Develon HX800AL Crawler Excavator Shop Manual (950106-02940_A_EN)

Out on big earthmoving sites, quarries, or demo jobs, the Develon HX800AL is working hard in dust, mud, and plenty of abuse. This shop manual’s what you’d use when you’re past simple filters and fluid changes and you’re ready to tear deep into the machine without guessing. It helps you plan the teardown, trace faults step by step, and then reassemble everything so you don’t end up with a crooked boom, a noisy final drive, or a swing motor that won’t track straight. Picture chasing a slow, hot hydraulic circuit: you’ll isolate sections, inspect components on the bench, then align and torque things back in sequence so the system bleeds out clean and runs like it should.

Applications & Use Cases

• Plan a major teardown of the upper or lower structure so you can route hoses, harnesses, and lines cleanly and not trap anything on reassembly.
• Check and verify boom, arm, and bucket pin bores while it’s apart, then align shims and bushings so it doesn’t come back with sloppy play.
• Trace hydraulic issues by section, test components off the machine, and follow typical torque sequences when you button up valves and pumps.
• Inspect and rebuild swing or travel gearboxes, then set backlash and bearing preload in a way that usually prevents early noise or failure.
• Isolate electrical faults, then re-route and secure looms during reassembly so they don’t chafe through in a few hundred hours.

FAQ

Q: Is this a PDF I can search on my laptop or tablet?

A: Yes, it’s typically a searchable PDF, so you can jump to systems or keywords instead of flipping pages all day.

Q: Can I print just the sections I need for the jobsite?

A: You usually can; most folks print the teardown and torque pages, stick them in a sleeve, and keep the full manual clean in the office or trailer.

Safety Note

When you’re working off this manual on a big excavator, always support booms, arms, and upper structure with rated stands or blocking before you loosen anything that could drop or swing.

Develon HX800AL Crawler Excavator Index:

• Safety, Specification and Systems Operation
  • Track Excavator Maintenance Safety
    • Safety Instructions
    • Safety Messages
    • General
    • Long Term Storage
    • Maintenance
    • Environment and Circumstances
  • General Specifications
    • General
    • Standard Specification
    • Performance Tests
    • Preparation for Performance Tests
    • Operational Performance Standard Table
    • Operational Performance Test
  • Engine Specifications
    • Safety Instructions
    • Engine Specification
    • Engine Performance Curves
    • Tightening Torques
  • Hydraulic Systems and Structure Specifications
    • Safety Instructions
    • Hydraulic System
    • Swing Mechanism
    • Travel System
    • Under Carriage
    • Structure
  • General Maintenance Instructions
    • Safety Instructions
    • Welding Precautions and Instructions
    • Hydraulic System – General Precautions
    • Maintenance Service and Repair Procedure
    • Hydraulic System Cleanliness and Oil Leaks
    • Cleaning and Inspection
  • Standard Torques
    • Safety Instructions
    • Torque Values for Standard Metric Fasteners
    • Torque Values for Standard U.S. Fasteners
    • Type 8 Phosphate Coated Hardware
    • Torque Values for Hose Clamps
    • ORFS Swivel Nut Recommended Torque
    • Torque Values for Split Flanges
    • Torque Wrench Extension Tools
    • Loctite Applications
  • Engine
    • Safety Instructions
    • General Information
    • Operation Section
    • Features and Controls
    • Engine Diagnostics
    • Engine Starting
    • Engine Operation
    • Engine Stopping
    • Cold Weather Operation
    • Maintenance Recommendations
    • Fuel System
    • Intake and Exhaust System
    • Engine Control and Electrical System
    • After Treatment System
  • Systems Operation, Description and Inspection
    • Safety Instructions
    • General
    • Main Oil Circuit
    • Pilot Oil Circuit
    • Return and Drain Oil Circuit
    • Main system operation
    • Pilot System Operation
  • Components Operation, Description and Inspection
    • Safety Instructions
    • Main Pump
    • Main Control Valve
    • Swing Device
    • Fan Pump
    • Fan Motor
    • Joystick Valve
    • Travel Control Valve
    • Solenoid Valve
    • EPPR Valve (One or Two Way)
    • Center Joint
    • Travel Device
  • Systems Operation and Description
    • Safety Instructions
    • General Schematics
    • Power Supply
    • Starting System
    • Charging System
    • AVM System
    • EPOS system
    • Air Conditioner System
    • Refrigerant System Repairs
    • Troubleshooting
• Removal and Installation
  • Engine
    • Safety Instructions
    • Before Removing and Installing
    • ECU (Engine Control Unit)
    • V-Belt
    • Alternator
    • Starter Motor
    • DEF (adblue®) Heater
    • Sensors – After Treatment
    • Engine Assembly
  • Hydraulic Systems and Structure
    • Safety Instructions
    • Before Removing And Instralling
    • Main Pump
    • Drive Coupling
    • Undercovers
    • Hydraulic Oil Tank
    • Fuel Tank
    • Swing Device
    • Fan Pump
    • Oil Cooler Fan Motor
    • Joystick Valve (Work Lever)
    • Travel Control Valve
    • Center Joint
    • Travel Device
    • Main Control Valve
    • Cabin
  • Electric and Electronic
    • Safety Instructions
    • Before Removing and Installing
    • Battery Assembly
    • EPOS Controller
    • TMS Controller
    • AVM Controller
    • Microphone Controller
    • Smart Key Controller
    • Wiper Controller
    • DC-DC Controller
    • Cabin Photo Sensor
    • Cabin Switches
    • Around View Monitor
    • Display Monitor
    • Hour Meter
    • Wiper Motor
• Troubleshooting Guide
  • Wiring Harness Layout
    • Safety Instructions
    • Wiring Device
  • Error Code
    • Safety Instructions
    • EPOS Error Code
    • Engine Error Code
• Schematics
  • Hydraulic Schematic
  • Electric Schematic
  • Main Harness
  • Cabin Harness

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