DX225LCA – Testing & adjusting (Hands on) SIN2007_3

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Course Name : Testing & adjusting (Hands on)

Target

- To understand correct checking and testing process for major component

- To check present condition or specific value for preparing problem definition
- To know how to adjust and set correct value with correct process

Model : DX225LCA

Course time : 24 Hours

Pressure gauge & multi meter (1/2)
1. Pressure gauge

Low pressure gauge (0 bar ~ 60 bar) High pressure gauge (0 bar ~ 600 bar)

- Before using the pressure gauge, range of pressure on system must be checked.
- Max. value of pressure which to be measured system
- Do not use low pressure gauge (60bar) on high range pressure system (350bar) line.
- IF NOT, IT WILL BE DAMAGED
Pressure gauge & multi meter (2/2)
2. Multi meter

Resistance (Ω) DC voltage (DCV) AC voltage (ACV) Current (A)

- Before using multi meter, unit type or value on system must be checked
- Max. value and units type which to be measured on electrical system
- Do not use low range set value with multi meter on high range value
- IF NOT, IT WILL BE DAMAGED
Engine (1/14)
- Engine speed sensor (Measuring value)
1. Tools : Multi meter
2. Test Condition : Engine running condition
3. Procedure
1) Disconnect the speed sensor terminal from main harness and install the test
harness to the end terminal of speed sensor (open circuit)
2) Start the engine.
3) Connect the test leads of multi meter to the test harness and set AC Voltage
4) Measure the output AC voltage and compare the measured value with spec.
Engine (2/14)
- Engine speed sensor (Measuring value)

AC voltage

Test condition Value Remarks

Low idle engine speed

Engine (3/14)
- Engine speed sensor (Measuring / Adjusting gap)
1. Tools : Open spanner (19 mm).
2. Test Condition : Engine stop condition
3. Procedure
1) Stop the engine.
2) Loosen the lock nut of speed sensor.
3) Turn in/tighten the speed sensor till it makes touching with the tooth of flywheel ring gear.
4) Turn out/loosen the speed sensor 1/2 ~ 3/4 turn (0.75~mm1.0mm) from the contact
position of flywheel ring gear.
5) Tighten the lock nut.

0.75mm ~ 1.0mm

Lock nut
Engine (4/14)
- Engine speed sensor
- Speed sensor resistance

Resistance (Ω)

Resistance (Ω) Remark

Resistance between two terminals Out of range, failure

Resistance between on of terminal and body ( Just for reference)
Engine (5/14)
- Engine RPM (Checking throttle lever position)
1. Tools : Open spanner (19 mm).
2. Test Condition : Engine stop
3. Procedure
1) Check Max. engine RPM with Power mode while engine running.
2) Compare the value with good condition value of the machine. the value is not meet
specific value of good condition machine, try to adjust the set RPM (Power Mode
engine RPM : 1950)
3) Stop engine with key Off and “On” (No engine running), Power mode “ON”, Auto
Idle “Off” and Engine control Dial Max position.

Power mode “ON” Key SW “ON”

AUTO idle “OFF” Max. engine RPM
Engine (6/14)
- Engine RPM (Checking throttle lever position)
4) Check A point till the injection pump throttle lever contacts maximum speed stopper B.
5) If the throttle lever does not contact on maximum speed stopper B, Need to adjust
cable to contact maximum speed stopper B with cable fixing nut(19mm nut) on the
bracket C
A

Throttle lever B

C
Check the lever contacts Max.
speed stopper

Adjust cable with fixing nut

Engine (7/14)
- Engine RPM (Checking throttle lever position)
6) Turn the engine control dial to Min. position.
7) Check the throttle lever contacts the minimum speed stopper screw.
(Low engine RPM : 800)
8) If the lever does not contact the stopper, move the cable to the next hole on the lever
9) Repeat the above step 1 ~ 5 for checking with Max. and Min. RPM with engine stop
condition

Key SW “ON”
Check the lever contacts Min. speed stopper
Min. engine RPM
Engine (8/14)
- Engine RPM (Adjust setting RPM)
1. Tools : Small screw driver ( “-” type)
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature (Over 50’C HYD. Oil
and over 80’C of coolant temp)
2) Auto idle Off and Turn the dial to max engine speed position.
3) Set standard mode on monitor and check engine RPM (Standard mode engine
RPM : 1950)
4) If the engine RPM does not meet specific value, need to adjust with throttle controller

AUTO idle “OFF”

Standard mode
Max. engine RPM
Check engine RPM
Engine (9/14)
- Engine RPM (Adjust setting RPM)

5) Try to adjust “VR2” screw on throttle controller, so that the engine speed
will change.
Note) When adjusting the “VR2” or other VR’s, you need a very small flat
blade “NON CONDUCTIVE” screw driver. If touching yellow edge with
screw driver, spark will be occurred
DO NOT TOUCH ON YELLOW HOLE EDGE WITH SCREW DRIVER,
IT MAY OCCUER ELECTRICAL SPARK
Engine (10/14)
- Engine RPM (Adjust setting RPM)

6) Set ECO mode and check engine RPM (ECO mode engine RPM : 1850)

7) If the engine RPM does not meet specific value, need to adjust with throttle controller.

