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Home / Wheel Loaders / Doosan Wheel Loaders / Doosan DL300-5

Doosan DL300-5 Troubleshooting

The Doosan DL300-5 wheel loader is powered by 567.5 cu.in (9.3L) Scania DC9 vertical 5-cylinder turbocharged diesel engine with a rated power of 271 hp (202 kW) at 1800 rpm. The Doosan DL300-5 is equipped with a 5x3 powershift transmission, power steering system, hydraulic dual multi-disc brakes, and 23.5R25 standard tires. The hydraulic system has a pump with fluid flow rate of 76.5 gpm (290 lpm). The hydraulic pressure is 3625 psi (250 bar). The wheel loader has a rated operating capacity of 14940 lbs (6790 kg) and tipping load of 29880 lbs (13580 kg). The maximum lift height is 156.5" (3975 mm) to hinge pin, and breakout force is 37690 lbs (17130 kg).

Engine Troubleshooting

Diesel hard to start or doesn't start
There is air in the fuel system - Bleed the system.
Fuel filter element is clogged - Replace filter element.
Dirty or faulty injection nozzles - Service or change injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve clearance is out of adjustment - Check and adjust as required.
Fuel injection pump malfunction - Change or repair the pump.

Diesel starts but then stops
Clogged air cleaner - Service or replace air cleaner.
Fuel filter plugging - Replace filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Clogged or defective injectors - Clean or replace fuel injectors.
Fuel injection pump malfunction - Repair or replace injection pump.

Engine stops suddenly during operation
Engine is not warmed up to required temperature - Normalize the temperature by warming up the engine.
Fuel filter plugging - Change the filter element.
Air in the fuel lines - Bleed the fuel lines.
Fuel injection nozzles fault - Service or change injection nozzles.
Incorrect adjustment of fuel injection pump timing - Set it up as required.

Engine stops at idle
Low idle speed adjustment is incorrect - Adjust the low idle speed.
Fuel injection pump malfunctioning - Repair or change injection pump.
Fuel injectors are faulty or clogged - Inspect fuel injectors and change as required.
The valve clearance is not adjusted - Need to adjust valve clearance.

Engine power is too low
Air filter is clogged - Change or service air filter element.
Clogged or burnt injection nozzle - Clean or change injection nozzles.
Uneven fuel injection pressure - Correct the pressure settings.
Excessive valve clearance - Adjust valve clearance.
Too low idle RPM - Correct the settings.
Fuel lines or hoses clogging - Clean fuel system hoses and lines.
Cylinder-head gasket is leaking - Gasket should be replaced.
Piston rings are broken or leaking - Replace piston rings.

Engine overheated
Lack of coolant in cooling system - Add coolant fluid to cooling system and also check it for leaks.
Lack of engine oil - Checking oil level and add if necessary.
Damaged radiator cap or dirty radiator core - Replace cap or clean radiator.
Fan belt is broken or worn - Belt change is required.
Engine overloaded - Reduce load on the engine.

Insufficient oil pressure
Engine oil insufficient - Fill up the engine oil.
Oil filter element is dirty - Service or replace engine oil filter.
Oil grade or viscosity is incorrect - Drain crankcase and refill with correct oil.
Crankshaft bearing has incorrect oil clearance - Install new bearings.
Oil pump failure - Remove and inspect oil pump.

Abnormal engine noise or knocking
Low engine oil level - Checking oil level and add if necessary.
Engine is not warmed up to required temperature - Warm up to required temperature.
Incorrect adjustment of fuel injection pump timing - Set up as recommended.
Low idle speed set incorrectly - Correct low idle settings.
Fuel injectors are faulty or clogged - Clean or replace fuel injectors.
Connecting rod is not aligned or defective - Align or change connecting rod.
Pistons are worn or scored - Pistons replacement required.

Transmission Troubleshooting

Transmission oil pressure is low
Lack of transmission fluid - Add fluid to the transmission housing.
Dirty transmission oil filter element (if equipped) - Service or replace the transmission oil filter.
Relief valve failure - Install a new relief valve.

Excessive transmission noise
Transmission fluid level is low - Add fluid to the transmission housing.
Transmission fluid is dirty - Transmission fluid change required.
Damaged gears or incorrect backlash - Change worn gears or adjust backlash correctly.
Bearings are broken or worn - Change the bearings.
Damaged or worn gear shift forks - Shift forks need to be changed.
Worn or damaged shaft splines - Replace the shaft.

Hard shifting
Gear shift linkage is corroded or worn - Replace or lubricate the shift linkage.
Worn or damaged gear shift forks - Change defective shift forks.
Gearshift mechanism malfunction - Identify and replace failed parts.
Worn or improperly adjusted clutch - Replace or adjust clutch.

Transmission oil leakage
High transmission fluid level - Drain the excess fluid.
Worn seals or gaskets - Install new gaskets or seal.

Hydraulics Troubleshooting

Hydraulic system has overheating
Hydraulic pressure incorrectly adjusted - Hydraulic pressure must be set correctly.
Main relief valve failure or improper setting - Adjust the valve or replace if necessary.
Hydraulic oil is contaminated - Hydraulic oil change required.
Lack of hydraulic fluid - Fill the hydraulic system with oil.
Hydraulic pump is defective - Install new pump or repair it.

Lift arm fails to drop or lift
Damaged lift controls - Replace or repair.
Hydraulic pump malfunction - Install new pump or repair it.
Hydraulic control valve failure - Repair or change the valve.
Broken hydraulic cylinder - Change or repair lift cylinder.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.

Bucket can't tilt
Defective bucket controls - Check and repair as required.
Hydraulic pump not working - Replace or repair pump if necessary.
Faulty hydraulic control valve - Install a new hydraulic valve or repair it.
Bucket cylinder malfunction - Change or repair cylinder.
Insufficient hydraulic fluid - Checking hydraulic fluid level and add if necessary.

Bucket or lift arm is working slowly
Worn hydraulic oil pump - Test the pump flow rate and change pump if required.
Leaking hydraulic cylinder - Replace cylinder piston seals.
Hydraulic fluid level low - Add fluid as required.
Hydraulic control valve is faulty or out of adjustment - Repair or adjust properly.
Hydraulic pressure is low - Hydraulic pressure must be set correctly.

Lift arm or bucket jerks when working
Air leaks in hydraulic system - Bleed air from hydraulic system.
Hydraulic oil filter element is dirty - Clean or replace the filter.
Hydraulic fluid contamination - Fill up with fresh hydraulic fluid.
Cylinder rod or tube is scratched - Replace worn component.

Hydraulic pump is excessively noisy
Lack of oil or hydraulic leakage - Remedy hydraulic leakage or refill oil as necessary.
Hydraulic filter is clogged - Service or replace hydraulic filter.
Plugged suction line - Service the suction line.
Pump is sucking air - Air bleeding is required.
Pump parts are damaged - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery is not charging
Corroded or loose electrical wire connections - Service or tighten cable connections.
Defective battery terminal clamps - Change terminal clamps.
Defective battery - Install a new battery.
Belt is loose or defective - Belt needs to be adjusted or changed.

Starter cranks slowly
Battery voltage is low - Low battery charging, charge as required.
Battery does not hold charge - Service battery or change it.
Battery cables are disconnected or terminals are faulty - Connect cables properly or replace terminals.

Starter will not crank
Battery is low or faulty - Replace or charge as required.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Battery power is low - Low battery charging, charge as required.
Starter motor is damaged - Repair or change starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders