine is not fully warmed up - Normalize the temperature by warming up the engine.
Fuel filter is plugged - Install new filter element.
Air in fuel tank - Bleed fuel tank.
Defective or clogged injection nozzle - Test injection nozzles and change if necessary.
Improper fuel injection timing - Check the fuel injection pump timing adjustment.
Engine stalls when idling
Incorrectly set low idle speed - Test and adjust.
Fuel injection pump is faulty - Replace or repair injection pump.
Defective fuel injectors - Clean fuel injectors or change it.
Valve clearance is wrong - Adjust to proper valve clearance.
Engine power loss
Air cleaner is clogged - Service or replace air cleaner.
Clogged or defective injection nozzles - Replace injection nozzles.
Fuel injection pressure is wrong - Test fuel injection pressure and adjust it correctly.
Valve clearance is wrong - Adjust to proper valve clearance.
Low idle speed setting is incorrect - Adjustment required.
Dirty fuel lines or hoses - Clean fuel system hoses and lines.
Blown cylinder head gasket - Replace cylinder head gasket.
Worn or broken piston rings - Replace piston rings.
Engine is overheated
Not enough coolant - The cooling system needs to be refilled and checked for faults.
Engine oil level low - Fill up the oil to required level.
Dirty radiator fins or faulty radiator cap - Clean radiator or change cap.
Loose or defective fan belt - Change as required.
Engine overload - Reduce load on the engine.
Low oil pressure
Engine oil level low - Add oil as required.
Clogged oil filter element - Service or replace engine oil filter.
Improper type of engine oil - Drain and refill with oil of correct grade and viscosity.
Incorrect crankshaft bearing oil clearance - Install new bearings.
Oil pump is worn or damaged - Replace as required.
Engine knocks or noises
Engine oil level is low - Add oil to the engine crankcase.
Engine not warmed up - Warm up engine as required.
Improper fuel injection timing - Check the fuel injection pump timing adjustment.
Too low idle RPM - Test and adjust.
Damaged or clogged injectors - Replace fuel injectors.
Connecting rod is misaligned or worn - Alignment procedure or replacement is required.
Scored or worn pistons - Replace the pistons as required.
| Transmission Troubleshooting |
Low transmission fluid pressure
Low oil level - Check transmission oil level and add oil as required.
Plugged transmission oil filter (if equipped) - Clean or change transmission oil filter.
Relief valve failure - Replace relief valve as required.
Transmission is making noise
Transmission oil level is low - Check and refill the transmission oil.
Transmission oil is dirty - Change the oil.
Improper backlash or worn gears - Change the gears or set backlash properly.
Worn or broken bearings - Faulty bearings should be changed.
Worn or damaged gear shift forks - Shift forks need to be replaced.
Damaged or worn shaft splines - Shaft need to be replaced.
Hard shifting
Gear shift linkage is rusty or worn - Install a new gear shift linkage.
Worn or bent shift forks - Replace defective shift forks.
Defective parts in the gearshift mechanism - Replace defective parts.
Clutch is faulty or misadjusted - Adjust or replace the clutch.
External oil leaks
High transmission fluid level - Drain the excess fluid.
Damaged seals or gaskets - Gaskets or seal replacement required.
| Hydraulics Troubleshooting |
Hydraulic system has overheating
Hydraulic pressure incorrectly adjusted - Adjust pressure correctly.
Main relief valve improper adjustment or failure - Adjust the valve or replace if necessary.
Hydraulic oil contamination - Hydraulic oil change required.
Hydraulic oil level is insufficient - Fill the hydraulic system with oil.
Faulty hydraulic oil pump - Repair or install new hydraulic pump.
Boom can't lift or drop
Defective lift controls - Inspect and repair if necessary.
Hydraulic pump is broken - Replace or repair pump if necessary.
Hydraulic control valve malfunction - Replace or repair the valve.
Defective hydraulic cylinder - Install a new boom cylinder or repair it.
Low hydraulic oil level - Need to add oil.
Bucket is not working
Bucket tilt controls malfunction - Repair or change.
Defective hydraulic pump - Install new pump or repair it.
Hydraulic control valve is faulty - Replace or repair the valve.
Hydraulic bucket cylinder not working - Install a new cylinder or repair it.
Hydraulic fluid level low - Checking hydraulic fluid level and add if necessary.
Bucket or lift arm is moving slowly
Defective hydraulic pump - Check pump flow and install new pump if necessary.
Hydraulic cylinder leaking - Install new cylinder seals.
Hydraulic oil level low - Need to add oil.
Hydraulic control valve is unadjusted or worn - Set properly or repair.
Hydraulic pressure loss - Set pressure correctly.
Bucket or boom is moving jerkily
Air trapped in hydraulic system - Need to bleed air.
Hydraulic oil filter element clogging - Replace or clean the filter.
Hydraulic fluid is dirty - Fill up with fresh hydraulic fluid.
Cylinder rod or tube is scratched - Change worn component.
Hydraulic pump is excessively noisy
Leaking hydraulic system or insufficient oil level - Correct hydraulic leaks or top up oil as needed.
Hydraulic filter is dirty - Service or change hydraulic filter.
Dirty suction line - Service the suction line.
Pump is sucking air - Need to bleed air.
Damaged pump parts - Replace or rebuild the pump.
| Electrical Troubleshooting |
Battery won’t charge
Corroded or loose cable connections - Tighten or service connections.
Defective battery terminal clamps - Terminal clamps should be changed.
Bad cell in battery - Install a new battery.
Worn or loose belt - Adjust belt tension or change the belt.
Starter turning slow
Low battery capacity - Recharge the battery.
Battery is not holding charge - Service or replace the battery.
Bad terminals or disconnected battery cables - Connect cables correctly or replace terminals.
Starter will not crank
Battery is low or faulty - Recharge or change battery.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Low battery power - Low battery charging, charge as required.
Damaged starter motor - Replace or repair starter.
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| WHEEL LOADERS SPECIFICATIONS |
Bobcat
Caterpillar
Case
Doosan
John Deere
Kubota