8) Try to adjust “VR3” screw on throttle controller, so that the engine speed will change.
Engine (11/14)
- Engine RPM (Adjust setting RPM)
9) Set Auto Idle on monitor and with for 4 sec, check engine RPM
(Auto idle engine RPM : 1100)
10) If the engine RPM does not meet specific value, need to adjust with throttle controller.
11) Try to adjust “VR1” screw on throttle controller, so that the engine speed will change.
Note) When adjusting the “VR1” or other VR’s, you need a very small flat blade “NON
CONDUCTIVE” screw driver. If touching yellow edge with screw driver, spark will
be occurred

Let’s try to adjust auto idle and standard mode speed with trainer !
Engine (12/14)
- Engine RPM (Adjust setting RPM)

Yellow
LED

Red LED Green LED

LED Output V
Input signal Status
Red Green Yellow 4(+) – 5(-)

Dial V < Potentio V

Increase rpm + 24 V
1V (High RPM) < 4V (Low RPM) (Off ) (Bright) (Light)
Dial V > Potentio V
Decrease rpm - 24 V
4V (Low RPM) > 1V (High RPM) (Bright) (Off) (Light)
Dial V = Potentio V Stop / Meet
0V
1V (High RPM) = 1V (High RPM) setting RPM (Light) (Light) (Light)

- Overloaded 0V
(Off) (Off) (Light)

- No power supply 0V
(Off) (Off) (Off)

Let’s try to adjust auto idle and standard mode speed with trainer !
Engine (13/14)
- Engine Stop
1. Tools : Open spanner (19 mm).
2. Test Condition : Engine stop
3. Procedure
1) Stop engine and Key “ON” position .
2) Check fuel cut (engine stop) lever position with releasing position (No tension of cable)

Fuel open
Engine start Fuel cut
(Release position) Engine stop
Engine (14/14)
- Engine Stop

3) Stop engine and Key “OFF” position .

4) Check fuel cut (engine stop) lever position with pulling position (Tension cable).
After 10 sec later, the lever will be released position like engine start
5) If the cable has high tension or the fuel cut (engine stop) lever does not be
pulled position, Need to adjust the cable fixing position with a fixing bolt on bracket
( It could be done before 10 sec. after key off)
Hydraulic system (1/64)
- Main pump (Measuring pump pressure)
1. Tools : Pressure gauge (High range), Adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank
3) Remove each pressure sensor from discharge hose of front and rear pump and install
adapter (coupler) with high range of pressure gauge
4) Start engine and measure front and rear pump pressure with performance testing process
Hydraulic system (2/64)
- Main pump (Measuring pump pressure)

- Remove pressure sensor both side and install test adapter

Hydraulic system (3/64)
- Main pump (Measuring pump pressure)
Measure Pump pressure
Loaded
Test condition No load
(Boom up or arm in / full stroke)
Front pump Rear pump Front pump Rear pump Pressure drop
Low RPM
None None None
(Min. Speed dial)
Auto Idle
None None None
(Power/Max. speed dial)
ECO mode
(Max. speed dial)
Standard mode
(Max. speed dial)
Power mode
(Max. speed dial)
Power mode
(Boost pressure On/ Max. speed dial)
Hydraulic system (4/64)
- Main pump (Measuring Pilot pump pressure)
1. Tools : Pressure gauge (Low range), Tee -Adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank
3) Remove discharging hose line and install Tee-adapter (with quick coupler)
4) Install low range pressure gauge
5) Start engine and measure pilot pump pressure with performance testing process

- Remove plug and install test adapter

Hydraulic system (5/64)
- Main pump (Measuring Pilot pump pressure)

Test condition Measure pilot pressure

No load condition
Low engine speed
Load (Boom up relief condition)
No load condition
Max. engine speed
Load (Boom up relief condition)

6) If the pilot pressure does not meet specific value, need to adjust the pressure
7) Loosen lock nut (24mm) and tightening or loosening the adjusting screw
(Tightening : increase pressure, Loosening : decrease pressure )
8) Repeat the above step 1 ~ 5 for checking the pressure
Hydraulic system (6/64)
- Main pump (Measuring Pilot pump pressure)

Try to reduce pilot pressure (Below 10bar) and check the pressure
and machine behavior with trainer!
Hydraulic system (7/64)
- Main pump (Nega-con pressure)
1. Tools : Pressure gauge (Low range), Tee -Adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank
3) Remove Nega con hose line on pump regulator and install Tee-adapter (with quick coupler)
4) Install low range pressure gauge
5) Start engine and measure nega-con pressure with performance testing process

Front pump regulator Rear pump regulator

Hydraulic system (8/64)
- Main pump (Nega-con pressure)

Install test adapter on front pump regulator

Install test adapter on rear pump regulator

Hydraulic system (9/64)
- Main pump (Nega-con pressure)

Nega-con pressure (bar)

Neutral condition
Front Pump Rear Pump

Low rpm

Max. rpm (STD mode)

Max. rpm (Power mode)

Nega-con pressure (bar)

Boom up condition
Front Pump Rear Pump

Cyl. Moving slowly(Half speed)

Low rpm
Cyl. Stall/Relief (Full speed)

Cyl. Moving slowly(Half speed)

Max. rpm
Cyl. Stall/Relief (Full speed)
Hydraulic system (10/64)
- Main pump (Nega-con pressure)

Nega-con pressure (bar)

Boom down condition
Front Pump Rear Pump

Cyl. Moving slowly(Half speed)

Low rpm
Cyl. Stall/Relief (Full speed)

Cyl. Moving slowly(Half speed)

Max. rpm
Cyl. Stall/Relief (Full speed)

Nega-con pressure (bar)

Arm in (Crowd) condition
Front Pump Rear Pump

Cyl. Moving slowly(Half speed)

Low rpm
Cyl. Stall/Relief (Full speed)

Cyl. Moving slowly(Half speed)

Max. rpm
Cyl. Stall/Relief (Full speed)
Hydraulic system (11/64)
- Main pump (Nega-con pressure)

