Testing and Adjusting

DL Wheel Loader

Feb, 2009
Overseas Product Support Team
Text No. TAA0004
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.

1
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 250 bar

2
1. Main pressure

- Main pressure adjustment

200 bar Main pump

Control valve

250 bar

DL200/250/300 DL400/500

3
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.
9
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

10
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

12
4. Steering LS pressure

- Steering LS pressure adjustment

LS relief valve (185bar)

LS relief valve (190bar)

EHPS valve Flow amplifier valve

DL300 DL400/500

13
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

15
5. Brake charging pressure

- Pressure adjustment

C1 cartridge valve (120 bar)

Brake, pilot, & fan supply valve

16
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

17
6. Pilot pressure

- Adjustment pressure

C2 cartridge valve (28 bar)

Brake, pilot, & fan supply valve

18
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.

19
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

20
8. Brake pressure

- Adjusting brake pressure

Brake pressure
adjustment screw

21
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

22
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)

23
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.

24
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)

25
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

26
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

28