jcb ENGLISH Fault Finding COMPLETE.pdf

HOW TO USE THIS DOCUMENT

1 Click on the Fault Index button. This will take you to an index of possible faults.

2 Click on the fault conditions you want to investigate. This will take you to a pagecontaining a list of Test Procedures relevant to the fault condition you have selected.

3 Click on the 1st Test Procedure. This will take you to the page containing the TestProcedure you have selected. Select 'File - Print'.

4 ENSURE THAT CURRENT PAGE IS SELECTED BEFORE YOU CLICK ON THEOK BUTTON. (If you dont do this you will print out the whole document.)

When the Print Window closes, click the Returnbutton. This will take you back to thelist of Test Procedures.

Note: If you have scrolled down the page you may have to press the return a fewtimes before you get back to the Index.

5 Repeat steps 3 and 4 for all the other Test Procedures.

Test Procedure Masters

This document contains all the Test Procedures, complete with theirExpected Readings. Clicking on the entry in the Test Procedure Indexwill take you to the relevant procedure. Print it out, return to the Indexand repeat as required.

WARNING

The procedures described in this publication must be used in conjunctionwith the relevant machine Service Manual and Operator Handbook.

Observe all relevant Safety Information contained in those documents.

PLEASE CLICK IN THE BOX BELOW TO SIGNIF Y THAT YOUHAVE READ AND UNDERSTAND THE ABOVE WARNING.

JCB HEAV Y PRODUCTS LIMITED

FAULT FINDING SYSTEM

FAULT FINDING INDEXISSUE

Fault 500 Boom up operation is slow or low powered XO130 / 160 / 180 2Fault 501 Arm operation is slow or low powered XO130 / 160 / 180 2Fault 502 Bucket operation is slow or low powered XO130 / 160 / 180 2Fault 503 Swing operation is slow or low powered XO130 / 160 / 180 1Fault 504 Boom down operation is harsh when selected XO130 / 160 / 180 2Fault 505 Swing operation is harsh when selected XO130 / 160 / 180 1Fault 506 Machine performance is unsatisfactory XO130 / 160 / 180 1

Fault 525 Boom up operation is slow or low powered XO130W / 160W 2Fault 526 Arm operation is slow or low powered XO130W / 160W 2Fault 527 Bucket operation is slow or low powered XO130W / 160W 2Fault 528 Swing operation is slow or low powered XO130W / 160W 2Fault 529 Boom down operation is harsh when selected XO130W / 160W 2Fault 530 Swing operation is harsh when selected XO130W / 160W 2Fault 531 Machine performance is unsatisfactory XO130W / 160W 1

Fault 550 Boom up operation is slow or low powered XO200 / 220 / 240 / 260 2Fault 551 Arm operation is slow or low powered XO200 / 220 / 240 / 260 2Fault 552 Bucket operation is slow or low powered XO200 / 220 / 240 / 260 2Fault 553 Swing operation is slow or low powered XO200 / 220 / 240 / 260 1Fault 554 Boom down operation is harsh when selected XO200 / 220 / 240 / 260 2Fault 555 Swing operation is harsh when selected XO200 / 220 / 240 / 260 1Fault 556 Machine performance is unsatisfactory XO200 / 220 / 240 / 260 1Fault 557 Poor Performance XO200W 3Fault 558 Poor Swing Effort XO200W 3

Fault 600 Boom up operation is slow or low powered XO330 / 450 2Fault 601 Arm operation is slow or low powered XO330 / 450 2Fault 602 Bucket operation is slow or low powered XO330 / 450 2Fault 603 Swing operation is slow or low powered XO330 / 450 1Fault 604 Boom down operation is harsh when selected XO330 / 450 2Fault 605 Swing operation is harsh when selected XO330 / 450 1Fault 606 Machine performance is unsatisfactory XO330 / 450 1

Fault 650 Machine tracks off line during straight tracking XO130 / 160 2Fault 651 Machine tracks off line during straight tracking XO200 / 220 / 240 / 260 2Fault 652 Machine tracks off line during straight tracking XO330 / 450 2Fault 653 Poor tractive effort XO130 / 160 / 180 2Fault 654 Poor tractive effort XO200 / 220 / 240 / 260 2Fault 655 Poor tractive effort XO330 / 450 2Fault 656 Loss of high speed tracking XO130 / 160 / 180 2Fault 657 Loss of high speed tracking XO200 / 220 / 240 / 260 1Fault 658 Loss of high speed tracking XO330 / 450 1Fault 659 Loss of creep speed tracking XO130 / 160 / 180 2Fault 660 Loss of creep speed tracking XO200 / 220 / 240 / 260 1Fault 661 Loss of creep speed tracking XO330 / 450 1Fault 662 Machine selects high gear even though monitor displays

another travel gear ( all tracked models ) 1

Fault 700 Wheeled machine poor top road speed XO130w / 160W 1Fault 701 Loss of high speed ( wheeled machine ) XO130W / 160W / XO200W 3Fault 702 Loss of creep speed ( wheeled machine ) XO130W / 160W / XO200W 3Fault 703 Poor tractive effort ( wheeled machine ) XO130W/ 160W / XO200W 3Fault 704 Loss of drive ( wheeled machine ) XO130W / 160W 1Fault 705 Harsh counterbalance on releasing drive pedal XO130W / 160W 1Fault 706 Poor Steering and Braking Performance XO200W 3

Fault 800 Excessive engine stall when stalling hydraulic service ( all models ) 2

Fault 900 Electrical problem and 0000 is displayed on monitor ( all models ) 2

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Fault Finding Index

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Section 1 Section 1

FF 500

Section 1 Fault Finding Index

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FF 500

Issue 2

Boom Up Operation Is Slow Or Low Powered XO130 / 160 / 180

If experiencing slow or underpowered boom up operation carry out following checks:

Test 001 Testing negative control signal Test 010 Testing max flow cut signalTest 021 Testing main pump pressuresTest 026 Testing horse power controlTest 054 Testing operation of main hydraulic spool ( for boom spool )Test 055 Testing operation of boom 2 / bucket 2 spoolTest 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times

Expected test time to complete all above tests 2.5 hrs

FF 501


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FF 501

Issue 2

Arm Service Operation Is Slow Or Low Powered XO130 / 160 / 180

If experiencing slow or underpowered arm service operation carry out following checks:

Test 001 Testing negative control signal Test 010 Testing max flow cut signalTest 021 Testing main pump pressuresTest 026 Testing horse power controlTest 054 Testing operation of main hydraulic spool (for arm main spool)Test 056 Testing operation of arm 2 boost spoolTest 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times

Additional information

If the arm cylinder has hose burst check valve fitted then also carry out :Test 041 Testing operation of arm HBCV


FF502


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Issue 2

Bucket Service Operation Is Slow Or Low Powered XO130 / 160 / 180

If experiencing slow or underpowered bucket service operation carry out following checks:

Test 001 Testing negative control signal Test 010 Testing max flow cut signalTest 021 Testing main pump pressuresTest 026 Testing horse power controlTest 054 Testing operation of main hydraulic spool (for bucket main spool)Test 055 Testing operation of boom 2 / bucket 2 boost spoolTest 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


FF 503

Swing Service Operation Is Slow Or Low Powered XO130 / 160 / 180

If experiencing slow or underpowered swing service operation carry out following checks:

Test 001 Testing negative control signal Test 010 Testing max flow cut signalTest 021 Testing main pump pressuresTest 053 Testing operation of swing brakeTest 054 Testing operation of main hydraulic spool (for swing main spool)Test 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


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Issue 1


FF504


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Issue 2

Boom Down Operation Is Harsh When Selected XO130 / 160 / 180

If experiencing harsh operation when selecting boom down carry out following checks:

Test 001 Testing negative control signal Test 100 Testing operation of pressure switches


Pay particular attention to negative control pressure when selecting boom down.

Expected test time to complete all above tests 1 hrs

FF 505


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FF 505

Issue 1

Swing Operation Operation Is Harsh When Selected XO130 / 160 / 180

If experiencing harsh operation when selecting swing service carry out following checks:

Test 053 Testing operation of swing brakeTest 100 Testing operation of pressure switches

Additional Information

Does the swing perform smother if boom down is selected at the same time as swing? If it does check to make sure thatconnections to the pressure switches on shuttle block are fitted to correct switch.


FF 506

Machine Performance is Unsatisfactory XO130 / 160 / 180

If experiencing poor machine performance carry out following checks:

Test 001 Testing negative control signal Test 010 Testing max flow cut signalTest 021 Testing main pump pressuresTest 026 Testing horse power controlTest 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


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Issue 1


Boom Up Operation Is Slow Or Low Powered XO130W / 160W


Test 002 Testing negative control signal Test 011 Testing max flow cut signalTest 022 Testing main pump pressuresTest 027 Testing horsepower controlTest 054 Testing operation of main hydraulic spool (for boom spool)Test 055 Testing operation of boom 2 / bucket 2 boost spoolTest 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times

FF 525


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Issue 2

Arm Service Operation Is Slow Or Low Powered XO130W / 160W


Test 002 Testing negative control signal Test 011 Testing max flow cut signalTest 022 Testing main pump pressuresTest 027 Testing horsepower controlTest 054 Testing operation of main hydraulic spool (for arm spool)Test 056 Testing operation of arm 2 boost spoolTest 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


If the machine has arm cylinder hose burst check valve fitted then also carry out :Test 041 Testing operation of arm HBCV


FF 527


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FF 527

Issue 2

Bucket Service Operation Is Slow Or Low Powered XO130W / 160W


Test 002 Testing negative control signal Test 011 Testing max flow cut signalTest 022 Testing main pump pressuresTest 027 Testing horsepower controlTest 054 Testing operation of main hydraulic spool (for bucket spool)Test 055 Testing operation of boom 2 / bucket 2 boost spoolTest 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


FF 528


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Swing Service Operation Is Slow Or Low Powered XO130W / 160W


Test 002 Testing negative control signal Test 011 Testing max flow cut signalTest 022 Testing main pump pressuresTest 053 Testing operation of swing brakeTest 054 Testing operation of main hydraulic spool (for swing spool)Test 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


FF 529


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Issue 2

Boom Down Operation Is Harsh When Selected XO130W / 160W






FF 530


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FF 530

Issue 1

Swing Operation Operation Is Harsh When Selected XO130W / 160W




Does the swing perform smother if boom down is selected at the same time as swing? If it does check to make sure thatconnections to the pressure switches on shuttle block are fitted to correct switch.


FF 531

Machine Performance is Unsatisfactory XO130W / 160W

If experiencing poor machine performance carry out following tests:

Test 002 Testing negative control signal Test 011 Testing max flow cut signalTest 022 Testing main pump pressuresTest 027 Testing horsepower controlTest 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


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Issue 1


FF 550


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Issue 2

Boom Up Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260


Test 003 Testing negative control signal Test 012 Testing max flow cut signalTest 023 Testing main pump pressuresTest 028 Testing horsepower controlTest 054 Testing operation of main hydraulic spool (for boom spool)Test 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


FF 551


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FF 551

Issue 2

Arm Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260


Test 003 Testing negative control signal Test 012 Testing max flow cut signalTest 023 Testing main pump pressuresTest 028 Testing horsepower controlTest 054 Testing operation of main hydraulic spool (for arm spool)Test 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


If arm cylinder has HBCV fitted then also carry out :Test 041 Testing operation of arm HBCV


FF 552


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FF 552

Issue 2

Bucket Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260


Test 003 Testing negative control signal Test 012 Testing max flow cut signalTest 023 Testing main pump pressuresTest 028 Testing horsepower controlTest 054 Testing operation of main hydraulic spool (for bucket spool)Test 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


FF553


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FF 553

Issue 1

Swing Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260




FF 554


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FF 554

Issue 2

Boom Down Operation Is Harsh When Selected XO200 / 220 / 240 / 260






FF 555


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FF 555

Issue 1

Swing Operation Operation Is Harsh When Selected XO200 / 220 / 240 / 260




Does the swing perform smoother if boom down is selected at the same time as swing? If it does check to make sure thatconnections to the pressure switches on shuttle block are fitted to correct switch.


FF 556

Machine Performance is Unsatisfactory XO200 / 220 / 240 / 260




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Issue 1


FF 557

Machine Performance is Unsatisfactory XO200W


Test 005 Testing load sense pressureTest 014 Testing P shift Test 015 Testing servo pressureTest 031 Testing pump milliampsTest 025 Testing main pump pressures Test 200 Testing engine speed settings


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FF 558

Poor Swing Effort XO200WTest 053 Testing operation of swing brake Test 057 Testing swing relief pressureTest 058 Testing swing/boom - priorityTest 054 Testing operation of main hydraulic spool (for swing spool)Test 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


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FF 600


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Issue 2

Boom Up Operation Is Slow Or Low Powered XO330 / 450


Test 004 Testing negative control signal Test 013 Testing max flow cut signalTest 024 Testing main pump pressuresTest 029 Testing horsepower controlTest 054 Testing operation of main hydraulic spool (for boom spool)Test 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


FF 601


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Issue 2

Arm Service Operation Is Slow Or Low Powered XO330 / 450


Test 004 Testing negative control signal Test 013 Testing max flow cut signalTest 024 Testing main pump pressuresTest 029 Testing horsepower controlTest 054 Testing operation of main hydraulic spool (for arm spool)Test 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


If arm cylinder has HBCV fitted then also carry out :Test 041 Testing operation of arm HBCV


FF 602


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Issue 2

Bucket Service Operation Is Slow Or Low Powered XO330 / 450


Test 004 Testing negative control signal Test 013 Testing max flow cut signalTest 024 Testing main pump pressuresTest 029 Testing horsepower controlTest 054 Testing operation of main hydraulic spool (for bucket spool)Test 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times


FF 603


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FF 603

Issue 1

Swing Service Operation Is Slow Or Low Powered XO330 / 450




The XO330 and 450 models have an additional feature of boom priority. This feature is used for truck loading to give the boomup service priority over the swing service, before carrying out any fault finding on swing circuit ensure that this function hasbeen deactivated. This function is turned on and off by rocker switch on left hand console which has picture of boom on it.


FF 604


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Issue 2

Boom Down Operation Is Harsh When Selected XO330 / 450






FF 605


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FF 605

Issue 1

Swing Operation Operation Is Harsh When Selected XO330 / 450




Does the swing perform smother if boom down or boom up is selected at the same time as swing? If it does check to makesure that connections to the pressure switches on shuttle block are fitted to correct switch.


FF 606

Machine Performance is Unsatisfactory XO330 / 450




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Issue 1


FF 650


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Issue 2

Machine Tracks Off Line During Straight Travel XO130 / 160

If experiencing machine tracking off line, carry out following checks:

Test 001 Testing negative control signalTest 021 Testing main pump pressuresTest 050 Testing track motor relief valve settingsTest 051 Testing track motor drain line ratesTest 052 Testing track motor speeds


Measure the amount of deviation over a 20 metre distance and record ground conditions.

If machine is fitted with priority valve in pump line (this valve usually feeds low flow / weedcutter circuit) try connecting the twomain service hoses together that are connected to the valve does this change the fault?

Swap the two main hoses on the hydraulic pump, does the problem change direction?


FF 651


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FF 651

Issue 2

Machine Tracks Off Line During Straight Travel XO200 / 220 / 240 / 260






Swap the two main hoses on the hydraulic pump, does the problem change direction?


FF 652


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Issue 2

Machine Tracks Off Line During Straight Travel XO330 / 450






Swap the two main hoses on the hydraulic pump , does the problem change direction?


FF 653


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FF 653

Issue 2

Poor Tractive Effort XO130 / 160 / 180

If experiencing poor tractive effort, carry out following checks:

Test 001 Testing negative control signalTest 021 Testing main pump pressuresTest 050 Testing track motor relief valve settingsTest 051 Testing track motor drain line rates


What travel gear is the machine operating in when the problem occurs?

See also Fault 662.


FF 654


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Issue 2

Poor Tractive Effort XO200 / 220 / 240 / 260





See also Fault 662.


FF 655


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FF 655

Issue 2

Poor Tractive Effort XO330 / 450





See also Fault 662.


FF 656


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FF 656

Issue 2

Loss of High Speed Tracking XO130 / 160 / 180

If experiencing loss of high speed tracking, carry out following checks:

Test 052 Testing track motor speedsTest 100 Testing pressure switches


When high speed tracking is selected is hare symbol displayed on monitor? yes / no

When high speed tracking has been selected what pressure is seen at pilot port to select high gear on track motor (seeillustration below)

When high speed tracking has been selected is electrical voltage seen at high speed tracking solenoid? yes / no ?


A318900

Pilot port to select high gear

A326403

High speed trackingsolenoid

Front view of 8spool valve

FF 657


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Issue 1

Loss of High Speed Tracking XO200 / 220 / 240 / 260





When high speed tracking has been selected what pressure is seen at pilot port to select high gear on track motor (seeillustration below).



A318900


A326403



Loss of High Speed Tracking XO330 / 450





When high speed tracking has been selected what pressure is seen at pilot port to select high gear on track motor (seeillustration below).


FF 658


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A318900


A326403



FF 659


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Issue 2

Loss of Creep Speed Tracking XO130 / 160 / 180

If experiencing loss of creep speed tracking, carry out following checks:

Test 010 Testing max flow cut signalTest 052 Testing track motor speedsTest 100 Testing pressure switches


When creep speed tracking is selected is tortoise symbol displayed on monitor? yes / no


FF 660


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Issue 1

Loss of Creep Speed Tracking XO200 / 220 / 240 / 260






FF 661


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FF 661

Issue 1

Loss of Creep Speed Tracking XO330 / 450






FF 662


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FF 662

Issue 1

Machine Selects High Gear Even Though Monitor Displays Another Travel Gear

If machine selects high tracking gear by itself even though the operator has not selected high gear and the monitor displayhas not changed carry out following checks :

What pressure is seen at pilot port X ( see below ) when :

1 middle tracking gear is selected?2 middle tracking gear is selected and tracking service is stalled , forwards and backwards on both left and right hand

tracks?3 high tracking gear is selected?

What electrical voltage is seen at high speed tracking solenoid when :1 middle tracking gear is selected?2 high tracking gear is selected?


A318900

Pilot port X

A326403



FF 700


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FF 700

Issue 1

Poor Top Road Speed XO130W / 160W

If experiencing poor top road speed, carry out following checks:

Test 011 Testing max flow cut / drive control signalTest 022 Testing main pump pressuresTest 060 Testing threshold pressureTest 061 Testing drive motor minimum displacement settingTest 062 Testing machine propshaft speedsTest 100 Testing pressure switchesTest 200 Testing engine speeds


FF 701


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FF 701

Issue 1

Loss of High Speed Travel XO130W/ 160W / XO200W

If experiencing loss of high speed travel (i.e. when changing from middle to high gear no increase of speed is achieved), carryout following checks:

Test 062 Testing propshaft speedsTest 063 Testing clutch pack pressure / park brake pressureTest 100 Testing pressure switches


The controller will not energise any solenoids if it thinks that the engine is not running , check to make sure that the controlleris receiving a signal from the engine speed sensor.(Check for reading on monitor rpm counter 0003 means that no signal is being received by the controller.)

Does the display on the monitor change from arrow to hare when selecting footswitch for gear change?


FF 702


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Issue 3

Loss of Creep Speed Travel XO130W / 160W / XO200W

If experiencing loss of creep speed travel (i.e. when changing from middle to creep gear no decrease of speed is achieved),carry out following checks:

Test 062 Testing propshaft speedsTest 063 Testing clutch pack pressure / park brake pressureTest 100 Testing pressure switches


The controller will not energise any solenoids if it thinks that the engine is not running , check to make sure that the controlleris receiving a signal from the engine speed sensor.(Check for reading on monitor rpm counter 0003 means that no signal is being received by the controller.)

Does the display on the monitor change from arrow to tortoise when selecting button on right hand side sub monitor?

Remember the machine will only change from middle gear to creep speed and is activated by button on right hand side submonitor and not by footswitch.


FF 703


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Issue 3

Poor Tractive Effort XO130W / 160W / XO200W


Test 011 Testing max flow cut / drive control signalTest 022 Testing main pump pressuresTest 060 Testing threshold pressureTest 061 Testing drive motor minimum displacement settingTest 062 Testing machine propshaft speedsTest 066 Checking theshold pressure - XO200W only,Test 100 Testing pressure switchesTest 200 Testing engine speeds


Loss of Drive XO130W / 160W

If experiencing loss of drive carry out following checks:

Test 063 Testing clutch pack pressure / park brake pressure


When the electrical connector is removed from drive safety switch (on transmission control valve, see below) and a piece ofwire used to bridge the contacts is drive restored?

When parkbrake solenoid is overridden is drive restored? To do this push and then twist the override button this will releasethe park brake solenoid (as below).

FF 704


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Issue 1


Park brake overide button

Link wire

View of transmission control valve

Harness connector

FF 705

Harsh Counterbalance on Releasing Drive Pedal XO130W / 160W

If experiencing harsh counterbalance braking when releasing drive pedal carry out following tests:

Test 060 Testing drive motor threshold pressure setting


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FF 705

Issue 1


FF 706

Poor Steering and Braking Performance XO200W

If experiencing Poor Steering and Braking Performance carry out following tests:

Test 032 Checking steering pressureTest 033 Checking latch brake pressure


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FF 800


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Issue 2

Excessive Engine Stalling When Operating Hydraulic Service All Models

When the machines engine speed reduces excessively when using a hydraulic service it is caused by one of two reasons:

1 Torque demanded by hydraulic pump is higher than available torque from engine, this is caused by incorrect regulation ofhydraulic pump either due to pump regulator sticking or incorrectly adjusted.

This can be confirmed by following test:

Test 030 Flow testing of hydraulic pump

2 Torque available from engine is lower than specification, this can be caused by:- fuel system fault- faulty injectors- faulty fuel injection pump

This can be confirmed by having component tested at recognised fuel equipment specialist

Test 200 Testing engine speeds


Expected test time to complete all above tests 1 hr

FF 900

Electrical Problem and 0000 is Displayed On Monitor

If experiencing electrical problem and 0000 is displayed on monitor carry out following checks:

Test 101 Testing throttle motor unit


Does the fault occur as soon as ignition is switched on ?

Has the throttle cable been replaced or adjusted prior to the fault happening ?

Pay close attention to the condition of throttle motor harness condition in pump bay, look for areas where harness has chaffedthrough.


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Issue 2


WARNING

The procedures described in this publication must be used in conjunctionwith the relevant machine Service Manual and Operator Handbook.

Observe all relevant Safety Information contained in those documents.

PLEASE CLICK IN THE BOX BELOW TO SIGNIF Y THAT YOUHAVE READ AND UNDERSTAND THE ABOVE WARNING.

JCB HEAV Y PRODUCTS LIMITED

FAULT FINDING SYSTEM

ISSUETest 001 Testing negative control signal, XO130 / XO160 / XO180 2Test 002 Testing negative control signal, XO130/ XO160W 2Test 003 Testing negative control signal, XO200 / XO220 / XO240 / XO260 2Test 004 Testing negative control signal, XO330 / XO450 2Test 005 Testing load sense pressures, XO200W 3

Test 010 Testing max flow cut signal, XO130 / XO160 / XO180 2Test 011 Testing max flow cut signal / drive control signal, XO130W / XO160W 2Test 012 Testing max flow cut signal, XO200 / XO220 / XO240 / XO260 2Test 013 Testing max flow cut signal, XO330 / XO450 2Test 014 Testing P shift, XO200W 3Test 015 Testing servo pressure, XO200W 3

Test 020 Testing main pump pressures , XO70 1Test 021 Testing main pump pressures, XO130 / XO160 / XO180 1Test 022 Testing main pump pressures, XO130W / XO160W 1Test 023 Testing main pump pressures, XO200 / XO220 / XO240 / XO260 1Test 024 Testing main pump pressures, XO330 / XO450 1Test 025 Testing main pump pressures, XO200W 3Test 026 Testing horsepower control, XO130 / XO160 / XO180 1Test 027 Testing horsepower control, XO130W / XO160W 1Test 028 Testing horsepower control, XO200 / XO220 / XO240 / XO260 1Test 029 Testing horsepower control, XO330 / XO450 1

Test 030 Flow testing pump, all models 2Test 031 Testing pump milliamps 3Test 032 Testing steering pressure 3Test 033 Testing latch brake pressure 3Test 034 Flow testing pump, XO200W 3Test 039 Testing for trapped air in HBCV pilot line, all models 1

Test 040 Testing H.B.C.Vs , XO130 boom ram, XO130W boom ram 1Test 041 Testing H.B.C.Vs , XO130 arm ram, XO160 arm ram, XO200 arm ram, XO240 arm ram,

XO240 arm ram, XO330 arm ram 1Test 042 Testing H.B.C.Vs, XO160 boom ram, XO160W boom ram, XO180 boom ram 1Test 043 Testing H.B.C.Vs , XO200 boom ram, XO200W boom ram, XO240 boom ram, XO330 boom ram 3Test 044 Testing H.B.C.Vs , XO220 T.A.B ram, XO200W T.A.B ram 3Test 045 Testing H.B.C.Vs , XO130W T.A.B ram, XO160W T.A.B ram 1

Test 050 Testing track motor relief valve settings, all models 1Test 051 Testing track motor drain line flow , all models 1Test 052 Testing track motor speeds, all models 1Test 053 Testing operation of swing brake , all models 1Test 054 Checking operation of main hydraulic spool, all models 1Test 055 Checking operation of boom 2 / bucket 2 boost spool, XO130, XO130W , XO160, XO160W 1Test 056 Checking operation of arm2 / boost spool, XO130, XO130W , XO160, XO160W 2Test 057 Testing Swing Relief Pressure, XO200W 3Test 058 Testing Swing/Boom - Priority, XO200W 3

Test 060 Testing drive motor threshold pressure, XO130W , XO160W 2Test 061 Testing drive motor minimum displacement setting , XO130W , XO160W 1Test 062 Testing wheeled machine propshaft speeds XO 130W , XO160W , XO200W 3Test 063 Testing clutch pack pressure / park brake pressure, XO130W , XO160W , XO200W 3Test 064 Testing condition of off road clutch, XO130W , XO160W / XO200W 1Test 065 Testing condition of on road clutch, XO130W, XO160W / XO200W 1Test 066 Testing Threshold Pressure, XO200W 3Test 067 Testing Drive Circuit, XO200W 3

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TEST PROCEDURE INDEX

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Test Procedures

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TEST PROCEDURE INDEX

Section 2 Section 2

ISSUETest 099 Testing pressure switchs- all AMS models 3Test 100 Testing pressure switchs 2Test 101 Testing throttle motor unit 1Test 102 Testing throttle motor driver unit 1Test 103 Testing monitor unit 1Test 104 Testing installation of engine speed sensor 1Test 105 AMS Throttle Fault Finding- All AMS machines 3

Test 200 Testing engine speed settings, all models except XO70 3Test 201 Testing engine speed settings, all AMS models except XO70 3

Test 300 Testing machine cycle times, all models 2Test 301 Testing machine cycle times, all AMS models 2Test 350 Checking slew bearing backlash, all models 1Test 351 Checking slew bearing vertical lift, all models 1

(Test 001 -099 hydraulic) (Test100 - 199 electrical) (Test 200 - 299 engine) (Test 300 - 349 general)(Test 350 -400 mechanical)

Section 2 Section 2

O Fit test gauges ( 0 - 60 bar ) into hose connections to ports P11 + P21 with tee piece adapterO Warm up machine hydraulic temperature to 50 C

A302850

TP 001

Testing Negative Control Signal - XO 130/XO 160/XO 180

Test Procedure

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TP 001

Issue 2

Port P11 Port P21

With max engine rpms and no services selected record negative control pressure (25 - 35 bar *) (25 - 35 bar*)

Select and stall boom up service record pressure (0 - 3 bar) (0 - 3 bar)

Fully select boom down record pressure when service first selected (25 - 35 bar)

Select and stall bucket open service record pressure (0 bar) (12 - 16 bar)

Select and stall bucket close service record pressure (0 bar) (12 - 16 bar)

Select and stall dipper open service record pressure (0 - 3 bar) (0 - 3 bar)

Select and stall arm close service record pressure (0 - 3 bar) (0 - 3 bar)

Select and stall swing left service record pressure (25 - 35 bar) (0 - 3 bar)

Select and stall swing right service record pressure (25 - 35 bar) (0 - 3 bar)

Select and stall left hand track forward record pressure (0 - 3 bar) (25 - 35 bar)

Select and stall left hand track backwards record pressure (0 - 3 bar) (25 - 35 bar)

Select and stall right hand track forwards record pressure (25 - 35 bar) (0 - 3 bar)

Select and stall right hand track backwards record pressure (25 - 35 bar) (0 - 3 bar)

* This pressure will vary with oil temperature and engine speed.

(Expected Pressures)

(40 bar when firstselected for 0.5 sec

then 0 bar)

P11P21

G1

G2

REAR VEIW OF HYDRAULICPUMP

Section 2 Section 2

TP 002

Test Procedure

9803/6500

TP 002

Issue 2

Testing Negative Control Signal - XO 130W/XO 160W

O Fit test gauges ( 0 - 60 bar ) into hose connections to ports P11 + P21 with tee piece adapterO Warm up machine hydraulic temperature to 50 C

Port P11 Port P21

With max engine rpms and no services selected record negative control pressure (25 - 35 bar*) (25 - 35 bar *)



Select and stall bucket open service record pressure (0 - 3 bar) (12 - 16 bar)

Select and stall bucket close service record pressure (0 - 3 bar) (12 - 16 bar)





Select and stall drive service forward record pressure (0 - 3 bar) (0 - 3 bar)

Select and stall drive service backwards record pressure (0 - 3 bar) (0 - 3 bar)


then 0 bar)



A302850

P11P21

G1

G2

REAR VEIW OF HYDRAULICPUMP

Section 2 Section 2

TP 003

Test Procedure

9803/6500

TP 003

Issue 2

A318950

Testing Negative Control Signal - XO 200/XO 220/XO 240/XO 260

O Fit test gauges ( 0 - 60 bar ) into hose connections to ports Pt1 + Pt2 with tee piece adapter

O Warm up machine hydraulic temperature to 50 C

Port pt1 Port pt2

With max engine rpms and no services selected record negative control pressure (30 - 35 bar*) (30 - 35 bar*)



Select and stall bucket open service record pressure (24 - 26 bar) (0 bar)

Select and stall bucket close service record pressure (24 - 26 bar) (0 bar)





Select and stall left hand track forward record pressure (30 - 35 bar) (0 - 3 bar)

Select and stall left hand track backwards record pressure (30 - 35 bar) (0 - 3 bar)

Select and stall right hand track forwards record pressure (0 - 3 bar) (30 - 35 bar)

Select and stall right hand track backwards record pressure (0 - 3 bar) (30 - 35 bar)



then 0 bar)


VIEW FROM REAR OFHYDRAULIC PUMP

Port Pt1

Port Pt2

TP 004

9803/6500

TP 004

Issue 3

Test ProcedureSection2 Section 2

A436100

Testing Negative Control Signal - XO 330/XO 450

O Fit test gauges ( 0 - 60 bar ) into hose connections to ports PZ1 + PZ1 with tee piece adapter


Port PZ1/Pi1 Port PZ2/Pi2

With max engine rpms and no services selected record negative control pressure (25 - 35 bar*) (25 - 35 bar*)


Fully select boom down record pressure when service first selected (25 - 35 bar*)

Select and stall bucket open service record pressure (16 - 20 bar) (0 - 3 bar)

Select and stall bucket close service record pressure (16 - 20 bar) (0 - 3 bar)



Select and stall swing left service record pressure (0 bar) (25 - 35 bar)

Select and stall swing right service record pressure (0 bar) (25 - 35 bar)

Select and stall left hand track forward record pressure (0 bar) (25 - 35 bar)

Select and stall left hand track backwards record pressure (0 bar) (25 - 35 bar)

Select and stall right hand track forwards record pressure (25 - 35 bar) (0 bar)

Select and stall right hand track backwards record pressure (25 - 35 bar) (0 bar)



then 0 - 3 bar)


PZ2PZ1

A436080Tier 2 Machines

Pi1 Pi2

TP 005

9803/6500

TP 005

Issue 3

Test Procedure

Testing Load Sense Cut Off Pressure XO200W

To check the Load Sense cut off pressure carry out the following:

O Warm up hydraulic system to 50C

O Connect a pressure gauge (0~400 bar) at the Load Sense port of the pump A or at B if test point is fitted.

O Generate MAX standard Load Sense pressure by stalling out the bucket service and recording the pressureon the gauge.

O Select Power boost and again stall out the bucket service, and record the pressure reading.

O If the pressures are incorrect then adjust as required.

Section2 Section 2

ExpectedPressures

Max pressure NO power boost 290 barMax pressure Power boost selected 320 bar

Adjusting the Load Sense Cut Off Valve

O Remove the pilot hose and cap off hose but leavethe valve open to atmosphere.

O Hold C and slacken off lock nut B.

O Screw in A clockwise as far as it will go, then lock off B.

O Hold E and slacken off lock nut D

O Operate and stall the dipper (max RPM) and byscrewing C adjust the pressure (recorded on the LSpressure gauge) to 320bar. Now lock nut D

O Hold C and slacken lock nut B.

O Again stall the dipper service and set the pressure to290bar by screwing out A.

O Re-tighten lock nut B.

O Re-fit the pilot hose.

A EDCB

B

A

A437080

Section2 Section 2

9803/6500 Issue 3

Test Procedure

TP 010 TP 010

JS11200

Test Max Flow Signal - XO 130/XO 160/XO 180

O Fit test gauges ( 0 - 60 bar ) into hose connections to ports P12 + P22 or Ports Pm1 to Pm2 with tee piece adapter


Port P12 Port P22

With max engine rpms and no services selected record max flow cut control pressure (0 - 1.5 bar) (0 - 1.5 bar)

Select F mode and record pressure (40 bar) (40 bar)

Select standard mode, select low speed tracking (tortoise on monitor)then select track service record pressure (40 bar) (40 bar)


P12

P22

A31895JS 130 from 890083JS160 from 703390JS180 from 27.05.01

Port Pm1 Port Pm2





Pm2

Pm1

Section2 Section 2

9803/6500 Issue 3

Test ProcedureTP 011 TP 011

Test Max Flow Cut Signal/Drive Control Signal - XO 130W/XO 160W

Fit test gauges ( 0 - 60 bar ) into hose connections to ports P12 + P22 or Ports Pm1 to Pm2 with tee piece adapter

Warm up machine hydraulic temperature to 50 C

Port P12/Pm1 Port P22/Pm2



Remove connector from drive pressure switch ( under cab floor ) connect terminals of harness connector together with a short length of wire

Port P12/Pm1 Port P22/Pm2

Select high speed gear ( hare on monitor ) record pressure (40 bar) (28 bar)

Select high speed gear and also select dozer mode( by switch on left hand controller ) but do not operate dozer, record presure (0 - 1.5 bar) (0 - 1.5 bar)

Select medium speed gear ( arrow on monitor ) record pressure (40 bar) (28 bar)

Select medium speed gear and also select dozer mode ( by switch on left hand controller ) but do not operate dozer, record pressure (0 - 1.5 bar) (0 - 1.5 bar)

Select creep speed gear ( tortoise on monitor ) record pressure (0 - 1.5 bar) (40 bar)

Select creep speed and also select dozer mode record pressure (0 - 1.5 bar) (40 bar)



JS11200

P12

P22

A31895

Pm2

Pm1

JS 130 from 890083JS160 from 703390 JS180 from 27.05.01

Section 2 Section 2

TP 012

Test Procedure

9803/6500

TP 012

Issue 2

A318950

Test Max Flow Signal - XO 200/XO 220/XO 240/XO 260

O Fit test gauges ( 0 - 60 bar ) into hose connections to ports Pm1 + Pm2 with tee piece adapter


Port Pm1 Port Pm2





Port Pm2

Port Pm1

VIEW FROM REAR OFHYDRAULIC PUMP

TP 013

9803/6500

TP 013

Issue 3


A436110

Test Max Flow Signal - XO 330/XO 450

Fit test gauge ( 0 - 60 bar ) to port SC or port Pm1/Pm2 with tee piece adapter

Warm up machine hydraulic temperature to 50 C

Port SC/ Pm1 /Pm2

With max engine rpms and no services selected record pressure (0 - 1.5 bar)

Select F mode and record pressure (40 bar)

Select standard mode, select low speed tracking (tortoise on monitor) then select track service record pressure (40 bar)


Port SC

A436080

Port Pm1 Port Pm2

Tier 2 Machines

TP014

9803/6500

TP014

Issue 3

Test Procedure

Testing P Shift XO200W

Section2 Section 2

A437080

O Fit test gauge ( 0 - 60 bar ) to A with tee piece adapter


A

TP015

9803/6500

TP015

Issue 3

Test Procedure

Testing Servo Pressure XO200W

Section2 Section 2

1 2 3A436040

O Fit test gauges ( 0 - 600 bar ) into test point 1


O Pressures to be tested at maximum engine speed

Expected Pressures

No Services 35 bar

Any service selected 35 bar

To adjust servo pressure:

O Remove blank plug A.