Nega-con pressure (bar)

Arm out (Dump)condition
Front Pump Rear Pump

Cyl. Moving slowly(Half speed)

Low rpm
Cyl. Stall/Relief (Full speed)

Cyl. Moving slowly(Half speed)

Max. rpm
Cyl. Stall/Relief (Full speed)

Nega-con pressure (bar)

Bucket in (Crowd) condition
Front Pump Rear Pump

Cyl. Moving slowly(Half speed)

Low rpm
Cyl. Stall/Relief (Full speed)

Cyl. Moving slowly(Half speed)

Max. rpm
Cyl. Stall/Relief (Full speed)
Hydraulic system (12/64)
- Main pump (Nega-con pressure)

Nega-con pressure (bar)

Bucket out (Dump) condition
Front Pump Rear Pump

Cyl. Moving slowly(Half speed)

Low rpm
Cyl. Stall/Relief (Full speed)

Cyl. Moving slowly(Half speed)

Max. rpm
Cyl. Stall/Relief (Full speed)
Hydraulic system (13/64)
- Main pump (Nega-con pressure)
Nega-con pressure (bar)
Swing condition
Front Pump Rear Pump

Left swing slowly (Half speed)

Left swing stall (Full speed)

Low rpm
Right swing slowly (Half speed)

Right swing stall (Full speed)

Left swing slowly (Half speed)

Left swing stall (Full speed)

Max. rpm
Right swing slowly (Half speed)

Right swing stall (Full speed)

Hydraulic system (14/64)
- Main pump (Nega-con pressure)
Nega-con pressure (bar)
Traveling (Jack up LH or RH track)
Front Pump Rear Pump

LH / Forward (Low speed)

LH / Forward (High speed)

Low rpm RH / Forward (Low speed)

RH / Forward (High speed)

Traveling stall

LH / Forward (Low speed)

LH / Forward (High speed)

Max. rpm RH / Forward (Low speed)

RH / Forward (High speed)

Traveling stall
Hydraulic system (15/64)
- Main pump (Nega-con pressure)

Nega-con pressure (bar)

Breaker operation
Front Pump Rear Pump

Low flow set on monitor / Breaker ON

Low rpm

High flow set on monitor / Breaker ON

Low flow set on monitor / Breaker ON

Max. rpm

High flow set on monitor / Breaker ON

Hydraulic system (16/64)
- Main pump (EPPR 2nd Pressure / EPPR Current )
1. Tools : Pressure gauge (Low range), Adapter (M14), Quick coupler(M10) , 2 pin extend wire
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank
3) Remove pressure check plug on EPPR block and install adapter (with quick coupler)
4) Install low range pressure gauge
5) Start engine and measure EPPR 2nd Pressure and EPPR current value with performance
testing process

- Remove plug and install test adapter

Hydraulic system (17/64)
- Main pump (EPPR 2nd Pressure / EPPR Current )

Measuring EPPR 2nd Pressure

Hydraulic system (18/64)
- Main pump (EPPR 2nd Pressure / EPPR Current )

- Dis-connect cable and measuring EPPR Current value

Hydraulic system (19/64)
- Main pump (EPPR 2nd Pressure / EPPR Current )

Test condition 2nd Pressure (bar) Current (mA) Remarks

Low RPM
Cut off lever OFF (Up)
/ No load
Idling RPM
Cut off lever OFF (Up)
(Over 1,000 RPM)
Max. RPM
Cut off lever OFF (Up)
/ No load
No load
Max. RPM
Cyl. Moving slowly(Half speed) ~ ~
/ Power mode ON
Cyl. Stall/Relief (Full speed) ~ ~

No load
Max. RPM Cyl. Moving slowly(Half speed) ~ ~
/Standard mode ON
Cyl. Stall/Relief (Full speed) ~ ~

No load
Max. RPM
Cyl. Moving slowly(Half speed) ~ ~
/ ECO mode ON
Cyl. Stall/Relief (Full speed) ~ ~
Hydraulic system (20/64)
- Main pump (EPPR 2nd Pressure / EPPR Current )
Test condition Current (mA) 2nd Pressure (bar) Remarks

No load
Disconnect
Cyl. Moving slowly(Half speed) ~ ~
/ EPPR Cable/Wire
Cyl. Stall/Relief (Full speed) ~ ~

No load
Max. RPM
/ Power mode ON
Cyl. Stall/Relief (Full speed)
/ Boost/Power Up
(ON or OFF)
Cyl. Stall/Relief + Boost ON
Hydraulic system (21/64)
- Main control valve (Main relief valve)
1. Tools : Pressure gauge (High pressure range), Adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank
3) Remove pressure gauges and install adapter (with quick coupler)
4) Install high range pressure gauge on pump
5) Start engine and measure main pressure with performance testing process
(Power mode, Auto idle OFF, Max. engine RPM, Boom up or arm in relief condition and
Boost up On or Off)
Measure Pump pressure
Loaded
Test condition No load
(Boom up or arm in / relief condition)
Front pump Rear pump Front pump Rear pump
Power mode
(Max. speed dial)
Power mode
(Boost pressure On/ Max. speed
dial)
Hydraulic system (22/64)
- Main control valve (Main relief valve)
Hydraulic system (23/64)
- Main control valve (Main relief valve)
6) If the main relief pressure does not meet specific value(330/350 bar), need to
adjust the pressure with main relief valve on main control valve
7) Install Tee-adapter on boost up pilot line with low range pressure gauge and
check the pressure whether the pressure is built up or not with boost pressure
operation (Boost pressure ON or OFF)
Hydraulic system (24/64)
- Main control valve (Main relief valve)

