TESTING & ADJUSTING

DL Model

2007. 7. 2
Overseas P/S team
Warning !

1. Read and follow all safety recommendation of safety section on shop

manual before testing machine.

2. Before testing & adjusting machine, the machine must be set on flat
ground with tire prop and stop engine.

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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.

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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
4. 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

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1. Main pressure

- Main pressure adjustment

200 bar Main pump

Control valve

250 bar

DL200/250/300 DL400/500

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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

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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

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1. Main pressure

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

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

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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

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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

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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.
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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

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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

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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

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4. Steering LS pressure

- Steering LS pressure adjustment

LS relief valve (185bar)

LS relief valve (190bar)

EHPS valve Flow amplifier valve

DL300 DL400/500

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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
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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

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5. Brake charging pressure

- Pressure adjustment

C1 cartridge valve (120 bar)

Brake, pilot, & fan supply valve

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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

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6. Pilot pressure

- Adjustment pressure

C2 cartridge valve (28 bar)

Brake, pilot, & fan supply valve

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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.

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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

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8. Brake pressure

- Adjusting brake pressure

Brake pressure
adjustment screw

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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

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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)

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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.

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10. Cooling system

ƒ T/M oil circulation

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

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11. Checking machine conditions

1. Engine Speed.

Measured (rpm)
Mode
Front + Steering+
No load Front only Front + Steering
Torque Converter
Low RPM

Max. RPM

2. Relief Pressure.

Main pump pressure (bar) Steering pump pressure (bar)

Engine
Speed
Neutral Cyl. stall Neutral Cyl. stall

Low speed

Max. speed

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11. Checking machine conditions

3. Brake & Parking brake pressure.

Measured (bar)
Mode
Neutral Pressed brake Parking Off Parking On

Low RPM

Max. RPM

4. Pilot pressure & Cooling fan speed

Pilot cut off switch (bar) Fan speed (rpm)

Mode
OFF switch ON switch Normal direction Reverse direction

Low RPM

Max. RPM

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11. Checking machine conditions

5. LS pressure

Main pump Steering pump

Mode
Neutral Cyl. stall Neutral Cyl. stall
Low RPM

High RPM

6. Time cycle
Mode
Measured (sec.)
(Max. Engine RPM)

Boom up
Boom down
Bucket crowd
Bucket dump
Steering

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