O Use an Allen key into B and adjust as required: Screw into increase pressure / out to de-crease pressure.

O Re-fit cap A

A436200

BA

Section 2 Section 2

TP 020

Test Procedure

9803/6500

TP 020

Issue 1

A297090

Testing Main Pump Pressure XO 70

O Fit test gauges ( 0 - 60 bar ) into hose connections to ports G1 + G2


Port G1 Port G2

With max engine rpms and no services selected record pump pressure (12 - 20 bar*) (12 - 20 bar*)

Select and stall boom up service record pressure (284 bar) (284 bar)

Select and stall bucket open service record pressure (12 - 20 bar*) (284 bar)

Select and stall bucket close service record pressure (12 - 20 bar*) (284 bar)

Select and stall dipper open service record pressure (284 bar) (284 bar)

Select and stall dipper close service record pressure (284 bar) (284 bar)

Select and stall swing left service record pressure (206 bar) (12 - 20 bar*)

Select and stall swing right service record pressure (206 bar) (12 - 20 bar*)

Select and stall left hand track service forwards record pressure (284 bar) (12 - 20 bar*)

Select and stall left hand track service backwards record pressure (284 bar) (12 - 20 bar*)

Select and stall right hand track service forwards record pressure (12 - 20 bar*) (284 bar)

Select and stall right hand track service backwards record pressure (12 - 20 bar*) (284 bar)

* This pressure will depend on engine speed and oil temperature.


G1 Main, Dipper, SwingG2 Main, Boom, Bucket

G1

G2

TP 021

9803/6500

TP 021

Issue 3


Testing Main Pump Pressure XO 130/XO 160/XO 180

O Fit test gauges ( 0 - 600 bar ) into hose connections to ports G1 + G2O Warm up machine hydraulic temperature to 50 C

Port G1 Port G2







Select and stall swing left service record pressure (25 - 35 bar) (310 bar)

Select and stall swing right service record pressure (25 - 35 bar) (310 bar)

Select and stall left hand track service forwards record pressure (345 bar) (25 - 35 bar)

Select and stall left hand track service backwards record pressure (345 bar) (25 - 35 bar)

Select and stall right hand track service forwards record pressure (25 - 35 bar) (345 bar)

Select and stall right hand track service backwards record pressure (25 - 35 bar) (345 bar)

Select F mode and then select stall boom up service record pressure (345 bar) (345 bar)

* This pressure will depend on oil temperature and engine speed.


G1

G2

REAR VIEW OFHYDRAULIC PUMP

403610

A302850

G1

G2

JS 130 from 890083JS160 from 703390JS180 from 27.05.01

Section 2 Section 2

TP 022

Test Procedure

9803/6500

TP 022

Issue 1

A302840

Testing Main Pump Pressure XO 130W/XO 160W



Port G1 Port G2







Select and stall swing left service record pressure (25 - 35 bar) (310 bar)

Select and stall swing right service record pressure (25 - 35 bar) (310 bar)

Select and stall drive service forwards record pressure (345 bar) (345 bar)

Select and stall drive service backwards record pressure (345 bar) (345 bar)

Select F mode and then select and stall boom up service record pressure (345 bar) (345 bar)



VIEW OFHYDRAULIC PUMP

G1

G2

Section 2 Section 2

TP 023

Test Procedure

9803/6500

TP 023

Issue 1

Testing Main Pump Pressure XO 200/XO 220/XO 240/XO 260



Port G1 Port G2









Select and stall left hand track service forwards record pressure (25 - 35 bar) (343 bar)

Select and stall left hand track service backwards record pressure (25 - 35 bar) (343 bar)

Select and stall right hand track service forwards record pressure (343 bar) (25 - 35 bar)

Select and stall right hand track service backwards record pressure (343 bar) (25 - 35 bar)




FRONT VIEW OFHYDRAULIC PUMP

Port G1(nearest engine)

Port G2

TP 024

9803/6500

TP 024

Issue 3


A436110

A436080Tier 2 Machines

Testing Main Pressure Excavator Services XO 330/XO 450

O Fit test gauges ( 0 - 600 bar ) into hose connections to ports MA1 + MA2 or ports a1 + a2 for Tier 2 machines


Port MA1/a1 Port MA2/a2









Select and stall left hand track service forwards record pressure (318 bar) (25 - 35 bar)

Select and stall left hand track service backwards record pressure (318 bar) (25 - 35 bar)

Select and stall right hand track service forwards record pressure (25 - 34 bar) (318 bar)

Select and stall right hand track service backwards record pressure (25 - 35 bar) (318 bar)



a1 a2

MA1MA2

TP025

9803/6500

TP025

Issue 3

Test Procedure

Testing Main Pump Pressure XO200W

Note: Operating power boost, (two stage relief) will increase the Main releif valve pressure to 343 bar.

Section2 Section 2

Test Point 3

With max engine rpms and no services selected record pump pressure (40bar*)

Select and stall boom up service record pressure (314 bar)

Select and stall bucket open service record pressure (314 bar)

Select and stall bucket close service record pressure (314 bar)

Select and stall dipper open service record pressure (314 bar)

Select and stall dipper close service record pressure (314 bar)

Select and stall swing left service record pressure (use swing lock bar) (240 bar)

Select and stall swing right service record pressure (use swing lock bar) (279 bar)

Apply brakes and select drive forwards record pressure (343 bar)

Apply brakes and select drive backwards record pressure (343 bar)

Select and stall dozer uo record pressure (250 bar)

Select and stall dozer down record pressure (250 bar)

Select and stall stabilisers up record pressure (250 bar)

Select and stall stabilisers down record pressure (250 bar)

Select and stall TAB out record pressure (314 bar)

Select and stall TAB in record pressure (280 bar)


O Fit test gauges ( 0 - 600 bar ) into test point 3


1 2 3A436040


TP 026

9803/6500

TP 026

Issue 3


A326230

O Fit gauge ( 0 - 60 bar ) into proportional solenoidsecondary pressure measurement port using suitable

adapter (port thread is 1/4 BSP O ring fitting).

O Separate proportional solenoid electrical connector.Using service connector from electrical test kit WDB0055connect fluke meter in series as shown right.

OR

O Using link wire, connect fluke meter in series as shown.

O Warm up machine hydraulic temperature to 50 C.

VIEW FROMUNDERSIDE OFHYDRAULIC PUMP

Proportional solenoidsecondary pressuremeasurement port

+ -

+ -

Pump sideharness

Link wire

Brown/Black (BrB) Brown/Black (BrB)

A407830

Tier 2Machines

Testing Horsepower Control XO130 / XO160 / XO180

XO 130 XO 160 X0 180

Horsepower Milliamps Horsepower Milliamps Horsepower MilliampsControl control controlsecondary secondary secondarypressure pressure pressure

With maximum engine rpms and noservices operated. Select H mode 11.5 bar 355 ma 12 bar 370 ma 12 bar 370 mameasure and record milliamps and +/- 10% +/- 10% +/- 10%secondary pressure.

With maximum engine rpms anddipper service selected and stalled. 11.5 bar 355 ma 12 bar 370 ma 12 bar 370 maSelect H mode measure and record +/- 10% +/- 10% +/- 10%milliamps and secondary pressure.