Boost up/power up Measured pilot

Operation condition
switch condition pressure (bar)
Released Relief condition
(Normal operation) (Boom up or arm in cylinder stall)
Pressed Relief condition
(Boost up / Pressure up) (Boom up or arm in cylinder stall)

Normal operation pressure (330 bar) adjuster

Boost up/Pressure up
pilot pressure line

Boost up/Pressure up (350 bar) adjuster

Hydraulic system (25/64)
- Main control valve (Main relief valve)
Inner lock nut for 350 bar
Outer lock nut for 330bar

Boost up/ Power up

pilot pressure line
#1 (330 bar)
#2 (350 bar)

1) Loosen adapter of pilot line connected with valve body of #1 (Do not loose it to much, oil may leak)
2) Loosen the outer lock nut (330 bar) and turn it anti-clockwise till it is fully seated on #1
3) Loosen the inner lock nut and start engine, make machine with test condition (Boom up/ arm in relief
condition with Boost up/Pressure up)
4) Check the boot up (Pressure up) pressure and adjust the pressure with #2 adjuster for 350 bar
5) Set 350 bar with boost up/pressure up and tighten the inner lock nut .
6) Check the normal pressure and adjust the pressure with #1 adjuster for 330 bar without boost
up/pressure up
7) Set 330 bar without boost up/pressure up and tighten the outer lock nut .
8) Recheck if both pressures are correct and if necessary, make final adjustment.
9) Tighten adapter of pilot line with valve body of #1
Hydraulic system (26/64)
- Main control valve (Main relief valve)

Pilot hose adapter Lock nut for 330 bar pressure Lock nut for 350 bar pressure

Set/adjust 350 bar with boost up Set/adjust 330 bar without boost up
Hydraulic system (27/64)
- Main control valve (PA / PT pilot pressure)
1. Tools : Pressure gauge (Low pressure range), Tee -Adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank
3) Remove PA/PT pilot hose on main control valve and install adapter (with quick coupler)
4) Install low range pressure gauge on pilot line
5) Start engine and measure PA/PT pressure as test condition on next page
(Power mode, Auto idle OFF, Max. engine RPM, Boom up or arm in relief condition
and Boost up On or Off)

PT PT

PA PA
Hydraulic system (28/64)
- Main control valve (PA / PT pilot pressure)

PA/PT pressure switch on main control valve

Hydraulic system (29/64)
- Main control valve (PA / PT pilot pressure)

PA pressure switch on swing motor

PT pressure switch on main control valve

Hydraulic system (30/64)
- Main control valve (PA / PT pilot pressure)
- Check PA pilot pressure

Remove PA pressure switch and install test adapter

Hydraulic system (31/64)
- Main control valve (PA / PT pilot pressure)
- Check PT pilot pressure

Remove PT pressure switch and install test adapter

Hydraulic system (32/64)
- Main control valve (PA / PT pilot pressure)

Test condition PA (bar) PT (bar)

Neutral

Boom up

Boom down

Arm in

Front attachment Arm out

Bucket in

Bucket out

Swing (Left)

Swing (Right)

Traveling (left side)

Traveling
Traveling (right side)

Front attachment + Traveling

Hydraulic system (33/64)
- Main control valve (Joystick pilot pressure)
1. Tools : Pressure gauge (Low pressure range), Tee -Adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank
3) Remove a pilot hose with boom up or arm in on main control valve and install adapter
(with quick coupler)
4) Install low range pressure gauge on pilot line with adapter
5) Start engine and measure pilot pressure with boom up and arm in operation
(Power mode, Auto idle OFF, Max. engine RPM, Boom up or arm in relief condition
and Boost up On or Off)
Hydraulic system (34/64)
- Main control valve (Joystick pilot pressure)

Remove pilot hose and Install test adapter on boom up or arm in position

Test condition Pilot pressure

Neutral
Boom up (Half stroke)
Front attachment Arm in (Half stroke)
Boom up (Full stroke)
Arm in (Full stroke)
Hydraulic system (35/64)
- Main control valve (Boom up priority valve pilot pressure)
1. Tools : Pressure gauge (Low pressure range), Tee -Adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank.
3) Remove pilot hose from boom priority valve on main control valve and install adapter
(with quick coupler)
4) Install low range pressure gauge on the pilot line with adapter
5) Start engine and measure pilot pressure with front and traveling operation
(Power mode, Auto idle OFF, Max. engine RPM)

Boom priority valve (LH) Boom priority valve (RH)

Hydraulic system (36/64)
- Main control valve (Boom up priority valve pilot pressure)

Boom priority valve (RH/LH)

Hydraulic system (37/64)
- Main control valve (Boom up priority valve pilot pressure)

Install test adapter on boom priority valve (LH)

Install test adapter on boom priority valve (RH)

Hydraulic system (38/64)
- Main control valve (Boom up priority valve pilot pressure)

BP valve
Test condition
Pilot pressure (bar)

Neutral

Boom up

Boom down

Arm in

Front attachment Arm out

Bucket in

Bucket out

Swing (Left)

Swing (Right)

Traveling (left side)

Traveling
Traveling (right side)
Hydraulic system (39/64)
- Main control valve (Boom / arm holding valve pilot pressure)
1. Tools : Pressure gauge (Low pressure range), Tee -Adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank.
3) Remove pilot hose from boom, arm holding valve on main control valve and install adapter
(with quick coupler)
4) Install low range pressure gauge on the pilot line with adapter
5) Start engine and measure pilot pressure with front and traveling operation
(Power mode, Auto idle OFF, Max. engine RPM)

