Troubleshooting and common problem solving for second-hand Doosan 225 excavator

The Doosan 225 excavator, as a mature and reliable piece of equipment, is widely used in various construction environments due to its excellent design and stable performance. However, with the increase in usage time and the intensity of work, the equipment may inevitably experience some common faults, especially after prolonged high-intensity operation. Over time, the various components may gradually wear out or age, leading to a decline in performance or the occurrence of faults. These issues not only affect the normal operation of the equipment but can also increase maintenance costs and extend downtime, thus impacting work efficiency. To assist users in efficiently troubleshooting and addressing these common problems, ensuring smooth operation and high productivity, here are detailed troubleshooting and solutions for the common faults of the second-hand Doosan 225 excavator, which we hope will provide valuable guidance and reference for users.

1. Engine Hard to Start

Common Causes:

Insufficient Battery Power: The battery may be aging or lacking power, preventing enough current for starting.

Fuel System Issues: Problems like a damaged fuel pump or clogged fuel filter, leading to poor fuel supply.

Starter Motor Fault: If the starter motor is aged or damaged, it may fail to operate properly.

Solutions:

Check and replace the battery, ensuring it has enough charge.

Inspect the fuel system, clean or replace the fuel filter, and check if the fuel pump works properly.

Test the starter motor and repair or replace it if necessary.

2. Hydraulic System Issues

Common Causes:

Hydraulic Oil Leaks: Worn or damaged seals can cause hydraulic oil to leak, affecting efficiency.

Hydraulic Pump Failure: A failed hydraulic pump can prevent the system from providing adequate pressure.

Contaminated or Expired Hydraulic Oil: Poor-quality oil or dirty oil can impair system operation.

Solutions:

Check the hydraulic system for leaks in pipes, joints, and seals; replace any faulty seals.

Inspect the hydraulic pump and check its pressure. Repair or replace if needed.

Change the hydraulic oil and clean the hydraulic oil filter regularly to maintain system cleanliness and reduce wear.

3. Track or Travel System Issues

Common Causes:

Loose or Severely Worn Tracks: Extended use can cause tracks to loosen or wear, affecting stability and movement.

Travel Motor Failure: If the travel motor is aged or damaged, it may stop working.

Solutions:

Regularly check track tension and adjust it if necessary. Replace worn-out tracks when needed.

Inspect the travel motor, checking both the wiring and the motor itself for functionality. Repair or replace as needed.

4. Unresponsive Controls

Common Causes:

Loose or Faulty Control Lever Connections: Loose or faulty connections in the control levers can result in imprecise movements.

Electrical Control System Issues: Problems with the electrical control module or sensors may cause delayed or incorrect response.

Solutions:

Check the control levers and connections to ensure they’re tight and not damaged. Repair or replace them if necessary.

Inspect the electrical control system and sensors. Ensure they’re working properly and replace faulty components.

5. Overheating

Common Causes:

Cooling System Failures: Issues like a clogged radiator, insufficient coolant, or a faulty cooling fan can cause overheating of the engine or hydraulic system.

Excessive Workload: Continuous high-load operation can lead to overheating.

Solutions:

Regularly inspect the cooling system, including the radiator, coolant level, and cooling fan. Ensure all parts are functioning well.

During high-load operations, avoid continuous running. Allow the machine to rest periodically to prevent overheating.

6. Transmission System Issues

Common Causes:

Low or Contaminated Transmission Fluid: Dirty or insufficient transmission fluid can cause the transmission system to malfunction.

Clutch Problems: Worn or damaged clutches may prevent smooth transmission shifting.

Solutions:

Regularly inspect and replace transmission fluid to ensure it is clean and properly lubricated.

Check for abnormal wear in the clutch. If issues are detected, repair or replace the clutch.

7. Electrical System Faults

Common Causes:

Worn or Loose Wires: Aging, loose, or short-circuiting electrical wiring can prevent the machine from starting or operating properly.

Control Module Failure: Faults in the control module may cause unstable operation or trigger warning alarms.

Solutions:

Inspect the electrical wiring, ensuring all wires and connections are intact with no wear, damage, or short circuits.

Check the control module and other electronic components for faults. Repair or replace them as necessary.

8. Alarm During Operation

Common Causes:

Sensor Failure: Failed sensors like oil temperature or pressure sensors may trigger alarms.

System Error: The control system detects abnormal conditions, such as incorrect working pressure, and triggers an alarm.

Solutions:

Use a diagnostic tool to read the alarm codes and identify the fault location.

Inspect the relevant sensors, control systems, or hydraulic systems, and repair or replace faulty components.

Troubleshooting used Doosan 225 excavators primarily focuses on issues with the engine, hydraulic system, tracks, control system, and electrical systems. Regular maintenance and timely troubleshooting are essential for extending the lifespan of the equipment and ensuring optimal performance. The solutions outlined above can help address common problems and keep the Doosan 225 running smoothly.