With maximum engine rpms and no 7.5 bar 250 ma* 8 bar 265 ma 8 bar 265 maservices operated. Select S mode +/- 10%* +/- 10%* +/- 10%*measure and record milliamps and 625 bar 220 ma*secondary pressure. +/- 10%*

With maximum engine rpms and noservices operated. Select L mode 0 bar 0 ma 0 bar 0 ma 0 bar 0 mameasure and record milliamps andsecondary pressure.

* Early XO 130 machines use 250 ma in S mode, later XO 130 machines use 220 ma

A326230

TP 027

9803/6500

TP 027

Issue 1


Testing Horsepower Control XO 130w/XO 160w

Fit gauge ( 0 - 60 bar ) into proportional solenoidsecondary pressure measurement port using suitable


Separate proportional solenoid electrical connector.Using service connector from electrical test kit WDB0055connect fluke meter in series as shown right.

OR

Using link wire, connect fluke meter in series as shown.

Warm up machine hydraulic temperature to 50 C.

VIEW FROMUNDERSIDE OFHYDRAULIC PUMP

Proportional solenoid secondarypressure measurement port

XO 130w XO 160w

Horsepower Milliamps Horsepower MilliampsControl controlsecondary secondarypressure pressure

With maximum engine rpms and noservices operated. Select H mode 11.5 bar 355 ma 12 bar 370 mameasure and record milliamps and +/- 10% +/- 10%secondary pressure.

With maximum engine rpms anddipper service selected and stalled. 11.5 bar 355 ma 12 bar 370 maSelect H mode measure and record +/- 10% +/- 10%milliamps and secondary pressure.

With maximum engine rpms and noservices operated. Select S mode 7.5 bar 250 ma 8 bar 265 mameasure and record milliamps and +/- 10% +/- 10%secondary pressure.

With maximum engine rpms and noservices operated. Select L mode 0 bar 0 ma 0 bar 0 mameasure and record milliamps andsecondary pressure.

Tier 2Machines

+ -

+ -

Pump sideharness

Link wire


A407830

Section2 Section 2

9803/6500 Issue 3

Test ProcedureTP 028 TP 028

A326240

Testing Horsepower Control XO200 / XO220 / XO240 /XO 260

O Fit gauge ( 0 - 60 bar ) into proportional solenoidsecondary pressure measurement port using suitable



OR



VIEW FROM UNDERSIDE OFHYDRAULIC PUMP


XO 200 / XO 220 XO 240 / XO 260


With maximum engine rpms and noservices operated. Select H mode 7 ~12 bar 570 ma 7 ~14 bar 520 mameasure and record milliamps and 10 ~16 bar* 495 ma 7 ~14 bar* 520 ma*secondary pressure.

With maximum engine rpms anddipper service selected and stalled. 7 ~12 bar 570 ma 7 ~14 bar 520 maSelect H mode measure and record 10 ~16 bar* 495 ma 7 ~14 bar* 520 ma*milliamps and secondary pressure.

With maximum engine rpms and noservices operated. Select S mode 28 bar 305 ma 26 bar 330 mameasure and record milliamps and +/- 1 bar +/- 1 barsecondary pressure.`

With maximum engine rpms and noservices operated. Select L mode 40 bar 0 ma 40 bar 0 mameasure and record milliamps andsecondary pressure.

* Pre low emission machines

+ -

+ -

Pump sideharness

Link wire


A407830

Later Machines

TP 029

9803/6500

TP 029

Issue 3


A326250

VIEW OFHYDRAULIC PUMP


Testing Horsepower Control XO 330 / XO 450

O Fit gauge ( 0 - 60 bar ) into proportional solenoidsecondary pressure measurement port using suitablead apter (port thread is 1/4 BSP O ring fitting).


OR



XO 330 XO 450


With maximum engine rpms and noservices operated. Select H mode 11.8 ~13.7 bar 520 ma TBA TBAmeasure and record milliamps andsecondary pressure.

With maximum engine rpms anddipper service selected and stalled. 11.8 ~13.7 bar 520 ma TBA TBASelect H mode measure and recordmilliamps and secondary pressure.

With maximum engine rpms and noservices operated. Select S mode 7.8 ~9.8 bar 410 ma TBA TBAmeasure and record milliamps andsecondary pressure.

With maximum engine rpms and noservices operated. Select L mode 0 bar 0 ma TBA TBAmeasure and record milliamps andsecondary pressure.

A436290

+ -

+ -

Pump sideharness

Link wire


Tier 2 Machines

Section 2 Section 2

TP 030

Test Procedure

9803/6500

TP 030

Issue 2

Flow Testing Pumps - all XO Models except XO 70

Install flow meter and load valve as close as possible to pump outlet in one of the pump lines.

Fit pressure test gauges (0 - 600 bar) to main pump test points.

Start engine and warm up hydraulic oil [at least 50 C].

To Confirm Minimum Flow Setting

Set machine to H mode.

Stall boom up service and record pressure in each pump, flow on flow meter and engine rpms ( record this on sheetattached).

Repeat this test for S mode, F mode and L mode.

To Confirm Maximum Flow Setting

Disconnect negative control pilot hose from pump which is being tested, plug the hoses and leave ports on pump opento atmosphere.

Set machine to max engine rpms in H mode have the load valve on flow meter fully open and do not operate anyservices.

Record the pressure on both pumps, the flow on flow meter and the engine rpms (record this on sheet attached).

Repeat this test for S mode, F mode and L mode.

To Confirm Horse Power Control

Disconnect negative control pilot hoses and max flow cut pilot hoses from both pumps.

Plug the hoses and leave ports on pump open to atmosphere.

Start the engine and set the machine to max engine rpms in H mode, make sure the load valve is fully open.

Record the pressure on both pumps, flow on flow meter, engine rpms and proportional solenoid current (record this onsheet attached).

SLOWLY increase the pressure using the load valve up to approx 100 bar.

Record the pressure on both pumps, flow on flow meter, engine rpms and proportional solenoid current (record this onsheet attached).

Increase the pressure in steps of 25 bar each time recording the pressure on both pumps, flow on the meter, enginerpms and proportional solenoid current (record this on sheet attached).

DO NOT increase pressure above 350 bar.

Reset the load valve to fully open.

Repeat test for S mode and L mode (record all results on sheet attached).

Remove flow meter from pump being tested and fit into second pump carry out tests to confirm minimum flow, maximumflow and horsepower control.

Section 2 Section 2Test Procedure

9803/6500 Issue 2

Flow testing Pumps - all XO Models except XO 70 (Continued)

Minimum Flow Pump 1Mode Pressure in P1 Pressure in P2 Flow Rpm

H

S

F

L

Minimum Flow Pump 2Mode Pressure in P1 Pressure in P2 Flow Rpm

H

S

F

L

Maximum Flow Pump 1Mode Pressure in P1 Pressure in P2 Flow Rpm

H

S

F

L

Horsepower Control Pump 1 H ModePressure in P1 Pressure in P2 Flow Rpm Pump Ma

Horsepower Control Pump 1 S ModePressure in P1 Pressure in P2 Flow Rpm Pump Ma

Horsepower Control Pump 1 L ModePressure in P1 Pressure in P2 Flow Rpm Pump Ma

Maximum Flow Pump 2Mode Pressure in P1 Pressure in P2 Flow Rpm

H

S

F

L

Horsepower Control Pump 2 H ModePressure in P1 Pressure in P2 Flow Rpm Pump Ma

Horsepower Control Pump 2 S ModePressure in P1 Pressure in P2 Flow Rpm Pump Ma

Horsepower Control Pump 2 L ModePressure in P1 Pressure in P2 Flow Rpm Pump Ma

TP 031

9803/6500

TP 031

Issue 3

Test Procedure

Testing Milliamps XO200W

Section2 Section 2


OR



+ -

+ -

330470

Pump sideharness

Link wire


Milliamps

With maximum engine rpms and noservices operated. Select H mode 495 mameasure and record milliamps.

With maximum engine rpms anddipper service stalled.Select H mode, 495 mameasure and record milliamps.

TP 032

9803/6500

TP 032

Issue 3

Test Procedure

Testing Steering Pressure XO200W

O Fit a high pressure gauge into test point 2

O Warm the hydraulic oil to 50C.

O Record pressure with engine at Max speed.

O Pressure should be recorded when the steering is held at full lock either way.

To Adjust Steering Pressure:

O Slacken locknut A.

O Use an Allen key to adjust pressure B.

Note: Screw B in to increase or out to de-crease pressure.

O Tighten locknut A.

Section2 Section 2

1 2 3

A436040

Expected Pressures

Steering held at full lock 175 bar

A436250

A

B

TP 033

9803/6500

TP 033

Issue 3

Test Procedure

Testing Brake Latch Pressure XO200W

O Fit a low pressure gauge into test point A on the rear axle of the machine (40 bar)O Run machine and latch the foot brake down, Record pressure.

Expected Brake Latch Pressure 65 bar

O If this pressure is incorrect then adjust pressure by increasing or decreasing length of rod B.

Section2 Section 2

A436190

Test Point A

A436120

A

B

TP 034

9803/6500

TP 034

Issue 3

Test Procedure

Flow Testing Pump - XO200W

O Fit pressure test gauges (0 - 600 bar) to main pump test points.O Install the special test spool SSP0099 in the bucket section of the main control valve.O Intall a flow meter and the metering orifice with the pressure gauge between the working ports A and B of the Bucket

section.O Install flow meter and load valve as close as possible to pump outlet in one of the pump lines.O Open the metering orifice completely.O Start the engine and warm up the hydraulic oil to at least 50 C.O Operated the bucket and record the maximum pump flow from the flow meter

Section2 Section 2

PTT

p

pc

P

Flowmeter

LS - pressure manometer

Adjustable Throttle

Pump Pressure

Test Spool for max pump flow Part No. SSP0099

Section 2 Section 2

Testing for Trapped Air in HBCV Pilot Line

All HBCV installations except XO130 boom, XO130Wboom, XO 130W/XO 160W TABcylinders.

Boom HBCV Installation

1 Warm up hydraulic system to 50 C and operate boom up and down several times.

2 Set dipper to fully extend position and lower boom until bucket rests on the ground.

3 Set the engine speed to idle.

4 Whilst operator slowly selects boom down, open the bleed screw on one of the HBCVs (this is located next to the P porton the valve).

5 Allow oil to flow through bled screw until a clear column of oil has been seen for at least three seconds.

6 Close bleed screw whilst operator is still selecting boom down.

7 Repeat procedure for other side.

Arm HBCV Installation

1 Warm up hydraulic system to 50 C and operate dipper in and out several times.

2 Set dipper to fully extended position and lower boom until bucket rests on the ground.

3 Set the engine speed to idle.

4 Whilst operator slowly selects dipper in, open the bleed screw on one of the HBCV (this is located next to the P porton the valve).

5 Allow oil to flow through bled screw until a clear column of oil has been seen for at least three seconds.

6 Close bleed screw whilst operator is still selecting dipper in.

TP 039

Test Procedure

9803/6500

TP 039

Issue 1

TP 040

9803/6500

TP 040

Issue 3


O Warm up the hydraulic system to 50 C.

O Set the Main Relief Valve (MRV) pressure above the Auxiliary Relief Valve (ARV) pressure.

O Set dipper to vertical position with bucket 300 mm (12) above ground and operate the emergency stop button to stopthe engine.

O Select boom down until the bucket rests on the ground, then fully select the lever for boom down, this will ensure that thepressure in the boom circuit has been vented.

O It is only possible to test the relief valve setting of one side at a time.

O Decide which side check valve you wish to test first.

O On the relevant side valve to be tested.

O Remove pilot hose from port P, plug hose and leave port open to atmosphere.

O Remove pilot hose from port E, plug hose an fit test gauge (0 - 600 bar) to port on valve.

O Start engine and raise boom.

O Carefully select boom down and slowly build pressure until boom starts to move slowly and steadily.

O Record pressure at this point, this is relief setting of HBCV.

O To adjust this setting, remove cap from small cartridge on end of HBCV and adjust as necessary.

O Refit pilot hoses and repeat this procedure for other side.

O Re-set Main Relief Valve to the orignal setting.

NB - If boom is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief setting.

Relief Valve Setting

XO130 350 barXO130W 350 bar

Testing Boom Hose Burst Check Valve XO 130/XO 130W Boom Ram

Port E

Port P

TP 041

9803/6500

TP 041

Issue 3




O Set dipper to fully extend position with bucket 300 mm (12) above ground and operate the emergency stop button, tostop the engine.

O Select arm in until the bucket rests on the ground, then fully select the lever for arm in, this will ensure that the pressurein the arm circuit has been vented.


O Fit test gauge (0 - 600 bar) to port E using appropriate adapter.

O Start engine, lift boom to give clearance to move arm.

O Carefully select arm in and slowly build pressure until arm starts to move slowly and steadily.


O To adjust this setting, remove cap from small cartridge A and adjust as necessary.

O Re-set the Main Relief Valve to the orignal setting.

NB - If arm is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief setting

Relief Valve Settings

XO130 758500 ~ 350 barXO130W 716500 ~ 350 barXO160 701000 ~ 702503 350 bar

702504 ~ 370 - 390 barXO200/220 705000 ~ 705824 350 bar

705824 ~ 370 - 390 barXO240/260 708500 ~ 708748 350 bar

708748 ~ 370 - 390 barXO330 702500 ~ 712562 350 bar

Testing Hose Burst Check Valve - Arm RamXO 130/XO 160/ XO 200/XO 220/ XO 240/XO 260/XO 330

A409671

Port P

Port E

A

TP 042

9803/6500

TP 042

Issue 3




O Set dipper to vertical position with bucket 300 mm (12) above ground and operate the emergency stop button to stopthe engine.



O Decide which side check valve you wish to test first.

O On the relevant side valve to be tested.


O Remove pilot hose from port E, plug hose and fit test gauge (0 - 600 bar) to port on valve.

O Start engine and raise boom.

O Carefully select boom down and slowly build pressure until boom starts to move slowly and steadily.


O To adjust this setting, remove cap from small cartridge on end of HBCV and adjust as necessary.

O Refit pilot hoses and repeat this procedure for other side.

O Re-set the Main Relief Valve to the orignal setting.

NB - If boom is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief setting.

Relief Valve Settings

XO160 702000 ~ 350 barXO160W 718500 ~ 350 bar

Testing Boom Hose Burst Check Valve XO160 / XO 160W / XO 180

VIEW FROM UNDERSIDE OFLEFT HAND BOOM RAM

Port P

Port E

TP 043

9803/6500

TP 043

Issue 3




O Set dipper to vertical position with bucket 300 mm (12) above ground and operate the emergency stop button to stop theengine.



O Decide which side check valve you wish to t

Documents

jcb ENGLISH Fault Finding COMPLETE.pdf