Arm holding valve Boom holding valve

Hydraulic system (40/64)
- Main control valve (Boom / arm holding valve pilot pressure)

Boom holding valve

Arm holding valve

Hydraulic system (41/64)
- Main control valve (Boom / arm holding valve pilot pressure)

Install test adapter on boom holding valve

Install test adapter on arm holding valve

Hydraulic system (42/64)
- Main control valve (Boom / arm holding valve pilot pressure)

Holding valve
Test condition
Pilot pressure (bar)

Neutral

Boom up

Boom down

Arm in

Front attachment Arm out

Bucket in

Bucket out

Swing (Left)

Swing (Right)

Traveling (left side)

Traveling
Traveling (right side)
Hydraulic system (43/64)
- Swing device (Swing pressure)
1. Tools : Pressure gauge (High pressure range), Adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank.
3) Remove measuring plug on the top of swing motor and install adapter with quick coupler
4) Install high range pressure gauge with adapter
5) Start engine and measure swing pressure with performance testing process
(Power mode, Auto idle OFF, Max. engine RPM, swing left or right and Boost up On or Off)
Hydraulic system (44/64)
- Swing device (Swing pressure)
- Adjusting swing pressure
1) Fix upper structure with bucket in the ground for checking swing pressure
2) Loosen lock nut and turn adjusting screw for setting the specific pressure (270
bar) with right or left swing
3) Check the set pressure and tighten lock nut.

Loosen lock nut and adjust swing pressure

Hydraulic system (45/64)
- Swing device (Swing pressure)

Test condition Port A (bar) Port B (bar)

Neutral

Swing/Left Start slowly (Half stroke)

Swing/Left Stop slowly

Swing/Right Start slowly (Half stroke)

Swing/Right Stop slowly

Swing/Left Start quickly (Full stroke)

Swing/Left Stop quickly

Swing/Right Start quickly (Full stroke)

Swing/Right Stop quickly

Swing stall (Left or Right) Start quickly (Full stroke)

Swing stall (Left or Right) Stop quickly

Hydraulic system (46/64)
- Swing device (PG / SH pilot pressure)
1. Pressure gauge (High pressure range), Tee- adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank.
3) Remove PG/SH pilot hose on brake valve of swing motor and install tee-adapter with
quick coupler
4) Install low range pressure gauge with installed adapter
5) Start engine and measure PG/SH pressure on swing motor with performance testing process
(Power mode, Auto idle OFF, Max. engine RPM, Front/ Traveling operation with Boost up On
or Off)
Hydraulic system (47/64)
- Swing device (PG / SH pilot pressure)

PG pressure SH pressure
Hydraulic system (48/64)
- Swing device (PG / SH pilot pressure)
Test condition PG (bar) SH (bar)

Neutral

Boom up

Boom down

Arm in

Front attachment Arm out

Bucket in

Bucket out

Swing (Left)

Swing (Right)

Traveling (left side)

Traveling
Traveling (right side)
Hydraulic system (49/64)
- Travel device (Traveling pressure)
1. Tools : Pressure gauge (High pressure range), Adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank.
3) Remove measuring plug on travel motor and install adapter with quick coupler
4) Install high range pressure gauge with installed adapter on travel motor
5) Start engine and measure traveling pressure on travel motor with performance testing
process (Power mode, Auto idle OFF, Max. engine RPM, Traveling operation with high
and low traveling speed)
Hydraulic system (50/64)
- Travel device (Traveling pressure)
Low speed High speed
Test condition
A port (bar) B port (bar) A port (bar) B port (bar)

Neutral

Start slowly (Half stroke)

Jack up traveling
Traveling fully (Full stroke)
(Left)
Stop quickly

Stall and traveling

Neutral

Start slowly (Half stroke)

Jack up traveling
Traveling fully (Full stroke)
(Right)
Stop quickly

Stall and traveling

Hydraulic system (51/64)
- Travel device (Pilot pressure for high / low speed)
1. Tools : Pressure gauge (High pressure range), Tee-adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running and traveling condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank.
3) Remove high/low speed pilot hose on travel motor and Tee install adapter with quick
coupler
4) Install low range pressure gauge with installed adapter on travel motor
5) Start engine and measure high/low speed pilot pressure on travel motor with performance
testing process (Power mode, Auto idle OFF, Max. engine RPM, Traveling operation with
high and low traveling speed)
Hydraulic system (52/64)
- Travel device (Pilot pressure for high / low speed)

Pilot pressure of High/low traveling speed

Test conditions
Low speed ON High speed ON Auto speed ON
(0 position) (I position) (II position)

Neutral

Below1400
Engine speed
Over1400

PT pressure switch e
On
nergized

Below 300bar
Main pump pressure
Over 300bar

Over 1400 engine RPM

+ PT energized
+Over 300 bar pump pressure
Hydraulic system (53/64)
- Pilot solenoid valve (Pilot cut off & accumulator)
1. Tools : Pressure gauge (Low pressure range), Tee-Adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running and stop / key on condition
3. Procedure
1) Remove pilot cut off hose on solenoid valve and install Tee adapter with quick coupler
2) Install low range pressure gauge with installed adapter on solenoid valve.
3) Measure cut off pressure as test condition without engine starting
4) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
5) Stop/start engine and measure cut off pressure with pilot cut off lever operation
6) Check /measuring the cut off pressure for accumulator performance with cut off lever
operation (Stop engine, key on and make cut off lever on or off)
Hydraulic system (54/64)
- Pilot solenoid valve (Pilot cut off & accumulator)

Pilot cut off line for checking pilot cut off function (Install test adapter)
Hydraulic system (55/64)
- Pilot solenoid valve (Pilot cut off & accumulator)

Pilot Cut off Switch "ON" Pilot Cut off Switch "OFF"
(Down position) (Up position)
Test condition
Pressure ( bar) Pressure ( bar)

Engine stop
(Before Itnitial starting)

Engine stop, Key on

(Before Itnitial starting)

Min. RPM

Max. RPM

Engine stop, Key ON

(After starting)

Engine stop, Key ON, Move joystick lever

(After starting)
Hydraulic system (56/64)
- Pilot solenoid valve (Boost up / Pressure up)
1. Tools : Pressure gauge (Low pressure range), Tee-Adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running and stop / key on condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank.
3) Remove Boost up/power up hose on solenoid valve and install Tee adapter with quick
coupler
4) Install low range pressure gauge with installed adapter on solenoid valve
5) Start engine and measure boost up/power up pressure with switch operation of boost
up/power up
6) Check /measuring the boost up/power up pressure
(Power mode, Auto idle OFF, Min.,Max. engine RPM, Boost up/Power up switch On or Off)
Hydraulic system (57/64)
- Pilot solenoid valve (Boost up / Pressure up)

Boost up/power up line for checking pilot pressure (Install test adapter)

Boost up/Power up "ON" Boost up/Power up "OFF"

Test condition
Pressure (bar) Pressure (bar)
Min. RPM
Max. RPM
Hydraulic system (58/64)
- Pilot solenoid valve (Travel high speed)
1. Tools : Pressure gauge (Low pressure range), Tee-adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running and traveling condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank.
3) Remove travel high speed pilot hose on solenoid valve and install Tee adapter with quick
coupler
4) Install low range pressure gauge with installed adapter on travel motor
5) Start engine and measure high speed pilot pressure on solenoid as test condition
(Power mode, Auto idle OFF, Min.,Max. engine RPM, High/auto speed on or off )
Hydraulic system (59/64)
- Pilot solenoid valve (Travel high speed)

Low speed ON High speed ON Auto speed ON

Test condition
Pressure (bar) Pressure (bar) Pressure (bar)

Min. RPM

Max. RPM
Hydraulic system (60/64)
- Pilot solenoid valve (Breaker)
1. Tools : Pressure gauge (Low pressure range), Tee-adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running and breaker operating condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank
3) Remove breaker pilot hose on solenoid valve and install Tee adapter with quick coupler
4) Install low range pressure gauge with installed adapter on solenoid valve
5) Start engine and measure pilot pressure of breaker operation with performance testing
process (Power mode, Auto idle OFF, Min., Max. engine RPM, Breaker Switch ON)
Hydraulic system (61/64)
- Pilot solenoid valve (Breaker)

Select Shear or boost/power up Select Breaker

Test condition Breaker OFF Breaker ON Breaker OFF Breaker ON
Pressure (bar) Pressure (bar) Pressure (bar) Pressure (bar)
Min. RPM

Max. RPM
Hydraulic system (62/64)
- Return line (Return / makeup pressure)
1. Tools : Pressure gauge (Low pressure range), Tee-adapter (M14), Quick coupler(M10)
2. Test Condition : Engine running and traveling condition
3. Procedure
1) Start engine and make machine normal working temperature with 20 Min. full operation
(Over 50’C HYD. Oil and over 80’C of coolant temperature)
2) Stop engine and breathing compressed air from inside of tank.
3) Remove measuring plug on return pipe and install adapter with quick coupler
4) Install low range pressure gauge with installed adapter on return pipe
5) Start engine and measure return pressure with performance testing process
(Power mode, Auto idle OFF, Max. engine RPM, Front operation)

Measuring plug

By pass valve
1.0 (bar)

By pass
valve 2.5
(bar)
Hydraulic system (63/64)
- Return line (Return / makeup pressure)
Hydraulic system (64/64)
- Return line (Return / makeup pressure)

Test condition Return pressure (bar) Remarks

Min. RPM
Idling
Max. RPM

Start

Swing While moving

Stopping

Start

Arm in While moving

Stall

Start

Arm out While moving Engine load

Stall
Electrical system (1/38)
- Battery voltage
1. Tools : Multi tester
2. Test Condition : Key on and off , (Initial) starting, pre heating
3. Procedure
1) Install multi tester on battery + and – terminal and select voltage range with multi tester for
measuring the voltage
2) Measuring the voltage with test condition on next page
Electrical system (2/38)
- Battery voltage

Test condition Volatage Remarks

Key OFF

Key ON

Pre heating
Check pre heater warning light
on monitor panel
Before19 sec. counting

Pre heating
Check pre heater warning light
on monitor panel
After 19 sec. counting

Cranking Check voltage drop value

After staring

Coolant Temp above 10'C

After staring

Coolant Temp below 0'C

Electrical system (3/38)
- Starter switch
1. Tools : Multi tester
2. Test Condition : Key on and off, starting, pre heating
3. Procedure
1) Install multi tester + lead line on start switch terminal and – lead line with ground and
select voltage range with multi tester for measuring the voltage
2) Measuring the voltage with test condition on next page
Electrical system (4/38)
- Starter switch

Voltage

Test condition
#B terminal #BR terminal #R1 terminal #R2 terminal #C terminal #ACC terminal
voltage voltage voltage voltage voltage voltage
(with ground) (with ground) (with ground) (with ground) (with ground) (with ground)

Key OFF

Preheat
Connect batte
ry master SW
and install fusi
ble link
Key ON

Start /
Engine
running
Electrical system (5/38)
- Fuse box
1. Tools : Multi tester
2. Test Condition : Key off, Key on, Starting and normal operating condition
3. Procedure
1) Install + lead line on fuse box terminal and – lead line with ground and measuring the
voltage with testing process
2) Check which number of fuse could be appeared with the specific voltage
Electrical system (6/38)
- Fuse box
Electrical system (7/38)
- Fuse box
Fuse Box 1 Fuse Box 2
Test condition
Voltage Fuse No. Voltage Fuse No.

Key OFF

Key ON

After staring
Engine running
Electrical system (8/38)
- Starter
1. Tools : Multi tester
2. Test Condition : Key off, Key on, Starting and normal operating condition
3. Procedure
1) Install + lead line with starter terminal and – lead line with ground for measuring the
voltage with testing process
2) Check the specific voltage on starter terminal
Electrical system (9/38)
- Starter
Starter

Test condition #B terminal #C terminal #E terminal

voltage voltage voltage
(with ground) (with ground) (with ground)

Key OFF

Key ON

Cranking

After staring

Hold key SW with cranking or

Restarting after engine running
Electrical system (10/38)
- Alternator
1. Tools : Multi tester
2. Test Condition : Key off, Key on, Starting and normal operating condition
3. Procedure
1) Install + lead line with alternator terminals and – lead line with ground for measuring the
voltage with testing process
2) Check the specific voltage on alternator terminal
Electrical system (11/38)
- Alternator
Electrical system (12/38)
- Alternator

Alternator

Test condition
#P(R) terminal #B(B+) terminal #R(I) terminal #E terminal
voltage voltage voltage voltage
(with ground) (with ground) (with ground) (with ground)

Key OFF

Key ON

Min. engine RPM

After staring
/ engine running

Max. engine RPM

Electrical system (13/38)
- Battery relay
1. Tools : Multi tester
2. Test Condition : Key off, preheating, Key on, Starting and normal operating condition
3. Procedure
1) Install + lead line with battery terminals and – lead line with ground for measuring the
voltage with testing process
2) Check the specific voltage on battery terminal
Electrical system (14/38)
- Battery relay
Battery relay

Test condition #A terminal #B terminal #BR terminal #E terminal

voltage voltage voltage voltage
(with ground) (with ground) (with ground) (with ground)

Preheating

Key OFF

Key ON

Cranking
/ Starting

After staring
/ engine running
Electrical system (15/38)
- Preheat relay
1. Tools : Multi tester
2. Test Condition : Key off, preheating, Key on, Starting and normal operating condition
3. Procedure
1) Install + lead line with preheat relay terminals and – lead line with ground for measuring
the voltage with testing process
2) Check the specific voltage on preheat relay terminal
Electrical system (16/38)
- Preheat relay
Preheat relay

Test condition #B terminal #C terminal #D terminal #H terminal

voltage voltage voltage voltage
(with ground) (with ground) (with ground) (with ground)

Preheating

Key OFF

Key ON

Cranking / Starting

After running
Electrical system (17/38)
- Starter controller
1. Tools : Multi tester
2. Test Condition : Key off, preheating, Key on, Starting and normal operating condition
3. Procedure
1) Install + lead line with starter controller terminals and – lead line with ground for
measuring the voltage with testing process
2) Check the specific voltage on starter controller terminal

Terminal N is for Wheel excavator or wheel loader for checking traveling neutral
Electrical system (18/38)
- Starter controller
Starter controller

Test condition #S terminal #P terminal #B terminal #E terminal

voltage voltage voltage voltage
(with ground) (with ground) (with ground) (with ground)

Preheating

Key OFF

Key ON

Cranking / Starting

Hold key
With starting position
after engine running
Electrical system (19/38)
- Throttle controller
1. Tools : Multi tester
2. Test Condition : Key off, Key on, Starting and normal operating condition with work
mode set
3. Procedure
1) Install + lead line with throttle controller terminals and – lead line with ground for
measuring the voltage with testing process
2) Check the specific voltage on throttle controller terminal
Electrical system (20/38)
- Throttle controller
Throttle controller

Test condition #10 terminal #14 terminal #15 terminal #16 terminal #17 terminal
voltage voltage voltage voltage voltage
(with ground) (with ground) (with ground) (with ground) (with ground)

Power mode

Standard mode

ECO mode
Key ON
/ Engine
running Auto idle OFF

Auto idle ON

Make overheating
condition with DMS
Electrical system (21/38)
- Throttle controller
1. Tools : Multi tester
2. Test Condition : Key off, Key on, Starting and normal operating condition with
increase or decrease engine RPM
3. Procedure
1) Install + lead line with throttle controller terminals and – lead line with ground for
measuring the voltage with testing process
2) Check the specific voltage on throttle controller terminal
Electrical system (22/38)
- Throttle controller
Throttle controller
Test condition #1 terminal #2 terminal #3 terminal #9 terminal
voltage voltage voltage voltage
(with ground) (with ground) (with ground) (with ground)

Min. engine RPM

Increase engine RPM

(Step by step)

Key ON Max. engine RPM

/ Engine
running
Decrease engine RPM
(Step by step)

Auto idle OFF

(with Max RPM)

Auto idle ON
(with Max RPM)
Electrical system (23/38)
- Throttle controller
1. Tools : Multi tester
2. Test Condition : Key off, Key on, Starting and normal operating condition , set auto
idle with increase or decrease engine RPM
3. Procedure
1) Install + lead line with throttle controller terminals and – lead line with ground for
measuring the voltage with testing process
2) Check the specific voltage on throttle controller terminal
Electrical system (24/38)
- Throttle controller
Throttle controller
Test condition
(Key ON / Engine running ) #4 terminal #5 terminal #6 terminal #7 terminal #8 terminal
voltage voltage voltage voltage voltage
(with ground) (with ground) (with ground) (with ground) (with ground)
Min. engine RPM

Increase engine RPM

(Step by step)
Auto idle OFF
Max. engine RPM

Decrease engine RPM

(Step by step)

Min. engine RPM

Increase engine RPM

(Step by step)
Auto idle ON
Max. engine RPM

Decrease engine RPM

(Step by step)
Electrical system (25/38)
- Engine throttle control motor
Electrical system (26/38)
- Engine throttle control motor
Engine throttle control motor
Test condition
#P4 terminal #P5 terminal #P1 terminal #P2 terminal #P3 terminal
(Key ON / Engine running )
voltage voltage voltage voltage voltage
(with ground) (with ground) (with ground) (with ground) (with ground)
Min. engine RPM

Increase engine RPM

(Step by step)
Auto idle OFF
Max. engine RPM

Decrease engine RPM

(Step by step)

Min. engine RPM

Increase engine RPM

(Step by step)
Auto idle ON
Max. engine RPM

Decrease engine RPM

(Step by step)
Electrical system (27/38)
- Engine throttle control dial
1. Tools : Multi tester
2. Test Condition : Key off, Key on, Starting and normal operating condition , set auto
idle with increase or decrease engine RPM
3. Procedure
1) Install + lead line with engine throttle control dial terminals and – lead line with ground for
measuring the voltage with testing process
2) Check the specific voltage on engine throttle control terminal
Electrical system (28/38)
- Engine throttle control dial

Engine throttle control dial

Test condition #1 terminal #2 terminal #3 terminal

voltage voltage voltage
(with ground) (with ground) (with ground)

Min. engine RPM

Increase engine RPM

(Step by step)
Key on

Max. engine RPM

Decrease engine RPM

(Step by step)
Electrical system (29/38)
- Engine stop motor
1. Tools : Multi tester
2. Test Condition : Key off, Key on, Starting and normal operating condition and stop
engine
3. Procedure
1) Install + lead line with engine stop motor terminals and – lead line with ground for
measuring the voltage with testing process
2) Check the specific voltage on engine stop motor terminal
Electrical system (30/38)
- Engine stop motor
Engine stop motor

Test condition #P1 terminal #P2 terminal #A terminal #B terminal #E terminal

voltage voltage voltage voltage voltage
(with ground) (with ground) (with ground) (with ground) (with ground)

Key OFF

Key ON

Starting /
Engine running

Engine stop

Engine stop
after 10 sec. later
Electrical system (31/38)
- Engine time delay
1. Tools : multi tester
2. Test Condition : Key off, Key on, Starting and normal operating condition and stop
engine
3. Procedure
1) Install + lead line with engine time delay terminals and – lead line with ground for
measuring the voltage with testing process
2) Check the specific voltage on engine time delay terminal
Electrical system (32/38)
- Engine time delay

Engine time delay

Test condition #1 terminal #2 terminal #3 terminal #4 terminal

voltage voltage voltage voltage
(with ground) (with ground) (with ground) (with ground)

Key OFF

Key ON

Starting
Engine running

Engine stop

Engine stop after 10 sec. later

Electrical system (33/38)
- Solenoid valve
1. Tools : multi tester
2. Test Condition : Key off, Key on, Starting and normal operating condition
3. Procedure
1) Install + lead line with magnetic coil of solenoid valve terminals and – lead line with ground
for measuring the voltage with testing process
2) Check the specific voltage or resistance on magnetic coil of solenoid valve terminal
Electrical system (34/38)
- Solenoid valve

Magnetic coil of solenoid valve

Test condition
Voltage
Resistance
(with ground)

Cut off SW OFF

Cut off SW ON -

Breaker SW OFF

Breaker SW ON -
Key ON
Engine running
High speed SW OFF

High speed SW ON -

Boost up/power up SW OFF

Boost up/power up SW ON -
Electrical system (35/38)
- WIF sensor
1. Tools : multi tester, Test harness
2. Test Condition : Key off, Key on, Starting and normal operating condition
3. Procedure
1) Install + lead line with magnetic coil of solenoid valve terminals and – lead line with
ground for measuring the voltage with testing process
2) Check the specific voltage or resistance on magnetic coil of solenoid valve terminal
Electrical system (36/38)
- WIF sensor
WIF sensor

Test condition #1 terminal #2 terminal #3 terminal

voltage voltage voltage
(with ground) (with ground) (with ground)

Key OFF

Key ON

Key on and sunk WIF sensor

in water
Electrical system (37/38)
- Auxiliary mode resistor
1. Tools : multi tester
2. Test condition : Key off
3. Procedure
1) Dis connect a connector, Install + lead line on one terminal of auxiliary resister and
– lead line with the other terminal of auxiliary resister auxiliary resister
2) Check the specific resistance value on auxiliary resister
Electrical system (38/38)
- Auxiliary mode resistor

Test condition Auxiliary mode resistance (Ohm)

Key Off
(Dis-connect the connector)
COURSE SUMMARY – DX225LCA, Testing & adjusting (Hands on)

Thank you for your attention

• In this course, you have

☞ Gotten major components specific value and feature for

securing problem definition skill

☞ Made better machine performance and condition

Continue to ‘Course survey’ & ‘Quiz’ to complete the course.