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Home / Wheel Loaders / Doosan Wheel Loaders / Doosan DL280-7

Doosan DL280-7 Troubleshooting

The Doosan DL280-7 wheel loader driveline system components: 359 cu.in (5.9L) Doosan DL06 vertical six-cylinder turbocharged diesel engine with a rated power of 190 hp (141 kW), and 4x3 or 5x3 auto powershift transmission with a torque converter. The hydraulic system has a pump with a rated capacity of 64.9 gal/min (246 l/min). The Doosan DL280-7 is equipped with a power steering system, hydraulic dual multi-disc brakes, and 20.5R25 tires. The wheel loader has a maximum lift height to hinge pin of 154.9" (3935 mm) and boom breakout force of 31420 lbs (14280 kg). The rated operating capacity is 11845 (5385 kg), and tipping load is 23690 lbs (10770 kg).

Engine Troubleshooting

Engine starts hard or won't start
Air trapped in fuel system - Bleed air.
Fuel filter plugging - Service the filter.
Faulty or dirty injection nozzles - If necessary, replace with a new nozzle.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Incorrect valve clearance - Adjustment procedure required.
Fuel injection pump is not working correctly - Change pump or rebuild it.

Diesel starts and suddenly stops
Plugged air filter - Service or replace the air filter.
Fuel filter element is clogged - Clean or replace the filter.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Fuel injectors are faulty or clogged - Clean fuel injectors or change it.
Fuel injection pump is not working correctly - Rebuild or install a new injection pump.

Engine stalls during operation
Coolant temperature is low - Warm up engine as required.
Fuel filter element is dirty - Replace the filter element.
Air in the fuel pipes - Bleed the fuel pipes.
Fuel injection nozzles are clogged or faulty - If necessary, replace with a new nozzle.
Wrong setting of fuel injection pump timing - Set up as recommended.

Engine stalls at idle
Incorrect low idle setting - Normalize low idle speed.
Fuel injection pump is broken - Repair or install a new fuel pump.
Clogged or defective injectors - Test and replace fuel injectors if necessary.
Valve clearance is out of adjustment - Correct valve clearance.

Lack of engine power
Clogged air filter - Install new air filter element.
Clogged or defective injection nozzles - If necessary, replace with a new nozzle.
Fuel injection pressure is wrong - Adjust to correct pressure.
Valve clearance is wrong - Have it adjusted.
Incorrectly set low idle speed - Correct low idle settings.
Dirt in the fuel lines or hoses - Service fuel hoses and lines.
Cylinder head gasket is damaged - Install a new gasket.
Defective or worn piston rings - Replace the piston rings as required.

Engine overheating
Insufficient coolant fluid - The cooling system needs to be refilled and checked for faults.
Engine oil level is low - Check and refill engine oil.
Clogged radiator fins or leaking radiator cap - Replace cap or clean radiator.
Fan belt is loose or defective - Replace as required.
Diesel engine is overloaded - Reduce engine load.

Oil pressure is low
Low oil level - Check oil level and add oil as required.
Oil filter element clogging - Replace or service engine oil filter.
Oil grade or viscosity is wrong - Use oil of proper viscosity.
Crankshaft bearing has excessive oil clearance - Replace bearings.
Worn oil pump - Inspect and change as required.

Engine noise or knocking
Engine oil level low - Fill the crankcase with engine oil.
Coolant temperature is low - Warm up engine as required.
Wrong setting of fuel injection pump timing - Adjust fuel injection pump as required.
Incorrectly set low idle speed - Adjust low idling as recommended.
Clogged or defective injectors - Inspect fuel injectors and change as required.
Connecting rod is defective or misaligned - Replace or align connecting rod.
Piston wear or scoring - Pistons replacement required.

Transmission Troubleshooting

Insufficient transmission fluid pressure
Transmission oil level is low - Fill the transmission housing with oil.
Transmission oil filter element clogging (if equipped) - Clean or replace the transmission filter.
Relief valve is damaged - Replace relief valve as required.

Transmission makes noise
Transmission fluid insufficient - Fill the transmission housing to proper fluid level.
Transmission fluid contamination - Fill up with fresh transmission fluid.
Improper backlash or worn gears - Replace defective gears or set backlash properly.
Worn or cracked bearings - Bearings need to be changed.
Shift forks are worn or bent - Change defective shift forks.
Shaft splines are stuck or worn out - Shaft need to be changed.

Difficulty shifting gears
Gear shift linkage is worn or rusty - Shift linkage need to be replaced.
Worn or bent gear shift forks - Shift forks need to be changed.
Gear shifting mechanism is defective - Defective parts must be replaced.
Malfunction or incorrect clutch adjustment - Adjust or change the clutch.

Transmission fluid leaks
Too much oil in transmission - Drain the excess oil.
Damaged gaskets or seals - Change defective gaskets or seal.

Hydraulics Troubleshooting

Hydraulic system overheats
Hydraulic pressure is not adjusted correctly - Correct adjustment is required.
Main relief valve is damaged or adjusted improperly - Adjust relief valve or change if required.
Hydraulic fluid contamination - 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 fails to lift or drop
Lift controls malfunction - Change or repair.
Damaged hydraulic oil pump - Change or repair hydraulic pump if required.
Hydraulic control valve is defective - Repair or replace the valve.
Hydraulic cylinder malfunction - Repair or change hydraulic cylinder.
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.

Bucket does not function
Bucket tilt controls are defective - Inspect and repair if necessary.
Hydraulic pump failure - Change or repair hydraulic pump if required.
Defective hydraulic control valve - Repair or change the valve.
Bucket cylinder is faulty - Replace or repair cylinder.
Hydraulic fluid is insufficient - Fill the system to proper hydraulic fluid level.

Boom or bucket is moving slowly
Hydraulic pump is faulty - Test the pump flow rate and install new pump if required.
Hydraulic cylinder oil leakage - Cylinder seals need to be replaced.
Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.
Faulty or incorrect setting hydraulic control valve - Set correctly or repair.
Hydraulic system loosing pressure - Correct adjustment is required.

Bucket or boom movements are jerky
Hydraulic system is leaking air - Need to bleed air.
Hydraulic oil filter is dirty - Service or replace the hydraulic filter.
Hydraulic fluid is contaminated - The fluid must be changed.
Scored cylinder tube or rod - Change damaged component.

Excessive hydraulic pump noise
Hydraulic leakage or low oil level - Repair hydraulic leaks or add oil as required.
Hydraulic filter clogging - Replace or clean the filter.
Plugged suction line - Suction line needs to be cleaned.
Pump sucks air - Bleed air from hydraulics.
Faulty pump parts - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery does not charge
Wiring connections are corroded or loose - Service or tighten connections.
Electrical terminal connectors are defective - Change terminal connectors.
Battery dead cell - Battery change required.
Belt is defective or loose - Change belt or adjust belt tension.

Starter turns slow
Low battery output voltage - Charge the battery.
Battery will not hold charge - Service or replace the battery.
Disconnected wires or corroded battery terminals - Check wiring and clean or replace terminals.

Starter is not working
Battery is low or faulty - Charge or replace the battery.
Wiring is incorrectly connected or disconnected - Inspect wiring and connect correctly.
Low battery power - Battery needs to be recharged.
Faulty starter motor - Repair or install a new starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders