TEST & ADJUSTING

DX Model

2007. 7. 2
Overseas P/S team
Index

1. Power/ Standard mode.

2. Pilot pressure.
3. Negacon (Negative Control) pressure.
4. Main relief pressure & pressure up.
5. PA/PT signal.
6. Cooling fan RPM.

2
1. Power / Standard mode

- Measuring point

Rexroth pump

Kawasaki pump
3
1. Power / Standard mode

Test Condition : Hydraulic oil temp  50 ℃ ↑, RPM  MAX

Model Work mode Engine RPM Current (mA) 2ndly pressure (bar)
Power mode 1,900 300 ~ 650 4 ~ 23

STD mode 1,900 350 ~ 650 7 ~23

DX480(520)LC
Auto idle 1,200 650 23

Low RPM 750 650 23

Power mode 1,880 200 ~ 650 2 ~ 23

STD mode 1,730 350 ~ 650 7 ~23

DX420LC
Auto idle 1,200 650 23

Low RPM 750 650 23

Power mode 1,900 200 ~ 600 4 ~ 23

STD mode 1,750 300 ~ 600 7 ~23

DX340LC
Auto idle 1,200 600 23

Low RPM 800 600 23

Power mode 2,000 150 ~ 400 1 ~ 16

STD mode 1,900 400 ~ 600 16 ~32

DX300LC
Auto idle 1,000 600 32

Low RPM 750 600 32

Power mode 2,000 150 ~ 600 0 ~ 31

STD mode 1,800 300 ~ 600 7~31

DX255LC
Auto idle 1,200 600 31

Low RPM 800 600 31

4
1. Power / Standard mode

Power mode 2,000 200 ~ 600 0 ~ 28

STD mode 1,900 300 ~ 600 8 ~28

DX225LC
Auto idle 1,000 600 28

Low RPM 800 600 28

Power mode 2,050 250 ~ 650 2 ~ 22

STD mode 1,950 320 ~ 650 7 ~23

DX180LC
Auto idle 1,200 650 23

Low RPM 800 650 23

Power mode 1,950 150 ~ 600 1 ~ 32

STD mode 1,850 250 ~ 600 6 ~32

DX140LC
Auto idle 1,000 600 32

Low RPM 800 600 32

Traveling 2,070 200 ~650 2 ~ 23

Power mode 1,900 270 ~ 650 2.5 ~ 23

DX210W STD mode 1,800 350 ~ 650 7 ~23

Auto idle 1,200 650 23

Low RPM 800 650 23

Traveling 2,070 240 ~ 650 0.5 ~22

Power mode 1,600 270 ~ 650 2.0 ~ 22

DX140W STD mode 1,500 320 ~ 650 4.7 ~22

Auto idle 1,000 650 22

Low RPM 800 650 22

5
2. Pilot pressure

- Measuring point

6
2. Pilot pressure

Test Condition : Hydraulic oil temp  50 ℃ ↑

Engine RPM Minimum pilot pressure

@ Min. engine speed 35 bar ↑

@ Max. engine speed 43 bar ↑

7
2. Pilot pressure

- Adjustment pilot pressure

Lock nut

Inside shim

8
2. Pilot pressure

3. Tools : 60 bar gauge, Tee type test adapter

Rexroth pump Kawasaki pump

Screw coupling (120-00002)

Tee Adapter PF3/8 (2181-2366D3 ) Tee Adapter PF1/4 (2181-2366D1 )

9
3. Negacon pressure

- Measuring point

10
4. Negacon pressure

Test Condition : Hydraulic oil temp  50 ℃ ↑, RPM  MAX(확인 요망)

Condition Nega con pressure (bar)

Neutral 32 ~ 34 bar
Max
rpm
Cyl. Stall 0 ~ 8 bar

Neutral 28 ~ 30 bar
Min
rpm

Cyl. Stall 0 ~ 8 bar

11
4. Negacon pressure

4. Tools : 60 bar gauge X 2, Tee type test adapter X 2

Screw coupling (120-00002)

Tee Adapter PF1/4 (2181-2366D1 )

12
5. Main relief pressure & pressure up

- Measuring point (Pressure up)

KVMG 270 KVMG 400

13
5. Main relief pressure & pressure up

1. Test Condition : Hydraulic oil temp 50 ℃↑, Power up button “On”, Engine max RPM

Push Button Operation Main press (bar) Pilot press (bar)

Released Cyl Stall 330 ± 5 % Near Zero

Pressed Cyl Stall 350 ± 5 % 35 ~ 45

14
5. Main relief pressure & pressure up

3. Tools : 60 bar gauge, Tee type test adapter. DMS

Screw coupling (120-00002)

Tee Adapter PF1/4 (2181-2366D1 )

15
5. Main relief pressure & pressure up

☞ Main Relief Valve Adjustment.

1 2

1. Loosen the upper jam nut and turn #1 clockwise till it is fully seated.
2. Loosen the lower jam nut and adjust #2 till the “Pressure – Up value” is obtained.
3. Set 350 bar and tighten the lower jam nut with #2 fixed.
4. Turn out #1 till the “Main relief pressure value” is obtained.
5. Set 330 bar and tighten the upper jam nut with #1 fixed.
6. Recheck if both pressures are correct and if necessary, make final adjustment.

16
6. PA/PT Signal

- Measuring point

PT

PA

17
6. PA/PT Signal

Test Condition : Over 50 ℃ of hydraulic oil temp., max engine RPM.

Condition PA (bar) PT (bar)

Neutral 0 bar 0 bar

Front Operation Pilot Pressure 0 bar

Travel Operation 0 bar Pilot Pressure

18
6. PA/PT Signal

3. Tools : 60 bar gauge, Tee type test adapter.

Screw coupling (120-00002)

Tee Adapter PF1/4 (2181-2366D1 )

19
12. Cooling fan RPM (DX420,DX480)

- Measuring point

Behind cabin

20
12. Cooling fan RPM (DX420,DX480)

Test Condition : Over 50 ℃ of hydraulic oil temp., max engine RPM.

Condition Fan RPM Pressure

Max engine RPM

21
12. Cooling fan RPM (DX420,DX480)

4. Tools : 600 bar gauge, Screw coupling, Speed meter.

Screw coupling (120-00002)

22
13. Transmission pilot pressure

- Measuring point

1. Test Condition : Over 50 ℃ of hydraulic oil

temp., Braking machine without parking brake.

AB

Travel speed switch A Port, High speed (bar) B Port, Low Speed( bar)

I (Inching travel) 0 33(검증필요)

II 0 33

III 33 0

23
13. Transmission pilot pressure

3. Tools : 60 bar gauge X 2, Straight type test adapter X 2

Screw coupling (120-00002)

Adapter M14 (2181-2201D3)

24
14. Inching traveling

- Measuring point
1. Test Condition : Over 50 ℃ of hydraulic oil
temp., Braking machine without parking
brake.
2. Procedure
1) Start the engine and Low engine speed
2) Select travel speed switch Low ( I,II
position) or High (III position) speed.
3) Measure check port pressure.

Travel select switch Pressure (bar)

I (Inching travel) 40

II 0

III 0

25
14. Inching traveling

4. Tools : 60 bar gauge, Straight type test adapter

Screw coupling (120-00002)

Adapter M14 (2181-2201D3)

26
TESTING & ADJUSTING
DL Model

2007. 7. 2
Overseas P/S team
Index

1. Main pump pressure.

2. Steering pump pressure.
3. Working LS pressure.
4. Steering LS pressure.
5. Brake charging pressure.
6. Pilot pressure.
7. Transmission pressure.
8. Brake pressure.
9. Parking brake pressure.
10. Cooling fan RPM.

28
1. Main pressure

- Measuring point DL300 DL400

1. Tools : 600 bar gauge

2. Test Conditions : 50 ℃ of Hyd. oil temp., Engine Min. or Max. RPM.
3. Procedure
1) Install dial gauge on main pressure check point.
2) Loader arm up or bucket should be stall condition, record the main pressure with gauge
installed on check point.

Engine RPM Operation Main pressure (bar)

Min. RPM Cyl. Stall
Max. RPM Cyl. Stall

29
1. Main pressure

- Main pressure adjustment

200 bar Main pump

Control valve

250 bar

DL200/250/300 DL400/500

30
1. Main pressure

- Adjusting main pump cut off pressure (DL400 / DL500)

1. Disconnect steering pump LS signal line and close both line with plug.
2. Install dial gauge on remote main pump pressure check port. (TPM Port)
3. Stall loader arm up or bucket with Max. engine RPM without steering and adjust main pump
pressure (250 bar) by relief valve on the pump.

250 bar

Main pump

31
1. Main pressure

- Adjusting steering pump cut off pressure (DL400 / DL500)

1. Disconnect main pump LS signal line and close the line with plug.
2. Install dial gauge on remote steering pump pressure check port. (TPS port)
3. Stall loader arm up or bucket with Max. engine RPM without steering and adjust steering
pump pressure(250 bar) by relief valve on the pump.

250 bar

Steering pump

32
1. Main pressure

- Adjusting steering pump cut off pressure (DL400 / DL500)

4. Tools : Plug (2181-2218D1), cap (DS2916007)

33
2. Working LS pressure

- Measuring point
DL400 / DL500

1. Tools : 600 bar gauge

2. Test Conditions : 50 ℃ of Hyd. oil temp., Engine Min. or Max. RPM.
3. Procedure
1) Connect dial gauge on check point,
2) Lift up loader arm or moving bucket slowly, record LS pressure (compare main pressure).
Engine RPM Operation LS press. (bar) Main press. (bar)
Min. RPM None
Min. RPM Lift up Loader arm or bucket
Max. RPM None
Max. RPM Lift up Loader arm or bucket

34
2. Working LS pressure

- Adjusting main pump LS pressure (DL400 / DL500)

1. Install dial gauge on remote main pump pressure check port (TPM) and LS pressure port (TPMLS)
2. Engine RPM should be MAX. with idling condition
3. Compare main pump pressure and LS pressure. The ΔP must be 20 bar
Main pump P

Flow control valve

Δ P= 20 bar

Main pump

Main pump LS P

35
3. Steering pressure

- Measuring point DL300 DL400

1. Tools : 600 bar gauge

2. Test Conditions : 50 ℃ of Hyd. oil temp., Engine Min. or Max. RPM.
3. Procedure
1) Connect dial gauge on check point.
2) Still steering cylinder left or right side, record the steering pressure.
Engine RPM Operation Steering pressure (bar)
Max. None
Min. RPM Steering Cyl. Stall
Max. RPM Steering Cyl. Stall
* To adjust steering pressure on this port, the LS relief valve should be adjusted.
36
4. Steering LS pressure

- Measuring point
DL300 DL400

EHPS Valve
1. Tools : 600 bar gauge
2. Test Conditions : 50 ℃ of Hyd. oil temp., Engine Min. or Max. RPM.
3. Procedure
1) Connect dial gauge on check point,
2) Still steering cylinder left or right side, record the steering pressure
Engine RPM Operation LS pressure (bar)
Min. RPM None
Min. RPM Steering Cyl. stall
Max. RPM None
Max. RPM Steering Cyl. stall

37
4. Steering LS pressure

- Checking LS pressure (DL400 / DL500)

1. Install dial gauge on remote steering pump LS pressure port (TPSLS)
2. Engine RPM should be MAX. and steering stall condition.
3. Steering LS pressure should be 185 bar

38
4. Steering LS pressure

- Checking LS pressure (DL250 / DL300)

1. Install dial gauge LS pressure port (LS) on EHPS valve
2. Engine RPM should be MAX. and steering stall condition.
3. Steering LS pressure should be 190 bar Tools

39
4. Steering LS pressure

- Steering LS pressure adjustment

LS relief valve (185bar)

LS relief valve (190bar)

EHPS valve Flow amplifier valve

DL300 DL400/500

40
4. Steering LS pressure

- Adjusting steering pump LS pressure (DL400 / DL500)

1. Install dial gauge on remote steering pump pressure check port (TPS) and LS pressure port (TPSLS)
2. Engine RPM should be MAX. and steering stall condition.
3. Compare steering pump pressure and steering LS pressure.
Steering pressure should be 205bar, Steering LS pressure should be 185 bar
The ΔP should be 20 bar

Flow control valve

Δ P= 20 bar

Steering pump

DL400/500
41
5. Brake charging pressure

- Measuring point
DL300 DL400

1. Tools : 600 bar gauge

2. Test Condition. : 50 ℃ of Hyd. oil temp., Engine Min. or Max. RPM
3. Procedure
4. 1) Install dial gauge on brake charging pressure check port.
2) Engine Low or Max. RPM, press or release brake pedal, record brake charging pressure.
Engine RPM Brake pedal Brake charging pressure (bar)
Min. PRM Released
Min. RPM Pressed
Max. RPM Released
Max. RPM Pressed

42
5. Brake charging pressure

- Pressure adjustment

C1 cartridge valve (120 bar)

Brake, pilot, & fan supply valve

43
6. Pilot pressure

- Measuring point
DL300 DL400

1. Tools : 60 bar gauge

2. Test Conditions : 50 ℃ of Hyd. oil temp., Engine Min. RPM
3. Procedure
4. 1) Install dial gauge on pilot pressure check point.
2) Shift pilot cur off switch on or off, record the pilot pressure on check point.

Pilot cut off S/W Pilot pressure (bar)

On
Off

44
6. Pilot pressure

- Adjustment pressure

C2 cartridge valve (28 bar)

Brake, pilot, & fan supply valve

45
7. Transmission pressure

- Measuring point
DL300 DL400

1. Tools : 60 bar gauge

2. Test Conditions : 80 ℃ of transmission oil temp., Engine Min. or Max. RPM.
3. Procedure
4. 1) Install dial gauge on transmission pressure check point.
2) Record the transmission pressure on check point.

Engine RPM Transmission pressure (bar)

Min.
Max.

* Not adjustable transmission pressure.

46
8. Brake pressure

- Measuring point

Front Axle

Rear Axle

1. Tools : 600 bar gauge

2. Test Conditions : 50 ℃ of Hyd. oil temp., Engine Min. RPM.
3. Procedure
4. 1) Install dial gauge on front and rear axle check point
2) Release and press brake pedal, record the brake pressure on check point.

Brake pressure (bar)

Brake pedal
Front Rear
Released
Pressed

47
8. Brake pressure

- Adjusting brake pressure

Brake pressure
adjustment screw

48
9. Parking brake pressure

- Measuring point

1. Tools : 600 bar gauge

2. Test Conditions : 50 ℃ of Hyd. oil temp., Engine Min. RPM.
3. Procedure
4. 1) Set machine on flat ground with tire prop and install dial gauge on front of parking brake
check point
2) Press or release parking brake switch, record the parking brake pressure.

Parking brake switch Parking brake press. (bar)

On
Off

49
10. Cooling system

- Measuring point

1. Tools : 600 bar gauge

2. Test Conditions : 50 ℃ of Hyd. oil temp., Engine Max. RPM.
3. Procedure
4. 1) Install dial gauge on P line check port and disconnect wire harness on proportional valve.
2) Engine Max. PRM, record the fan RPM and pressure with gauge installed on check port.

Fan RPM Pressure (bar)

50
10. Cooling system

- Adjusting fan speed

Adjustment screw

Do not tighten the adjustment screw until end stroke, when adjust fan speed,
If inner spool under adjustment screw is touched to end stroke point, proportional
control function is not working.

51
10. Cooling system

 T/M oil circulation

T/M (Hot oil) → T/M oil cooler (Water) → T/M oil cooler (Air) → T/M (Cool oil)

52